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Summary of Contents for ITW Gema OptiGun 2-AE1
- Page 1 Operating instructions and spare parts list OptiGun 2-AE1 Enamel automatic gun (GA02-E1 type) 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
A summary of the rules and regulations ............8 Product specific security measures ..............10 About this manual General information ....................11 Function description Field of application ....................13 OptiGun 2-AE1 Enamel automatic gun..............13 Typical characteristics...................13 Scope of delivery ....................14 OptiGun 2-AE1 Enamel automatic gun..............14 Structure....................14 High voltage generation ................14 Circuit .......................15... - Page 4 General information ....................33 Spare parts list Ordering spare parts..................... 35 OptiGun 2-AE1 Enamel automatic gun - spare parts list ........36 Remarks ....................36 OptiGun 2-AE1 Enamel automatic gun - gun body ..........37 OptiGun 2-AE1 Enamel automatic gun - shaft ............. 38 OptiGun 2-AE1 Enamel automatic gun - gun cable ..........
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Page 5: General Safety Regulations
V 03/06 General safety regulations This chapter sets out the fundamental safety regulations that must be fol- lowed by the user and third parties using the OptiGun 2-AE1 Enamel automatic gun. These safety regulations must be read and understood before the OptiGun 2-AE1 Enamel automatic 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-AE1 Enamel automatic gun has been set up and wired according to the guide- lines for machinery (98/37 EG). EN 60204-1 (machine safety) must also be observed. -
Page 7: Safety Conscious Working
3. For dangerous materials, the employer has to provide an operat- ing instructions manual for specifying the dangers arising for hu- mans and environment by handling dangerous materials, as well General safety regulations • 5 OptiGun 2-AE1 Enamel automatic gun... -
Page 8: Notes On Special Types Of Hazard
The appropriate measuring devices must be kept ready in the workplace in order to check the earthing. 6 • General safety regulations OptiGun 2-AE1 Enamel automatic gun... -
Page 9: Safety Requirements For Electrostatic Powder Coating
Repairs must only be carried out by specialists or in ITW-Gema work- shops. 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 Electric- ity”) Guidelines for electrostatic coating with synthetic pow- VDMA 24371 - Part 1 General requirements - Part 2 Examples of use 8 • General safety regulations OptiGun 2-AE1 Enamel automatic gun... - Page 11 Beuth Verlag GmbH, Burgrafenstrasse 4, 1000 Berlin 30 General secretariat, Rue Bréderode 2, B-1000 Bruxelles, or the appro- priate national committee VDE Verlag GmbH, Bismarckstrasse 33, 1000 Berlin 12 General safety regulations • 9 OptiGun 2-AE1 Enamel automatic gun...
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Page 12: Product Specific Security Measures
(input and ex- haust air) It must be observed, that all components are grounded accord- ing to the local regulations, before start-up 10 • General safety regulations OptiGun 2-AE1 Enamel automatic gun... -
Page 13: About This Manual
General information This operating manual contains all the important information which you require for the working with the OptiGun 2-AE1 Enamel automatic gun. It will safely guide you through the start-up process and give you refer- ences and tips for the optimal use of your new powder coating system. -
Page 15: Function Description
V 03/06 Function description Field of application The OptiGun 2-AE1 Enamel automatic gun is built exclusively for electro- static coating with anorganic, non-flammable enamel powders. Any other use is considered as non-conform. The manufacturer is not responsible for any damage resulting from this - the risk for this is assumed by the... -
Page 16: Scope Of Delivery
(approx. 100 kV). The high voltage is now fed to the electrode within the spray nozzle (e). OptiGun 2-AE1 Enamel automatic gun - high voltage generation 14 • Function description OptiGun 2-AE1 Enamel automatic gun... -
Page 17: Circuit
V 03/06 Circuit The OptiGun 2-AE1 Enamel automatic gun is switched on and off by the gun control unit. The control unit operates the low voltage, the powder flow and the rinsing air to the gun. Powder flow and rinsing air... -
Page 18: Flat Jet Nozzle With Vented Central Electrode
The rinsing air adjustment on the control module is explained in the cor- responding operating manual. High voltage Rinsing air Round jet nozzle with deflector and vented central electrode 16 • Function description OptiGun 2-AE1 Enamel automatic gun... -
Page 19: Technical Data
In these systems, the danger of an electric shock or explosive energy does not exist. Attention: The OptiGun 2-AE1 Enamel automatic gun may only be connected to the OptiTronic CG02/CG03, MultiTronic CG04 and OptiStar CG06 control units! Technical data • 17... -
Page 21: Start-Up And Operation
73 PSI Control unit OptiTronic 1.1 IN Gun 2 Input 24 VDC 2,0 AT Gun 1 OptiGun 2-AE1 Enamel automatic gun - connecting guide Rinsing air hose Supplementary air hose Powder hose Conveying air hose Gun cable Injector Function check General information 1. -
Page 22: Troubleshooting Guide
5. Point the gun into the booth and press the gun switch Select the electrode rinsing 1. Select the correct electrode rinsing (setting range 0-2,8 Nm³/h, default value 0,2 Nm³/h) 2. Adjust the powder cloud to a test object 20 • Start-up and operation OptiGun 2-AE1 Enamel automatic gun... -
Page 23: Powder Coating
(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- Start-up and operation • 21 OptiGun 2-AE1 Enamel automatic gun... -
Page 25: Maintenance And Cleaning
Maintenance and cleaning Note: Regular and conscientious maintenance increases the service life of the OptiGun 2-AE1 Enamel automatic gun and provides for a longer continuous coating quality! Daily maintenance The OptiGun 2-AE1 Enamel automatic gun must be cleaned daily and thoroughly (see in addition the chapter "Cleaning and repair"). -
Page 27: Cleaning And Repair
Cleaning and repair Cleaning the gun Attention: Before cleaning the OptiGun 2-AE1 Enamel automatic 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 28: Dismantling The Gun
It is only to be dismantled so far, as the desired part is accessible! Attention: Before dismantling the OptiGun 2-AE1 Enamel automatic gun, the control unit must be switched off and the gun plug disconnected! Components OptiGun 2-AE1 Enamel automatic gun - components... - Page 29 V 03/06 Dismantling procedure (cont.) Cleaning and repair • 27 OptiGun 2-AE1 Enamel automatic gun...
