Gema OptiGun GA03 Guide

V 12/13 En
Translation of the original operating instructions
Order no. 1010 772
Operating instructions and spare parts list
OptiGun GA03
Automatic powder gun
0102 II 2D

V 12/13
Documentation OptiGun GA03 Automatic powder gun
© Copyright 2012 Gema Switzerland GmbH
All rights reserved.
This publication is protected by copyright. Unauthorized copying is
prohibited by law. No part of this publication may be reproduced,
photocopied, translated, stored on a retrieval system or transmitted in
any form or by any means for any purpose, neither as a whole nor
partially, without the express written consent of Gema Switzerland
GmbH.
MagicCompact, MagicCylinder, MagicPlus, MagicControl, OptiFlex,
OptiControl, OptiGun, OptiSelect, OptiStar and SuperCorona are
registered trademarks of Gema Switzerland GmbH.
OptiFlow, OptiCenter, OptiMove, OptiSpeeder, OptiFeed, OptiSpray,
OptiSieve, OptiAir, OptiPlus, OptiMaster, MultiTronic, EquiFlow, Precise
Charge Control (PCC), Smart Inline Technology (SIT) and Digital Valve
Control (DVC) are trademarks of Gema Switzerland GmbH.
All other product names are trademarks or registered trademarks of their
respective holders.
Reference is made in this manual to different trademarks or registered
trademarks. Such references do not mean that the manufacturers
concerned approve of or are bound in any form by this manual. We have
endeavored to retain the preferred spelling of the trademarks, and
registered trademarks of the copyright holders.
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.
For the latest information about Gema products, visit
www.gemapowdercoating.com.
For patent information, see www.gemapowdercoating.com/patents or
www.gemapowdercoating.us/patents.
Printed in Switzerland
Gema Switzerland GmbH
Mövenstrasse 17
9015 St.Gallen
Switzerland
Phone: [phone]
Fax.: [phone]
E-Mail: [email protected]

V 12/13
OptiGun GA03 Table of contents •1
Table of contents
General safety regulations 3
Safety symbols (pictograms)...................................................................................3
Proper use...............................................................................................................3
Product-specific safety measures ...........................................................................4
OptiGun GA03 automatic powder gun.......................................................4
About this manual 5
General information ................................................................................................5
Product description 7
Field of application ..................................................................................................7
Utilization....................................................................................................7
Reasonably foreseeable misuse................................................................7
Technical data.........................................................................................................8
Electrical data ............................................................................................8
Dimensions ................................................................................................8
Processible powders..................................................................................8
Design and function ................................................................................................9
Scope of delivery ....................................................................................................9
Available accessories ................................................................................9
SuperCorona ring.....................................................................................10
Principle of function...............................................................................................12
High voltage generation ...........................................................................12
Circuit ....................................................................................................... 12
Powder flow and electrode rinsing air......................................................12
Spray nozzle ............................................................................................13
Typical properties – Characteristics of the functions ............................................14
Powder hose quick release connection ...................................................14
Connection for SuperCorona Ring...........................................................14
Commissioning 15
Preparation for start-up .........................................................................................15
Basic conditions .......................................................................................15
Connect the OptiGun automatic powder gun........................................................15
Initial start-up 17
Operation ..............................................................................................................18
Setting of total air .....................................................................................18
Setting the powder quantity .....................................................................19
Setting the electrode rinsing air ...............................................................19
Functional check ...................................................................................................20
General information .................................................................................20
Troubleshooting .......................................................................................20
Start-up and powder coating.................................................................................20
Shut-down .............................................................................................................21

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2 •Table of contents OptiGun GA03
Cleaning and maintenance 23
General information .............................................................................................. 23
Cleaning................................................................................................................ 23
Cleaning the Automatic gun .................................................................... 23
Cleaning the spray nozzle ....................................................................... 24
Maintenance ......................................................................................................... 25
Replacing parts........................................................................................ 25
Dismantling the gun.............................................................................................. 25
General information ................................................................................. 25
Dismantling procedure............................................................................. 26
Assembling the powder gun ................................................................................. 31
Repairing the powder gun .................................................................................... 31
Powder hose connection ...................................................................................... 32
Fault localization 33
General information .............................................................................................. 33
Spare parts list 35
Ordering spare parts............................................................................................. 35
OptiGun GA03 – complete ................................................................................... 36
OptiGun GA03 – gun body ................................................................................... 37
OptiGun GA03 – shaft .......................................................................................... 38
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 – angled nozzles.......................................................................... 45
OptiGun GA03 – accessories ............................................................................... 46
OptiGun GA03 flat jet nozzles – overview (wearing parts)...................... 46
OptiGun GA03 round jet nozzles – overview (wearing parts) ................. 47
OptiGun GA03 gun extensions................................................................ 48
OptiGun GA03 spray nozzles for extensions – overview (wearing parts)49
Powder hoses – overview........................................................................ 50

