Gema OptiSpray AP01.1-E Guide

Rev. 03 1011 526 EN
Operating instructions and Spare parts list
Application pump
OptiSpray AP01.1-E
Translation of the original operating instructions

Rev. 03 01/21
Documentation OptiSpray AP01.1-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 and OptiStar 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) und
SuperCorona are 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 patent information, see www.gemapowdercoating.com/patents or
www.gemapowdercoating.us/patents.
Printed in Switzerland
Gema Switzerland GmbH
Mövenstrasse 17
9015 St.Gallen
Switzerland
Phone:[phone]
Fax.: [phone]
E-mail: [email protected]

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OptiSpray AP01.1-E Table of contents
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3
Table of contents
About these instructions 7
General information ................................................................................................7
Keeping the Manual................................................................................................7
Safety symbols (pictograms)...................................................................................7
Structure of Safety Notes...........................................................................8
Presentation of the contents...................................................................................8
Figure references in the text......................................................................8
Safety 9
Basic safety instructions .........................................................................................9
Product specific security regulations ....................................................................10
Product description 11
Intended use .........................................................................................................11
Reasonably foreseeable misuse...........................................................................12
Technical Data......................................................................................................12
Electrical data ..........................................................................................12
Pneumatic data........................................................................................12
Powder output (reference values)............................................................13
Dimensions ..............................................................................................13
Sound pressure level...............................................................................13
Rating plate..............................................................................................14
Design and function..............................................................................................15
Overall view..............................................................................................15
Powder hoses ..........................................................................................15
Spraying air function / diffusers................................................................16
Connections.............................................................................................17
Scope of delivery ..................................................................................................17
Typical properties - Characteristics of the functions.............................................18
Main functions..........................................................................................18
Secondary functions ................................................................................18
Conveying direction .................................................................................18
Powder hose rinsing ................................................................................18
Maintenance interval monitoring..............................................................19
Assembly / Connection 21
Assembly guide.....................................................................................................21
Connection instructions.........................................................................................22
Start-up 25
Preparation for start-up.........................................................................................25
Basic conditions.......................................................................................25
Basic information .....................................................................................25
Operation 27
Operation ..............................................................................................................27

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Table of contents OptiSpray AP01.1-E
Switching on and off the conveying procedure........................................ 27
Switching on and off the rinsing procedure............................................. 27
Maintenance / Repairs 29
General information.............................................................................................. 29
Maintenance of the dense phase pump............................................................... 30
Maintenance schedule............................................................................. 30
Daily maintenance................................................................................... 30
Pinch valve diagnostic............................................................................. 30
Wearing parts.......................................................................................... 30
Cleaning................................................................................................................ 31
Cleaning the Application pump (color change)........................................ 31
Periodic checks .................................................................................................... 31
Repair work........................................................................................................... 32
Replacing the pinch valve hoses and filter elements........................................... 32
Pump disassembly .................................................................................. 33
Replacing the pinch valve hoses............................................................. 34
Replacing the filter elements................................................................... 35
Replacing the solenoid valves for pinch valves control........................................ 36
Requirements on personnel carrying out the work.................................. 36
Replacing the solenoid valves................................................................. 37
Replacing the Application pump in an OptiCenter .................................. 40
Fault clearance 41
Decommissioning / Storage 45
Shutdown.............................................................................................................. 45
If in disuse for several days..................................................................... 45
Storage conditions................................................................................................ 45
Hazard notes........................................................................................... 45
Type of storage........................................................................................ 45
Storage duration...................................................................................... 45
Space requirements ................................................................................ 45
Physical requirements............................................................................. 46
Maintenance during storage................................................................................. 46
Maintenance schedule............................................................................. 46
Maintenance works.................................................................................. 46
Disposal 47
Introduction........................................................................................................... 47
Requirements on personnel carrying out the work.................................. 47
Disposal regulations................................................................................ 47
Materials.................................................................................................. 47
Disassembly of component groups...................................................................... 47
Spare parts list 49
Ordering spare parts............................................................................................. 49
OptiSpray AP01.1-E Application pump ................................................................ 50
OptiSpray AP01.1-E –spare parts....................................................................... 51
OptiSpray Twin AP01.1-E Application pump........................................................ 52
OptiSpray Twin AP01.1-E –spare parts .............................................................. 53
Connecting material.............................................................................................. 54
Diffuser (OptiGun GA03-E)................................................................................... 55
Diffuser (OptiSelect Pro GM04-E)........................................................................ 56
Diffuser (OptiSelect GM03-E)............................................................................... 57

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OptiSpray AP01.1-E Table of contents
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Rev. 03 01/21
OptiSpray AP01.1-E About these instructions

7
About these instructions
General information
This operating manual contains all important information which you
require for the working with the OptiSpray AP01.1-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 OptiSpray AP01.1-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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OptiSpray AP01.1-E Safety
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9
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.

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
Safety OptiSpray AP01.1-E
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!
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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OptiSpray AP01.1-E Product description
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11
Product description
Intended use
The Application pump is intended for conveying enamel powder to the
powder gun. 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.
The application pump operates only in combination with the OptiStar
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-E automatic gun or with other Gema models with a suitable diffuser
(spraying air adapter). Please contact Gema if you have any further
queries.
fig.
1
Observance of the operating, service and maintenance instructions
specified by the manufacturer is also part of conformity of 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.

