Gema OptiSpray DPP01 Guide

En
Translation of the original operating instructions
Operating instructions and spare parts list
OptiSpray DPP01
Dense phase pump

V 03/13
Documentation OptiSpray DPP01
©Copyright 2006 Gema Switzerland GmbH
All rights reserved.
This publication is protected by copyright. Unauthorized copying is pro-
hibited by law. No part of this publication may be reproduced, photocop-
ied, 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.
OptiFlex, OptiTronic, OptiGun, EasyTronic, OptiSelect, OptiFlow and
SuperCorona are registered trademarks of Gema Switzerland GmbH.
OptiStar, OptiSpray, OptiMatic, OptiMove, OptiMaster, OptiPlus, Multi-
Tronic and Gematic 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 con-
cerned approve of or are bound in any form by this manual. We have en-
deavored to retain the preferred spelling of the trademarks, and regis-
tered 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 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.
Printed in Switzerland
Gema Switzerland GmbH
Mövenstrasse 17
9015 St. Gallen
Switzerland
Phone: [phone]
Fax.: [phone]
E-Mail: [e-mail]
Homepage: www.gemapowdercoating.com

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OptiSpray DPP01 Table of contents •1
Table of contents
General safety regulations 3
Safety symbols (pictograms) ...................................................................................3
Conformity of use ....................................................................................................3
Product specific security measures.........................................................................4
About this manual 5
General information.................................................................................................5
Function description 7
Field of application ..................................................................................................7
OptiSpray DPP01 Dense phase pump.......................................................7
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 11
OptiSpray DPP01 Dense phase pump..................................................................11
Powder output (guide values) ..................................................................11
Electrical data...........................................................................................11
Pneumatic data ........................................................................................11
Dimensions...............................................................................................12
Start-up and operation 13
Preparation for start-up .........................................................................................13
Basic conditions .......................................................................................13
Basic information......................................................................................13
OptiSpray DPP01 - connections ...........................................................................14
OptiSpray DPP01 - connections ...........................................................................15
Pin assignment.........................................................................................15
OptiSpray DPP01 - start-up...................................................................................16
Configuration ............................................................................................16
Fluidized powder hopper ..........................................................................16
Connection and control .........................................................................................16
Connection by the Control IN connector ..................................................16
OptiSpray DPP01 - operating elements ................................................................17
LEDs and operating keys .........................................................................17
Pressure display....................................................................................................17
Pinch valve pressure (PINCH VALVES) ..................................................17
Backpressure (BACK PRESSURE) .........................................................17
OptiSpray DPP01 - characteristics........................................................................18
Conveying direction..................................................................................18
Powder hose rinsing.................................................................................18

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2 •Table of contents OptiSpray DPP01
Maintenance interval monitoring .............................................................. 18
OptiSpray DPP01 - functional check and operation ............................................. 19
Operation ................................................................................................. 19
Switching on and off the conveying procedure ........................................ 19
Switching on and off the rinsing procedure.............................................. 19
Manual switching on and off the rinsing procedure on the pump ............ 19
Display of the pinch valve pressure (PINCH VALVES) ...........................20
Display of the backpressure (BACK PRESSURE) .................................. 20
OptiSpray DPP01 - shutdown............................................................................... 20
Special functions 21
Keyboard lock ....................................................................................................... 21
Activation/deactivation of the keyboard lock............................................ 21
Test program for error diagnosis .......................................................................... 21
Cleaning and maintenance 23
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....................................................................................... 24
Replacing the filter elements ................................................................... 24
Replacing the pinch valves ...................................................................... 25
Service position........................................................................................ 27
Internal pressure regulators ..................................................................... 28
Checking the injector set pressure ..........................................................28
Troubleshooting 29
General information .............................................................................................. 29
Schematic diagrams 31
OptiSpray DPP01 - block diagram........................................................................ 31
OptiSpray DPP01 - pneumatic diagram................................................................ 32
Spare parts list 33
Ordering spare parts ............................................................................................. 33
OptiSpray DPP01 - spare parts list....................................................................... 34
OptiSpray DPP01 – Spare parts ........................................................................... 35
OptiSpray DPP01 - rear view................................................................................36
OptiSpray DPP01 - inside rear view .....................................................................37
OptiSpray DPP01 - inside front view ....................................................................38

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OptiSpray DPP01 General safety regulations •3
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.
Safety symbols (pictograms)
The following warnings with their meanings can be found in the Gema
operating instructions. The general safety precautions must also be fol-
lowed as well as the regulations in the operating instructions.
DANGER!
Danger due to live electricity or moving parts. Possible consequences:
Death or serious injury
WARNING!
Improper use of the equipment could damage the machine or cause it to
malfunction. Possible consequences: minor injuries or damage to equip-
ment
INFORMATION!
Useful tips and other information
Conformity of use
1. The OptiSpray DPP01 Dense phase pump is built to the latest
specification and conforms to the recognized technical safety
regulations. It is designed for the normal application of powder
coating.
2. Any other use is considered as non-conform. The manufacturer
is not responsible for damage resulting from improper use of this
equipment; the end-user alone is responsible. If the OptiSpray
DPP01 Dense phase pump is to be used for other purposes or
other substances outside of our guidelines then Gema Switzer-
land GmbH should be consulted.

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4 •General safety regulations OptiSpray DPP01
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.
4. Start-up (i.e. the execution of a particular operation) is forbidden
until it has been established that the OptiSpray DPP01 Dense
phase pump has been set up and wired according to the guide-
lines for machinery (2006/42/EG). EN 60204-1 (machine safety)
must also be observed.
5. Unauthorized modifications to the OptiSpray DPP01 Dense
phase pump exempt the manufacturer from any liability from re-
sulting damage.
6. The relevant accident prevention regulations, as well as other
generally recognized safety regulations, occupational health and
structural regulations are to be observed.
7. Furthermore the country-specific safety regulations must be ob-
served.
Explosion protection Protection type Temperature class
II 3 D IP54 T6
Product specific security measures
- The installation work, to be done by the customer, must be
carried out according to local regulations
- It must be observed, that all components are grounded ac-
cording to the local regulations, before start-up
Note:
For further security information, see the more detailed Gema safety
regulations!

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OptiSpray DPP01 About this manual •5
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.
Information about the function mode of the individual system components
- reciprocators, booths, powder gun control units, powder guns etc. -
should be referenced to their corresponding documents.

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OptiSpray DPP01 Function description •7
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
from this - the risk for this is assumed by the user alone!
The OptiSpray DPP01 Dense phase pump operates only in combination
with the CG09-P Control unit.
OptiSpray DPP01 Dense phase pump

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8 •Function description OptiSpray DPP01
Structure and function
OptiSpray DPP01 - structure
OptiSpray DPP01 Dense phase pump - structure
A Suction side 4 Status LEDs
B Transport side 5 Diagnostic LEDs
1 Y-piece 6 Operating keys
2 Pinch valves 7 Pneumatic system and elec-
tronics
3 Distribution block with filter ele-
ments 8 Pressure gauge
Powder hoses
Depending the application, different powder hoses are used for the suc-
tion and conveying procedure. The corresponding hose connections with
nuts with kink protection must be used!
Field of application Suction side Transport side
OptiFlex FP Manual
equipment
Inside diameter 4.5 mm,
hose length < 1.2 m Inside diameter 7 mm
Automatic equipment Inside diameter 4.5 mm,
hose length < 3 m Inside diameter 7 mm
Note:
On the transport side, a powder hose with conductive strip must be
used (electrically conductive)!
1
B
A
2
3
2
1
6
8
4
7
5