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Gema OptiGun 2-A Translation Of The Original Operating Instructions

Automatic powder gun
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Operating instructions and spare parts list
OptiGun 2-A(X)
Automatic powder gun
(GA02 type)
0102
II 2 D
Translation of the original operating instructions

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Summary of Contents for Gema OptiGun 2-A

  • Page 1 Operating instructions and spare parts list OptiGun 2-A(X) Automatic powder gun (GA02 type) 0102 II 2 D 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 issue. Gema Switzerland GmbH makes no representations or warranties with respect to the con- tents or use of this publication, and reserves the right to revise this publi- cation and make changes to its content without prior notice.

  • Page 3: Table Of Contents

    About this manual General information ....................11 Function description Field of application ....................13 OptiGun 2-A(X) Automatic powder gun - overview ..........13 Typical characteristics ................13 Scope of delivery....................14 Structure and function OptiGun 2-A(X) Automatic powder gun ..............15 High voltage generation ..................
  • Page 4 General information ....................39 Spare parts list Ordering spare parts ..................... 41 OptiGun 2-A Automatic powder gun - complete ........... 42 OptiGun 2-A Automatic powder gun - gun body........... 43 OptiGun 2-A Automatic powder gun - shaft ............44 OptiGun 2-AX Automatic powder gun - complete ..........45 OptiGun 2-AX Automatic powder gun - gun body ..........

  • Page 5: General Safety Regulations

    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-A(X) Automatic powder gun (GA02 type). These safety regulations must be read and understood before the OptiGun 2-A(X) Automatic powder gun (GA02 type) 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) Automatic powder gun (GA02 type) has been set up and wired according to the guidelines for machinery (2006/42 EG). EN 60204-1 (ma- chine safety) must also be observed.

  • Page 7: Safety Conscious Working

    Safety precautions specified by local legislation must be observed! 8. Only original Gema spare parts should be used, because the ex- plosion protection will also be preserved that way. Damage caused by other parts is not covered by guarantee.

  • 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-A(X)

  • Page 9: Safety Requirements For Electrostatic Powder Coating

    Damage caused by other parts is not covered by guarantee. Repairs must only be carried out by specialists or in Gema workshops. Unauthorized conversions and modifications may lead to injury or dam- age to machinery. The Gema Switzerland GmbH guarantee would no longer be valid.

  • Page 10: A Summary Of The Rules And Regulations

    14. For your own safety, only use accessories and attachments listed in the operating instructions. The use of other parts can lead to risk of injury. Only original Gema replacement parts should be used. 15. Repairs must only be carried out by specialists and under no cir- cumstances should they be carried out in the operating area.

  • Page 11: Special Security Measures

    Before starting up the plant a check must be made that no for- eign objects are in the booth or in the ducting (input and ex- haust air) It must be observed, that all components are grounded accord- ing to the local regulations, before start-up General safety regulations • 9 OptiGun 2-A(X)
  • Page 12 V 12/13 10 • General safety regulations OptiGun 2-A(X)

  • Page 13: About This Manual

    Information about the function mode of the individual system components - booth, gun control unit, manual gun or powder injector - you will find in the corresponding enclosed documentations. About this manual • 11 OptiGun 2-A(X)

  • Page 15: Function Description

    V 12/13 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 12/13 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)

  • Page 17: Structure And Function

    V 12/13 Structure and function OptiGun 2-A(X) Automatic powder gun OptiGun 2-A(X) Automatic powder gun Spray nozzle Powder gun attachment Threaded sleve Powder tube Shaft with removable high voltage Clamping sleeve cascade SuperCorona ring Structure and function • 15 OptiGun 2-A(X)

  • 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 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 strength depends on the powder and its sintering ability. 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)

  • Page 21: Technical Data

    1.63 pounds with SuperCo- rona ring) OptiGun 2-AX weight (depending on gun length) Attention: The OptiGun 2-A(X) Automatic powder gun may only be connected to the following control units: OptiStar CG07, OptiStar CG06, OptiTronic CG02 , OptiTronic CG03 and MultiTronic CG04! Technical Data •...

  • Page 23: Start-Up

    V 12/13 Start-up Connecting the OptiGun 2-A(X) Automatic powder gun 1. Connect the gun plug to gun control unit (see the gun control unit operating instructions) 2. Connect the rinsing air hose of the control unit to the gun 3. Connect the powder hose from the gun to injector...

  • Page 24: Troubleshooting

    If all tests ran positive, the gun is ready for application. If malfunctions take place, the cause of the fault can be located by the corresponding troubleshooting guide. 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)

  • Page 25: Operation

    The operation mode of the injector and the effect of the supplementary air are described in the corresponding injector operating instructions. Operation • 23 OptiGun 2-A(X)

  • 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)

  • Page 27: Maintenance

    Maintenance General information Note: 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! Attention: All unauthorized conversions and modifications to the OptiGun 2- A(X) Automatic powder gun are forbidden for safety reasons and...

