Rev.

01 1011 454 EN

Operating instructions and Spare parts list

Manual gun
OptiSelect GM03

Translation of the original operating instructions

 Rev. 01 08/16

Documentation OptiSelect GM03

© Copyright 2018 Gema Switzerland GmbH

All rights reserved.

This publication is protected by copyright. Unauthorized copying is

prohibited by law. No part of this publication may be reproduced,
photocopied, translated, stored on a retrieval system or transmitted in any
form or by any means for any purpose, neither as a whole nor partially,
without the express written consent of Gema Switzerland GmbH.
Gema, EquiFlow, MagicCompact, MagicCylinder, OptiCenter, OptiFlex,
OptiGun, OptiSelect and OptiStar are registered trademarks of Gema
Switzerland GmbH.
ClassicLine, ClassicStandard, ClassicOpen, DVC (Digital Valve Control),
GemaConnect, MagicControl, MagicPlus, MonoCyclone, MRS,
MultiColor, MultiStar, OptiAir, OptiControl, OptiColor, OptiFeed, OptiFlow,
OptiHopper, OptiMove, OptiSieve, OptiSpeeder, OptiSpray, PCC (Precise
Charge Control), RobotGun, SIT (Smart Inline Technology) und
SuperCorona are trademarks of Gema Switzerland GmbH.
All other product names are trademarks or registered trademarks of their
respective holders.
Reference is made in this manual to different trademarks or registered
trademarks. Such references do not mean that the manufacturers
concerned approve of or are bound in any form by this manual. We have
endeavored to retain the preferred spelling of the trademarks, and
registered trademarks of the copyright holders.
To the best of our knowledge and belief, the information contained in this
publication was correct and valid on the date of publication. Gema
Switzerland GmbH makes no representations or warranties with respect
to the contents or use of this publication, and reserves the right to revise
this publication and make changes to its content without prior notice.
For the latest information about Gema products, visit
www.gemapowdercoating.com.
For patent information, see www.gemapowdercoating.com/patents or
www.gemapowdercoating.us/patents.

Printed in Switzerland

Gema Switzerland GmbH

Mövenstrasse 17
9015 St.Gallen
Switzerland
Phone: +41-71-313 83 00
Fax.: +41-71-313 83 83
E-mail: info@gema.eu.com
 Rev. 01 08/16

Table of contents
About these instructions 5
General information ................................................................................................ 5
Keeping the Manual ................................................................................................ 5
Safety symbols (pictograms)................................................................................... 5
Structure of Safety Notes ........................................................................... 6
Presentation of the contents ................................................................................... 6
Figure references in the text ...................................................................... 6

Safety 7
General information ................................................................................................ 7
Basic safety instructions ......................................................................................... 7
Product specific security regulations ...................................................................... 8

Product description 9
Intended use ........................................................................................................... 9
Reasonably foreseeable misuse .............................................................. 10
Technical Data ...................................................................................................... 10
Electrical data .......................................................................................... 10
Dimensions .............................................................................................. 10
Processible powders ................................................................................ 10
Structure................................................................................................................ 11
Overall view.............................................................................................. 11
Operating elements.................................................................................. 12
Scope of delivery .................................................................................................. 12
Available accessories** ......................................................................................... 13
PowerClean™ module – Option .............................................................. 13
SuperCorona ring ..................................................................................... 14
Principle of operation ............................................................................................ 15
High voltage generation ........................................................................... 15
Circuit ....................................................................................................... 15
Powder flow and electrode rinsing air ...................................................... 15
Flat jet nozzle with vented central electrode ............................................ 16
Round jet nozzle with vented deflector and vented central electrode ..... 16
Typical characteristics – properties of the functions ............................................. 17
Remote control ......................................................................................... 17
Powder hose quick release connection ................................................... 17
Connection for SuperCorona Ring ........................................................... 17

Assembly / Connection 19
Connecting the gun ............................................................................................... 19

Start-up 21
Preparation for start-up ......................................................................................... 21
Basic conditions ....................................................................................... 21
Initial start-up......................................................................................................... 22

OptiSelect GM03 Table of contents  3

 Rev. 01 08/16

Operation 23
Operation .............................................................................................................. 23
Setting powder output and powder cloud ................................................ 23
Setting the electrode rinsing air ............................................................... 24
Rinsing mode ........................................................................................................ 25
Activating the rinsing function .................................................................. 25
Activate/deactivate the program change function via remote control .................. 27
Activate/deactivate the program change function on the gun control unit27

Decommissioning / Storage 29
Decommissioning ................................................................................................. 29
If in disuse for several days ..................................................................... 29
Storage conditions ................................................................................................ 29
Hazard notes ........................................................................................... 29
Type of storage ........................................................................................ 29
Storage duration ...................................................................................... 29
Space requirements ................................................................................ 29
Physical requirements ............................................................................. 30
Maintenance during storage ................................................................................. 30
Maintenance schedule............................................................................. 30
Maintenance works.................................................................................. 30

