Related Manuals for Gema OptiGun GA04-E
Summary of Contents for Gema OptiGun GA04-E
- Page 1 Rev. 00 1024 616 Operating instructions and Spare parts list Enamel automatic gun OptiGun GA04-E 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 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.
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Page 3: Table Of Contents
Assembly / Connection Connecting the gun ....................19 Start-up Preparation for start-up ..................21 Basic conditions ..................21 Initial start-up ......................22 Functional check ....................22 General information ................. 22 Troubleshooting ..................23 Table of contents • 3 OptiGun GA04-E... - Page 4 Requirements on personnel carrying out the work ........41 Disposal regulations ................41 Materials ....................41 Spare parts list Ordering spare parts ..................... 43 OptiGun GA04-E – complete ................44 Powder gun body ....................45 Gun rear piece ...................... 46 Gun cable ......................47 SuperCorona ......................48 Angled nozzles .....................
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Page 5: About These Instructions
General information This operating manual contains all the important information that is needed to operate the OptiGun GA04-E. 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. -
Page 6: Structure Of Safety Notes
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 OptiGun GA04-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. - Page 8 ► 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. 8 • Safety OptiGun GA04-E...
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Page 9: Product Description
European directives and complies with the following standards. The product is suitable for the intended purpose and can be used in the appropriate areas. For further information, also refer to the enclosed Declaration of Conformity. Product description • 9 OptiGun GA04-E... -
Page 10: Reasonably Foreseeable Misuse
Reasonably foreseeable misuse – Coating of non grounded objects – Use of metallic or organic powder – Incorrectly configured values for powder conveyance – Incorrectly configured values for electrode rinsing air – Use of moist powder 10 • Product description OptiGun GA04-E... -
Page 11: Technical Data
IP64 0102 II 2D Approvals PTB 23 ATEX 5002 ATTENTION The OptiGun GA04-E Automatic powder gun may only be connected to the following control units: ► OptiStar All-in-One CG22-C OptiStar CG20 MultiStar CG10* OptiStar CG08 The PowerBoost functionality is not available. -
Page 12: Structure
Round jet nozzles – Gun extension 150 and 300 mm – Angled nozzles 45°, 60° and 90° – Collision protection (see applicable operating instructions) For more information, see Spare parts list "Spare parts list"! 12 • Product description OptiGun GA04-E... -
Page 13: Supercorona
– see Spare parts list "SuperCorona" Before fitting the SuperCorona, make sure that the connection and the plug-in connector are free from grease and powder, otherwise the electric contact cannot be guaranteed. Product description • 13 OptiGun GA04-E... - Page 14 Rev. 00 12/23 14 • Product description OptiGun GA04-E...
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Page 15: Principle Of Operation
(see the operating manual of the gun control unit). The functions of the spray nozzles are described in the following sections. Product description • 15 OptiGun GA04-E... -
Page 16: Flat Jet Nozzle With Rinsed Central Electrode
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 16 • Product description OptiGun GA04-E... -
Page 17: Connection For Supercorona
Rev. 00 12/23 Connection for SuperCorona – Quick and simple connection to and disconnection from the SuperCorona • As standard, the gun is delivered without SuperCorona Product description • 17 OptiGun GA04-E... - Page 18 Rev. 00 12/23 18 • Product description OptiGun GA04-E...
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Page 19: Assembly / Connection
The compressed air must be free of oil and water! Fig. 7: Connection instructions – overview Gun cable Conveying air hose Powder hose OptiStar Control unit Electrode rinsing air hose Injector Supplementary air hose Power supply Grounding connection Assembly / Connection • 19 OptiGun GA04-E... - Page 20 Rev. 00 12/23 20 • Assembly / Connection OptiGun GA04-E...
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Page 21: Start-Up
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 Start-up • 21 OptiGun GA04-E... -
Page 22: Initial Start-Up
Adjust the desired coating parameters (powder volume, total air and high voltage) on the gun control unit (see also the control unit operating instructions) Adjust the electrode rinsing air on the control unit dependent upon the nozzle used 22 • Start-up OptiGun GA04-E... -
Page 23: Troubleshooting
If malfunctions take place, the cause of the fault can be located by the corresponding troubleshooting guide. Troubleshooting If a malfunction occurs, see chapter "Fault clearance" on page 39. Please consider also the control unit operating instructions. Start-up • 23 OptiGun GA04-E... - Page 24 Rev. 00 12/23 24 • Start-up OptiGun GA04-E...
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Page 25: Operation
Setting the total air volume 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 correct powder cloud too little total air Operation • 25 OptiGun GA04-E... - Page 26 To achieve maximum efficiency, we recommend using the lowest possible powder volume where possible! Check fluidization of the powder in the powder container Point the gun into the booth, switch the gun on and visually check the powder output 26 • Operation OptiGun GA04-E...
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Page 27: Setting The Electrode Rinsing Air
(deflector plate, flat jet nozzle) ≈ 0.1 Nm³/h ≈ 0.5 Nm³/h too much electrode rinsing air If in this display level is no operation for 3 seconds, the dispay will automatically switch back to main default display level. Operation • 27 OptiGun GA04-E... - Page 28 Rev. 00 12/23 28 • Operation OptiGun GA04-E...
