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Summary of Contents for Gema OptiSpray DPP01
- Page 1 Operating instructions and spare parts list OptiSpray DPP01 Dense phase pump Translation of the original operating instructions...
- Page 2 To the best of our knowledge and belief, the information contained in this publication was correct and valid on the date of issue. Gema Switzerland GmbH makes no representations or warranties with respect to the con- tents or use of this publication, and reserves the right to revise this publi- cation and make changes to its content without prior notice.
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Page 3: Table Of Contents
Structure and function ..................... 8 OptiSpray DPP01 - structure ..............8 Powder hoses ..................... 8 Diffusers ..................... 9 OptiSpray DPP01 Dense phase pump - functioning ........9 Main functions ..................10 Secondary functions .................10 Technical data OptiSpray DPP01 Dense phase pump ..............11 Powder output (guide values) ..............11... - Page 4 Test program for error diagnosis ................21 Cleaning and maintenance Cleaning the dense phase pump (color change) ..........23 Maintenance of the OptiSpray DPP01 Dense phase pump ......... 23 Daily maintenance ................... 23 OptiSpray DPP01 - maintenance plan ............. 23 Maintenance set ..................
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Page 5: General Safety Regulations
V 03/13 General safety regulations This chapter specifies the fundamental safety regulations that must be followed by the user and third parties using the OptiSpray DPP01 Dense phase pump. These safety regulations must be read and understood before the OptiS- pray DPP01 Dense phase pump is used. -
Page 6: Product Specific Security Measures
3. Observance of the operating, service and maintenance instruc- tions specified by the manufacturer is also part of conformity of use. The OptiSpray DPP01 should only be used, maintained and started up by trained personnel, who are informed about and are familiar with the possible hazards involved. -
Page 7: About This Manual
General information This operating manual contains all the important information which you require for the working with the OptiSpray DPP01 Dense phase pump. It will safely guide you through the start-up process and give you refer- ences and tips for the optimal use of your new powder coating system. -
Page 9: Function Description
Field of application OptiSpray DPP01 Dense phase pump The OptiSpray DPP01 Dense phase pump is intended for conveying coating powder to the powder gun. Any other use is considered as non- conform. The manufacturer is not responsible for any damage resulting... -
Page 10: Structure And Function
V 03/13 Structure and function OptiSpray DPP01 - structure OptiSpray DPP01 Dense phase pump - structure Suction side Status LEDs Transport side Diagnostic LEDs Y-piece Operating keys Pneumatic system and elec- Pinch valves tronics Distribution block with filter ele- Pressure gauge... -
Page 11: Diffusers
OptiSpray DPP01 Dense phase pump - functioning Powder quantity control The OptiSpray DPP01 Dense phase pump operates always with the same frequency. The powder quantity is controlled by the opening time of the pinch valves on the inlet of the dense phase pump. The longer the... -
Page 12: Main Functions
Display of the pressure for the pinch valves and display of the backpressure during conveying procedure Internal pressure regulator for vacuum injector, pinch valve pressure and cleaning mode Keyboard lock - prevents an unmeant, manual intervention 10 • Function description OptiSpray DPP01... -
Page 13: Technical Data
V 03/13 Technical data OptiSpray DPP01 Dense phase pump Powder output (guide values) OptiSpray DPP01 Conveying hose till 25 m - internal Ø 7 mm 400 g/min Suction hose till 3 m - internal Ø 4,5 mm Conveying hose till 20 m - internal Ø 7 mm 500 g/min Suction hose till 1.2 m - internal Ø... -
Page 14: Dimensions
V 03/13 Dimensions OptiSpray DPP01 Height 360 mm Width 210 mm Depth 160 mm Weight 11,9 kg 12 • Technical data OptiSpray DPP01... -
Page 15: Start-Up And Operation
V 03/13 Start-up and operation Preparation for start-up Basic conditions By the start-up of the OptiSpray DPP01 Dense phase pump, the following basic conditions, which have an influence on the powder transport, must be considered: Characteristic of hose layout (suction hose) Length and height difference of the suction distance - max. -
Page 16: Optispray Dpp01 - Connections
V 03/13 OptiSpray DPP01 - connections The OptiSpray DPP01 Dense phase pump is supplied ready for use by the manufacturer. Just a few cables and hoses must be connected. The connection of the OptiSpray DPP01 Dense phase pump takes place according to following instructions: 1. -
Page 17: Optispray Dpp01 - Connections
V 03/13 OptiSpray DPP01 - connections Pin assignment Power IN connection Neutral conductor N Phase (100-240 VAC) P empty Grounding PE Control IN socket, 12 pins Control signal IDENT / Recognition REQUEST / Request Enclosure - shield Start-up and operation • 15... -
Page 18: Optispray Dpp01 - Start-Up
V 03/13 OptiSpray DPP01 - start-up Configuration The start-up of the OptiSpray DPP01 Dense phase pump takes place ac- cording to following instructions: 1. Connect the compressed air supply (6 bar) 2. Connect the power supply (100-240 VAC) 3. Ensure the grounding 4. -
Page 19: Optispray Dpp01 - Operating Elements
