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Summary of Contents for Gema OptiSpray AP01.1
- Page 1 Rev. 00 1011 525 Operating instructions and spare parts list OptiSpray AP01.1 Application 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 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.
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Page 3: Table Of Contents
Assembly guide ..................... 19 Connection instructions ..................20 Start-up Preparation for start-up ..................23 Basic conditions ..................23 Basic information ..................23 Operation Operation ......................25 Switching on and off the conveying procedure ........25 Table of contents • 3 OptiSpray AP01.1... - Page 4 Materials ....................39 Disassembly of component groups ..............39 Spare parts list Ordering spare parts ..................... 41 OptiSpray AP01.1 Application pump ..............42 OptiSpray AP01.1 – spare parts ................43 Connecting material ....................44 4 • Table of contents OptiSpray AP01.1...
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Page 5: About This Instructions
General information This operating manual contains all important information you will need to work with the OptiSpray AP01.1. 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. -
Page 6: Presentation Of The Contents
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." 6 • About this instructions OptiSpray AP01.1... -
Page 7: Safety
If this product is to be used for other purposes or other substances outside of our guidelines then Gema Switzerland GmbH should be consulted. -
Page 8: Product Specific Security 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! WARNING Working without instructions Working without instructions or with individual pages from these instructions may result in damage to property and personal injury if relevant safety information is not observed. -
Page 9: Product Description
CG12-CP (automatic equipment) or the OptiStar CG11-P Control unit (manual equipment). The application pump will only operate in combination with the OptiGun GA03-P automatic gun or with other Gema models with a suitable diffuser (spraying air adapter). Please contact Gema if you have any further queries. -
Page 10: Reasonably Foreseeable Misuse
Use with insufficient compressed air quality – Input pressure too low – Use in connection with unauthorized coating devices or components Technical Data Electrical data OptiSpray AP01.1 Nominal input voltage 24 VDC Output 10 VA Protection type IP54 +15 °C - +40 °C Temperature range (+59 °F - +104 °F) -
Page 11: Powder Output (Guide Values)
Rev. 00 05/17 Powder output (guide values) OptiSpray AP01.1 In OptiCenter: Conveying hose till 20 m – internal Ø 7 50-300 g/min Suction tube/hose till 30 cm – internal Ø 4,5 mm In manual equipment: Conveying hose till 20 m – internal Ø 7 50-300 g/min Suction hose max. -
Page 12: Rating Plate
Rev. 00 05/17 Rating plate fig. 2 12 • Product description OptiSpray AP01.1... -
Page 13: Design And Function
Inside diameter 4.5 mm In OptiCenter Inside diameter 7 mm OptiCenter suction OC03/OC05 tube/hose max. 30 cm In manual Inside diameter 4.5 mm, equipment Inside diameter 7 mm hose length max. 1.5 m OptiFlex 2 Spray Product description • 13 OptiSpray AP01.1... -
Page 14: Spraying Air Function / Diffusers
Spraying air The OptiGun GA02 automatic gun and the OptiSelect GM03 manual gun must also be equipped with an appropriate diffuser adapter. The diffuser is grounded through the powder transport hose with conductive strips! 14 • Product description OptiSpray AP01.1... -
Page 15: Connections
Transport air (Conveying Air IN) connection Pinch valve air connection External signal connection Pin assignment Connection 2.5 Ext., 12-pins Control signal +24 VDC Body – grounding PE Scope of delivery – Mains cable – Operating manual Product description • 15 OptiSpray AP01.1... -
Page 16: Typical Properties - Functional Characteristics
Powder chamber emptying combined with hose cleaning in both directions – Cleaning the hose to the gun only – Cleaning the hose on the suction side only (For details, see the operating instructions of the corresponding gun control unit) 16 • Product description OptiSpray AP01.1... -
Page 17: Maintenance Interval Monitoring
OptiSpeeder! The pump is to be cleaned as a component of the entire system. Maintenance interval monitoring This function is provided by the OptiStar CG12-CP or the CG11-P Control unit. Product description • 17 OptiSpray AP01.1... - Page 18 Rev. 00 05/17 18 • Product description OptiSpray AP01.1...
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Page 19: Assembly / Connection
Install the Application pump only in locations with an ambient temperature of between +15 and +40 °C, i.e. never next to heat sources (such as an enameling furnace) or electromagnetic sources (such as a control cabinet). Assembly / Connection • 19 OptiSpray AP01.1... -
Page 20: Connection Instructions
8.1 Application pump no. 2 Gun cable Gun control Pinch valve air 10 Compressed air hose Spraying air hose 11 Hose coupling Ø 8/6 – Ø 6/4 mm Transport air hose 12 Powder container Control signal cable 20 • Assembly / Connection OptiSpray AP01.1... - Page 21 – Check ground connections with Ohm meter and ensure 1 MOhm or less! The compressed air must be free of oil and water! Close the unused connections with the provided dust protection caps! Assembly / Connection • 21 OptiSpray AP01.1...
- Page 22 Rev. 00 05/17 22 • Assembly / Connection OptiSpray AP01.1...
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Page 23: Start-Up
– At the suction area, a homogeneous fluidization must be ensured, so that no air ducts (craters) can be formed – The Application pump is not intended for use with enamel powders Start-up • 23 OptiSpray AP01.1... - Page 24 Rev. 00 05/17 24 • Start-up OptiSpray AP01.1...
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Page 25: Operation
For a better understanding of the interrelationships in powder coating, it is recommended to read completely the operating instructions of the control unit and the powder gun, so as to be familiar with their functions too. Operation • 25 OptiSpray AP01.1... - Page 26 Rev. 00 05/17 26 • Operation OptiSpray AP01.1...