V 12/13
OptiGun GA03 General safety regulations •3
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.
Safety symbols (pictograms)
The following warnings with their meanings can be found in the Gema
Switzerland operating instructions. The general safety precautions must
also be followed as well as the regulations in the operating instructions.
DANGER!
Danger due to electrically live or moving parts. Possible consequences:
death or serious injury
WARNING!
Improper use of the equipment could damage the machine or cause it to
malfunction. Possible consequences: minor injuries or damage to
equipment
INFORMATION!
Useful tips and other information
Proper use
1. The OptiGun GA03 Automatic powder gun is built to the latest
specification and conforms to the recognized technical safety
regulations and is designed for the normal application of powder
coating.
2. 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. Gema Switzerland
GmbH must be consulted prior to any use of the OptiGun GA03
for any purposes or substances other than those indicated in our
guidelines.

V 12/13
4 •General safety regulations OptiGun GA03
3. Observance of the operating, service and maintenance
instructions specified by the manufacturer is also part of
conformity of use. The OptiGun GA03 should only be used,
maintained and started up by trained personnel informed about
and familiar with the possible hazards involved.
4. Start-up (i.e. the execution of a particular operation) is forbidden
until it has been established that the OptiGun GA03 Automatic
powder gun has been set up and wired according to the
guidelines for machinery (2006/42 EG). EN 60204-1 (machine
safety) must also be observed.
5. Unauthorized modifications to the OptiGun GA03 Automatic
powder gun exempt the manufacturer from any liability from
resulting damage.
6. The relevant accident prevention regulations, as well as other
generally recognized safety regulations, occupational health and
structural regulations are to be observed.
7. Furthermore, the country-specific safety regulations also must be
observed.
Explosion protection Protection type Temperature class
0102 II 2D IP64 T6 (zone 21)
T4 (zone 22)
Product-specific safety measures
- Installation work performed by the customer must be carried
out according to local regulations.
- All components must be grounded according to the local
regulations before start-up.
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.
NOTE:
For further security information, see the more detailed Gema safety
regulations!

V 12/13
OptiGun GA03 About this manual •5
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.
Information about the function mode of the individual system components
– booth, gun control unit or powder injector – should be referenced to
their enclosed corresponding documents.
DANGER:
Working without operating instructions
Working without operating instructions or with individual pages
from the operating instructions may result in damage to property
and personal injury if relevant safety information is not observed.
►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.

V 12/13
OptiGun GA03 Product description •7
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.
OptiGun GA03 automatic powder gun
Utilization
The Automatic gun type OptiGun GA03 is suited for the electrostatic
coating of objects (in all shapes and geometries) that must be grounded.
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

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8 •Product description OptiGun GA03
Technical data
Electrical data
OptiGun GA03
Nominal input voltage 12 V
Frequency 18 kHz (average)
Nominal output voltage 100 kV
Polarity negative
(optional: positive)
Max. output current 100 µA
Ignition protection Type A acc. EN 50177
Ex 2 mJ T6
Temperature range 0 °C - +40 °C
(+32 °F - +104 °F)
Max. surface temperature 85 °C (+185 °F)
Protection type IP64
Approvals 0102 II 2D
PTB 11 ATEX 5006-1
Dimensions
OptiGun GA03
Weight 600 g
Processible powders
OptiGun GA03
Plastic powder yes
Metallic powder yes
Enamel powder no
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!

V 12/13
OptiGun GA03 Product description •9
Design and function
OptiGun GA03 automatic powder gun
1 Spray nozzle 5 Gun fixture
2 Threaded sleeve 6 Powder tube
3 Shaft with removable high voltage
cascade
7 Clamp ring
4 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
- Gun cleaning brush
- Spare parts kit
- Operating manual
* standard
Available accessories
- SuperCorona ring
- Flat jet nozzle (for specific applications)
- Round jet nozzles
- Gun extension 150 and 300 mm
- Angled nozzles 45°, 60° and 90°
- Gun cable extensions
- Powder tube extensions (when using several powder
hoses)
For more information, see spare parts list!
36 5 4 2 1

V 12/13
10 •Product description OptiGun GA03
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. By coating with several powder types, an "orange peel"
finish can be completely avoided. By coating with structure powder, the
"picture frame effect" is hardly visible.
The performance of the OptiGun with SuperCorona is convincing due to
its very good charging and very high deposition rate as well as an
improved penetration into Faraday cages. The distance between nozzle
and workpiece can be reduced to 100 mm without influencing the surface
finish.
SuperCorona – retrofit
Due to its modular structure, the OptiGun Automatic powder gun can be
extended quickly and easily with the lightweight SuperCorona (approx. 75
g). The OptiGun remains repair-friendly and easy to maintain even after
reconfiguration.

