ITW Gema OptiGun 2-A Guide

En
Operating instructions and spare parts list
OptiGun 2-A(X) (GA02)
Automatic powder gun
0102 II 2 D

V 10/04
Documentation OptiGun 2-A(X) (GA02) Automatic powder gun
© Copyright 2004 ITW Gema AG
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 ITW Gema AG.
OptiTronic, OptiGun, EasyTronic, EasySelect, EasyFlow and
SuperCorona are registered trademarks of ITW Gema AG.
OptiMatic, OptiMove, OptiMaster, OptiPlus, MultiTronic and Gematic are
trademarks of ITW Gema AG.
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 issue. ITW Gema AG
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.
Printed in Switzerland
ITW Gema AG
Mövenstrasse 17
9015 St. Gallen
Switzerland
Phone: [phone]
Fax.: [phone]
E-Mail: [email protected]
Homepage: www.itwgema.ch

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OptiGun 2-A(X) (GA02) Automatic powder gun Table of contents •1
Table of contents
General safety regulations 3
Safety symbols (pictograms)...................................................................................3
Conformity of use....................................................................................................3
Technical safety regulations for stationary electrostatic powder spraying
equipment ...............................................................................................................4
General information ...................................................................................4
Safety conscious working ..........................................................................5
Individual safety regulations for the operating firm and/or operating
personnel ...................................................................................................5
Notes on special types of hazard...............................................................6
Safety requirements for electrostatic powder coating................................7
A summary of the rules and regulations ....................................................8
Special security measures ....................................................................................10
About this manual 11
General information ..............................................................................................11
Function description 13
Field of application ................................................................................................13
OptiGun 2-A(X) Automatic powder gun - overview...............................................13
Typical characteristics..............................................................................13
Scope of delivery ..................................................................................................14
Structure and function 15
OptiGun 2-A(X) Automatic powder gun ................................................................15
High voltage generation ........................................................................................16
Circuit ....................................................................................................................16
Powder flow and rinsing air...................................................................................16
Spray nozzles........................................................................................................17
Flat jet nozzle with vented central electrode............................................17
Round jet nozzle with vented deflector and vented central electrode .....17
Technical Data 19
OptiGun 2-A(X) Automatic powder gun ................................................................19
Electrical data ..........................................................................................19
Dimensions ..............................................................................................19
Start-up 21
Connecting the OptiGun 2-A(X) Automatic powder gun .......................................21
Function check ......................................................................................................21
General information .................................................................................21
Troubleshooting .......................................................................................22
Operation 23
Start-up and powder coating.................................................................................23

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2 •Table of contents OptiGun 2-A(X) (GA02) Automatic powder gun
Shut-down............................................................................................................. 23
Setting powder output and powder cloud ............................................................. 23
Setting total air volume ......................................................................................... 23
Selecting powder output volume .......................................................................... 24
Selecting electrode rinsing ................................................................................... 24
Rinsing the powder hose ...................................................................................... 24
Maintenance 25
General information .............................................................................................. 25
Daily maintenance ................................................................................................ 25
Weekly maintenance ............................................................................................ 25
Cleaning and repair 27
Cleaning the gun .................................................................................................. 27
Daily......................................................................................................... 27
Weekly..................................................................................................... 27
Dismantling the powder gun ................................................................................. 28
General information ................................................................................. 28
Dismantling procedure............................................................................. 28
Reassembling the powder gun ............................................................................. 34
Repairing the powder gun .................................................................................... 35
Powder hose connection ...................................................................................... 35
Cleaning the spray nozzles .................................................................................. 36
Daily or after each shift............................................................................ 36
Weekly..................................................................................................... 36
Monthly .................................................................................................... 36
Cleaning the SuperCorona ................................................................................... 36
Troubleshooting guide 37
General information .............................................................................................. 37
Spare parts list 39
Ordering spare parts............................................................................................. 39
OptiGun 2-A Automatic powder gun - complete................................................... 40
OptiGun 2-A Automatic powder gun - gun body................................................... 41
OptiGun 2-A Automatic powder gun - shaft.......................................................... 42
OptiGun 2-AX Automatic powder gun - complete ................................................ 43
OptiGun 2-AX Automatic powder gun - gun body ................................................ 44
Gun cable ............................................................................................................. 45
Nozzle combinations ............................................................................................ 46
OptiGun 2-A(X) Automatic powder gun - SuperCorona ....................................... 47
OptiGun 2-A(X) - system overview....................................................................... 48