  • Page 29: Cleaning And Repair

    V 12/13 Cleaning and repair Cleaning the gun Attention: Before cleaning the OptiGun 2-A(X) automatic powder gun, the con- trol unit must be switched off! The compressed air used for cleaning must be free from oil and wa- ter! Note:...

  • Page 30: Dismantling The Powder Gun

    It is only to be dismantled so far, as the desired part is accessible! Attention: 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 12/13 Dismantling procedure (cont.) Cleaning and repair • 29 OptiGun 2-A(X)
  • Page 32 V 12/13 Dismantling procedure (cont.) 30 • Cleaning and repair OptiGun 2-A(X)
  • Page 33 V 12/13 Dismantling procedure (cont.) Cleaning and repair • 31 OptiGun 2-A(X)
  • Page 34 V 12/13 Dismantling procedure (cont.) 32 • Cleaning and repair OptiGun 2-A(X)
  • Page 35 V 12/13 Dismantling procedure (cont.) OptiGun 2-A(X) Automatic powder gun with extension Cleaning and repair • 33 OptiGun 2-A(X)

  • 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 unproblemat- ic. The repair of the gun cable connection, however, may only be made by an authorized Gema service center. Ask your Gema Switzerland GmbHency! 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

    The wedge of the electrode holder is worn down On nozzles with deflector, the wedge of the electrode holder can be worn down. In this case, the electrode holder is to be replaced! 36 • Cleaning and repair OptiGun 2-A(X)

  • Page 39: Cleaning The Supercorona

    In the case of a disassembly of the SuperCorona ring, the SuperCorona connection must be cleaned and closed with the corresponding plug cap (order no. 1001 037). This prevents powder deposits and contact prob- lems on SuperCorona connection. SuperCorona plug cap Cleaning and repair • 37 OptiGun 2-A(X)

  • Page 41: Troubleshooting Guide

    Workpiece not properly Check the grounding powder, high voltage is grounded available, powder does not adhere to work- piece Attention: Additional error descriptions are to be found also in the gun control unit operating instructions! Troubleshooting guide • 39 OptiGun 2-A(X)
  • Page 42 V 12/13 40 • Troubleshooting guide OptiGun 2-A(X)

  • Page 43: Spare Parts List

    Ø 8/6 mm, 8 mm outside diameter (o/d) / 6 mm inside diameter (i/d) WARNING! Only original Gema spare parts should be used, because the explo- sion protection will also be preserved that way. The use of spare parts from other manufacturers will invalidate the Gema guarantee conditions! Spare parts list •...

  • Page 44: Optigun 2-A Automatic Powder Gun - Complete

    If the powder gun cable is defective, it is to be completely sent in for repair! 393 568 OptiGun 2-A Automatic powder gun - complete, negative polarity, incl. pos. 1-6 393 576 OptiGun 2-A Automatic powder gun - complete, positive polarity, incl. pos. 1-6...

  • Page 45: Optigun 2-A Automatic Powder Gun - Gun Body

    V 12/13 OptiGun 2-A Automatic powder gun - gun body 1 OptiGun 2-A shaft - complete, negative polarity (see "Shaft" spare parts list) 393 665 OptiGun 2-A shaft - complete, positive polarity (see "Shaft" spare parts list) 393 673 2 Powder tube - complete...

  • Page 46: Optigun 2-A Automatic Powder Gun - Shaft

    V 12/13 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 47: 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 • 45 OptiGun 2-A(X)

  • Page 48: 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, without pos. 4 OptiGun 2-AX - 1650...

  • Page 49: Gun Cable

    Stuffing box - PG7 with kink protection 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 • 47 OptiGun 2-A(X)

  • Page 50: Nozzle Combinations - Nf08

    9 Electrode holder, incl. pos. 5 (round jet central electrode) 382 914# # Wearing part Note: Further nozzle versions are described in the "System overview" spare parts list! OptiGun 2-A(X) Automatic powder gun - nozzle combination 48 • Spare parts list OptiGun 2-A(X)

  • Page 51: Nozzle Combinations - Nf18-M

    2 Flat jet nozzle 1004 527# 3 Threaded sleeve 379 166 # Wearing part Note: Further nozzle versions are described in the "System overview" spare parts list! OptiGun 2-A(X) Automatic powder gun - nozzle combination Spare parts list • 49 OptiGun 2-A(X)

  • Page 52: Nozzle Combinations - Ns03

    4.5 Deflector plate - Ø 50 mm (not shown) 302 023# # Wearing part Note: Further nozzle versions are described in the "System overview" spare parts list! OptiGun 2-A(X) Automatic powder gun - nozzle combination 50 • Spare parts list OptiGun 2-A(X)

  • Page 53: Optigun 2-A(X) Automatic Powder Gun - Supercorona

    V 12/13 OptiGun 2-A(X) Automatic powder gun - SuperCorona SuperCorona - complete, 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 54: Optigun 2-A(X) - System Overview

    V 12/13 OptiGun 2-A(X) - system overview 52 • Spare parts list OptiGun 2-A(X)
  • Page 55 V 12/13 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...

This manual is also suitable for:

Optigun 2-axGa02

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