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
Product description OptiSpray AP01.1-E
Any other use is considered non-compliant. The manufacturer is not
responsible for any incorrect use and the risks associated with such
actions are assumed by the user alone!
For a better understanding of the interrelationships in powder coating, it is
recommended that the operating instructions for all other components be
read as well, so as to be familiar with their functions too.
Reasonably foreseeable misuse
–Operation without the proper training
–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
Performance
10 VA
Protection type
IP54
Temperature range
+15 °C - +40 °C
(+59 °F - +104 °F)
Temperature class
T6
Approvals
II 3 D
Pneumatic data
OptiSpray AP01.1
Compressed air connection
Quick release connection
- 8 mm
Inlet pressure
6 bar
Max. compressed air consumption
≈ 2.0 Nm³/h
Max. water vapor content of the
compressed air
1.3 g/m³
Max. oil vapor content of the compressed
air
0.1 mg/m³

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OptiSpray AP01.1-E Product description
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13
Powder output (reference values)
OptiSpray AP01.1
In OptiCenter:
Conveying hose till 20 m –internal Ø 7
mmSuction tube/hose till 30 cm –
internal Ø 4,5 mm
50-300 g/min
In manual equipment:
Conveying hose till 20 m –internal Ø 7
mmSuction hose max. 1.5 m –internal
Ø 4,5 mm
50-300 g/min
Dimensions
OptiSpray AP01.1
Height (basic module, without
connections)
275 mm
Width
40 mm
Depth
183 mm
Weight (basic module, without
connections)
3.2 kg
Sound pressure level
OptiSpray AP01.1
Normal operation
< 60 dB(A)
The sound pressure level was measured while the unit was in operation;
measurements were taken at the most frequent operator positions and at
a height of 1.7 m from the ground.
The specified value is applicable only for this product itself and does not
take into account external noise sources or cleaning impulses.
The sound pressure level may vary, depending on the product
configuration and space constraints.

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Product description OptiSpray AP01.1-E
Rating plate
fig.
2

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OptiSpray AP01.1-E Product description
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15
Design and function
Overall view
fig.
3
ASuction side
1 Pinch valve housing (suction
side)
2 Filter element bodies with
filter elements (suction side)
BTransport side
3 Pinch valve housing
(transport side)
4 Filter element bodies with
filter elements (transport
side)
5 Pneumatic system and
electronics
Powder hoses
Depending the application, different powder hoses are used for the
suction and conveying procedure. The corresponding hose connections
with nuts with kink protection must be used!
Application
Suction side
Transport side
In OptiCenter
OC03/OC05
Inside diameter 4.5 mm
OptiCenter suction
tube/hose max. 30 cm
Inside diameter 7
mm
In manual
equipment
OptiFlex 2 Spray
Inside diameter 4.5 mm,
hose length max. 1.5 m
Inside diameter 7
mm

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Product description OptiSpray AP01.1-E
Other hose diameters can also be used for certain applications.
–Only use other hose diameters with the explicit recommendation
of Gema!
–On the transport side, a powder hose with conductive strip must
be used (electrically conductive)!
Spraying air function / diffusers
The coating guns to be used must be equipped with the appropriate
spraying air function or with an appropriate diffuser adapter.
fig.
4
: Air streams in the diffuser adapter
GL
Total air
TL
Transport air
ZL
Spraying air
P
Gun
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!

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OptiSpray AP01.1-E Product description
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17
Connections
Compressed air hoses / cables
fig.
5
: Connections –Compressed air hoses / cables
Connection
Description
1.1
Compressed air (Air Supply IN) connection
1.2
Transport air (Conveying Air IN) connection
1.6
Pinch valve air connection
2.5
External signal connection
Pin assignment
Connection 2.5 Ext., 12-pins
A-H
Control signal
J-M
+24 VDC
Body –grounding PE
Scope of delivery
–Mains cable
–Operating manual

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Product description OptiSpray AP01.1-E
Typical properties - Characteristics of the functions
Main functions
–Conveying coating powder from or a fluidized container to the
powder gun
–Processing signals from the superordinated OptiStar CG12-CP or
CG11-P Control unit
Secondary functions
–Powder hose rinsing and cleaning of the filter elements
Conveying direction
The Application 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).
Powder hose rinsing
The powder hose rinsing enables the cleaning of the powder hoses and
the filter elements in the Application pump. If color changes take place,
rinsing must be done in conveying and in suction direction.
Cleaning programs
The OptiStar Gun control unit features three cleaning programs:
–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)

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OptiSpray AP01.1-E Product description
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19
ATTENTION
Large dust formation possible!
►The conveying hose and the powder gun must be pointed into the
booth during the cleaning procedure!
The Ultra sonic sieve can be damaged during cleaning when being
used with an OptiCenter.
►Only the original lid (without any sieve insert) must be assembled
and closed on the 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.

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Product description OptiSpray AP01.1-E