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OptiGun 2-A(X) (GA02) Automatic powder gun 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 2-A(X) (GA02)
Automatic powder gun.
These safety regulations must be read and understood before the
OptiGun 2-A(X) (GA02) Automatic powder gun is used.
Safety symbols (pictograms)
The following warnings with their meanings can be found in the ITW
Gema operating instructions. The general safety precautions must also
be followed as well as the regulations in the operating instructions.
DANGER!
danger due to live electricity 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
Conformity of use
1. The OptiGun 2-A(X) (GA02) Automatic powder gun is built to the
latest specification and conforms to the recognized technical
safety regulations. It is designed for the normal application of
powder coating.
2. Any other use is considered as non-conform. The manufacturer
is not responsible for damage resulting from improper use of this
equipment; the end-user alone is responsible. If the OptiGun 2-
A(X) (GA02) Automatic powder gun is to be used for other
purposes or other substances outside of our guidelines, then ITW
Gema AG should be consulted.
3. Observance of the operating, service and maintenance
instructions specified by the manufacturer is also part of

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4 •General safety regulations OptiGun 2-A(X) (GA02) Automatic powder gun
conformity of use. The OptiGun 2-A(X) (GA02) Automatic powder
gun should only be used, maintained and started up by trained
personnel, who are informed about and are 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 2-A(X) (GA02)
Automatic powder gun has been set up and wired according to
the guidelines for machinery (98/37 EG). EN 60204-1 (machine
safety) must also be observed.
5. Unauthorized modifications to powder spraying equipment
exempts 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 must be
observed.
Explosion protection Type of protection Temperature class
0102 II 2 D
IP54 T6 (zone 21)
T4 (zone 22)
Technical safety regulations for stationary
electrostatic powder spraying equipment
General information
The powder spraying equipment from ITW Gema is designed with safety
in mind and is built according to the latest technological specifications.
This equipment can be dangerous if it is not used for its specified
purpose. Consequently it should be noted that there exists a danger to
life and limb of the user or third party, a danger of damage to the
equipment and other machinery belonging to the user and a hazard to
the efficient operation of the equipment.
1. The powder spraying equipment should only be started up and
used once the operating instructions have been carefully studied.
Improper use of the controlling device can lead to accidents,
malfunction or damage to the control itself.
2. Before every start-up check the equipment for operational safety
(regular servicing is essential)!
3. Safety regulations BGI 764 and VDE regulations DIN VDE 0147,
Part 1, must be observed for safe operation.
4. Safety precautions specified by local legislation must be
observed.
5. The plug must be disconnected before the machine is opened for
repair.
6. The plug and socket connection between the powder spraying
equipment and the mains network should only be taken out when
the power is switched off.

