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Summary of Contents for Gema OptiGun GA03
- Page 1 V 12/13 Operating instructions and spare parts list OptiGun GA03 Automatic powder gun 0102 II 2D Order no. 1010 772 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
Table of contents General safety regulations Safety symbols (pictograms) ................... 3 Proper use ....................... 3 Product-specific safety measures ................4 OptiGun GA03 automatic powder gun ............4 About this manual General information ....................5 Product description Field of application ....................7 Utilization .................... - Page 4 OptiGun GA03-X – complete ................39 OptiGun GA03-X – gun body ................40 OptiGun GA03-X – Extension tube ..............41 OptiGun GA03-X – options when using several powder hoses ......42 Gun cable ......................43 OptiGun GA03 – SuperCorona ................44 OptiGun GA03 –...
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Page 5: General Safety Regulations
V 12/13 General safety regulations This chapter sets out the fundamental safety regulations that must be followed by the user and third parties using the OptiGun GA03 Automatic powder gun. These safety regulations must be read and understood before the OptiGun GA03 is put into operation. -
Page 6: Product-Specific Safety Measures
OptiGun GA03 automatic powder gun The OptiGun GA03 Automatic powder gun is a constituent part of the system and is thus integrated into the safety system of the plant. If it is to be used in a manner outside the scope of the safety concept, then corresponding measures must be taken. -
Page 7: About This Manual
General information This operating manual contains all the important information you require for the working with the OptiGun GA03 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 9: Product Description
V 12/13 Product description Field of application The OptiGun GA03 Automatic powder gun is built exclusively for the electrostatic coating with organic powders. Any other use is considered non-compliant. The manufacturer shall not be liable for damage resulting from such use; the user bears sole responsibility for such actions. -
Page 10: Technical Data
Processible powders OptiGun GA03 Plastic powder Metallic powder Enamel powder WARNING: The OptiGun GA03 Automatic powder gun may only be connected to the following control units: OptiStar CG08, OptiStar CG09, OptiStar CG12 and OptiStar CG13! 8 • Product description OptiGun GA03... -
Page 11: Design And Function
Shaft with removable high voltage Clamp ring cascade SuperCorona ring Scope of delivery OptiGun GA03 Automatic powder gun with gun cable (20 m)*, negative polarity Electrode rinsing air hose (20 m)* Flat jet nozzle NF20, complete (incl. electrode holder) Cable tie with Velcro closure... -
Page 12: Supercorona Ring
V 12/13 SuperCorona ring Field of application The SuperCorona is an optional extension for the OptiGun GA03 Automatic powder 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 requirements. - Page 13 V 12/13 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...
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Page 14: Principle Of Function
(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... -
Page 15: Spray Nozzle
Since powder can accumulate on the baffle plate, it must be rinsed with compressed air. The electrode rinsing air cleaning ability depends on the powder and its sintering ability. The electrode rinsing air adjustment on the gun control unit is described in the corresponding operating manual. Product description • 13 OptiGun GA03... -
Page 16: Typical Properties - Characteristics Of The Functions
Easily removable cascade because free of grease, with integrated current limiting resistors Powder hose quick release connection Quick and simple connection and disconnection of powder hose Connection for SuperCorona Ring Quick and simple connection and disconnection of SuperCorona ring 14 • Product description OptiGun GA03... -
Page 17: Commissioning
V 12/13 Commissioning Preparation for start-up Basic conditions When starting up the OptiGun GA03 Automatic powder gun, 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... - Page 18 V 12/13 5.5 bar 6.0 bar 6.5 bar OptiGun GA03 Automatic powder gun - Connection instructions - overview Electrode rinsing air hose 4 Supplementary air hose Powder hose 5 Conveying air hose Gun cable 6 Injector 16 • Commissioning OptiGun GA03...