Maintenance / Repairs 31
Interval .................................................................................................................. 31
Gun maintenance .................................................................................... 31
Cleaning................................................................................................................ 31
Gun cleaning ........................................................................................... 31
Cleaning the spray nozzle ....................................................................... 32
Replacing parts ........................................................................................ 33

Fault clearance 35

Disposal 37
Introduction ........................................................................................................... 37
Requirements on personnel carrying out the work .................................. 37
Disposal regulations ................................................................................ 37
Materials .................................................................................................. 37

Spare parts list 39

Ordering spare parts............................................................................................. 39
OptiSelect GM03 – Spare parts list ...................................................................... 40
PowerClean™ module (Option)............................................................................ 42
SuperCorona ........................................................................................................ 43
Accessories .......................................................................................................... 44
Flat jet nozzles – overview (wearing parts) ............................................. 44
Round jet nozzle – Overview (wearing parts).......................................... 45
Gun extensions ........................................................................................ 46
Spray nozzles for extensions – overview (wearing parts) ....................... 47
Powder hoses – overview........................................................................ 48
Other accessories .................................................................................... 48

4  Table of contents OptiSelect GM03

 Rev. 01 08/16

About these instructions

General information
This operating manual contains all important information which you
require for the working with the OptiSelect GM03. It will safely guide you
through the start-up process and give you references and tips for the
optimal use when working with your powder coating system.
Information about the functional mode of the individual system
components should be referenced in the respective enclosed documents.

Keeping the Manual

Please keep this Manual ready for later use or if there should be any
queries.

Safety symbols (pictograms)

The following warnings with their meanings can be found in the Gema
instructions. The general safety precautions must also be followed as well
as the regulations in the relevant instructions.

DANGER
Indicates a hazardous situation which, if not avoided, will result in death
or serious injury.

WARNING
Indicates a hazardous situation which, if not avoided, could result in
death or serious injury.

CAUTION
Indicates a hazardous situation which, if not avoided, could result in
minor or moderate injury.

ATTENTION
Indicates a potentially harmful situation. If not avoided, the equipment or
something in its surrounding may be damaged.

OptiSelect GM03 About these instructions  5

 Rev. 01 08/16

ENVIRONMENT
Indicates a potentially harmful situation which, if not avoided, may have
harmful consequences for the environment.

MANDATORY NOTE
Information which must be observed.

NOTICE
Useful information, tips, etc.

Structure of Safety Notes

Every note consists of 4 elements:
– Signal word
– Nature and source of the danger
– Possible consequences of the danger
– Prevention of the danger

SIGNAL WORD
Nature and source of the hazard!
Possible consequences of the danger
► Prevention of the danger

Presentation of the contents

Figure references in the text

Figure references are used as cross references in the descriptive text.
Example:
"The high voltage (H) created in the gun cascade is guided through the
center electrode."

6  About these instructions OptiSelect GM03

 Rev. 01 08/16

Safety

General information
This chapter provides the user and third parties who operate this product
with all essential safety regulations, the adherence to which is imperative.
These safety regulations must be read and understood in their entirety
before the product is put into operation.
The standards and guidelines applied during the development,
manufacture and configuration are described in the EC declaration of
conformity and in the manufacturer’s declaration.

WARNING
Working without instructions
Working without instructions or with individual pages from the
instructions may result in damage to property and personal injury
if relevant safety information is not observed.
► Before working with the device, organize the required documents
and read the section "Safety regulations".
► Work should only be carried out in accordance with the
instructions of the relevant documents.
► Always work with the complete original document.

Basic safety instructions

– This product is built to the latest specification and conforms to the
recognized technical safety regulations and is designed for the
normal application of powder coating.
– Any other use is considered non-compliant. The manufacturer shall
not be liable for damage resulting from such use; the user bears sole
responsibility for such actions. If this product is to be used for other
purposes or other substances outside of our guidelines then Gema
Switzerland GmbH should be consulted.
– Start-up (i.e. the execution of intended operational tasks) is
forbidden until it has been established that this product has been set
up and wired according to the guidelines for machinery. The
standard "Machine safety" must also be observed.
– Unauthorized modifications to the product exempt the manufacturer
from any liability from resulting damage.

OptiSelect GM03 Safety  7

 Rev. 01 08/16

– The relevant accident prevention regulations, as well as other

generally recognized safety regulations, occupational health and
structural regulations are to be observed.
– Furthermore, the country-specific safety regulations also must be
observed.

Product specific security regulations

– This product is a constituent part of the equipment and is therefore
integrated in the system's safety concept.
– If it is to be used in a manner outside the scope of the safety
concept, then corresponding measures must be taken.
– The installation work to be done by the customer must be carried out
according to local regulations.
– It must be ensured, that all components are earthed according to the
local regulations before start-up.