V 12/13
OptiGun GA03 Product description •11
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.
1.
2.
3.
4.
CLICK

V 12/13
12 •Product description OptiGun GA03
Principle of function
High voltage generation
The control unit supplies a high-frequency low voltage signal of approx.
12 V. This voltage is fed through the gun cable (11) and the gun plug to
the high voltage cascade (4) in the gun body.
In the high voltage cascade (4), the low voltage is high-transformed in a
first step (c). This primary high voltage is subsequently rectified and
multiplied in the high voltage cascade in a second step (d), until the
required high voltage is obtained at the end (approx. 100 kV). The high
voltage is now fed to the electrode (e) within the spray nozzle.
High voltage generation
Circuit
The OptiGun Automatic powder gun is switched on and off by the gun
control module.
The control unit allows also the adjustment of low voltage, powder flow
and electrode rinsing air to the gun.
Powder flow and electrode rinsing air
The electrode rinsing air is used by vented spray nozzles and is
connected with its designated connection on the rear side of the gun
control unit (see the operating manual of the gun control unit).
The functions of the spray nozzles are described in the following
sections.
11
c d
e
4

V 12/13
OptiGun GA03 Product description •13
Spray nozzle
Flat jet nozzle with vented central electrode
The vented flat jet nozzle serves for the spraying and the charging of the
powder. The powder is charged by the central electrode. The high
voltage created in the gun cascade is guided through the center
electrode.
Flat jet nozzle with vented central electrode
In order to prevent powder from sintering on the electrode, compressed
air is used during the spray process.
The electrode rinsing air adjustment on the gun control unit is described
in the corresponding operating manual.
Round jet nozzle with vented deflector and vented
central electrode
The vented deflector is used, to give the powder stream emerging from
the gun, a cloud formation. The powder is charged by the central
electrode. The high voltage created in the gun cascade is guided through
the center electrode.
Round jet nozzle with vented deflector and vented central electrode
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.
High voltage
Rinsing ai
r
Rinsing ai
r
High voltage

V 12/13
14 •Product description OptiGun GA03
Typical properties – Characteristics of the functions
- Continuous, tightly sealed gun body with separate channels
for cascade and electrode rinsing air
- Quickly removable SuperCorona ring
- Powder tube coupling with quick-release fastener
- Covered hose and cable duct
- Simple conversion to a quick color change gun
- 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
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

V 12/13
OptiGun GA03 Commissioning •15
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
- Powder preparation and powder quality
Connect the OptiGun automatic powder gun
The OptiGun GA03 Automatic powder gun is delivered ready-to-use by
the manufacturer. Just a few cables and hoses must be connected.
NOTE:
The compressed air must be free of oil and water!
The gun is connected as follows:
1. Connect electrode rinsing air hose and powder hose to gun
2. Lay out gun cable, electrode rinsing air hose and powder
hose and bind using Velcro strips (included)
3. Connect the gun cable plug to the socket 2.3 on the rear side
of the control unit
4. Connect electrode rinsing air hose to coupling 1.4
5. Connect powder hose to injector
6. Connect the gun plug to the gun control unit (see therefore
the operating manual of the gun control unit)
7. Connect the electrode rinsing air hose of the control unit to
the gun
8. Connect the powder hose from the gun to the injector

V 12/13
16 •Commissioning OptiGun GA03
OptiGun GA03 Automatic powder gun - Connection instructions - overview
1 Electrode rinsing air hose 4 Supplementary air hose
2 Powder hose 5 Conveying air hose
3 Gun cable 6 Injector
6
5
4
3
2
1
5.5 ba
r
6.0 bar
6.5 bar

V 12/13
OptiGun GA03 Initial start-up •17
Initial start-up
NOTE:
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" and "Daily start-up")!

V 12/13
18 •Initial start-up OptiGun GA03
Operation
DANGER!
Touching the gun parts
During the coating process, the gun can discharge along the body
of the coater if touching it.
►Do not touch any parts of the gun!
Setting of total air
correct powder cloud too little total air
NOTE:
A total air volume of 4 Nm³/h and a 50% powder share are
recommended as the base values.
The total air volume is depending on the powder hose length, the number
of hose curvatures, the hose diameter, the conveying air pressure and
the supplementary air. The operation mode of the injector and the effect
of the supplementary air are described in the corresponding injector
operating instructions.
NOTE:
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!