V 03/13 OptiSpray DPP01 - operating elements LEDs and operating keys Status LEDs Power Power - equipment is switched on Status Status - reserved Error Error - reserved Diagnostic LEDs These LEDs are assigned to the corresponding valves and illuminate when the valve is activated. -
Page 20: Optispray Dpp01 - Characteristics
V 03/13 OptiSpray DPP01 - characteristics Conveying direction The OptiSpray DPP01 Dense phase pump conveying direction is defined by the direction of arrow, that means, the suction side is on the bottom, the transport side on the top (see picture). -
Page 21: Optispray Dpp01 - Functional Check And Operation
Operation The OptiSpray DPP01 Dense phase pump is switched on by pressing the Mains Switch key on the rear side, the status LED Power on the front side illuminates. The OptiSpray DPP01 Dense phase pump is ready for operation. -
Page 22: Display Of The Pinch Valve Pressure (Pinch Valves)
The backpressure may not exceed 1.2 bar (Hot Coating: 1.8 bar). OptiSpray DPP01 - shutdown The OptiSpray DPP01 Dense phase pump is switched off by pressing the Mains Switch on the rear side and the Power status LED on the front side expires. -
Page 23: Special Functions
The keyboard lock will be activated/deactivated. Test program for error diagnosis The OptiSpray DPP01 Dense phase pump has an internal test program, which simplifies the error diagnosis. The test mode will be activated by pressing both keys, when switching on the device. -
Page 25: Cleaning And Maintenance
Maintenance of the OptiSpray DPP01 Dense phase pump The OptiSpray DPP01 Dense phase pump is designed in such a way, that only a minimum maintenance is required. Daily maintenance Clean the dense phase pump with a dry cloth and check the connection points of the powder hoses. -
Page 26: Maintenance Set
V 03/13 Maintenance set The wearing parts to be replaced during the OptiSpray DPP01 Dense phase pump maintenance, are available in two maintenance sets (see the spare parts list). One set contains 2 filter elements, the other set con- tains 8 pinch valves. -
Page 27: Replacing The Pinch Valves
The assembly takes place in reverse order! By assembling the Y-piece, do not tighten the screws too strong! Replacing the pinch valves Required spare parts - 4 pinch valve hoses NW 7.5 (spare parts set) Cleaning and maintenance • 25 OptiSpray DPP01... - Page 28 Attention! When cleaning the acryl pinch valve bodies, do not use alcohol, ac- etone, benzol or other solvents! For cleaning, use benzine, light lye or acid, acryl glass cleaner or a cleaning agent! 26 • Cleaning and maintenance OptiSpray DPP01...
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Page 29: Service Position
V 03/13 Service position Service position The front plate can be opened and swiveled in service position by loosing the six screws. Cleaning and maintenance • 27 OptiSpray DPP01... -
Page 30: Internal Pressure Regulators
Indicator BACK PRESSURE 0.3 – 1.0 bar 0.3 – 1.8 bar Checking the injector set pressure The set pressure can be checked by simple disconnecting/switching of the pneumatic hose. Checking the injector set pressure 28 • Cleaning and maintenance OptiSpray DPP01... -
Page 31: Troubleshooting
Check the compressed air supply No fluidization in the Ensure the fluidization suction zone Service life of the pinch Change the pinch valve, valve runs off (defective) check the pneumatic system for defects and replace, if necessary Troubleshooting • 29 OptiSpray DPP01... - Page 32 Oil or water in the sys- Ensure that oil or water will be separated before entering into the dense phase pump Equipment cannot be Keyboard lock is acti- Deactivate the keyboard operated by the keys vated lock 30 • Troubleshooting OptiSpray DPP01...
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Page 33: Schematic Diagrams
V 03/13 Schematic diagrams OptiSpray DPP01 - block diagram OptiSpray DPP01 - block diagram Schematic diagrams • 31 OptiSpray DPP01... -
Page 34: Optispray Dpp01 - Pneumatic Diagram
V 03/13 OptiSpray DPP01 - pneumatic diagram OptiSpray DPP01 - pneumatic diagram 32 • Schematic diagrams OptiSpray DPP01... -
Page 35: Spare Parts List
Ø 8/6 mm, 8 mm outside diameter (o/d) / 6 mm inside diameter (i/d) WARNING! Only original Gema spare parts should be used, because the haz- ardous location approval will be preserved that way! The use of spare parts from other manufacturers will invalidate the Gema guar- antee conditions! Spare parts list •... -
Page 36: Optispray Dpp01 - Spare Parts List
V 03/15 OptiSpray DPP01 - spare parts list OptiSpray DPP01 Dense phase pump - complete 1005 823 OptiSpray DPP01 Dense phase pump (HF version) - complete 1005 822 Filter ring bush - complete (pos. 2, 3, 4, 5) 1004 832... -
Page 37: Optispray Dpp01 - Spare Parts
V 03/13 OptiSpray DPP01 – Spare parts OptiSpray DPP01 Dense phase pump - spare parts Spare parts list • 35 OptiSpray DPP01... -
Page 38: Optispray Dpp01 - Rear View
V 03/13 OptiSpray DPP01 - rear view Fuse - 2 AT 221 872 Power supply extension - 1.2 m 1002 636 Power supply extension - 12 m 1002 637 1000 991 Connecting cable - 12 pins, 1.5 m Connecting cable - 12 pins, 5 m... -
Page 39: Optispray Dpp01 - Inside Rear View
V 03/13 OptiSpray DPP01 - inside rear view Power pack - 24 VDC 1003 100 Filter plate 1004 846 OptiSpray DPP01 - inside rear view Spare parts list • 37 OptiSpray DPP01... -
Page 40: Optispray Dpp01 - Inside Front View
V 03/13 OptiSpray DPP01 - inside front view Electronics board - complete 1004 171 Pressure gauge - 1-9 bar 1005 827 Pressure regulator - 0.5-7 bar 1005 177 1004 317 Solenoid valve - MHA2 Solenoid valve - MHA3 1004 318... - Page 41 V 03/13 Spare parts list • 39 OptiSpray DPP01...
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