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Page 27: Maintenance / Repairs
The parts to be replaced during maintenance work are available as spare parts. For further information see chapter "Spare parts list". General information The product is designed in such a way, that only a minimum maintenance is required. Maintenance / Repairs • 27 OptiSpray AP01.1... -
Page 28: Maintenance Of The Dense Phase Pump
– see below. Wearing parts The wearing parts to be replaced during the OptiSpray AP01 Application pump maintenance are available separately (see spare parts list). 28 • Maintenance / Repairs OptiSpray AP01.1... -
Page 29: Cleaning
Periodic checks The periodic checks include examining all connecting cables and hoses. The corresponding parts should be replaced immediately if any damage to cables or hoses is discovered. All plugs must be properly tightened. Maintenance / Repairs • 29 OptiSpray AP01.1... -
Page 30: Repair Work
Repair work In the event of a fault, the product must be checked and repaired by an authorized Gema service workshop. The repairs must only be performed by an authorized specialist. Improper tampering can result in serious danger for user and equipment. -
Page 31: Pump Disassembly
Rev. 00 05/17 Required Tools fig. 9 Dismantling tool Allen key size 4 mm (Order number: 1012 909) Allen key size 3 mm Open-ended wrench 16 mm Pump disassembly Maintenance / Repairs • 31 OptiSpray AP01.1... -
Page 32: Replacing The Pinch Valve Hoses
– Make sure that the positioning tabs are set correctly! ATTENTION Broken pinch valve hose may cause the clogging of the fluid blocking plate – Clean or replace the corresponding fluid blocking plate! 32 • Maintenance / Repairs OptiSpray AP01.1... -
Page 33: Replacing The Filter Elements
Operate the Application pump with powder at least 1/2 hour after replacing the filter elements. – After the running-in of the filter elements a stable powder output value will be reached. Maintenance / Repairs • 33 OptiSpray AP01.1... -
Page 34: Replacing The Application Pump In An Opticenter
Replacing the Application pump in an OptiCenter Remove the powder from the system Start the cleaning program, rinse in both directions Depressurize/vent OptiCenter Next steps are described in the corresponding OptiCenters operating manual 34 • Maintenance / Repairs OptiSpray AP01.1... -
Page 35: Fault Clearance
Powder hoses tend to clogging Clean or replace the powder hoses due to sintering Oil or water in the system Ensure that oil or water will be separated before entering into the Application pump Fault clearance • 35 OptiSpray AP01.1... - Page 36 Rev. 00 05/17 Incident Causes Corrective action Transport air offset C3 not Adapt transport air offset C3 (see adapted to powder output operating manual OptiStar CG12- CP or CG11-P, section "Correction values") 36 • Fault clearance OptiSpray AP01.1...
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Page 37: Decommissioning / Storage
If the physical conditions are maintained, the unit can be stored indefinitely. Space requirements The space requirements correspond to the size of the product. There are no special requirements concerning distance to neighboring equipment. Decommissioning / Storage • 37 OptiSpray AP01.1... -
Page 38: Physical Requirements
Storage must be inside a dry building at a temperature between +5 and +50 °C. Do not expose to direct sunlight. Maintenance during storage Maintenance schedule No maintenance schedule is necessary. Maintenance works During long-term storage, periodically perform a visual check. 38 • Decommissioning / Storage OptiSpray AP01.1... -
Page 39: Disposal
Requirements on personnel carrying out the work The disposal of the product is to be carried out by the owner or operator. When disposing of components that are not manufactured by Gema, the instructions in the respective third-party manufacturer’s documentation must be observed. - Page 40 Rev. 00 05/17 40 • Disposal OptiSpray AP01.1...
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Page 41: Spare Parts List
When using the spare parts from other manufacturers the explosion protection is no longer guaranteed. If any damage is caused by this use all guarantee claims become invalid! ► Only original Gema spare parts should be used! Spare parts list • 41 OptiSpray AP01.1... -
Page 42: Optispray Ap01.1 Application Pump
Rev. 00 05/17 OptiSpray AP01.1 Application pump OptiSpray AP01.1 Application pump – complete (pos. 1-14, 24, 27) 1015 447 Allen cylinder screw – M5x130 mm 1010 431 Upper end piece 1010 428 Filter element – 3 µm, complete 1014 060# Allen cylinder screw –... -
Page 43: Optispray Ap01.1 - Spare Parts
Rev. 00 05/17 OptiSpray AP01.1 – spare parts fig. 10 Item Tightening torque [Nm] 4.4 (greased) 3.1 (greased) 4.4 (greased) Spare parts list • 43 OptiSpray AP01.1... -
Page 44: Connecting Material
Connecting cable – 12 pins, 10 m 1000 976 Connecting cable – 12 pins, 15 m 1000 977 Connecting cable – 12 pins, 20 m 1000 978 * Please indicate length fig. 11: Connecting material 44 • Spare parts list OptiSpray AP01.1... - Page 45 Intended use ............9 Interval .............. 27 Safety ..............7 Safety symbols ..........5 Scope of delivery ..........15 Secondary functions ........16 Keeping the Manual ........... 5 Sound pressure level ........11 Spare parts list ..........41 Index • 45 OptiSpray AP01.1...
- Page 46 Spraying air function / diffusers ....... 14 Start-up ............23 Technical Data ..........10 Storage ............37 Typical characteristics ........16 Storage conditions ........... 37 Switching on and off Conveying procedure ........25 Rinsing procedure ........25 Wearing parts ........... 28 46 • Index OptiSpray AP01.1...
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