Related Manuals for Gema OptiGun GA04-R
Summary of Contents for Gema OptiGun GA04-R
- Page 1 Rev. 00 1024 617 Operating instructions and Spare parts list Automatic gun OptiGun GA04-R 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
Start-up Preparation for start-up ..................23 Basic conditions ..................23 Gun connection flange ................23 Tool center point (TCP) ................24 Initial start-up ......................25 Functional check ....................25 General information ................. 25 OptiGun GA04-R Table of contents • 3... - Page 4 Requirements on personnel carrying out the work ........43 Disposal regulations ................43 Materials ....................43 Spare parts list Ordering spare parts ..................... 45 OptiGun GA04-R – complete ................46 Powder gun body ....................47 Gun rear piece ...................... 48 Gun cable ......................49 SuperCorona ......................50 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-R. 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-R... -
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-R...
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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. OptiGun GA04-R Product description • 9... -
Page 10: Reasonably Foreseeable Misuse
Reasonably foreseeable misuse – Coating of non grounded objects – Use of enameled powder – Incorrectly configured values for powder conveyance – Incorrectly configured values for electrode rinsing air – Use of moist powder 10 • Product description OptiGun GA04-R... -
Page 11: Technical Data
IP64 0102 II 2D Approvals PTB 23 ATEX 5002 ATTENTION The OptiGun GA04-R Automatic powder gun may only be connected to the following control units: ► OptiStar All-in-One CG22-C OptiStar CG20/-C MultiStar CG10*/-X* OptiStar CG08/-C The PowerBoost functionality is not available. -
Page 12: Structure
Flat jet nozzle NF50, complete (incl. electrode holder and threaded sleeve) – Multispray adapter (to NF20, NF25 and NF27) – Gun cleaning brush – Parts kit (cable ties with Velcro closure, quick-release coupling, fixing screw) – Operating manual * standard 12 • Product description OptiGun GA04-R... -
Page 13: Available Accessories
Gun extension 150, 300 and 500 mm – Angled nozzles 45°, 60° and 90° – Powder tube extensions (when using several powder hoses) For more information, see chapter "Spare parts list" on page 45! OptiGun GA04-R Product description • 13... -
Page 14: Supercorona
SuperCorona assembly 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. 14 • Product description OptiGun GA04-R... - Page 15 Rev. 00 12/23 OptiGun GA04-R Product description • 15...
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Page 16: Principle Of Operation
(see the operating manual of the gun control unit). The functions of the spray nozzles are described in the following sections. 16 • Product description OptiGun GA04-R... -
Page 17: Flat Jet Nozzle With Rinsed Central Electrode
Since powder can accumulate on the baffle plate, it must be rinsed with compressed air. This compressed air (S) (known as electrode rinsing air) can be adjusted on the gun control unit, depending on the gun type (see corresponding operating manual). OptiGun GA04-R Product description • 17... -
Page 18: Typical Properties - Characteristics Of The Functions
For more information, see chapter "Gun connection flange" on page 23! Connection for SuperCorona – Quick and simple connection to and disconnection from the SuperCorona • As standard, the gun is delivered without SuperCorona 18 • Product description OptiGun GA04-R... -
Page 19: Range Of Nozzles
Rev. 00 12/23 Range of nozzles Type of nozzle Application For more information, NF20 NF25 NF21 NF27 NF40 NF50 NS04 NS09 Legend: very well suited; well suited; suitable; conditionally suitable OptiGun GA04-R Product description • 19... - Page 20 Rev. 00 12/23 20 • Product description OptiGun GA04-R...
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Page 21: 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 OptiGun GA04-R Assembly / Connection • 21... - Page 22 Rev. 00 12/23 22 • Assembly / Connection OptiGun GA04-R...
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Page 23: Start-Up
Gun correctly connected – Gun control unit correctly connected – Corresponding power and compressed air supply available – Powder preparation and powder quality OK Gun connection flange Fig. 8: Hole pattern (for 4 screws M6x16 mm) OptiGun GA04-R Start-up • 23... -
Page 24: Tool Center Point (Tcp)
Rev. 00 12/23 Tool center point (TCP) Fig. 9: Angle X [mm] Y [mm] 90° 75° 60° 45° 30° 15° 0° -15° -30° -108 -45° -190 -60° -257 -75° -305 -90° -332 24 • Start-up OptiGun GA04-R... -
Page 25: 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 OptiGun GA04-R Start-up • 25... -
Page 26: 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 41. Please consider also the control unit operating instructions. 26 • Start-up OptiGun GA04-R... -
Page 27: 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 OptiGun GA04-R Operation • 27... - Page 28 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 28 • Operation OptiGun GA04-R...
