Gema OptiGun GA03-E Page 1 Operating Instructions And Spare Parts List Download

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1011 507

Translation of the original operating instructions

Operating instructions and spare parts list

Enamel automatic gun

OptiGun GA03-E

II 2D

Summary of Contents for OptiGun GA03-E

Page 1: ...1011 507 En Translation of the original operating instructions Operating instructions and spare parts list Enamel automatic gun OptiGun GA03 E II 2D ...

Page 2: ...mes 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 con cerned approve of or are bound in any form by this manual We have en deavored to retain the preferred spelling of the trademarks and registered trademarks of the copyright holders To the best...

Page 3: ...Processible powders 8 Design and function 9 Scope of delivery 9 Available accessories 9 SuperCorona ring 10 Principle of operation 12 High voltage generation 12 Circuit 12 Powder flow and electrode rinsing air 12 Spray nozzle 13 Typical properties characteristics of the functions 14 Connection for SuperCorona Ring 14 Start up 15 Preparation for start up 15 Basic conditions 15 Connecting the OptiGu...

Page 4: ...e gun 25 General information 25 Dismantling procedure 26 Assembling the powder gun 29 Repairing the powder gun 29 Troubleshooting 31 General information 31 Spare parts list 33 Ordering spare parts 33 OptiGun GA03 E complete 34 Powder gun body 35 Shaft 36 Gun cable 37 Nozzle combinations 38 Nozzle combinations 39 Flat jet nozzle NF29 E 60 40 Angled nozzles 41 SuperCorona 42 Diffuser OptiSpray AP01 ...

Page 5: ... documents Keeping the manual Please keep this Manual ready for later use or if there should be any que ries Safety symbols pictograms The following contains a list of warnings with their meanings found in the Gema operating instructions Apart from the regulations in the relevant operating instructions the general safety precautions must also be fol lowed DANGER Indicates a hazardous situation whi...

Page 6: ...if not avoided may have harmful consequences for the environment NOTE Useful tips and other information Pos 14 Kapitel Über diese Anleitung Für alle Anleitungen Darstellung des Inhalts 1 mod_1452784296568_6 docx 23800 23 4 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 c...

Page 7: ...uct 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 not considered as intended use 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 substanc...

Page 8: ...Protection type Temperature class II 2D IP64 T6 zone 21 T4 zone 22 Product specific safety measures This product is a constituent part of the equipment and is therefore in tegrated 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 accor...

Page 9: ...not be liable for damage resulting from such use the user bears sole responsibil ity for such actions fig 1 Utilization The Enamel automatic gun type OptiGun GA03 E is suited for the elec trostatic coating of objects in all shapes and geometries that must be grounded Reasonably foreseeable misuse Coating of non grounded objects Use of metallic or organic powder Incorrectly configured values for po...

Page 10: ...Type A acc EN 50177 Ex 2 mJ T6 Temperature range 0 C 40 C 32 F 104 F Max surface temperature 85 C 185 F Protection type IP64 Approvals II 2D Dimensions OptiGun GA03 E Weight 600 g Processible powders OptiGun GA03 E Enamel powder yes Plastic powder No Metallic powder No ATTENTION The OptiGun GA03 E Enamel automatic gun may only be connect ed to the following control units OptiStar CG06 CG07 CG08 CG...

Page 11: ...g air hose 20 m Flat jet nozzle NF28 E complete incl electrode holder or Round jet nozzle NS11 E with deflector Ø 28 mm Cable tie with Velcro closure Gun cleaning brush Spare parts kit Operating manual standard Available accessories SuperCorona ring Flat jet nozzle for specific applications Round jet nozzles Gun extension 150 and 300 mm Angled nozzles 45 und 60 Gun cable extensions Collision prote...

Page 12: ...l finish can be completely avoided By coating with structure powder the picture frame effect is hardly visible The performance of the OptiGun with SuperCorona is convincing due to its very good charging and very high deposition rate as well as an im proved penetration into Faraday cages The distance between nozzle and workpiece can be reduced to 100 mm without influencing the surface fin ish Fig 3...

Page 13: ...oduct description 11 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 CLICK ...

Page 14: ... 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 Fig 4 High voltage generation Circuit The OptiGun Enamel automatic gun is switched on and off by the gun control module The control unit allows also the adjustment of low voltage powder flow and electrode rinsing air to the gun Powder flow and electrode rin...

Page 15: ...n the gun control unit is de scribed in the corresponding operating manual Round jet nozzle with vented deflector and vented elec trodes The vented deflector is used to give the powder stream emerging from the gun a cloud formation The powder is charged by radial arranged electrodes E The high voltage H created in the gun cascade is guided through the electrodes Fig 6 Round jet nozzle with vented ...