For further security information, see the more detailed Gema

safety regulations!

8  Safety OptiSelect GM03

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Product description

Intended use
This gun is used for electrostatic coating of objects connectable to ground
with organic powders in conjunction with the control units and
accessories, as specified in the corresponding Type Examination
Certificate.

fig. 1
Observance of the operating, service and maintenance instructions
specified by the manufacturer is also part of conformity of use. This
product should only be used, maintained and started up by trained
personnel, who are informed about and are familiar with the possible
hazards involved.
Any other use is considered non-compliant. The manufacturer is not
responsible for any incorrect use and the risks associated with such
actions are assumed by the user alone!

OptiSelect GM03 Product description  9

 Rev. 01 08/16

Reasonably foreseeable misuse

– Use with insufficient compressed air quality
– Input pressure too low

Technical Data

Electrical data
OptiSelect GM03
Nominal input voltage eff. 10 V
Frequency 18 kHz (average)
Nominal output voltage 100 kV
negative (optional
Polarity
positive)
Max. output current 100 µA
High voltage display with LED
Ignition protection Ex 2 mJ T6
0 °C - +40 °C
Temperature range
(+32 °F - +104 °F)
Max. surface temperature 85 °C (+185 °F)
Protection type IP64

Approvals 0102 II 2D
PTB 11 ATEX 5006

Dimensions
OptiSelect GM03
Weight 520 g

Processible powders
OptiSelect GM03
Plastic powder yes
Metallic powder yes
Enamel powder no

10  Product description OptiSelect GM03

 Rev. 01 08/16

Structure
Overall view

fig. 2:
1 Spray nozzle system 8 Gun cable
2 Threaded sleeve 9 Powder hose connection
3 Shaft 10 Powder hose quick release
4 Cover with remote control connection
and hooks 11 Electrode rinsing air
5 Remote control connection
6 SuperCorona connection 12 Trigger
7 Gun handle

OptiSelect GM03 Product description  11

 Rev. 01 08/16

Operating elements
LED and remote control buttons

fig. 3

Designation Function
L1 Display High voltage (intensity)
T1 Powder output + key
T2 Powder output – key
T3 Activate/stop rinsing process key

Scope of delivery
 Manual gun with gun cable (6 m), negative polarity
 Powder hose (6 m, ID 10 mm)
 Rinsing air hose (6 m)
 Flat jet nozzle NF20, complete (incl. electrode holder)
 Flat jet nozzle NF21
 Cable tie with Velcro closure
 Gun cleaning brush
 Spare parts kit
 Operating manual

12  Product description OptiSelect GM03

 Rev. 01 08/16

Available accessories**
 Rinsing module (with OptiStar CG09/CG13 manual powder gun
control unit only)
 SuperCorona ring
 Flat jet nozzle (for specific applications)
 Round jet nozzles
 Gun extension 150 and 300 mm
 Gun cable extensions
 Application cup 150 and 500 ml
 Multi-spray adapter
 Various adapters for connection to earlier generations of control
units
 Gloves, anti-static
**for more information, see spare parts list

PowerClean™ module – Option

Field of application
The PowerClean module can be used in combination with the
OptiStar CG09/CG13 control unit.
The PowerClean module provides increased stability in application
processes. It prevents the bridging phenomena that can lead to short
circuiting when handling powders such as metallic powders.
In moist or tropical environments, any moisture is driven from the injector,
powder hose and powder gun. The color change is also accelerated
during non-extreme color switches.

fig. 4

OptiSelect GM03 Product description  13

 Rev. 01 08/16

SuperCorona ring
Field of application
The SuperCorona is an optional extension for the gun, allowing for a
better surface quality when coating with the powder coating equipment.
When coating wheel rims, drawers, radiators, lamps etc. the surface
quality is exceptional, also in places with higher coating layer
requirements. By coating with several powder types, an "orange peel"
finish can be completely avoided. By coating with structure powder, the
"picture frame effect" is hardly visible.
The performance of the gun with SuperCorona is convincing due to its
very good charging and very high deposition rate as well as an improved
penetration into Faraday cages. The distance between nozzle and
workpiece can be reduced to 100 mm without influencing the surface
finish.

fig. 5
Due to its modular structure, the gun can be fast and easily extended with
the light SuperCorona (approx. 60 g). The gun remains repair-friendly and
easy to maintain even after reconfiguration.

SuperCorona assembly
Before fitting the SuperCorona ring, make sure that the connection and
the plug-in connector are free from grease and powder, otherwise the
electric contact cannot be guaranteed.

1. 2.

