Gema OptiSpray AP01.1 User manual

Rev. 00 1011 525 EN
Operating instructions and spare parts list
OptiSpray AP01.1
Application Pump
Translation of the original operating instructions

Rev. 00 05/17
Documentation OptiSpray AP01.1
© 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.
MagicCompact, MagicCylinder, MagicPlus, MagicControl, OptiFlex,
OptiControl, OptiGun, OptiSelect, OptiStar and SuperCorona are
registered trademarks of Gema Switzerland GmbH.
OptiFlow, OptiCenter, OptiMove, OptiSpeeder, OptiFeed, OptiSpray,
OptiSieve, OptiAir, OptiPlus, OptiMaster, MultiTronic, EquiFlow, Precise
Charge Control (PCC), Smart Inline Technology (SIT) and Digital Valve
Control (DVC) 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.Gall
Switzerland
Phone: [phone]
Fax.: [phone]
E-mail: [email protected]

Rev. 00 05/17
OptiSpray AP01.1 Table of contents •3
Table of contents
About this instructions 5
General information ................................................................................................ 5
Keeping the Manual ................................................................................................5
Safety symbols (pictograms)...................................................................................5
Presentation of the contents ...................................................................................6
Figure references in the text ......................................................................6
Safety 7
Basic safety instructions .........................................................................................7
Product specific security regulations ......................................................................8
Product description 9
Intended use ...........................................................................................................9
Reasonably foreseeable misuse...........................................................................10
Technical Data ......................................................................................................10
Electrical data ..........................................................................................10
Pneumatic data ........................................................................................10
Powder output (guide values) ..................................................................11
Dimensions ..............................................................................................11
Sound pressure level ...............................................................................11
Rating plate..............................................................................................12
Design and function ..............................................................................................13
General view ............................................................................................13
Powder hoses ..........................................................................................13
Spraying air function / diffusers................................................................14
Connections .............................................................................................15
Scope of delivery .................................................................................................. 15
Typical properties – functional characteristics ...................................................... 16
Main functions..........................................................................................16
Secondary functions ................................................................................16
Conveying direction ................................................................................. 16
Powder hose rinsing ................................................................................16
Maintenance interval monitoring.............................................................. 17
Assembly / Connection 19
Assembly guide.....................................................................................................19
Connection instructions.........................................................................................20
Start-up 23
Preparation for start-up .........................................................................................23
Basic conditions .......................................................................................23
Basic information .....................................................................................23
Operation 25
Operation ..............................................................................................................25
Switching on and off the conveying procedure ........................................25

Rev. 00 05/17
4 •Table of contents OptiSpray AP01.1
Switching on and off the rinsing procedure ............................................. 25
Maintenance / Repairs 27
General information .............................................................................................. 27
Maintenance of the dense phase pump ............................................................... 28
Maintenance schedule............................................................................. 28
Daily maintenance ................................................................................... 28
Pinch valve diagnostic ............................................................................. 28
Wearing parts .......................................................................................... 28
Cleaning................................................................................................................ 29
Cleaning the Application pump (color change)........................................ 29
Periodic checks .................................................................................................... 29
Repair work........................................................................................................... 30
Replacing the pinch valve hoses and filter elements .............................. 30
Pump disassembly .................................................................................. 31
Replacing the pinch valve hoses............................................................. 32
Replacing the filter elements ................................................................... 33
Replacing the Application pump in an OptiCenter .................................. 34
Fault clearance 35
Decommissioning / Storage 37
Decommissioning ................................................................................................. 37
If in disuse for several days ..................................................................... 37
Storage conditions................................................................................................ 37
Hazard notes ........................................................................................... 37
Type of storage........................................................................................ 37
Storage duration ...................................................................................... 37
Space requirements ................................................................................ 37
Physical requirements ............................................................................. 38
Maintenance during storage................................................................................. 38
Maintenance schedule............................................................................. 38
Maintenance works.................................................................................. 38
Disposal 39
Introduction ........................................................................................................... 39
Requirements on personnel carrying out the work.................................. 39
Disposal regulations ................................................................................ 39
Materials .................................................................................................. 39
Disassembly of component groups ...................................................................... 39
Spare parts list 41
Ordering spare parts............................................................................................. 41
OptiSpray AP01.1 Application pump .................................................................... 42
OptiSpray AP01.1 – spare parts........................................................................... 43
Connecting material.............................................................................................. 44

Rev. 00 05/17
OptiSpray AP01.1 About this instructions •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.
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
operating instructions. The general safety precautions must also be
followed as well as the regulations in the relevant operating instructions.
DANGER
Indicates a hazardous situation which,
if not avoided, will result in death or serious injury.
WARNING
Indicates a potentially hazardous situation which,
if not avoided, could result in death or serious injury.
CAUTION
Indicates a potentially hazardous situation which,
if not avoided, could result in minor or moderate injury.

Rev. 00 05/17
6 •About this instructions OptiSpray AP01.1
ATTENTION
Indicates a potentially harmful situation which,
if not avoided, the equipment or something in its surrounding may be
damaged.
ENVIRONMENT
Indicates a potentially harmful situation which,
if not avoided, may have harmful consequences for the environment.
MANDATORY NOTE
Information which must be observed.
NOTE
Useful information, tips, etc.
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."

Rev. 00 05/17
OptiSpray AP01.1 Safety •7
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.

Rev. 00 05/17
8 •Safety OptiSpray AP01.1
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 these
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.

Rev. 00 05/17
OptiSpray AP01.1 Product description •9
Product description
Intended use
The Application pump is intended for conveying coating powder to the
powder gun.
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-P 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.
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!

Rev. 00 05/17
10 •Product description OptiSpray AP01.1
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
Output 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

Rev. 00 05/17
OptiSpray AP01.1 Product description •11
Powder output (guide 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.

Rev. 00 05/17
12 •Product description OptiSpray AP01.1
Rating plate
fig. 2

Rev. 00 05/17
OptiSpray AP01.1 Product description •13
Design and function
General view
fig. 3
ASuction side
1 Pinch valve housing (suction
side)
2 Filter element bodies with
filter elements (suction side)
BConveyance 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!
Field of
application Suction side Conveyance 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

Rev. 00 05/17
14 •Product description OptiSpray AP01.1
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!

Rev. 00 05/17
OptiSpray AP01.1 Product description •15
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

Rev. 00 05/17
16 •Product description OptiSpray AP01.1
Typical properties – functional characteristics
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)

Rev. 00 05/17
OptiSpray AP01.1 Product description •17
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.

Rev. 00 05/17
18 •Product description OptiSpray AP01.1

Rev. 00 05/17
OptiSpray AP01.1 Assembly / Connection •19
Assembly / Connection
Assembly guide
The application pump can be used in an OptiCenter OC03/OC05 Powder
management center or as a part of the OptiFlex 2 Spray (B or F) manual
equipment.
fig. 6
ATTENTION
Surrounding temperature too high
– 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).

Rev. 00 05/17
20 •Assembly / Connection OptiSpray AP01.1
Connection instructions
The Gun control unit and the Application pump(s) are supplied ready for
use by the manufacturer. Just a few cables and hoses must be
connected.
fig. 7: Connection instructions – overview
1 Electrode rinsing air hose
2 Powder hose
3 Gun cable
4 Pinch valve air
5 Spraying air hose
6 Transport air hose
7 Control signal cable
8 Application pump no. 1
8.1 Application pump no. 2
9 Gun control
10 Compressed air hose
11 Hose coupling
Ø 8/6 – Ø 6/4 mm
12 Powder container