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OptiGun 2-A(X) (GA02) Automatic powder gun General safety regulations •5
7. The connecting cable between the controlling device and the
spray gun must be set up so that it cannot be damaged during
operation. Safety precautions specified by local legislation must
be observed!
8. Only original ITW-Gema spare parts should be used, because
the explosion protection will also be preserved that way. Damage
caused by other parts is not covered by guarantee.
9. If ITW-Gema powder spraying equipment is used in conjunction
with machinery from other manufacturers then their safety
regulations must also be taken into account.
10. Before starting work familiarize yourself with all installations and
operating elements, as well as with their functions!
Familiarization during operation is too late!
11. Caution must be exercised when working with a powder/air
mixture! A powder/air mixture in the right concentration is
flammable! No smoking during powder coating!
12. As a general rule for all powder spraying installations, persons
with pacemakers should never enter high voltage areas or areas
with electromagnetic fields. Persons with pacemakers should not
enter areas with powder spraying installations!
WARNING!
We emphasize that the customer himself is responsible for the safe
operation of equipment. ITW-Gema is in no way responsible for any
resulting damages!
Safety conscious working
Each person responsible for the assembly, start-up, operation, service
and repair of powder spraying equipment must have read and
understood the operating instructions and the “Safety regulations”
chapter. The operator must ensure that the user has had the appropriate
training for powder spraying equipment and is aware of the possible
sources of danger.
The control devices for the spray guns must only be set up and used in
zone 22. Only the spray gun should be used in zone 21.
The powder spraying equipment should only be used by trained and
authorized personnel. This applies to modifications to the electrical
equipment, which should only be carried out by a specialist.
The operating instructions and the necessary closing down procedures
must be followed before any work is carried out concerning the set-up,
start-up, operation, modification, operating conditions, mode of operation,
servicing, inspection or repairs.
The powder spray equipment can be turned off by using the main switch
or failing that, the emergency shut-down. Individual components can be
turned off during operation by using the appropriate switches.
Individual safety regulations for the operating
firm and/or operating personnel
1. Any operating method which will negatively influence the
technical safety of the powder spraying equipment is to be
avoided.

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6 •General safety regulations OptiGun 2-A(X) (GA02) Automatic powder gun
2. The operator should care about no non-authorized personnel
works on the powder spraying equipment (e.g. this also includes
using the equipment for non-conform work).
3. The operator is under obligation to check the powder spraying
equipment at least once every shift for signs of external damage,
defects or changes (including the operating characteristics)
which could influence safety and to report them immediately.
4. The operator is obliged to check that the powder spraying
equipment is only operated when in satisfactory condition.
5. As far as is necessary, the operating firm must ensure that the
operating personnel wear protective clothing (e.g. facemasks).
6. The operating firm must guarantee cleanliness and an overview
of the workplace with suitable instructions and checks in and
around the powder spraying equipment.
7. No safety devices should be dismantled or put out of operation. If
the dismantling of a safety device for set-up, repair or servicing is
necessary, reassembly of the safety devices must take place
immediately after the maintenance or repair work is finished. The
powder spraying device must be turned off while servicing is
carried out. The operator must train and commit the responsible
personnel to this.
8. Activities such as checking powder fluidization or checking the
high voltage spray gun etc. must be carried out with the powder
spraying equipment switched on.
Notes on special types of hazard
Power
It is necessary to refer once more to the danger of life from high voltage
current if the shut-down procedures are not observed. High voltage
equipment must not be opened - the plug must first be taken out -
otherwise there is danger of electric shock.
Powder
Powder/air mixtures can be ignited by sparks. There must be sufficient
ventilation in the powder coating booth. Powder lying on the floor around
the powder spraying device is a potentially dangerous source of slipping.
Static charges
Static charges can have the following consequences: Charges to people,
electric shocks, sparking. Charging of objects must be avoided - see
"Earthing".
Grounding/Earthing
All electricity conducting parts and machinery found in the workplace
(according to DIN VDE 0745, part 102) must be earthed 1.5 meters either
side and 2.5 meters around each booth opening. The earthing resistance
must amount to maximally 1 MOhm. The resistance must be tested on a
regular basis. The condition of the machinery surroundings as well as the
suspension gear must ensure that the machinery remains earthed. If the
earthing of the machinery includes the suspension arrangements, then
these must constantly be kept clean in order to guarantee the necessary

