Gema OptiGun GA03-E Guide

1011 507 En
Translation of the original operating instructions
Operating instructions and spare parts list
Enamel automatic gun
OptiGun GA03-E
II 2D

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Documentation Enamel Automatic Gun OptiGun GA03-E
© Copyright 2012 Gema Switzerland GmbH
All rights reserved.
This publication is protected by copyright. Unauthorized copying is prohib-
ited 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, Opti-
Control, OptiGun, OptiSelect, OptiStar and SuperCorona are registered
trademarks of Gema Switzerland GmbH.
OptiFlow, OptiCenter, OptiMove, OptiSpeeder, OptiFeed, OptiSpray, Op-
tiSieve, 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 con-
cerned approve of or are bound in any form by this manual. We have en-
deavored 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 Swit-
zerland 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 information regarding patents, visit
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]
Email: [email protected]

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OptiGun GA03-E Table of contents
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1
Table of contents
About this instructions 3
General information ................................................................................................3
Keeping the manual................................................................................................3
Safety symbols (pictograms)...................................................................................3
Presentation of the contents...................................................................................4
Figure references in the text......................................................................4
Safety 5
General information ................................................................................................5
Intended use ...........................................................................................................5
Product-specific safety measures...........................................................................6
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 operation............................................................................................12
High voltage generation...........................................................................12
Circuit.......................................................................................................12
Powder flow and electrode rinsing air......................................................12
Spray nozzle ............................................................................................13
Typical properties –characteristics of the functions.............................................14
Connection for SuperCorona Ring...........................................................14
Start-up 15
Preparation for start-up.........................................................................................15
Basic conditions.......................................................................................15
Connecting the OptiGun Enamel automatic 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.................................................................................21

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Table of contents OptiGun GA03-E
Shut-down............................................................................................................. 21
Cleaning and maintenance 23
General information.............................................................................................. 23
Cleaning................................................................................................................ 23
Gun cleaning ........................................................................................... 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................................................................................. 29
Repairing the powder gun .................................................................................... 29
Troubleshooting 31
General information.............................................................................................. 31
Spare parts list 33
Ordering spare parts............................................................................................. 33
OptiGun GA03-E –complete................................................................................ 34
Powder gun body.................................................................................................. 35
Shaft ..................................................................................................................... 36
Gun cable ............................................................................................................. 37
Nozzle combinations ............................................................................................ 38
Nozzle combinations ............................................................................................ 39
Flat jet nozzle NF29-E-60° ................................................................................... 40
Angled nozzles ..................................................................................................... 41
SuperCorona ........................................................................................................ 42
Diffuser (OptiSpray AP01.1-E version)................................................................. 43

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OptiGun GA03-E About this instructions
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3
About this instructions
General information
This operating manual contains all the important information you require
for the working with the OptiGun GA03-E 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 functional mode of the individual system compo-
nents can be found in the respective enclosed documents.
Keeping the manual
Please keep this Manual ready for later use or if there should be any que-
ries.
Safety symbols (pictograms)
The following contains a list of warnings with their meanings found in the
Gema operating instructions. Apart from the regulations in the relevant
operating instructions, the general safety precautions must also be fol-
lowed .
DANGER
Indicates a hazardous situation which,
if not avoided, will result in death or serious injury.
WARNING
Indicates a potentially hazardous situation which,
if not avoided, could result in death or serious injury.
CAUTION
Indicates a potentially hazardous situation which,
if not avoided, could result in minor or moderate injury.

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About this instructions OptiGun GA03-E
ATTENTION
Indicates a potentially harmful situation which,
if not avoided, the equipment or something in its surrounding may be
damaged.
ENVIRONMENT
Indicates a potentially harmful situation which,
if not avoided, may have harmful consequences for the environment.
NOTE
Useful tips and other information.
Pos:14 /Kapitel/Über diese Anleitung++++ Für alle Anleitungen ++++/Darstellungdes Inhalts @ 1\mod_1452784296568_6.docx@ 23800 @ 23 @ 4
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."

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OptiGun GA03-E Safety
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5
Safety
General information
This chapter sets out the fundamental safety regulations, that must be fol-
lowed by the user and third parties using the powder gun.
These safety regulations must be read and understood before the gun is
put into operation.
WARNING
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 on "Safety regulations".
►Work should only be carried out in accordance with the instruc-
tions in the relevant documents.
►Always work with the complete original document.
Intended use
–This product is built to the latest specification and conforms to the
recognized technical safety regulations and is designed for the normal
application of powder coating.
–Any other use is not considered as intended use. The manufacturer
shall not be liable for damage resulting from such use; the user bears
sole responsibility for such actions. If this product is to be used for
other purposes or other substances outside of our guidelines then
Gema Switzerland GmbH should be consulted.
–Observance of the operating, service and maintenance instructions
specified by the manufacturer is also part of the intended use. This
product should only be used, maintained and started up by trained
personnel, who are informed about and are familiar with the possible
hazards involved.
–Start-up (i.e. the execution of intended operational tasks) is forbidden
until it has been established that this product has been set up and
wired according to the guidelines for machinery. The standard "Ma-
chine safety" must also be observed.

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Safety OptiGun GA03-E
–Unauthorized modifications to the product exempt the manufacturer
from any liability from resulting damage.
–The relevant accident prevention regulations, as well as other gener-
ally recognized safety regulations, occupational health and structural
regulations are to be observed.
–Furthermore, the country-specific safety regulations also must be ob-
served.
Explosion protection
Protection
type
Temperature class
II 2D
IP64
T6 (zone 21)
T4 (zone 22)
Product-specific safety measures
–This product is a constituent part of the equipment and is therefore in-
tegrated in the system's safety concept.
–If it is to be used in a manner outside the scope of the safety concept,
then corresponding measures must be taken.
–The installation work to be done by the customer must be carried out
according to local regulations.
–It must be ensured, that all components are earthed according to the
local regulations before start-up.
For further security information, see the more detailed Gema
safety regulations!