14  Product description OptiSelect GM03

 Rev. 01 08/16

Principle of operation
High voltage generation
The control unit supplies a high-frequency low voltage signal of approx.
10 V eff. This voltage is fed through the gun cable (1) to the high voltage
cascade (2) in the gun shaft.
In the high voltage cascade (2), the low voltage is high-transformed in a
first step (c). This primary high voltage is subsequently rectified and
multiplied in the high voltage cascade in a second step (d), until the
required high voltage is obtained at the end (approx. 100 kV). The high
voltage is now fed to the electrode (E) within the spray nozzle.

Circuit
In addition to the modulated low voltage needed for high voltage
generation, there are signal lines fed trough the gun cable. The control
signals are used for monitoring gun trigger status and gun remote control
functions.
The gun is released by a touch-free switch (3), which is operated by a
magnet (4) in the trigger (5). The gun control unit switches on the
modulated low voltage, the powder transport and the rinsing air.

fig. 6

Powder flow and electrode rinsing air

The electrode rinsing air is used by vented spray nozzles and is
connected with its designated connection on the rear side of the gun
control unit (see the operating manual of the gun control unit). The
functions of the spray nozzles are described in the corresponding section
of this manual.

OptiSelect GM03 Product description  15

 Rev. 01 08/16

Flat jet nozzle with vented central electrode

The vented flat jet nozzle serves for the spraying and the charging of the
powder. The powder is charged by the central electrode (E). The high
voltage (H) created in the gun cascade is guided through the center
electrode.

Fig. 7
In order to prevent powder from sintering on the electrode, compressed
air is used during the spray process.
The rinsing air (S) adjustment on the gun control unit is described in the
corresponding operating manual.

Round jet nozzle with vented deflector and

vented central electrode
The vented deflector is used, to give the powder stream emerging from
the gun, a cloud formation. The powder is charged by the central
electrode (E). The high voltage (H) created in the gun cascade is guided
through the center electrode.

Fig. 8
Since powder can accumulate on the baffle plate, it must be rinsed with
compressed air.
The electrode rinsing air (S) adjustment on the gun control unit is
described in the corresponding operating manual.

16  Product description OptiSelect GM03

 Rev. 01 08/16

Typical characteristics – properties of the functions

Remote control
– Adapt powder output (The powder output is correspondingly
increased or reduced) – factory setting
or
– Program change (It is switching between programs P01-P20) –
See chapter "Activate/deactivate the program change function via
remote control" on page 27.

– Activate/stop PowerClean process (injector, powder hose and

gun are rinsed) – only if the optional PowerClean module is
present and attached

Powder hose quick release connection

– Quick and simple connection and disconnection from powder
hose and application cup

Connection for SuperCorona Ring

– Quick and simple connection and disconnection of the
SuperCorona ring

OptiSelect GM03 Product description  17

 Rev. 01 08/16

18  Product description OptiSelect GM03

 Rev. 01 08/16

Assembly / Connection

Connecting the gun

The gun is delivered ready-to-use by the manufacturer. Just a few cables
and hoses must be connected.

The compressed air must be free of oil and water!

The gun is connected as follows:

1. Connect electrode rinsing air hose and powder hose to gun
2. Lay out gun cable, electrode rinsing air hose and powder hose and
bind using Velcro strips (included)
3. Connect the gun cable plug to the socket 2.3 on the rear side of the
control unit
4. Connect electrode rinsing air hose to coupling 1.4
5. Connect powder hose to injector

OptiSelect GM03 Assembly / Connection  19

 Rev. 01 08/16

fig. 9

1 Gun 4 Maintenance unit

2 Injector 5 PowerClean™ module
3 Fluidizing air hose (Option)

20  Assembly / Connection OptiSelect GM03

 Rev. 01 08/16

Start-up

Preparation for start-up

Basic conditions
When starting up the gun control unit, the following general conditions
impacting the coating results must be taken into consideration:
– Gun correctly connected
– Gun control unit correctly connected
– Corresponding power and compressed air supply available
– Powder preparation and powder quality OK

OptiSelect GM03 Start-up  21

 Rev. 01 08/16

Initial start-up
If a malfunction occurs, see the troubleshooting guide, as well as
the gun control unit operating manual!

Fig. 10

The remainder of the start-up procedure for the Gun is explicitly

described in the operating instructions for the OptiStar
CG08/CG13 powder gun control unit (chapter "Initial start-up" and
"Start-up")!

22  Start-up OptiSelect GM03

 Rev. 01 08/16

Operation

WARNING
Holding the gun incorrectly
During the coating process, the gun can discharge along the body
of the coater if not held using its intended handle, which has been
grounded.
► Always hold gun only by the handle!
► Do not touch any other parts of the gun!
Bedienung

Operation

Setting powder output and powder cloud

The powder output depends on the selected powder output (in %), and
the powder cloud on the selected total air volume.