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Page 29: 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. OptiGun GA04-R Operation • 29... - Page 30 Rev. 00 12/23 30 • Operation OptiGun GA04-R...
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Page 31: 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. OptiGun GA04-R Decommissioning / Storage • 31... -
Page 32: 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. 32 • Decommissioning / Storage OptiGun GA04-R... -
Page 33: 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. OptiGun GA04-R Maintenance / Repairs • 33... -
Page 34: 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 34 • Maintenance / Repairs OptiGun GA04-R... -
Page 35: 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 36 Rev. 00 12/23 Dismantling procedure Remove the threaded sleeve Remove the nozzle 36 • Maintenance / Repairs OptiGun GA04-R...
- Page 37 Rev. 00 12/23 OptiGun GA04-R Maintenance / Repairs • 37...
- Page 38 Rev. 00 12/23 38 • Maintenance / Repairs OptiGun GA04-R...
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Page 39: 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! OptiGun GA04-R Maintenance / Repairs • 39... - Page 40 Rev. 00 12/23 40 • Maintenance / Repairs OptiGun GA04-R...
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Page 41: 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 42 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 42 • Fault clearance OptiGun GA04-R...
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Page 43: 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 44 Rev. 00 12/23 44 • Disposal OptiGun GA04-R...
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Page 45: 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 46: Optigun Ga04-R - Complete
Negative polarity 1025 231 Positive polarity 1025 232 Gun body OptiGun GA04-R – complete, see Spare parts list "Flat jet nozzles" Flat jet nozzle NF20 – complete, see Spare parts list "Flat jet nozzles" Threaded sleeve – complete, see Spare parts list "Flat jet nozzles"... -
Page 47: Powder Gun Body
Sealing piece – complete, see Spare parts list "Gun rear piece" Rear piece – complete, see Spare parts list "Gun rear piece" Powder tube 1025 156# # Wearing part Fig. 12: OptiGun GA04-R – gun body OptiGun GA04-R Spare parts list • 47... -
Page 48: Gun Rear Piece
1025 282 Screw – M4x5 mm 1025 163 Threaded bolt – complete, incl. pos. 16 1025 182 O-ring – Ø 4x1.5 mm 1025 168 Compression spring 1023 265 Fig. 13: Gun rear piece 48 • Spare parts list OptiGun GA04-R... -
Page 49: 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. 14: Gun cable (complete) Pin allocation white green Bridge brown Shield OptiGun GA04-R Spare parts list • 49... -
Page 50: Supercorona
SuperCorona – complete 1025 121# SuperCorona connection – complete (pos. 2-4) 1025 131 SuperCorona connection 1025 128 Screw – M4x6 mm 1008 639 Retaining washer – M4 1025 111 # Wearing part Fig. 15: SuperCorona 50 • Spare parts list OptiGun GA04-R... -
Page 51: Angled Nozzles
1012 654 Flat jet nozzle NF27 – see Spare parts list "Flat jet nozzles" Round jet nozzle NS04 – see Spare parts list "Round jet nozzles"(not shown) # Wearing part Fig. 16: Angled nozzles OptiGun GA04-R Spare parts list • 51... -
Page 52: Nozzle Combinations - Overview (Wearing Parts)
NF20 1010 090 1007 229 NF21 1025 270 NF21 1025 265 1007 683 NF24 1025 273 NF24 1025 186 NF40 1025 116 NF40 1025 187 1008 326 NF50 1025 279 NF50 1025 185 52 • Spare parts list OptiGun GA04-R... -
Page 53: Round Jet Nozzles
Ø 24 mm 301 191 Ø 28 mm 405 736 302 031 NS12-11 Ø 32 mm 301 205 1010 922 NS12-11 Ø 50 mm 1000 346 1010 925 302 023 Ø 60 mm 1000 611 OptiGun GA04-R Spare parts list • 53... -
Page 54: Mini Nozzles
Ø 32 mm 1008 257 331 325 Ø 50 mm 345 822 Multi-spray adapter Suitable for the following flat jet nozzles: – NF20, NF25 and NF27 Multi-spray adapter 1003 634# # Wearing part Fig. 17: 54 • Spare parts list OptiGun GA04-R... -
Page 55: Gun Extensions
► The extensions (150 mm/300 mm) may be connected TO ONLY ONE ADDITONAL extension (150 mm/300 mm/500 mm). ► The coupling of more than two extensions is not subject to approval. OptiGun GA04-R Spare parts list • 55... -
Page 57: Index
Standards, European ........10 Start-up ............23 Storage ............31 Storage conditions ........... 31 Guidelines, European ........10 TCP ..............24 Intended use ............9 Technical Data ..........11 Tool center point ..........24 Maintenance ............. 33 OptiGun GA04-R Index • 57... - Page 58 Rev. 00...
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