Page 16: ...ir Powder tube coupling with quick release fastener Covered hose and cable duct Easily dismountable by a few hand movements therefore very easy to service Few wearing parts nozzle and SuperCorona Easily removable cascade because free of grease with integrated current limiting resistors Connection for SuperCorona Ring Quick and simple connection to and disconnection from the SuperCorona ring ...

Page 17: ...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 e...

Page 18: ... Start up OptiGun GA03 E Fig 7 Connection instructions overview 1 Electrode rinsing air hose 2 Powder hose 3 Gun cable 4 Conveying air hose 5 Supplementary air hose 6 Injector 5 4 3 2 1 5 5 bar 6 0 bar 6 5 bar 6 ...

Page 19: ... see the troubleshooting guide as well as the gun control unit operating manual Fig 8 The remainder of the start up procedure for the OptiGun GA03 E gun is explicitly described in the operating instructions for the OptiStar gun control unit chapter Initial start up and Daily start up ...

Page 20: ...hare are rec ommended as the base values The total air volume is depending on the powder hose length the number of hose curvatures the hose diameter the conveying air pressure and the supplementary air The operation mode of the injector and the effect of the supplementary air are described in the corresponding injector operat ing instructions The adjusted value of the total air volume can be left ...

Page 21: ...e and the adjusted total air volume see therefore the control unit operating manual much powder little powder To achieve maximum efficiency we recommend avoided an over ly high powder volume where possible Setting the electrode rinsing air 1 Select the correct electrode rinsing 0 1 Nm h 0 5 Nm h too much electrode rinsing air 2 Adjust the powder cloud with a test object If flat jet nozzles are use...

Page 22: ... work piece in the coating booth All connections must be attached 2 Turn on the gun control unit see also the control unit operating in structions the gun starts spraying 3 Adjust the desired coating parameters powder volume total air and high voltage on the gun control unit see also the control unit oper ating instructions 4 Adjust the electrode rinsing air on the control unit dependent upon the ...

Page 23: ...dization 2 The installed gun must be pointed towards a grounded work piece in the coating booth 3 Switch on the gun control unit 4 Adjust the coating parameters or select one of the programs Check by observing the LED displays 5 The workpieces can be coated now Shut down 1 Switch off the powder gun control unit The adjustments for high voltage powder output volume and electrode rinsing air remain ...

Page 24: ......

Page 25: ...parts can be found in the corresponding spare parts list Cleaning Gun cleaning ATTENTION The following solvents may not be used to clean the gun Ethylene chloride acetone ethyl acetate methyl ethyl ketone methylene chloride premium gasoline turpentine tetrachloro methane toluene trichloroethylene xylene 1 Only cleaning agents with a flash point of a least 5 Kelvin above the ambient temperature or ...

Page 26: ...k 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 1 Weekly Remove the spray nozzle and clean on the inside with compressed air If sinterings should have formed then they have to be removed Monthly Check spr...

Page 27: ... The replacement of the cascade and the repair of the powder gun cable connection is only permitted by an authorized Gema Ser vice center Contact your Gema representative for details Dismantling the gun General information The gun should only be dismantled if this is required because of a defect or pollution Dismantle the gun only so far as the desired part is accessible WARNING Touching the gun p...

Page 28: ...V 02 22 26 Cleaning and maintenance OptiGun GA03 E Dismantling procedure 1 Remove the threaded sleeve 2 Remove the nozzle 3 4 5 6 ...

Page 29: ...V 02 22 OptiGun GA03 E Cleaning and maintenance 27 7 8 9 10 ...

Page 30: ...V 02 22 28 Cleaning and maintenance OptiGun GA03 E 11 12 13 14 ...

Page 31: ... out in the reverse order to that shown above Repairing the powder gun Apart from the replacement of possibly defective parts hardly any repairs have to be made The cascade can be replaced trouble free The repair of the gun cable connection however may only be made by an authorized Gema Service center Contact your Gema representative for details ...

Page 32: ......

Page 33: ...l unit is switched on Compressed air not present Connect the equip ment to the com pressed air Injector check valve or throttle on injector powder hose or powder gun clogged Clean or replace the corresponding part Insert sleeve in injector is worn Replace Insert sleeve in the in jector is clogged Clean replace Pressure valve in the control unit defective Replace Solenoid valve in the control unit ...

Page 34: ...tact local Gema representative Electronic board in the OptiTronic defective Send in for repair Powder gun sprays powder high voltage is available powder does not adhere to workpiece The objects are not properly grounded Check the grounding Gun achieving on ly poor spray pro file Total air incorrectly configured Increase the powder quantity and or total air volume on the control unit Bend or damage...

Page 35: ...hen 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 The wearing parts are always marked with a marked 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 WARNING Use of non original Gema spare parts When usin...