- Page 30 V 03/06 Dismantling procedure (cont.) 28 • Cleaning and repair OptiGun 2-AE1 Enamel automatic gun...
- Page 31 V 03/06 Dismantling procedure (cont.) Cleaning and repair • 29 OptiGun 2-AE1 Enamel automatic gun...
- Page 32 V 03/06 Dismantling procedure (cont.) 30 • Cleaning and repair OptiGun 2-AE1 Enamel automatic gun...
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Page 33: Assembling The Powder Gun
Dismantling procedure (cont.) Assembling the powder gun The assembling of the OptiGun 2-AE1 Enamel automatic gun is to be carried out in the reverse order to that shown above. It is to be noted, that the powder tube is pushed in up to the stop. -
Page 34: Cleaning The Spray Nozzles
The wedge of the electrode holder is worn On the nozzle with deflector, the wedge of the electrode holder can be worn. In this case, the electrode holder is to be replaced! 32 • Cleaning and repair OptiGun 2-AE1 Enamel automatic gun... -
Page 35: Troubleshooting Guide
Check the grounding powder, high voltage is grounded available, powder does not adhere to work- piece Note: Additional error descriptions are to be found also in the corre- sponding control unit operating instructions! Troubleshooting guide • 33 OptiGun 2-AE1 Enamel automatic gun... -
Page 37: Spare Parts List
WARNING! Only original ITW-Gema spare parts should be used, because the hazardous location approval will be preserved that way! The use of spare parts from other manufacturers will invalidate the ITW Gema guarantee conditions! Spare parts list • 35 OptiGun 2-AE1 Enamel automatic gun... -
Page 38: Optigun 2-Ae1 Enamel Automatic Gun - Spare Parts List
If the powder gun cable is defective, it is to be completely sent in for repair! OptiGun 2-AE1 Enamel automatic gun - complete, polarity negative, incl. pos. 1-6 406 732 1 OptiGun 2-AE1 gun body, see "Gun body" spare parts list 2 Round jet nozzle - complete, see "Nozzle combinations"... -
Page 39: Optigun 2-Ae1 Enamel Automatic Gun - Gun Body
OptiGun 2-AE1 Enamel automatic gun - gun body OptiGun 2-AE1 gun body - complete, polarity negative 406 724 1 OptiGun 2-AE1 shaft - complete, negative polarity (see spare parts list "Shaft") 2 Powder tube GA02-E1 - complete, Ø 9 mm 1001 289#... -
Page 40: Optigun 2-Ae1 Enamel Automatic Gun - Shaft
V 03/06 OptiGun 2-AE1 Enamel automatic gun - shaft OptiGun 2-AE1 shaft - complete, polarity negative 393 665 1 Cascade - complete, negative polarity 393 703 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 41: Optigun 2-Ae1 Enamel Automatic Gun - Gun Cable
V 03/06 OptiGun 2-AE1 Enamel automatic gun - gun cable Gun cable - complete, 11 m 393 800 393 819 Gun cable - complete, 15 m 393 827 Gun cable - complete, 20 m 395 935 Gun cable - complete, 30 m... -
Page 42: Optigun 2-Ae1 Enamel Automatic Gun - Nozzle Combinations
V 03/06 OptiGun 2-AE1 Enamel automatic gun - nozzle combi- nations 1 Flat jet nozzle NF15-E - complete 1002 255# 2 Fixation piece NF15-E - complete 1002 253# 3 Flat jet nozzle set (without pos. 5.1) 404 225# 4 Contact ring... -
Page 43: Optigun 2-Ae1 Enamel Automatic Gun - Nozzle Combinations
V 03/06 OptiGun 2-AE1 Enamel automatic gun - nozzle combi- nations OptiGun 2-AE1 Enamel automatic gun - nozzle combinations Spare parts list • 41 OptiGun 2-AE1 Enamel automatic gun... -
Page 44: Optigun 2-Ae1 Enamel Automatic Gun - Angled Nozzle
V 03/06 OptiGun 2-AE1 Enamel automatic gun - angled nozzle A Angled nozzle PA02-E-60° - complete 1001 299# 1 Tensioning screw - small 405 876 2 Angled body PA02-E-60° - complete (incl. pos. 7) 1001 298 3 Flat jet nozzle set (incl. pos. 4, 5 and 6, without pos. 5.1) -
Page 45: Optigun 2-Ae1 Enamel Automatic Gun - Supercorona
V 03/06 OptiGun 2-AE1 Enamel automatic gun - SuperCorona A SuperCorona for round jet nozzle 394 246# SuperCorona PC01-277 - retrofit set (L=277 mm) SuperCorona PC01-427 - retrofit set (L=427 mm) 394 270# SuperCorona PC01-577 - retrofit set (L=577 mm)
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