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OptiGun 2-A(X) (GA02) Automatic powder gun General safety regulations •7
conductivity. The appropriate measuring devices must be kept ready in
the workplace in order to check the earthing.
Compressed air
When there are longer pauses or stand-still times between working, the
powder spraying equipment should be drained of compressed air. There
is a danger of injury when pneumatic hoses are damaged and from the
uncontrolled release and improper use of compressed air.
Crushing and cutting
During operation, moving parts may automatically start to move in the
operating area. It must be ensured that only instructed and trained
personnel go near these parts. The operator should ensure that barriers
comply with the local security regulations.
Access under exceptional circumstances
The operating firm must ensure that local conditions are met when
repairs are made to the electronic parts or when the equipment is
restarted so that there are additional measures such as barriers to
prevent unauthorized access.
Prohibition of unauthorized conversions and
modifications to machines
All unauthorized conversions and modifications to electrostatic spraying
equipment are forbidden for safety reasons.
The powder spraying equipment should not be used if damaged, the
faulty part must be immediately replaced or repaired. Only original ITW-
Gema replacement parts should be used. Damage caused by other parts
is not covered by guarantee.
Repairs must only be carried out by specialists or in ITW-Gema
workshops. Unauthorized conversions and modifications may lead to
injury or damage to machinery. The ITW Gema AG guarantee would no
longer be valid.
Safety requirements for electrostatic powder
coating
1. This equipment is dangerous if the instructions in this operating
manual are not followed.
2. All electrostatic conductive parts, in particular the machinery
within 5 meters of the coating equipment, must be earthed.
3. The floor of the coating area must conduct electricity (normal
concrete is generally conductive).
4. The operating personnel must wear electricity conducting
footwear (e.g. leather soles).
5. The operating personnel should hold the gun with bare hands. If
gloves are worn, these must also conduct electricity.
6. The supplied earthing cable (green/yellow) must be connected to
the earthing screw of the electrostatic powder spraying hand
appliance. The earthing cable must have a good metallic
connection with the coating booth, the recovery unit and the
conveyor chain and with the suspension arrangement of the
objects.

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8 •General safety regulations OptiGun 2-A(X) (GA02) Automatic powder gun
7. The electricity and powder supply to the hand guns must be set
up so that they are fully protected against heat and chemical
damage.
8. The powder coating device may only be switched on once the
booth has been started up. If the booth cuts out then the powder
coating device must be switched off.
9. The earthing of all electricity conducting devices (e.g. hooks,
conveyor chains) must be checked on a weekly basis. The
earthing resistance must amount to maximally 1 MOhm.
10. The control device must be switched off if the hand gun is
cleaned or the nozzle is changed.
11. When working with cleaning agents there may be a risk of
hazardous fumes. The manufacturers instructions must be
observed when using such cleaning agents.
12. The manufacturers instructions and the applicable environmental
requirements must be observed when disposing of powder
lacquer and cleaning agents.
13. If any part of the spray gun is damaged (broken parts, tears) or
missing then it should not be used.
14. For your own safety, only use accessories and attachments listed
in the operating instructions. The use of other parts can lead to
risk of injury. Only original ITW-Gema replacement parts should
be used.
15. Repairs must only be carried out by specialists and under no
circumstances should they be carried out in the operating area.
The former protection must not be reduced.
16. Conditions leading to dangerous levels of dust concentration in
the powder spraying booths or in the powder spraying areas
must be avoided. There must be sufficient technical ventilation
available, to prevent a dust concentration of more than 50% of
the lower explosion limit (UEG) (UEG = max. permissible
powder/air concentration). If the UEG is not known then a value
of 10 g/m³ should be used.
A summary of the rules and regulations
The following is a list of relevant rules and regulations which are to be
observed:
Guidelines and regulations, German professional
association
BGV A1 General regulations
BGV A2 Electrical equipment and material
BGI 764 Electrostatic coating
BGR 132 Guidelines for the avoidance of the dangers of ignition
due to electrostatic charging (Guideline “Static
Electricity”)
VDMA 24371 Guidelines for electrostatic coating with synthetic
powder1)
- Part 1 General requirements
- Part 2 Examples of use