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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! NOTE: The remainder of the start-up procedure for the OptiGun GA03 Automatic powder gun is explicitly described in the operating instructions for the OptiStar gun control unit (chapter "Initial 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 diameter changes, the total air volume must be reset! 18 • Initial start-up OptiGun GA03... -
Page 21: Setting The Powder Quantity
3. Unscrew the threaded sleeve approx. 45°, so that the flat jet nozzle (or its extension) can be moved slightly 4. Turn the flat jet nozzle to desired axis direction 5. Tighten the threaded sleeve firmly again Initial start-up • 19 OptiGun GA03... -
Page 22: Functional Check
3. Switch on the gun control unit 4. Adjust the coating parameters or select one of the programs. Check by observing the LED displays 5. The workpieces can be coated now 20 • Initial start-up OptiGun GA03... -
Page 23: Shut-Down
1. Switch off the powder gun control unit. The adjustments for high voltage, powder output volume and electrode rinsing air remain stored. 2. If working interruptions take place, such as lunch time, night time etc. disconnect the main compressed air supply Initial start-up • 21 OptiGun GA03... -
Page 25: Cleaning And Maintenance
General information NOTE: Regular, careful cleaning and maintenance extends the service life of the OptiGun GA03 Automatic powder gun and ensures long- lasting, uniform coating quality! The parts, which are to be replaced during maintenance work, are available as spare parts. These parts will be found in the... -
Page 26: Cleaning The Spray Nozzle
7. Clean the powder hose 8. Reassemble the gun and connect it WARNING: The following solvents may not be used to clean the OptiGun GA03 Automatic powder gun: Ethylene chloride, acetone, ethyl acetate, methyl ethyl ketone, methylene chloride, premium gasoline, turpentine,... -
Page 27: Maintenance
V 12/13 Maintenance The OptiGun GA03 is designed to require only a minimum amount of maintenance. 1. Clean gun with dry cloth, see chapter "Maintenance" 2. Check connection points to powder house. 3. Replace the powder hoses, if necessary. Replacing parts Except for the replacement of possible defective parts, there are very few repairs to be made. -
Page 28: Dismantling Procedure
V 12/13 Dismantling procedure 26 • Cleaning and maintenance OptiGun GA03... - Page 29 V 12/13 Cleaning and maintenance • 27 OptiGun GA03...
- Page 30 V 12/13 28 • Cleaning and maintenance OptiGun GA03...
- Page 31 V 12/13 Cleaning and maintenance • 29 OptiGun GA03...
- Page 32 V 12/13 30 • Cleaning and maintenance OptiGun GA03...
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Page 33: 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 • 31 OptiGun GA03... -
Page 34: Powder Hose Connection
The hose connection should be left on the powder hose, for as long as this is used, that means, if two sets of powder hoses are available, the double number of hose connections will be required. CLICK Powder hose connection – assembly 32 • Cleaning and maintenance OptiGun GA03... -
Page 35: Fault Localization
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 Remote control on Contact local Gema powder gun defective representative Compressed air not Connect the equipment... - Page 36 Insert sleeve in the Replace or insert it injector worn or not inserted Fluidization not running see above NOTE: Additional error descriptions are to be found also in the control unit operating instructions! 34 • Fault localization OptiGun GA03...
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Page 37: Spare Parts List
When using the spare parts from other manufacturers the explosion protection is no longer guaranteed. If any damage is caused by this use all guarantee claims become invalid! ► Only original Gema spare parts should be used. Spare parts list • 35 OptiGun GA03... -
Page 38: Optigun Ga03 - Complete
If the powder gun cable (4) is defective, it is to be sent in complete for repair! OptiGun GA03 Automatic powder gun – complete, polarity negative, incl. pos. 1-9 1010 198 OptiGun GA03 Automatic powder gun – complete, polarity positive, incl. pos. 1-9 1010 199 1 Powder gun body OptiGun GA03 –... -
