Gema OptiGun GA03-E Guide

Rev. 00 1011 507 EN
Operating instructions and Spare parts list
Enamel automatic gun
OptiGun GA03-E
Translation of the original operating instructions

Rev. 00 02/23
Documentation OptiGun GA03-E
© Copyright 2017 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.
Gema, EquiFlow, MagicCompact, MagicCylinder, OptiCenter, OptiFlex,
OptiGun, OptiSelect, OptiStar, OptiStar All-in-One and PowerBoost are
registered trademarks of Gema Switzerland GmbH.
ClassicLine, ClassicStandard, ClassicOpen, DVC (Digital Valve Control),
GemaConnect, MagicControl, MagicPlus, MonoCyclone, MRS,
MultiColor, MultiStar, OptiAir, OptiControl, OptiColor, OptiFeed, OptiFlow,
OptiHopper, OptiMove, OptiSieve, OptiSpeeder, OptiSpray, PCC (Precise
Charge Control), RobotGun, SIT (Smart Inline Technology) and
SuperCorona are registered 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 information regarding patents, see
www.gemapowdercoating.com/patents or
www.gemapowdercoating.us/patents.
Printed in Switzerland
Gema Switzerland GmbH
Mövenstrasse 17
9015 St.Gallen
Switzerland
Phone: [phone]
Email: [email protected]

Rev. 00 02/23
OptiGun GA03-E Table of contents
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3
Table of contents
About these instructions 5
General information ................................................................................................5
Keeping the Manual................................................................................................5
Safety symbols (pictograms)...................................................................................5
Structure of Safety Notes...........................................................................6
Presentation of the contents...................................................................................6
Figure references in the text......................................................................6
Safety 7
Basic safety instructions .........................................................................................7
Product specific security regulations ......................................................................7
Product description 9
Intended use ...........................................................................................................9
A summary of the directives and standards...............................................9
Reasonably foreseeable misuse..............................................................10
Technical Data......................................................................................................11
Electrical data ..........................................................................................11
Dimensions ..............................................................................................11
Processible powders................................................................................11
Structure................................................................................................................12
Overall view..............................................................................................12
Scope of delivery ..................................................................................................12
Available accessories**............................................................................12
SuperCorona ring.....................................................................................13
Principle of operation............................................................................................14
High voltage generation...........................................................................14
Circuit.......................................................................................................14
Powder flow and electrode rinsing air......................................................14
Flat jet nozzle with vented central electrode............................................15
Round jet nozzle with vented deflector and vented electrodes ...............15
Typical properties –characteristics of the functions.............................................16
Connection for SuperCorona Ring...........................................................16
Assembly / Connection 17
Connecting the gun...............................................................................................17
Start-up 19
Preparation for start-up.........................................................................................19
Basic conditions.......................................................................................19
Basic conditions.......................................................................................19
Initial start-up.........................................................................................................20
Functional check...................................................................................................20
General information .................................................................................20
Troubleshooting.......................................................................................21

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Table of contents OptiGun GA03-E
Operation 23
Operation..............................................................................................................23
Setting powder output and powder cloud................................................23
Setting the electrode rinsing air...............................................................24
Decommissioning / Storage 27
Shutdown..............................................................................................................27
If in disuse for several days.....................................................................27
Storage conditions................................................................................................27
Hazard notes...........................................................................................27
Type of storage........................................................................................27
Storage duration......................................................................................27
Space requirements ................................................................................27
Physical requirements.............................................................................28
Maintenance during storage.................................................................................28
Maintenance schedule.............................................................................28
Maintenance works..................................................................................28
Maintenance / Repairs 29
Cleaning................................................................................................................29
Gun cleaning ...........................................................................................29
Cleaning the spray nozzle.......................................................................30
Interval..................................................................................................................31
Gun maintenance....................................................................................31
Replacing parts........................................................................................31
Dismantling the gun.................................................................................31
Assembling the powder gun.................................................................................35
Fault clearance 37
Disposal 39
Introduction...........................................................................................................39
Requirements on personnel carrying out the work..................................39
Disposal regulations................................................................................39
Materials..................................................................................................39
Spare parts list 41
Ordering spare parts.............................................................................................41
OptiGun GA03-E –complete................................................................................42
Powder gun body..................................................................................................43
Shaft .....................................................................................................................44
Gun cable .............................................................................................................45
SuperCorona ........................................................................................................46
Nozzle combinations ............................................................................................47
Nozzle combinations ............................................................................................48
Flat jet nozzle NF29-E-60° ...................................................................................49
Angled nozzles .....................................................................................................50
Diffuser (OptiSpray AP01.1-E version).................................................................51

Rev. 00 02/23
OptiGun GA03-E About these instructions
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5
About these instructions
General information
This operating manual contains all the important information which you
require for the working with the OptiGun GA03-E. It will safely guide you
through the start-up process and give you references and tips for the
optimal use when working with your powder coating system.
Information about the functional mode of the individual system
components should be referenced in the respective enclosed documents.
Keeping the Manual
Please keep this Manual ready for later use or if there should be any
queries.
Safety symbols (pictograms)
The following warnings with their meanings can be found in the Gema
instructions. The general safety precautions must also be followed as well
as the regulations in the relevant instructions.
DANGER
Indicates a hazardous situation which, if not avoided, will result in death
or serious injury.
WARNING
Indicates a hazardous situation which, if not avoided, could result in
death or serious injury.
CAUTION
Indicates a hazardous situation which, if not avoided, could result in
minor or moderate injury.
ATTENTION
Indicates a potentially harmful situation. If not avoided, the equipment or
something in its surrounding may be damaged.

