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Summary of Contents for ITW Gema OptiGun 2-A
- Page 1 Operating instructions and spare parts list OptiGun 2-A(X) (GA02) Automatic powder gun 0102 II 2 D...
- Page 2 To the best of our knowledge and belief, the information contained in this publication was correct and valid on the date of issue. ITW Gema AG 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.
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Page 3: Table Of Contents
Round jet nozzle with vented deflector and vented central electrode ..17 Technical Data OptiGun 2-A(X) Automatic powder gun ..............19 Electrical data ..................19 Dimensions ....................19 Start-up Connecting the OptiGun 2-A(X) Automatic powder gun ........21 Function check ......................21 General information .................21 Troubleshooting ..................22 Operation Start-up and powder coating.................23 Table of contents •... - Page 4 Spare parts list Ordering spare parts..................... 39 OptiGun 2-A Automatic powder gun - complete........... 40 OptiGun 2-A Automatic powder gun - gun body........... 41 OptiGun 2-A Automatic powder gun - shaft............42 OptiGun 2-AX Automatic powder gun - complete ..........43 OptiGun 2-AX Automatic powder gun - gun body ..........
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Page 5: General Safety Regulations
V 10/04 General safety regulations This chapter sets out the fundamental safety regulations that must be followed by the user and third parties using the OptiGun 2-A(X) (GA02) Automatic powder gun. These safety regulations must be read and understood before the OptiGun 2-A(X) (GA02) Automatic powder gun is used. -
Page 6: Technical Safety Regulations For Stationary Electrostatic Powder Spraying Equipment
4. Start-up (i.e. the execution of a particular operation) is forbidden until it has been established that the OptiGun 2-A(X) (GA02) Automatic powder gun has been set up and wired according to the guidelines for machinery (98/37 EG). EN 60204-1 (machine safety) must also be observed. -
Page 7: Safety Conscious Working
Individual safety regulations for the operating firm and/or operating personnel 1. Any operating method which will negatively influence the technical safety of the powder spraying equipment is to be avoided. General safety regulations • 5 OptiGun 2-A(X) (GA02) Automatic powder gun... -
Page 8: Notes On Special Types Of Hazard
If the earthing of the machinery includes the suspension arrangements, then these must constantly be kept clean in order to guarantee the necessary 6 • General safety regulations OptiGun 2-A(X) (GA02) Automatic powder gun... -
Page 9: Safety Requirements For Electrostatic Powder Coating
Repairs must only be carried out by specialists or in ITW-Gema workshops. Unauthorized conversions and modifications may lead to injury or damage to machinery. The ITW Gema AG guarantee would no longer be valid. Safety requirements for electrostatic powder coating 1. -
Page 10: A Summary Of The Rules And Regulations
Guidelines for the avoidance of the dangers of ignition due to electrostatic charging (Guideline “Static Electricity”) VDMA 24371 Guidelines for electrostatic coating with synthetic powder - Part 1 General requirements - Part 2 Examples of use 8 • General safety regulations OptiGun 2-A(X) (GA02) Automatic powder gun... - Page 11 Beuth Verlag GmbH, Burgrafenstrasse 4, 1000 Berlin 30 General secretariat, Rue Bréderode 2, B-1000 Bruxelles, or the appropriate national committee VDE Verlag GmbH, Bismarckstrasse 33, 1000 Berlin 12 General safety regulations • 9 OptiGun 2-A(X) (GA02) Automatic powder gun...