As a factory default value, a powder rate of 50% and a total air

volume of 4 Nm³/h are recommended.
– If values are entered that the gun control unit cannot implement,
then the operator is informed of this by a blinking in the relevant
display and a temporary error message!

Setting the total air volume

1.
Adjust the total air volume on the gun control unit with the T3/T4
keys
– Adjust the total air volume according to the corresponding coating
requests

OptiSelect GM03 Operation  23

 Rev. 01 08/16

correct powder cloud too little total air

Setting the powder output

1. or

much powder little powder

Adjust the powder output volume (e.g. according to the desired

coating thickness)
– Factory default setting of 50% is recommended for initial
operation. The total air volume is thereby kept constant
automatically by the control unit.

To achieve maximum efficiency, we recommend avoided an

overly high powder volume where possible!

2. Check fluidization of the powder in the powder container

3. Point the gun into the booth, switch the gun on and visually check
the powder output

Setting the electrode rinsing air

1. Press the key.

The second display level will be shown.

2.

24  Operation OptiSelect GM03

 Rev. 01 08/16

Adjust the correct electrode rinsing air according to the applied

nozzles (deflector plate, flat jet nozzle)

≈ 0,1 Nm³/h

≈ 0,5 Nm³/h

too much electrode rinsing air

3. If in this display level is no operation for 3 seconds, the first display

level is switched over independently.

Rinsing mode
The rinsing mode enables blowing off powder accumulations in the
powder hose.

Activating the rinsing function

Manual equipment without optional PowerClean module
(system parameter P01=0)
The rinsing mode can only be activated from standby mode (main menu
display, no powder conveying).

On OptiFlex 2 F Manual coating equipment, the injector must be

disconnected prior to cleaning procedure, on OptiFlex 2 B, the
suction unit must be lifted, and on OptiFlex 2 S, the powder
container must be empty.

1. Detach the injector

2. or

OptiSelect GM03 Operation  25

 Rev. 01 08/16

3. START =

Procedure Effect
– The rinsing process is started
– Injector, powder hose, gun and spray nozzle
are purged using compressed air
Automatic – The PowerClean function enables parallel
(automatic) cleaning of other components, such as the
fluid intake unit, powder container, etc.
– The rinsing mode is exited if the automatic
rinsing sequence has finished.

Manual The operator controls the number and length of the

PowerClean impulse by pressing the gun trigger a
(manual) second time
4. STOP =

or or
the cleaning mode is terminated automatically.
After completion of the PowerClean procedure, the controller switches
back to coating mode.

Manual equipment with optional PowerClean module

(system parameter P01= 1 or P01=2)
The rinsing mode can only be activated from standby mode (main menu
display, no powder conveying).

1. or

26  Operation OptiSelect GM03

 Rev. 01 08/16

2. START =

Procedure Effect
– The rinsing process is started
– Injector, powder hose, gun and spray nozzle
are purged using compressed air
Automatic – The PowerClean function enables parallel
(automatic) cleaning of other components, such as the
fluid intake unit, powder container, etc.
– The rinsing mode is exited if the automatic
rinsing sequence has finished.

Manual The operator controls the number and length of the

PowerClean impulse by pressing the gun trigger a
(manual) second time
3. STOP =

or or
the cleaning mode is terminated automatically.
After completion of the PowerClean procedure, the controller switches
back to coating mode.

Activate/deactivate the program change function via

remote control
The remote control function has been set in the factory to change the
powder output.
If the operator prefers the possibility to switch between the programs, this
function is to be activated/deactivated on the control unit.

Activate/deactivate the program change function

on the gun control unit

1. Hold key pressed

2. Press the key

– The display flashes once, and the program change function is
activated/deactivated

OptiSelect GM03 Operation  27

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28  Operation OptiSelect GM03

 Rev. 01 08/16

Decommissioning / Storage

Decommissioning
1. End the coating procedure
2. Switch off the control unit

The adjustments for high voltage, powder output volume and

electrode rinsing air remain stored.

If in disuse for several days

1. Separate from power mains
2. Clean guns, injectors and powder hoses (see therefore the
corresponding user manuals)
3. Turn off the compressed air main supply

Storage conditions

Hazard notes
There is no danger to personnel or the environment if the unit is stored
properly.

Type of storage
For safety reasons, the product should only be stored in a horizontal
position

Storage duration
If the physical conditions are maintained, the unit can be stored
indefinitely.

Space requirements
The space requirements correspond to the size of the product.
There are no special requirements concerning distance to neighboring
equipment.

OptiSelect GM03 Decommissioning / Storage  29

 Rev. 01 08/16

Physical requirements
Storage must be inside a dry building at a temperature between +5 and
+50 °C. Do not expose to direct sunlight!

Maintenance during storage

Maintenance schedule
No maintenance schedule is necessary.

Maintenance works
During long-term storage, periodically perform a visual check.