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OptiGun GA03-E Product description
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7
Product description
Field of application
The OptiGun GA03-E Enamel automatic gun is built exclusively for elec-
trostatic coating with inorganic, non-flammable enamel powders. Any oth-
er use is not considered as intended use. The manufacturer shall not be
liable for damage resulting from such use; the user bears sole responsibil-
ity for such actions.
fig.
1
Utilization
The Enamel automatic gun type OptiGun GA03-E is suited for the elec-
trostatic coating of objects (in all shapes and geometries) that must be
grounded.
Reasonably foreseeable misuse
–Coating of non grounded objects
–Use of metallic or organic powder
–Incorrectly configured values for powder conveyance
–Incorrectly configured values for electrode rinsing air
–Use of moist powder

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Product description OptiGun GA03-E
Technical Data
Electrical data
OptiGun GA03-E
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
II 2D
Dimensions
OptiGun GA03-E
Weight
600 g
Processible powders
OptiGun GA03-E
Enamel powder
yes
Plastic powder
No
Metallic powder
No
ATTENTION
The OptiGun GA03-E Enamel automatic gun may only be connect-
ed to the following control units:
►OptiStar CG06, CG07, CG08, CG09, CG10, CG12, CG13, CG20,
CG21, CG23, CG24 and MultiStar CG10!

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OptiGun GA03-E Product description
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9
Design and function
Fig.
2
: Structure
1 Powder tube
2 Gun fixture
3 SuperCorona connection
4 Shaft with removable high
voltage cascade
5 Threaded sleeve
6 Spray nozzle
Scope of delivery
–OptiGun GA03-E Enamel automatic gun with gun cable (20 m)*,
negative polarity
–Rinsing air hose (20 m)*
–Flat jet nozzle NF28-E, complete (incl. electrode holder) or Round jet
nozzle NS11-E with deflector Ø 28 mm
–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° und 60°
–Gun cable extensions
–Collision protection
–Diffuser (additional functions when used with application pumps)
For more information, see spare parts list!

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Product description OptiGun GA03-E
SuperCorona ring
Field of application
The SuperCorona is an optional extension for the OptiGun GA03-E
Enamel automatic 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 require-
ments. 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 im-
proved penetration into Faraday cages. The distance between nozzle and
workpiece can be reduced to 100 mm without influencing the surface fin-
ish.
Fig.
3
: SuperCorona –retrofit
Due to its modular structure, the OptiGun Enamel automatic 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.

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OptiGun GA03-E Product description
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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.
CLICK

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Product description OptiGun GA03-E
Principle of operation
High voltage generation
The control unit supplies a high-frequency low voltage signal of approx.
12 V eff. 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 mul-
tiplied 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.
Fig.
4
: High voltage generation
Circuit
The OptiGun Enamel automatic 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 connect-
ed 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.

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OptiGun GA03-E Product description
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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 (E). The high
voltage (H) created in the gun cascade is guided through the center elec-
trode.
Fig.
5
: 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 (S) adjustment on the gun control unit is de-
scribed in the corresponding operating manual.
Round jet nozzle with vented deflector and vented elec-
trodes
The vented deflector is used, to give the powder stream emerging from
the gun, a cloud formation. The powder is charged by radial arranged
electrodes (E). The high voltage (H) created in the gun cascade is guided
through the electrodes.
Fig.
6
: Round jet nozzle with vented deflector and vented electrodes
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 (S) adjustment on the gun con-
trol unit is described in the corresponding operating manual.

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Product description OptiGun GA03-E
Typical properties –characteristics of the functions
–Continuous, tightly sealed gun body with separate channels for cas-
cade and electrode rinsing air
–Powder tube coupling with quick-release fastener
–Covered hose and cable duct
–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
Connection for SuperCorona Ring
–Quick and simple connection to and disconnection from the
SuperCorona ring

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OptiGun GA03-E Start-up
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15
Start-up
Preparation for start-up
Basic conditions
When starting up the OptiGun GA03-E Enamel automatic gun, the follow-
ing 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
Connecting the OptiGun Enamel automatic gun
The OptiGun GA03-E Enamel automatic gun is delivered ready-to-use by
the manufacturer. Just a few cables and hoses must be connected.
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 oper-
ating 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

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Start-up OptiGun GA03-E
Fig.
7
: Connection instructions –overview
1 Electrode rinsing air hose
2 Powder hose
3 Gun cable
4 Conveying air hose
5 Supplementary air hose
6 Injector
5
4
3
2
1
5.5 bar
6.0 bar
6.5 bar
6

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OptiGun GA03-E Initial start-up
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17
Initial start-up
If a malfunction occurs, see the troubleshooting guide, as well as
the gun control unit operating manual!
Fig.
8
:
The remainder of the start-up procedure for the OptiGun GA03-E
gun is explicitly described in the operating instructions for the
OptiStar gun control unit (chapter "Initial start-up" and "Daily
start-up")!

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Initial start-up OptiGun GA03-E
Operation
WARNING
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
A total air volume of 4 Nm³/h and a 50% powder share are rec-
ommended 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 operat-
ing instructions.
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 di-
ameter changes, the total air volume must be reset!