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]

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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

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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.

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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.

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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!