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Summary of Contents for Gema OptiSpray AP01
- Page 1 Operating instructions and spare parts list OptiSpray AP01 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
Conveying direction ................. 16 Powder hose rinsing ................16 Maintenance interval monitoring .............. 17 OptiSpray AP01 - functional check and operation ..........17 Switching on and off the conveying procedure ........17 Switching on and off the rinsing procedure ..........17 OptiSpray AP01 - shutdown .................. - Page 4 V 03/13 Cleaning and maintenance Cleaning the Application pump (color change) ............. 19 Maintenance of the OptiSpray AP01 Application pump ........19 Daily maintenance ................... 19 OptiSpray AP01 - maintenance plan ............19 Wearing parts ..................20 Replacing the filter elements ..............20 Replacing the pinch valves ..............
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Page 5: General Safety Regulations
Gema Switzerland GmbH must be consulted prior to any use of the OptiSpray AP01 for any purposes or substances other than those indicated in our guidelines. -
Page 6: Product-Specific Safety Measures
V 03/13 conformity of use. The OptiSpray AP01 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 intended operational tasks) is... -
Page 7: About This Manual
General information This operating manual contains all the important information you require for the working with the OptiSpray AP01 Application pump. 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 9: Function Description
Control unit (manual equipment). The OptiSpray AP01 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: Design And Function
V 03/13 Design and function OptiSpray AP01 - structure OptiSpray AP01 Application pump - structure Suction side Transport side Filter element bodies with filter Pneumatic system and elements electronics Pinch valve housing Powder hoses Depending the application, different powder hoses are used for the suction and conveying procedure. -
Page 11: Spraying Air Function / Diffusers
Powder quantity control The OptiSpray AP01 Application 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 Application pump. The longer the pinch... -
Page 13: Technical Data
V 03/13 Technical data OptiSpray AP01 Application pump Powder output (guide values) OptiSpray AP01 Conveying hose till 20 m - internal Ø 7 mm 80-300 g/min Suction hose or tube till 30 cm - internal Ø 4,5 mm Electrical data... -
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 AP01 Application pump, the following basic conditions, which have an influence on the powder transport, must be considered: Characteristic of hose layout Length and height difference of the suction distance - max. -
Page 16: Optispray Ap01 - Connections
V 03/13 OptiSpray AP01 - connections The OptiSpray AP01 Application pump is supplied ready for use by the manufacturer. Just a few cables and hoses must be connected. The connection of the OptiSpray AP01 Application pump takes place according to following instructions: 1. -
Page 17: Optispray Ap01 - Connections
V 03/13 OptiSpray AP01 - connections Pin assignment Control IN socket, 12 pins Control signal IDENT / Recognition REQUEST / Request Enclosure - shield Start-up and operation • 15 OptiSpray AP01... -
Page 18: Optispray Ap01 - Start-Up
V 03/13 OptiSpray AP01 - Start-up Configuration The start-up of the OptiSpray AP01 Application pump takes place according to following instructions: 1. Connect the compressed air supply to the connection 1.1 (6 bar) 2. Connect the transport air hose to the connection 1.2 3. -
Page 19: Maintenance Interval Monitoring
CG11-P Control unit (see the corresponding operating manual). OptiSpray AP01 - shutdown The OptiSpray AP01 Application pump is switched off by the CG12-CP or the CG11-P control unit. The compressed air supply to the Application pump must also be interrupted! Start-up and operation •... -
Page 21: Cleaning And Maintenance
The rinsing procedure can be started and stopped only externally via control unit or plant control. Maintenance of the OptiSpray AP01 Application pump The OptiSpray AP01 Application pump is designed in such a way, that only a minimum maintenance is required. Daily maintenance Clean the Application pump with a dry cloth and check the connection points of the powder hoses. -
Page 22: Wearing Parts
V 03/13 Wearing parts The wearing parts to be replaced during the OptiSpray AP01 Application pump maintenance are available separately (see the spare parts list). Replacing the filter elements WARNING! Before dismantling/changing the filter elements, it is necessary to clean the Application pump in both directions by using the rinsing... - Page 23 V 03/13 Cleaning and maintenance • 21 OptiSpray AP01...
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Page 24: Replacing The Pinch Valves
For cleaning, use benzine, light lye or acid or a cleaning agent! Braided sleeve NOTE! The assembly takes place in reverse order! By assembling, do not tighten the screws too strong! 22 • Cleaning and maintenance OptiSpray AP01... -
Page 25: Replacing The Application Pump
V 03/13 Replacing the Application pump 1. Remove the powder from the system 2. Start the cleaning program, rinse in both directions 3. Depressurize/vent OptiCenter Cleaning and maintenance • 23 OptiSpray AP01... -
Page 27: Fault Remedying
Powder hoses tend to Clean or replace the powder clogging due to sintering hoses Oil or water in the Ensure that oil or water will system be separated before entering into the Application pump Fault remedying • 25 OptiSpray AP01... -
Page 29: 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 explosion protection will also be preserved that way. The use of spare parts from other manufacturers will invalidate the Gema guarantee conditions! Spare parts list •... -
Page 30: Optispray Ap01 - Spare Parts List
V 03/13 OptiSpray AP01 – spare parts list OptiSpray AP01 Application pump – complete, boxed Allen cylinder screw - M5x120 mm 1010 369 Upper end piece 1010 049 Filter element – 3 µm, 10 mm, complete (incl. pos. 3.1) 1009 312# O-ring - Ø... -
Page 31: Optispray Ap01 - Spare Parts
V 03/13 OptiSpray AP01 – spare parts OptiSpray AP01 Application pump – spare parts Spare parts list • 29 OptiSpray AP01... -
Page 32: Optispray Ap01 - Connections
V 03/13 OptiSpray AP01 - connections Plastic tube - Ø 8/6 mm, blue 103 497* Plastic tube - Ø 8/6 mm, black 103 152* Plastic tube - Ø 8/6 mm, green 103 519* Connecting cable - 12 pins, 1.5 m 1000 991 Connecting cable - 12 pins, 2.2 m... - Page 33 V 03/13 Spare parts list • 31 OptiSpray AP01...
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