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Page 29: Decommissioning / Storage
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. Decommissioning / Storage • 29 OptiGun GA04-E... -
Page 30: 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 OptiGun GA04-E... -
Page 31: Maintenance / Repairs
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. Maintenance / Repairs • 31 OptiGun GA04-E... -
Page 32: 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 32 • Maintenance / Repairs OptiGun GA04-E... -
Page 33: Interval
Except for the replacement of possible defective parts, there are very few repairs 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! Dismantling the gun... - Page 34 Phillips screwdriver #2 ATTENTION Incorrectly assembled parts may cause malfunctions or defects ► Observe the tightening torques when assembling! ► Use the appropriate torque wrench! Dismantling procedure Remove the threaded sleeve Remove the nozzle 34 • Maintenance / Repairs OptiGun GA04-E...
- Page 35 Rev. 00 12/23 Maintenance / Repairs • 35 OptiGun GA04-E...
- Page 36 Rev. 00 12/23 36 • Maintenance / Repairs OptiGun GA04-E...
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Page 37: Assembling The Powder Gun
The assembling of the gun is to be carried out in the reverse order to that shown above. ATTENTION Incorrectly assembled parts may cause malfunctions or defects ► Observe the tightening torques when assembling! ► Use the appropriate torque wrench! Maintenance / Repairs • 37 OptiGun GA04-E... - Page 38 Rev. 00 12/23 38 • Maintenance / Repairs OptiGun GA04-E...
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Page 39: Fault Clearance
Gun not connected Connect the gun H11 (Help code on control unit) Gun plug or gun cable defective Contact local Gema representative Powder does not adhere to High voltage and current Check the high voltage and object, although the gun... - Page 40 Bend or damage to air lines to Check air lines to injector injector Cartridge/insert sleeve in the Replace or insert it injector worn or not inserted Fluidization not running See above 40 • Fault clearance OptiGun GA04-E...
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Page 41: Disposal
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. - Page 42 Rev. 00 12/23 42 • Disposal OptiGun GA04-E...
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Page 43: Spare Parts List
Ø 8/6 mm, 8 mm outside diameter (o/d) / 6 mm inside diameter (i/d) WARNING Use of non-original Gema spare parts Use of Non-Gema replacement spare parts may invalidate some or all approval certificates and accreditations; and the user assumes all explosion risks associated with use of these parts. Use of these replacement spare parts may void any and all warranty claims. -
Page 44: Optigun Ga04-E - Complete
– If the powder gun cable is defective, it is to be completely sent in for repair! OptiGun GA04-E Automatic gun – complete with flat jet nozzle, polarity negative, 1025 224 incl. pos. 1-14 (without pos. 4, 5, 6) OptiGun GA04-E Automatic gun – complete with round jet nozzle, polarity 1025 223 negative, incl. -
Page 45: Powder Gun Body
"Gun rear piece" Rear piece – complete, see Spare parts list "Gun rear piece" Hollow screw 1025 129# Powder tube – complete 1009 405# # Wearing part Fig. 11: OptiGun GA04-E – gun body Spare parts list • 45 OptiGun GA04-E... -
Page 46: Gun Rear Piece
1025 101 Ground plate 1025 282 Screw – M4x5 mm 1025 163 Threaded bolt – complete, incl. pos. 14 1025 182 O-ring – Ø 4x1.5 mm 1025 168 Fig. 12: Gun rear piece 46 • Spare parts list OptiGun GA04-E... -
Page 47: Gun Cable
1025 174 Screw – M4x6 mm 1008 639 O-ring – Ø 9.5x1.5 mm 1025 166# O-ring – Ø 7.5x1.5 mm 1025 165# Fig. 13: Gun cable (complete) Pin allocation white green Bridge brown Shield Spare parts list • 47 OptiGun GA04-E... -
Page 48: Supercorona
SuperCorona connection – complete (pos. 1-3) 1025 130 SuperCorona connection 1025 150 Screw – M4x14 mm 1025 161 Retaining washer – M4 1025 111 # Wearing part Fig. 14: SuperCorona Fig. 15: SuperCorona – connection 48 • Spare parts list OptiGun GA04-E... -
Page 49: Angled Nozzles
1010 479 # PA03-E-45° knee piece – complete 1013 669 # Threaded sleeve 1010 476 Flat jet nozzle – See chapter "Flat jet nozzles" on page 50. # Wearing part Fig. 16: Angled nozzles Spare parts list • 49 OptiGun GA04-E... -
Page 50: Nozzle Combinations - Overview (Wearing Parts)
A + B + C Adaptor Threaded sleeve NF28-E 404 225 NF28-E 404 128 NF29-E-60° 1007 465 NF29-E-60° 318 760 404 209 1009 429 1007 462 405 728 NF47-E-60° 1022 059 NF47-E-60° 1022 058 50 • Spare parts list OptiGun GA04-E... -
Page 51: Round Jet Nozzles
Lever forces when coupling more than two extensions can damage the gun. ► The extensions (150 mm/300 mm) may be connected TO ONLY ONE ADDITONAL extension (150 mm/300 mm). ► The coupling of more than two extensions is not subject to approval. Spare parts list • 51 OptiGun GA04-E... - Page 52 Rev. 00 12/23 52 • Spare parts list OptiGun GA04-E...
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Page 53: Index
Shutdown ............29 Spare parts list ..........43 Standards, European ........10 Start-up ............21 Guidelines, European ........10 Storage ............29 Storage conditions ........... 29 Intended use ............9 Technical Data ..........11 Maintenance ............. 31 Index • 53 OptiGun GA04-E... - Page 54 Rev. 00...
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