Page 39: Optigun Ga03 - Gun Body
V 12/13 OptiGun GA03 – gun body 1 OptiGun GA03 shaft – complete, negative polarity (see spare parts list "Shaft") Powder tube – complete (incl. pos. 2-5) 1008 644# 2 Powder tube 1008 641# 3 O-ring – Ø 12x1 mm, FPM75... -
Page 40: Optigun Ga03 - Shaft
V 12/13 OptiGun GA03 – shaft Shaft OptiGun GA03 – complete, polarity negative, incl. pos. 1-9 1008 681 Shaft OptiGun GA03 – complete, polarity positive, incl. pos. 1.1-9 1008 682 1 Cascade – complete, negative polarity 1007 231 1.1 Cascade – complete, positive polarity... -
Page 41: Optigun Ga03-X - Complete
V 12/13 OptiGun GA03-X – complete OptiGun GA03-X Automatic powder gun - complete, polarity negative, incl. pos. 1-7 OptiGun GA03-700 1010 203 OptiGun GA03-900 1010 204 OptiGun GA03-1100 1010 205 OptiGun GA03-1300 1010 206 OptiGun GA03-1500 1010 207 OptiGun GA03-1700... -
Page 42: Optigun Ga03-X - Gun Body
1008 736 OptiGun GA03-1900 1008 737 OptiGun GA03-2100 1008 738 1 OptiGun GA03 shaft – complete, negative polarity (see spare parts list "Shaft") Powder tube – complete (incl. pos. 2-5) 1008 644# 2 Powder tube 1008 641# 3 O-ring – Ø 12x1 mm, FPM75... -
Page 43: Optigun Ga03-X - Extension Tube
V 12/13 OptiGun GA03-X – Extension tube 1 Extension tube for: OptiGun GA03-700, L=711 mm 385 484 OptiGun GA03-900, L=911 mm 385 476 OptiGun GA03-1100, L=1111 mm 385 468 OptiGun GA03-1300, L=1311 mm 385 450 OptiGun GA03-1500, L=1511 mm 385 441... -
Page 44: Optigun Ga03-X - Options When Using Several Powder Hoses
OptiGun GA03-1500 1009 561# OptiGun GA03-1700 1009 562# OptiGun GA03-1900 1009 563# OptiGun GA03-2100 1009 564# 2 Clamp ring 1008 643 # Wearing part OptiGun GA03-X – options when using several powder hoses 42 • Spare parts list OptiGun GA03... -
Page 45: Gun Cable
1008 664 Cylinder screw – M4x6 mm 1008 639 O-ring – Ø 9.5x1.5 mm 1008 665 O-ring – Ø 8.5x1 mm 1008 666 Pin allocation white green Bridge brown Shield Gun cable (complete) Spare parts list • 43 OptiGun GA03... -
Page 46: Optigun Ga03 - Supercorona
V 12/13 OptiGun GA03 – SuperCorona SuperCorona – PC07-291, complete 1009 766# 1 SuperCorona ring – complete 1009 761# 2 SuperCorona connection 1009 764 3 Screw – M5x6 mm 263 907 # Wearing part OptiGun GA03 – SuperCorona 44 • Spare parts list... -
Page 47: Optigun Ga03 - Angled Nozzles
2 PA03-60° knee piece – complete 1009 134# 3 PA03-45° knee piece – complete 1009 133# 4 Threaded sleeve 1009 128 5 Nozzle – see "OptiGun GA03 – accessories" # Wearing part OptiGun GA03 – angled nozzles Spare parts list • 45 OptiGun GA03... -
Page 48: Optigun Ga03 - Accessories
V 12/13 OptiGun GA03 – accessories OptiGun GA03 flat jet nozzles – overview (wearing parts) Field of A + B Threaded sleeve application NF20 (Hybrid) 1010 160 Profiles/flat parts (standard nozzle) NF20 NF20 (Hybrid) 1010 090 1007 931 1007 934... -
Page 49: Optigun Ga03 Round Jet Nozzles - Overview (Wearing Parts)
V 12/13 OptiGun GA03 round jet nozzles – overview (wearing parts) Field of A + B Threaded sleeve Deflectors application Suitable for large NS04 Ø 16 mm 331 341 surfaces 1008 150 Ø 24 mm 331 333 1008 152 1008 151 Ø... -
Page 50: Optigun Ga03 Gun Extensions
V 12/13 OptiGun GA03 gun extensions Gun extensions L = 150 mm L = 300 mm without nozzle 1008 616 1008 617 without nozzle 1007 718 1007 719 with Flat jet nozzle NF25 1007 747 1007 746 with Round jet nozzle... -
Page 51: Optigun Ga03 Spray Nozzles For Extensions - Overview (Wearing Parts)
V 12/13 OptiGun GA03 spray nozzles for extensions – overview (wearing parts) Field of A + B Threaded sleeve Deflectors application NF25 Profiles/flat parts 1007 743 1007 735 NF25 1007 684 NF26 Complex profiles and depressions 1007 744 1007 742... -
Page 52: Powder Hoses - Overview
Ø 11/16 mm 105 139 Fast color changes antistatic Fast color changes – Ø 10/15 mm 1001 673 antistatic low powder flow Fast color changes – Ø 12/18 mm 1001 674 antistatic high powder flow 50 • Spare parts list OptiGun GA03... - Page 53 V 12/13 OptiGun GA03...
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