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About these instructions OptiGun GA03-E
ENVIRONMENT
Indicates a potentially harmful situation which, if not avoided, may have
harmful consequences for the environment.
MANDATORY NOTE
Information which must be observed.
NOTICE
Useful information, tips, etc.
Structure of Safety Notes
Every note consists of 4 elements:
–Signal word
–Nature and source of the danger
–Possible consequences of the danger
–Prevention of the danger
SIGNAL WORD
Nature and source of the hazard!
Possible consequences of the danger
►Prevention of the danger
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
•
7
Safety
Basic safety instructions
–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 considered non-compliant. 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.
–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 "Machine safety" must also be observed.
–Unauthorized modifications to the product exempt the manufacturer
from any liability from resulting damage.
–The relevant accident prevention regulations, as well as other
generally recognized safety regulations, occupational health and
structural regulations are to be observed.
–Furthermore, the country-specific safety regulations also must be
observed.
Product specific security regulations
–This product is a constituent part of the equipment and is therefore
integrated 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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Safety OptiGun GA03-E
WARNING
Working without instructions
Working without instructions or with individual pages from the
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-E Product description
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9
Product description
Intended use
This gun is used for electrostatic coating of objects connectable to ground
with inorganic, non-flammable enamel powders in conjunction with the
control units and accessories, as specified in the corresponding Type
Examination Certificate.
fig.
1
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.
Any other use is not considered as intended use. The manufacturer is not
responsible for any incorrect use and the risks associated with such
actions are assumed by the user alone!
A summary of the directives and standards
This product was built according to the current state of the art. The
product is subject to the European directives and complies with the
following standards.
The product is suitable for the intended purpose and can be used in the
appropriate areas.
For further information, also refer to the enclosed Declaration of
Conformity.

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•
Product description OptiGun GA03-E
European directives RL
EG-RL
2006/42/EU
Machinery
EG-RL
2014/34/EU
Equipment and Protective Systems in Potentially
Explosive Atmospheres (ATEX)
EG-RL
2014/30/EU
Electromagnetic compatibility
EN European standards
EN 50177
Stationary electrostatic application equipment for
ignitable liquid coating material - Safety requirements
EN 50050-2
Electrostatic equipment for areas where there is
danger of explosion - electrostatic hand held
equipment
Part 2: Electrostatic hand-held spraying equipment
EN 16985
Spray booths for organic coating material - Safety
requirements
Recognized safety-related regulations
764 / DGUV
Information
209-052
Electrostatic coating
Trade Union information concerning health and
safety during work (BGI)
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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OptiGun GA03-E Product description
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11
Technical Data
Electrical data
OptiGun GA03-E
Nominal input voltage
12 V
Frequency
18 kHz (average)
Nominal output voltage
100 kV
Polarity
negative
(option: 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 gun gun may only be connected to the following control units:
►OptiStar CG06, CG07, CG08, CG09, CG10, CG12, CG13, CG20,
CG21, CG23, CG24 and MultiStar CG10!

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•
Product description OptiGun GA03-E
Structure
Overall view
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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OptiGun GA03-E Product description
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13
SuperCorona ring
Field of application
The SuperCorona is an optional extension for the 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
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.
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.
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
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.
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
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.

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OptiGun GA03-E Product description
•
15
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
electrode.
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
described in the corresponding operating manual.
Round jet nozzle with vented deflector and
vented electrodes
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
control 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
cascade 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 Assembly / Connection
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17
Assembly / Connection
Connecting the gun
The 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!
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
6.0-10 bar /
87-145 psi

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Assembly / Connection OptiGun GA03-E

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OptiGun GA03-E Start-up
•
19
Start-up
Preparation for start-up
Basic conditions
When starting up the gun control unit, 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 OK
Basic conditions
When starting up the Enamel automatic 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

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Start-up OptiGun GA03-E
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 Gun is explicitly
described in the operating instructions for the OptiStar
CG08/CG13 powder gun control unit (chapter "Initial start-up" and
"Start-up")!
Functional check
General information
1. The installed gun must be pointed towards a grounded work piece in
the coating booth. All connections must be attached!
2. Turn on the gun control unit (see also the control unit operating
instructions) –the gun starts spraying
3. Adjust the desired coating parameters (powder volume, total air and
high voltage) on the gun control unit (see also the control unit
operating instructions)
4. Adjust the electrode rinsing air on the control unit dependent upon
the nozzle used