30  Decommissioning / Storage OptiSelect GM03

 Rev. 01 08/16

Maintenance / Repairs

Interval

Gun maintenance
The gun is designed to require only a minimum amount of maintenance.
1. Clean the gun with dry cloth, see chapter "Maintenance"
2. Check connection points to powder house.

Reinigung
3. Replace the powder hoses, if necessary.

Cleaning
ATTENTION
Any unauthorized modifications and alterations to the product are
not permitted for safety reasons and exclude the manufacturer’s
liability for any resulting damage!

Regular and conscientious cleaning and maintenance increase

the service life of the product and ensure consistent high coating
quality!
– The parts to be replaced during maintenance work are available
as spare parts. These parts can be found in the appropriate
spare parts list!

Gun cleaning
ATTENTION
Impermissible solvents
The following solvents may not be used to clean the gun:
► Ethylene chloride, acetone, ethyl acetate, methyl ethyl ketone,
methylene chloride, premium gasoline, turpentine,
tetrachloromethane, toluene, trichloroethylene, xylene!

OptiSelect GM03 Maintenance / Repairs  31

 Rev. 01 08/16

Only cleaning agents with a flash point of a least 5 Kelvin above

the ambient temperature, or cleaning places with technical
ventilation are allowed!

Before cleaning the powder gun, switch off the control unit. The
compressed air used for cleaning must be free of oil and water!

Daily:
1. Blow off the outside of the gun and wipe, clean etc.

Weekly:
2. Remove powder hose
3. Remove the spray nozzle from the gun and clean it with compressed
air
4. Blow through the gun with compressed air, beginning from the
connection in flow direction
5. Blow through the gun with compressed air, beginning from the
connection in flow direction
6. Clean the integrated gun tube with the brush supplied if necessary
7. Blow through the gun with compressed air again
8. Clean the powder hose
9. Reassemble the gun and connect it

Cleaning the spray nozzle

Daily or after every shift
1. Clean the inside and outside of the spray nozzle with compressed
air.
Never immerse the parts in solvents!
2. Check the seating of the spray nozzles.

ATTENTION
Threaded sleeve not tightened well
If the spray nozzle is just fitted loosely, there is danger of a flash-
over of the gun high voltage, which can damage the gun!
► Always tighten the threaded sleeve well!

Weekly:
1. Remove the spray nozzle and clean on the inside with compressed
air. If sinterings should have formed, then they have to be removed!

Monthly
1. Check spray nozzle for wear
The flat jet nozzle is to be replaced, if:
– the spray pattern is no longer a regular oval

32  Maintenance / Repairs OptiSelect GM03

 Rev. 01 08/16

– deeper grooves are in the nozzle slot, or even the wall thickness
is no longer recognizable
– the wedge of the electrode holder is worn
Nozzles with deflectors:
– if the wedge of the electrode holder is worn down, then the
electrode holder is to be replaced

Replacing parts
Except for the replacement of possible defective parts, there are very few
repairs to be made.

The replacement of the cascade and the repair of the powder gun
cable connection is only permitted by an authorized Gema
Service center!
– Contact your Gema representative!

OptiSelect GM03 Maintenance / Repairs  33

 Rev. 01 08/16

34  Maintenance / Repairs OptiSelect GM03

 Rev. 01 08/16

Fault clearance

Additional error descriptions are to be found also in the control

unit operating instructions!

Incident Causes Corrective action

H11 (Help code on control Gun not connected Connect the gun
unit) Gun plug or gun cable defective Contact local Gema
representative
Remote control on powder gun Contact local Gema
defective representative
Gun LED remains dark, High voltage adjustment is set Increase high voltage
although the gun is triggered too low
Gun plug or gun cable defective Contact local Gema
representative
LED on gun defective Contact local Gema
representative
Powder does not adhere to High voltage and current Check the high voltage and
object, although the gun is deactivated current setting
triggered and sprays powder High voltage cascade defective Contact local Gema
representative
The objects are not properly Check the grounding
grounded
The gun does not spray Compressed air not present Connect the equipment to the
powder, although the control compressed air
unit is switched on and the Injector or nozzle on the Clean the corresponding part
gun trigger is pressed injector, powder hose or
powder gun clogged
Insert sleeve in the injector is Clean/replace
clogged
Pressure valve in the control Replace
unit defective
Solenoid valve in the control Replace
unit defective
No conveying air:
– Throttle motor defective Contact local Gema
– Solenoid valve defective representative
Front plate defective Contact local Gema
representative

OptiSelect GM03 Fault clearance  35

 Rev. 01 08/16

Incident Causes Corrective action

Gun achieving only poor Total air incorrectly configured Increase the powder quantity
spray profile and/or total air volume on the
control unit
Bend or damage to air lines to Check air lines to injector
injector
Insert sleeve in the injector Replace or insert it
worn or not inserted
Fluidization not running see above

36  Fault clearance OptiSelect GM03

 Rev. 01 08/16

Disposal

Introduction
Requirements on personnel carrying out the
work
The disposal of the product is to be carried out by the owner or operator.
When disposing of components that are not manufactured by Gema, the
instructions in the respective manufacturer’s documentation must be
observed.