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OptiGun 2-A(X) (GA02) Automatic powder gun General safety regulations •9
Leaflets
ZH 1/310 Leaflet for the use of tools in locations where there is
danger of explosion 1)
EN European standards
RL94/9/EC The approximation of the laws of the Member States
relating to apparatus and safety systems for their
intended use in potentially explosive atmospheres
EN 292-1
EN 292-2
Machine safety 2)
EN 50 014 to EN
50 020, identical:
DIN VDE
0170/0171
Electrical equipment for locations where there is danger
of explosion 3)
EN 50 050 Electrical apparatus for potentially explosive
atmospheres - Electrostatic hand-held spraying
equipment 2)
EN 50 053, Part 2 Requirements for the selection, installation and use of
electrostatic spraying equipment for flammable
materials - Hand-held electrostatic powder spray guns 2)
EN 50 177 Stationary electrostatic spraying equipment for
flammable coating powder 2)
PR EN 12981 Coating plants - Spray booths for application of organic
powder coating material - Safety requirements
EN 60529,
identical: DIN
40050
IP-Type protection: contact, foreign bodies and water
protection for electrical equipment 2)
EN 60 204
identical: DIN VDE
0113
VDE regulations for the setting up of high voltage
electrical machine tools and processing machines with
nominal voltages up to 1000 V 3)
VDE (Association of German Engineers) Regulations
DIN VDE 0100 Regulations for setting-up high voltage equipment with
nominal voltages up to 1000V 4)
DIN VDE 0105
Part 1
Part 4
VDE regulations for the operation of high voltage
equipment 4)
General regulations
Supplementary definitions for stationary electrical
spraying equipment
DIN VDE 0147
Part 1
Setting up stationary electrostatic spraying equipment 4)
DIN VDE 0165 Setting up electrical equipment in locations in areas with
danger of explosion 4)
Sources:
1) Carl Heymanns Verlag KG, Luxemburger Strasse 449, 5000 Köln 41,
or from the appropriate employers association
2) Beuth Verlag GmbH, Burgrafenstrasse 4, 1000 Berlin 30
3) General secretariat, Rue Bréderode 2, B-1000 Bruxelles, or the
appropriate national committee
4) VDE Verlag GmbH, Bismarckstrasse 33, 1000 Berlin 12

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10 •General safety regulations OptiGun 2-A(X) (GA02) Automatic powder gun
Special security measures
- The installation work, to be done by the customer, must be
carried out according to local regulations
- Before starting up the plant a check must be made that no
foreign objects are in the booth or in the ducting (input and
exhaust air)
- It must be observed, that all components are grounded
according to the local regulations, before start-up

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OptiGun 2-A(X) (GA02) Automatic powder gun About this manual •11
About this manual
General information
These operating manual contains all important information which you re-
quire for the working with the OptiGun 2-A(X) (GA02) 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 sys-
tem.
Information about the function mode of the individual system components
- booth, gun control unit, manual gun or powder injector - you will find in
the corresponding enclosed documentations.

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OptiGun 2-A(X) (GA02) Automatic powder gun Function description •13
Function description
Field of application
The OptiGun 2-A(X) Automatic powder gun is intended exclusively for the
electrostatic coating with organic powders. Any other use is considered
as non-conform. The manufacturer is not responsible for any damage re-
sulting from this; the risk for this is assumed by the user alone.
OptiGun 2-A(X) Automatic powder gun - overview
The extremely light OptiGun 2-A(X) Automatic powder gun with inte-
grated high voltage generation persuades by optimal penetrating ability
and high charging. The vented central electrode allows a high, constant
transfer efficiency and a high coating efficiency by symmetrical coating
structure.
Typical characteristics
The OptiGun 2-A(X) Automatic powder gun can be easily dismantled and
is therefore maintenance and repair-friendly.
- Continuous, tightly sealed gun body with separate channels
for cascade and rinsing air
- Continuous guided powder tube, self-sealing
- Quickly dismantlable SuperCorona ring
- Powder tube coupling with quick-release fastener
- Covered hose and cable ducting
- Excellent access to the connections due to snap lock
- Simple convertion to a quick color change gun (powder tube
and gun fixture tube)
- Same nozzles and extensions as EasySelect manual gun
- Easily dismantlable by a few hand movements, therefore
very easy to service
- Few wear parts (powder tube, nozzle and SuperCorona)
- Self-sealing powder tube (housing tube seat)
- Easily removable cascade because free of grease, with inte-
grated current limiting resistors
- Spring loaded contact between cascade and contact pin

