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Summary of Contents for Gema OptiGun GA03-E
- Page 1 1011 507 Operating instructions and spare parts list Enamel automatic gun OptiGun GA03-E II 2D Translation of the original operating instructions...
- Page 2 To the best of our knowledge and belief, the information contained in this publication was correct and valid on the date of publication. Gema Swit- zerland 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.
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Page 3: Table Of Contents
Setting of total air ..................18 Setting the powder quantity ..............19 Setting the electrode rinsing air ............... 19 Functional check ....................20 General information ................. 20 Troubleshooting ..................20 Start-up and powder coating ................. 21 Table of contents • 1 OptiGun GA03-E... - Page 4 Repairing the powder gun ..................29 Troubleshooting General information ....................31 Spare parts list Ordering spare parts ..................... 33 OptiGun GA03-E – complete ................34 Powder gun body ....................35 Shaft ........................36 Gun cable ......................37 Nozzle combinations .................... 38 Nozzle combinations ....................
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Page 5: About This Instructions
General information This operating manual contains all the important information you require for the working with the OptiGun GA03-E 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 system. -
Page 6: Presentation Of The Contents
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." 4 • About this instructions OptiGun GA03-E... -
Page 7: Safety
If this product is to be used for other purposes or other substances outside of our guidelines then Gema Switzerland GmbH should be consulted. – Observance of the operating, service and maintenance instructions specified by the manufacturer is also part of the intended use. -
Page 8: Product-Specific Safety Measures
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! 6 • Safety OptiGun GA03-E... -
Page 9: Product Description
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 –... -
Page 10: Technical Data
Enamel powder Plastic powder Metallic powder ATTENTION The OptiGun GA03-E Enamel automatic gun may only be connect- ed to the following control units: ► OptiStar CG06, CG07, CG08, CG09, CG10, CG12, CG13, CG20, CG21, CG23, CG24 and MultiStar CG10! 8 • Product description... -
Page 11: Design And Function
Threaded sleeve SuperCorona connection Spray nozzle Scope of delivery – OptiGun GA03-E Enamel automatic gun with gun cable (20 m)*, negative polarity – Rinsing air hose (20 m)* – Flat jet nozzle NF28-E, complete (incl. electrode holder) or Round jet nozzle NS11-E with deflector Ø... -
Page 12: Supercorona Ring
V 02/22 SuperCorona ring Field of application The SuperCorona is an optional extension for the OptiGun GA03-E Enamel automatic 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 require- ments. - Page 13 V 02/22 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. CLICK Product description • 11 OptiGun GA03-E...
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Page 14: Principle Of Operation
(see the operating manual of the gun control unit). The functions of the spray nozzles are described in the following sections. 12 • Product description OptiGun GA03-E... -
Page 15: Spray Nozzle
The electrode rinsing air cleaning ability depends on the powder and its sintering ability. The electrode rinsing air (S) adjustment on the gun con- trol unit is described in the corresponding operating manual. Product description • 13 OptiGun GA03-E... -
Page 16: Typical Properties - Characteristics Of The Functions
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 14 • Product description OptiGun GA03-E... -
Page 17: Start-Up
V 02/22 Start-up Preparation for start-up Basic conditions When starting up the OptiGun GA03-E Enamel automatic gun, the follow- ing general conditions impacting the coating results must be taken into consideration: – Gun correctly connected – Gun control unit correctly connected –... - Page 18 V 02/22 5.5 bar 6.0 bar 6.5 bar Fig. 7: Connection instructions – overview Electrode rinsing air hose Conveying air hose Powder hose Supplementary air hose Gun cable Injector 16 • Start-up OptiGun GA03-E...
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Page 19: Initial Start-Up
If a malfunction occurs, 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: 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 di- ameter changes, the total air volume must be reset! 18 • Initial start-up OptiGun GA03-E... -
Page 21: Setting The Powder Quantity
If flat jet nozzles are used: Unscrew the threaded sleeve approx. 45°, so that the flat jet nozzle (or its extension) can be moved slightly Turn the flat jet nozzle to desired axis direction Initial start-up • 19 OptiGun GA03-E... -
Page 22: Functional Check
If all tests have been completed positively, the gun is ready for operation. If malfunctions take place, the cause of the fault can be located by the corresponding troubleshooting guide. Troubleshooting If a malfunction occurs, see section "Troubleshooting". Please consider also the control unit operating instructions. 20 • Initial start-up OptiGun GA03-E... -
Page 23: Start-Up And Powder Coating
Switch off the powder gun control unit. The adjustments for high voltage, powder output volume and electrode rinsing air remain stored. If working interruptions take place, such as lunch time, night time etc. disconnect the main compressed air supply Initial start-up • 21 OptiGun GA03-E... -
Page 25: Cleaning And Maintenance
Before cleaning the powder gun, switch off the control unit. The compressed air used for cleaning must be free of oil and water! Daily Blow off the outside of the gun and wipe, clean etc. Weekly Remove powder hose Cleaning and maintenance • 23 OptiGun GA03-E... -
Page 26: Cleaning The Spray Nozzle
– 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 24 • Cleaning and maintenance OptiGun GA03-E... -
Page 27: Maintenance
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 Ser- vice center! –... -
Page 28: Dismantling Procedure
V 02/22 Dismantling procedure Remove the threaded sleeve Remove the nozzle 26 • Cleaning and maintenance OptiGun GA03-E... - Page 29 V 02/22 Cleaning and maintenance • 27 OptiGun GA03-E...