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Page 12: Special Security Measures
(input and exhaust air) It must be observed, that all components are grounded according to the local regulations, before start-up 10 • General safety regulations OptiGun 2-A(X) (GA02) Automatic powder gun... -
Page 13: About This Manual
General information These operating manual contains all important information which you re- quire for the working with the OptiGun 2-A(X) (GA02) Automatic powder gun. It will safely guide you through the start-up process and give you references and tips for the optimal use of your new powder coating sys- tem. -
Page 15: Function Description
V 10/04 Function description Field of application The OptiGun 2-A(X) Automatic powder gun is intended exclusively for the electrostatic coating with organic powders. Any other use is considered as non-conform. The manufacturer is not responsible for any damage re- sulting from this; the risk for this is assumed by the user alone. -
Page 16: Scope Of Delivery
V 10/04 Easily dismantlable and cleanable SuperCorona Scope of delivery OptiGun 2-A(X) Automatic powder gun Flat jet nozzle with electrode holder Cable binder with Velcro closure Gun cleaning brush Parts set 14 • Function description OptiGun 2-A(X) (GA02) Automatic powder gun... -
Page 17: Structure And Function
OptiGun 2-A(X) Automatic powder gun OptiGun 2-A(X) Automatic powder gun Spray nozzle Powder gun attachment Sleeve nut Powder tube Shaft with removeable high volt- Clamping sleeve age cascade SuperCorona ring Structure and function • 15 OptiGun 2-A(X) (GA02) Automatic powder gun... -
Page 18: High Voltage Generation
(e). High voltage generation Circuit The OptiGun 2-A(X) Automatic powder gun is switched on and off by the OptiTronic gun control unit. The control unit allows also the adjustment of low voltage, powder flow and rinsing air to the gun. -
Page 19: Spray Nozzles
The rinsing air adjustment on the control module is explained in the corresponding operating manual. High voltage Rinsing air Round jet nozzle with vented deflector and vented central electrode Structure and function • 17 OptiGun 2-A(X) (GA02) Automatic powder gun... -
Page 21: Technical Data
5 mJ. In these systems, the danger of an electric shock or explosive energy does not exist. The OptiGun 2-A(X) Automatic powder gun may only be connected to the OptiTronic or MultiTronic control unit! Technical Data • 19... -
Page 23: Start-Up
V 10/04 Start-up Connecting the OptiGun 2-A(X) Automatic powder gun 1. Connect the gun plug to gun control unit (see the OptiTronic con- trol unit operating instructions) 2. Connect the rinsing air hose of the control unit to the gun 3. -
Page 24: Troubleshooting
Troubleshooting In the case of possible faults, see chapter "Troubleshooting guide". Please consider also the control unit operating instructions. 22 • Start-up OptiGun 2-A(X) (GA02) Automatic powder gun... -
Page 25: Operation
The adjusted value of the total air volume can be left as it is, as long as the same diameter powder hose is used. If the hose diameter changes, the total air volume must be reset! Operation • 23 OptiGun 2-A(X) (GA02) Automatic powder gun... -
Page 26: Selecting Powder Output Volume
(order no. 346 055) 3. The foam cubes can be ordered in sheets of 100 pieces (order no. 241 717) 4. Fit the powder hose again to the hose connection on the injec- 24 • Operation OptiGun 2-A(X) (GA02) Automatic powder gun... -
Page 27: Maintenance
V 10/04 Maintenance General information Regular and conscientious maintenance increases the service life of the OptiGun 2-A(X) automatic powder gun and provides for a longer continuous coating quality! Daily maintenance The OptiGun 2-A(X) Automatic powder gun must be cleaned daily and thoroughly (see in addition the chapter "Cleaning and repair"). -
Page 29: Cleaning And Repair
Cleaning and repair Cleaning the gun Before cleaning the OptiGun 2-A(X) automatic powder gun, the con- trol unit must be switched off and the gun plug disconnected! The compressed air used for cleaning must be free from oil and wa-... -
Page 30: Dismantling The Powder Gun
It is only to be dismantled so far, as the desired part is accessible! Before dismantling the OptiGun 2-A(X) automatic powder gun, the control unit must be switched off and the gun plug disconnected! OptiGun 2-A(X) Automatic powder gun - components... - Page 31 V 10/04 Dismantling procedure (cont.) Cleaning and repair • 29 OptiGun 2-A(X) (GA02) Automatic powder gun...
- Page 32 V 10/04 Dismantling procedure (cont.) 30 • Cleaning and repair OptiGun 2-A(X) (GA02) Automatic powder gun...
- Page 33 V 10/04 Dismantling procedure (cont.) Cleaning and repair • 31 OptiGun 2-A(X) (GA02) Automatic powder gun...
- Page 34 V 10/04 Dismantling procedure (cont.) 32 • Cleaning and repair OptiGun 2-A(X) (GA02) Automatic powder gun...
- Page 35 V 10/04 Dismantling procedure (cont.) OptiGun 2-A(X) Automatic powder gun with extension Cleaning and repair • 33 OptiGun 2-A(X) (GA02) Automatic powder gun...