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14 •Function description OptiGun 2-A(X) (GA02) Automatic powder gun
- Easily dismantlable and cleanable SuperCorona
Scope of delivery
- OptiGun 2-A(X) Automatic powder gun
- Flat jet nozzle with electrode holder
- Cable binder with Velcro closure
- Gun cleaning brush
- Parts set

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OptiGun 2-A(X) (GA02) Automatic powder gun Structure and function •15
Structure and function
OptiGun 2-A(X) Automatic powder gun
OptiGun 2-A(X) Automatic powder gun
1 Spray nozzle 5 Powder gun attachment
2 Sleeve nut 6 Powder tube
3 Shaft with removeable high volt-
age cascade
7 Clamping sleeve
4 SuperCorona ring
3
41 2 5 6 7

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16 •Structure and function OptiGun 2-A(X) (GA02) Automatic powder gun
High voltage generation
The OptiTronic control module supplies a high-frequency low voltage of
approximately 10 V eff. This voltage is fed through the gun cable (11) and
the gun plug to the high voltage cascade (4) in the shank of the gun.
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 attained at the end (approx. 100 kV). The high voltage is
now fed in the spray nozzle to the electrode (e).
4
cde
11
High voltage generation
Circuit
The OptiGun 2-A(X) Automatic powder gun is switched on and off by the
OptiTronic gun control unit.
The control unit allows also the adjustment of low voltage, powder flow
and rinsing air to the gun.
Powder flow and rinsing air
The rinsing air, used by the vented spray nozzle, is connected with its
designated connection on the rear of the gun control unit (see operating
instructions of the OptiTronic powder gun control unit).
Powder flow and rinsing air
The functions of the spray nozzles are described in the following chapter.
Rinsing air
Powder

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OptiGun 2-A(X) (GA02) Automatic powder gun Structure and function •17
Spray nozzles
Flat jet nozzle with vented central electrode
The vented flat jet nozzle serves for the atomizing and charging of the
powder. The powder cloud obtains an oval spray pattern by the slot-
shaped opening. The powder is charged by the central electrode. The
high voltage, which is created in the gun cascade, is conducted through
the black contact ring of the nozzle holder to the central electrode.
In order to prevent a powder sintering on the electrode, this is rinsed with
compressed air during spraying procedure. Therefore, the rinsing air is
fed through the small hole in the black contact ring of the nozzle holder
into the electrode attachment. The rinsing air adjustment on the control
module is explained in the corresponding operating manual.
Flat jet nozzle with vented central electrode
Round jet nozzle with vented deflector and
vented central electrode
The vented deflector is used to give to the powder stream emerging from
the gun the form of a powder cloud. The powder is charged by the central
electrode. The high voltage, which is created in the gun cascade, is con-
ducted through the black contact ring of the nozzle holder to the central
electrode.
Since powder can accumulate on the rear side of the deflector, this must
be rinsed with compressed air. The rinsing air is fed through the small
hole in the black contact ring of the nozzle holder into the electrode at-
tachment, and is driven in such a way, that it flows over the surface of the
deflector rear side. The rinsing air strength depends on the powder and
its sintering ability. The rinsing air adjustment on the control module is
explained in the corresponding operating manual.
Round jet nozzle with vented deflector and vented central electrode
High voltage
Rinsing air
High voltage
Rinsing air