Disposal regulations
The product must be disassembled and disposed of properly at
the end of its service life.
► When disposing of the product, the applicable local and regional
laws, directives and environmental regulations must be
complied with!

Materials
The materials must be sorted according to material groups and taken to
the appropriate collection points.

OptiSelect GM03 Disposal  37

 Rev. 01 08/16

38  Disposal OptiSelect GM03

 Rev. 01 08/16

Spare parts list

Ordering spare parts

When ordering spare parts for powder coating equipment, please indicate
the following specifications:
– Type and serial number of your powder coating equipment
– Order number, quantity and description of each spare part

Example:
– Type OptiGun GA03 automatic powder gun
Serial number 1234 5678
– Order no. 203 386, 1 piece, Clamp – Ø 18/15 mm

When ordering cable or hose material, the required length must also be
given. The spare part numbers of this bulk stock is always marked with
an *.
Wearing parts are always marked with a #.
All dimensions of plastic hoses are specified with the external and internal
diameter:
Example:
Ø 8/6 mm, 8 mm outside diameter (o/d) / 6 mm inside diameter (i/d)

ATTENTION
Use of non-original Gema spare parts
When using the spare parts from other manufacturers the
explosion protection is no longer guaranteed. If any damage is
caused by this use all guarantee claims become invalid!
► Only original Gema spare parts should be used!

OptiSelect GM03 Spare parts list  39

 Rev. 01 08/16

OptiSelect GM03 – Spare parts list

Only parts were included in the spare parts list, which the user
can replace himself without problems!
► If the powder gun cable is defective, it is to be completely sent
in for repair!

OptiSelect GM03 manual powder gun – complete

A negative polarity, incl. gun cable – 6 m, rinsing air hose – 6 m, flat jet nozzle, 1008 070
brush and parts kit, without powder hose
OptiSelect GM03 manual powder gun – complete
positive polarity, incl. gun cable – 6 m, rinsing air hose – 6 m, flat jet nozzle, 1008 073
brush and parts kit, without powder hose
B Manual powder gun shaft OptiSelect GM03 (incl. cascade) with:
Gun cable 2 m, negative polarity (–) 1007 971
Gun cable 6 m, negative polarity (–) 1007 972
Gun cable 12 m, negative polarity (–) 1007 973
Gun cable 2 m, positive polarity (+) 1007 974
Gun cable 6 m, positive polarity (+) 1007 975
Gun cable 12 m, positive polarity (+) 1007 968
1 Gun body 1007 220
2 Cascade – complete, negative polarity 1007 231
Cascade – complete, positive polarity 1007 232
3 Print holder – complete 1007 216
4 End plate with hook 1007 217
5 Grip – complete (incl. pos. 5.1 and 5.2) 1007 961
5.1 Grub screw – M3x8 mm 1008 157
5.2 Grip sealing 1007 633
6 Trigger – complete 1007 213
7 Trigger cover 1007 212
8 Countersunk-head screw – M4x6 mm 1000 845
9 SuperCorona connection 1007 238
10 Gun cable 2 m – complete 1007 963
Gun cable 6 m – complete 1007 964
Gun cable 12 m – complete 1007 965
11 Rinsing air connection 1000 804
11.1 Rinsing air hose 100 854*
12 Powder tube – complete 1007 958 #
13 Compression spring 1001 488
14 Clip ring 1007 960
15 Hose connection Ø 11-12 mm – complete (incl. pos 15.1) 1001 340 #
Hose connection Ø 9-10 mm – complete (incl. pos 15.1) 1002 030 #
15.1 O-ring for pos. 15 1000 822 #
16 Threaded sleeve (see corresponding spare parts list)

40  Spare parts list OptiSelect GM03

 Rev. 01 08/16

17 Nozzle (see corresponding spare parts list)

18 Cascade space gasket 1007 635#
Cleaning brush – Ø 12 mm 389 765
Parts set (not shown), consisting of: 1008 302
Flat jet nozzle NF21 1007 935#
MultiSpray-Adapter NF08 1003 634#
Cable clamp 303 070
Hose connector – complete, for hose interior Ø 9-10 mm 1002 030

Powder hose – Ø 10 mm (not shown) 1001 673*#

Powder hose – Ø 11 mm (not shown) 105 139*#
* Please indicate length
# Wearing part

fig. 11: OptiSelect GM03 – spare parts

OptiSelect GM03 Spare parts list  41

 Rev. 01 08/16

PowerClean™ module (Option)