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Page 36: Reassembling The Powder Gun
Dismantling procedure (cont.) Reassembling the powder gun The reassembly of the OptiGun 2-A(X) Automatic powder gun is to be carried out in the reverse order to the procedure shown above. It is to be noted, that the powder tube is pushed in up to the stop. -
Page 37: Repairing The Powder Gun
Apart from the replacement of possibly defective parts, hardly any repairs have to be made. The cascade can be replaced completely unproblem- atic. The repair of the gun cable connection, however, may only be made by an authorized ITW Gema service center. Ask your ITW Gema agency! Powder hose connection The powder hose (11) can be plugged directly into the hose holder (10) and locked by pulling the locking ring back to the stop. -
Page 38: Cleaning The Spray Nozzles
(order no. 1001 037). This prevents powder deposits and contact prob- lems on SuperCorona connection. SuperCorona plug cap 36 • Cleaning and repair OptiGun 2-A(X) (GA02) Automatic powder gun... -
Page 39: Troubleshooting Guide
Check the grounding powder, high voltage is grounded available, powder does not adhere to work- piece Additional error descriptions are to be found also in the OptiTronic control unit operating instructions! Troubleshooting guide • 37 OptiGun 2-A(X) (GA02) Automatic powder gun... -
Page 41: Spare Parts List
WARNING! Only original ITW-Gema spare parts should be used, because the explosion protection will also be preserved that way. The use of spare parts from other manufacturers will invalidate the ITW Gema guarantee conditions! Spare parts list • 39 OptiGun 2-A(X) (GA02) Automatic powder gun... -
Page 42: Optigun 2-A Automatic Powder Gun - Complete
If the powder gun cable (4) is defective, it is to be completely sent in for repair! 393 568 OptiGun 2-A Automatic powder gun - complete, negative polarity, incl. pos. 1-6 OptiGun 2-A Automatic powder gun - complete, positive polarity, incl. pos. 1-6 393 576... -
Page 43: Optigun 2-A Automatic Powder Gun - Gun Body
V 10/04 OptiGun 2-A Automatic powder gun - gun body 1 OptiGun 2-A shaft - complete, negative polarity (see "Shaft" spare parts list) 393 665 393 673 OptiGun 2-A shaft - complete, positive polarity (see "Shaft" spare parts list) 2 Powder tube - complete... -
Page 44: Optigun 2-A Automatic Powder Gun - Shaft
V 10/04 OptiGun 2-A Automatic powder gun - shaft 1 Cascade - complete, negative polarity 393 703 1 Cascade - complete, positive polarity 393 711 2 Adaptor - complete, incl. pos. 2.4 and 2.5 385 158 2.4 Screw-in nipple - 1/8"a, Ø 6 mm 251 542 2.5 Plug cap - 1/8"a... -
Page 45: Optigun 2-Ax Automatic Powder Gun - Complete
6 Powder hose - Ø 16/11 mm (not shown) 103 012* 7 Rinsing air hose - Ø 6/4 mm (not shown) 103 144* * Please indicate length OptiGun 2-AX Automatic powder gun - complete Spare parts list • 43 OptiGun 2-A(X) (GA02) Automatic powder gun... -
Page 46: Optigun 2-Ax Automatic Powder Gun - Gun Body
393 622 OptiGun 2-AX - 650, L = 646 mm (25,43 in) 393 630 1 OptiGun 2-A shaft - complete, negative polarity (see spare parts list "Shaft") 393 665 2 Powder tube - complete, incl. pos. 4 OptiGun 2-AX - 1650... -
Page 47: Gun Cable
Stuffing box - PG7 with kink protection 208 426 Cable - 3x0,75 mm², shielded 892* Connecting plug - 7-pin 200 085 * Please indicate length black plug cap Bridge green brown Shield Gun cable (complete) Spare parts list • 45 OptiGun 2-A(X) (GA02) Automatic powder gun... -
Page 48: Nozzle Combinations
9 Electrode holder, incl. pos. 5 (round jet central electrode) 382 914# # Wearing part Further nozzle versions are described in the "System overview" spare parts list! OptiGun 2-A(X) Automatic powder gun - nozzle combination 46 • Spare parts list OptiGun 2-A(X) (GA02) Automatic powder gun... -
Page 49: Optigun 2-A(X) Automatic Powder Gun - Supercorona
V 10/04 OptiGun 2-A(X) Automatic powder gun - SuperCorona SuperCorona - completa, retrofit set, L=215 mm 385 174# Version with extension 150 mm - L=365 mm 394 254# Version with extension 300 mm - L=515 mm 394 289# 1 SuperCorona-Ring - complete, retrofit set... -
Page 50: Optigun 2-A(X) - System Overview
V 10/04 OptiGun 2-A(X) - system overview 48 • Spare parts list OptiGun 2-A(X) (GA02) Automatic powder gun... - Page 51 V 10/04 OptiGun 2-A(X) - system overview 1 OptiGun 2-AX Automatic powder gun 2 OptiGun 2-A Automatic powder gun - complete, with flat jet nozzle set, gun cable 393 568 (20 m), parts set, cleaning brush, without SuperCorona, negative polarity...
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