Page 36: ...ed sleeve see Nozzle combinations spare parts list 3 Flat jet nozzle complete see Nozzle combinations spare parts list 4 Gun cable complete 20 m see also spare parts list Gun cable 1008 663 5 Cylinder screw M8x50 mm 235 113 6 Washer Ø 8 4 20x2 mm 215 880 7 Cable tie with Velcro closure 8x not shown 303 070 8 Quick release connection NW5 Ø 6 mm for pos 11 not shown 200 840 9 Cleaning brush Ø 12 mm ...

Page 37: ...omplete negative polarity see spare parts list Shaft 2 Powder tube complete 1009 405 3 Hollow screw 1009 406 4 Gun fixture 1008 711 5 Ground plate 1011 457 6 SuperCorona connection 1012 089 7 Cylinder screw M5x12 mm 1012 109 Wearing part X 347 mm Y 20 mm Fig 10 OptiGun GA03 E gun body ...

Page 38: ...ithout cascade 1009 400 3 Sealing piece complete incl pos 6 1008 690 6 Axial gasket 1008 687 8 Threaded bolt 1009 587 9 O ring Ø 4x1 5 mm 264 466 10 Gun rear end complete incl pos 10 13 1008 701 11 Lock knob 382 833 12 Screw M3x3 mm 266 795 13 Screw in nipple M7 Ø 6 mm 1008 699 14 Rear end cover 1008 697 15 Countersunk head screw M4x6 mm 214 639 Fig 11 OptiGun GA03 E shaft ...

Page 39: ...r repair Gun cable complete 11 m 1008 661 Gun cable complete 15 m 1008 662 Gun cable complete 20 m 1008 663 Gun cable complete 30 m 1008 664 1 Cylinder screw M4x6 mm 1008 639 2 O ring Ø 9 5x1 5 mm 1008 665 3 O ring Ø 8 5x1 mm 1008 666 Fig 12 Gun cable complete Pin allocation ws white gn green bru Bridge bn brown sch Shield ...

Page 40: ...002 249 12 Muzzle NS11 E complete 1009 439 13 Threaded sleeve PU04 E NS complete 405 736 14 Deflector Ø 15 mm 400 262 14 1 Deflector Ø 24 mm 400 181 14 2 Deflector Ø 28 mm 400 254 14 3 Deflector Ø 32 mm 400 238 14 4 Deflector Ø 50 mm 400 246 20 Extension PE08 E 150 complete 150 mm 1010 501 20 1 Extension PE08 E 300 complete 300 mm 1010 502 Wearing part ATTENTION Connecting more than two extensions...

Page 41: ...V 02 22 OptiGun GA03 E Spare parts list 39 Nozzle combinations Fig 13 OptiGun GA03 E Nozzle combinations ...

Page 42: ... 2 3 1009 435 1 Fixation piece complete 1009 429 2 Flat jet nozzle set without pos 5 1 1007 465 3 Threaded sleeve complete 405 728 4 Flat jet nozzle 1007 462 5 Electrode holder complete ETFE 404 209 5 1 Electrode holder complete PTFE 406 058 6 Contact ring 318 760 Wearing part Fig 14 Flat jet nozzle NF29 E 60 ...

Page 43: ...ozzle PA03 E 45 complete 1013 670 B Angled nozzle PA03 E 60 complete 1010 480 1 PA03 E 60 knee piece complete 1010 479 2 Threaded sleeve 1010 476 3 Nozzle see OptiGun GA03 E Nozzle combinations 4 PA03 E 60 knee piece complete 1013 669 Wearing part Fig 15 Angled nozzles ...

Page 44: ...tension 150 mm 1012 098 PC08 599 L 599 mm for extension 300 mm 1012 100 B SuperCorona ring for Round jet nozzle complete PC08 319 L 319 mm 1012 097 PC08 469 L 469 mm for extension 150 mm 1012 099 PC08 619 L 619 mm for extension 300 mm 1012 101 1 Plug cap for SuperCorona connection complete not shown 1001 037 Wearing part Fig 16 OptiGun GA03 E SuperCorona ...

Page 45: ...6 4 mm 103 144 3 Screw in nipple M7 Ø 6 mm 1008 699 Connector complete incl pos 4 8 and 9 1011 627 4 Connector 1011 638 5 Fluidizing tube 1005 262 6 O ring Ø 13x1 5 mm 1009 943 7 Adaptor piece complete incl pos 6 1011 625 8 Tube connection complete incl pos 9 1011 632 9 O ring Ø 9x1 5 mm 1011 637 Please indicate length Wearing part Fig 17 Diffuser OptiGun GA03 E ...

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Gema OptiGun GA03-E, Operating Instructions And Spare Parts List

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