PowerClean module – complete 1009 528
1 Elastomer valve 1000 089#
2 O ring – Ø 16x2 mm, anti-static 1007 794#
3 Fluidizing tube bearing 1007 356
4 Fluidizing tube 1007 355
5 Retaining bracket 1009 524
6 Gasket 1010 101
7 O-ring – Ø 27x2 mm 1009 525
# Wearing part

fig. 12

42  Spare parts list OptiSelect GM03

 Rev. 01 08/16

SuperCorona
1 SuperCorona PC05 1008 165#
# Wearing part

Fig. 13

OptiSelect GM03 Spare parts list  43

 Rev. 01 08/16

Accessories

Flat jet nozzles – overview (wearing parts)

Application A B A+B Threaded sleeve

Profiles/flat parts NF20

(standard nozzle) 1010160
NF20
1010 090

NF27
Profiles/flat parts
1010 754
NF27
1010 752

Complex profiles NF21 1007 229

and depressions 1007 932
NF21
1007 683
1007 935

Complex parts
NF22
(deep recess);
target spraying 1008 140
NF22
1008 145

NF24
Large surfaces
1008 142
NF24*
1008 147 1008 326
* not suitable for angled nozzles

44  Spare parts list OptiSelect GM03

 Rev. 01 08/16

Round jet nozzle – Overview (wearing parts)

Application A B A+B Threaded sleeve Deflectors

Ø 16 mm
331 341
Suitable for NS04
Ø 24 mm
large surfaces 1008 150
331 333
NS04 1008 152
1008 151 Ø 32 mm
1007 229
331 325
Ø 50 mm
345 822

OptiSelect GM03 Spare parts list  45

 Rev. 01 08/16

Gun extensions

Gun extensions
L = 150 mm L = 300 mm

without nozzle1
1008 616 1008 617

without nozzle2
1007 718 1007 719

with Flat jet nozzle

NF25 1007 746 1007 747

with Round jet nozzle

NS09 1007 748 1007 749

1
see NF27, NF20, NF21, NF24, NS04
2
see NF25, NF26, NS09

ATTENTION
Connecting more than two extensions
It is not permitted to connect more than two extensions together,
in order to prevent the gun from being damaged by arising
leverage force.
► The extensions (150 mm/300 mm) may be connected TO ONLY
ONE ADDITONAL extension (150 mm/300 mm), if necessary.

46  Spare parts list OptiSelect GM03

 Rev. 01 08/16

Spray nozzles for extensions – overview

(wearing parts)

1007 718 1007 719

Deflecto
Application A B A+B Threaded sleeve
rs

Profiles/flat NF25
--
parts 1007 743
NF25
1007 735

1007 684
Complex NF26
profiles and --
depressions 1007 744
NF26
1007 742

1007 740

Ø 16 mm
Suitable for 331 341
NS09
large Ø 24 mm
surfaces 1008 259
NS09 1008 258 331 333
1008 257 Ø 32 mm
331 325
Ø 50 mm
345 822

OptiSelect GM03 Spare parts list  47

 Rev. 01 08/16

Powder hoses – overview

Powder hose Parts

Application Diameter Material Type
(antistatic) No.*

Fast color
Ø 11/16 mm 105 139 POE 66
changes

Fast color
changes - low Ø 10/15 mm 1001 673 POE 74
powder flow

Fast color
changes -
Ø 12/18 mm 1001 674 POE 75
high powder
flow
* Please indicate length

Other accessories

150 ml 500 ml

Application cup

1004 552 1002 069

Gun extension
cables L=6 m 1002 161
L=14 m 1002 162

Gloves, anti-static
(1 pair)

800 254

48  Spare parts list OptiSelect GM03

 Rev. 01 08/16

Index
A
M
About these instructions ..................................... 5
Assembly .......................................................... 19 Maintenance .................................................... 31
Maintenance during storage ............................ 30
B
O
Basic safety instructions..................................... 7
Operation ......................................................... 23
C
P
Cleaning ........................................................... 31
Connection ....................................................... 19 Pictograms ......................................................... 5
Presentation of the contents .............................. 6
D Product description ............................................ 9
Product specific security regulations ................. 8
Decommissioning ............................................. 29
Disposal............................................................ 37 R
Disposal regulations ......................................... 37
Disuse for several days .................................... 29 Repairs ............................................................ 31

E S
Electrical data ................................................... 10 Safety................................................................. 7
Safety symbols .................................................. 5
F Spare parts list ................................................. 39
Start-up ............................................................ 21
Fault clearance ................................................. 35 Storage ............................................................ 29
Figure references in the text .............................. 6 Storage conditions ........................................... 29

I T
Intended use ...................................................... 9 Technical Data ................................................. 10

OptiSelect GM03 Index  49

Rev. 01