- Page 30 V 02/22 28 • Cleaning and maintenance OptiGun GA03-E...
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Page 31: Assembling The Powder Gun
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! Cleaning and maintenance • 29 OptiGun GA03-E... -
Page 33: Troubleshooting
Fault Causes Corrective action Gun not connected Connect the gun H11 (Help code on control unit) Gun plug or gun cable Contact local Gema defective representative Compressed air not Connect the equip- The powder gun present ment to the com-... - Page 34 Gun cable (gun plug or Test the gun cable to workpiece gun connection) defec- on another control tive unit High voltage cascade Contact local Gema defective representative Electronic board in the Send in for repair OptiTronic defective The objects are not Check the grounding...
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Page 35: Spare Parts List
When using the spare parts from other manufacturers the explo- sion protection is no longer guaranteed. If any damage is caused by this use all warrantee claims become invalid! ► Only original Gema spare parts should be used! Spare parts list • 33 OptiGun GA03-E... -
Page 36: Optigun Ga03-E - Complete
– If the powder gun cable (4) is defective, it is to be completely sent in for repair! OptiGun GA03-E Enamel automatic gun – complete with Flat jet nozzle, polarity 1009 422 negative, incl. pos. 1-9 OptiGun GA03-E Enamel automatic gun – complete with Round jet nozzle, polari- 1009 421 ty negative, incl. -
Page 37: Powder Gun Body
V 02/22 Powder gun body OptiGun GA03-E shaft – complete, negative polarity, see spare parts list "Shaft" Powder tube – complete 1009 405# Hollow screw 1009 406 Gun fixture 1008 711 Ground plate 1011 457 SuperCorona connection 1012 089 Cylinder screw – M5x12 mm... -
Page 38: Shaft
V 02/22 Shaft Shaft OptiGun GA03-E – complete, polarity negative, incl. pos. 1-9 1009 410 Cascade – complete, negative polarity 1007 231 Shaft (without cascade) 1009 400 Sealing piece – complete (incl. pos. 6) 1008 690 Axial gasket 1008 687... -
Page 39: Gun Cable
Cylinder screw – M4x6 mm 1008 639 O-ring – Ø 9.5x1.5 mm 1008 665 O-ring – Ø 8.5x1 mm 1008 666 Fig. 12: Gun cable (complete) Pin allocation white green Bridge brown Shield Spare parts list • 37 OptiGun GA03-E... -
Page 40: Nozzle Combinations
► The extensions (150 mm/300 mm) may be connected TO ONLY ONE ADDITONAL extension (150 mm/300 mm), if necessary. 38 • Spare parts list OptiGun GA03-E... -
Page 41: Nozzle Combinations
V 02/22 Nozzle combinations Fig. 13: OptiGun GA03-E – Nozzle combinations Spare parts list • 39 OptiGun GA03-E... -
Page 42: Flat Jet Nozzle Nf29-E-60
405 728 Flat jet nozzle 1007 462# Electrode holder – complete (ETFE) 404 209# Electrode holder – complete (PTFE) 406 058# Contact ring 318 760# # Wearing part Fig. 14: Flat jet nozzle NF29-E-60° 40 • Spare parts list OptiGun GA03-E... -
Page 43: Angled Nozzles
1010 480# PA03-E-60° knee piece – complete 1010 479# Threaded sleeve 1010 476 Nozzle – see "OptiGun GA03-E – Nozzle combinations" PA03-E-60° knee piece – complete 1013 669# # Wearing part Fig. 15: Angled nozzles Spare parts list • 41... -
Page 44: Supercorona
PC08-469 (L=469 mm) – for extension 150 mm 1012 099# PC08-619 (L=619 mm) – for extension 300 mm 1012 101# Plug cap for SuperCorona connection – complete (not shown) 1001 037 # Wearing part Fig. 16: OptiGun GA03-E – SuperCorona 42 • Spare parts list OptiGun GA03-E... -
Page 45: Diffuser (Optispray Ap01.1-E Version)
Adaptor piece – complete, incl. pos. 6 1011 625 Tube connection – complete, incl. pos. 9 1011 632 O-ring – Ø 9x1.5 mm 1011 637 * Please indicate length # Wearing part Fig. 17: Diffuser (OptiGun GA03-E) Spare parts list • 43 OptiGun GA03-E...
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