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
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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-
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Printed in Switzerland
Gema Switzerland GmbH
Mövenstrasse 17
9015 St. Gallen
Switzerland
Phone: [phone]
Fax.: [phone]
E-Mail: [e-mail]
Homepage: www.gemapowdercoating.com

V 03/13
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

V 03/13
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

V 03/13
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.

V 03/13
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!

V 03/13
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.

V 03/13
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

V 03/13
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

V 03/13
OptiSpray DPP01 Function description •9
Diffusers
The powder guns must be equipped with a corresponding diffuser. The
diffuser is grounded by transport hoses with conductive strips!
OptiSpray DPP01 Dense phase pump - function-
ing
Suction procedure
In powder chamber 1, a vacuum (negative pressure) is produced. This
vacuum aspirates the coating powder in the powder chamber. A fine-
porous filter element (1) in the powder chamber separates the powder.
The powder chamber is closed at the output side by a pinch valve (2).
Conveying procedure
The pinch valve (3) on the input side of the powder chamber 2 is closed,
the pinch valve (4) on the output side is opened. The coating powder is
pressed out of the powder chamber by overpressure, which is created
with compressed air by the fine-porous filter element, and continued to
convey.
The suction and the conveying procedure alternate between both powder
chambers.
OptiSpray DPP01 Dense phase pump - functioning
Powder quantity control
The OptiSpray DPP01 Dense phase 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 dense phase pump. The longer the
pinch valves on the inlet of the dense phase pump remain open during
the suction procedure, the more powder will be aspirated into the powder
chamber and then will be transported in conveying direction.
Powder chamber 1
1
2
3
Suction
procedure
V
acuum
Compr. ai
r
Conveying
procedure
Powder chamber 2
4

V 03/13
10 •Function description OptiSpray DPP01
Main functions
- Conveying coating powder from or a fluidized container to
the powder gun
- Processing signals from the superordinated CG09-P Control
unit
Secondary functions
- Powder hose rinsing and cleaning of the filter elements - can
be started in suction and blowing off direction
- Display of the pressure for the pinch valves and display of
the backpressure during conveying procedure
- Internal pressure regulator for vacuum injector, pinch valve
pressure and cleaning mode
- Keyboard lock - prevents an unmeant, manual intervention

V 03/13
OptiSpray DPP01 Technical data •11
Technical data
OptiSpray DPP01 Dense phase pump
Powder output (guide values)
OptiSpray DPP01
Conveying hose till 25 m - internal Ø 7 mm
Suction hose till 3 m - internal Ø 4,5 mm 400 g/min
Conveying hose till 20 m - internal Ø 7 mm
Suction hose till 1.2 m - internal Ø 4.5 mm 500 g/min
Conveying hose till 20 m - internal Ø 7 mm
Suction hose till 1.2 m - internal Ø 4.5 mm 700 g/min
Electrical data
OptiSpray DPP01
Nominal input voltage 100-240 VAC
Frequency 50/60 Hz
Performance 20 VA
Protection type IP54
Temperature range 0°C - 40°C
(+32°F - +104°F)
Temperature class T6
Approval II 3 D
Pneumatic data
OptiSpray DPP01
Compressed air main connection Quick release connection - 8
mm
Input pressure 6 bar
Max. compressed air consumption 12 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

V 03/13
12 •Technical data OptiSpray DPP01
Dimensions
OptiSpray DPP01
Height 360 mm
Width 210 mm
Depth 160 mm
Weight 11,9 kg

V 03/13
OptiSpray DPP01 Start-up and operation •13
Start-up and operation
Preparation for start-up
Basic conditions
By the start-up of the OptiSpray DPP01 Dense phase pump, the following
basic conditions, which have an influence on the powder transport, must
be considered:
- Characteristic of hose layout (suction hose)
- Length and height difference of the suction distance - max. 3 m
- Length of the conveying distance - min. 10 m
- Powder preparation and powder quality
- Spatial arrangement of the OptiSpray DPP01 Dense phase
pump (layout, length and internal diameter of the suction
hose)
Basic information
The adherence of the following principles leads to a successful start-up of
the OptiSpray DPP01 Dense phase pump:
- The suction distance is to be kept as short as possible
- If the powder hose can be arranged wavy in plump line, then
this is to be preferred to the horizontal arrangement (flat on
the floor)
- At the suction area, a homogeneous fluidization must be en-
sured, so that no air ducts (craters) can be formed
- Basically, the powder transport with the OptiSpray DPP01
Dense phase pump works with every powder type, which can
be fluidized. If the powder is for example humid or contami-
nated with other materials, then the conveying can be nega-
tively influenced or does not work at all
- The OptiSpray DPP01 Dense phase pump has to be in-
stalled vertically

V 03/13
14 •Start-up and operation OptiSpray DPP01
OptiSpray DPP01 - connections
The OptiSpray DPP01 Dense phase pump is supplied ready for use by
the manufacturer. Just a few cables and hoses must be connected.
The connection of the OptiSpray DPP01 Dense phase pump takes place
according to following instructions:
1. Connect the powder hoses to the dense phase pump input
and output
2. Connect the compressed air supply to the connection Air
Supply IN
3. Connect the transport air to the connection Conveying Air
IN
4. Connect the control signal cable to the connection Control
IN
5. Connect the grounding cable (or ensure the grounding by
fasten it to a grounded plate)
6. Connect the pump operating voltage to the connection Pow-
er IN
Note:
The further start-up procedure for the OptiSpray DPP01 Dense
phase pump is explicitly described in the CG09-P Gun control unit
operating instructions (chapter "Initial start-up" and "Daily start-
up")!
Signal connection
(Control IN)
Grounding
Compressed air
connection
(Air Supply IN)
Power supply
(Power IN)
Transport ai
r
connection
(Conveying Air IN)

V 03/13
OptiSpray DPP01 Start-up and operation •15
OptiSpray DPP01 - connections
Pin assignment
Power IN connection
1 Neutral conductor N
2 Phase (100-240 VAC) P
3 empty
PE Grounding PE
Control IN socket, 12 pins
A-J Control signal
K IDENT / Recognition
L REQUEST / Request
M GND
Enclosure - shield
2
PE 3
1

V 03/13
16 •Start-up and operation OptiSpray DPP01
OptiSpray DPP01 - start-up
Configuration
The start-up of the OptiSpray DPP01 Dense phase pump takes place ac-
cording to following instructions:
1. Connect the compressed air supply (6 bar)
2. Connect the power supply (100-240 VAC)
3. Ensure the grounding
4. Switch on the OptiSpray DPP01 Dense phase pump
5. Adapt the adjusting parameters for total air and powder out-
put (see also the CG09-P operating instructions)
6. Adjust the fluidization on the control unit
7. Start the pumping procedure by pressing the gun trigger
Fluidized powder hopper
The powder is fluidized in the powder container by fluidizing air forced
through a porous plastic plate from below. Thereby, the powder becomes
loose and acquires fluid-like characteristics.
Note:
For a better understanding of the interrelationships in powder coat-
ing, it is recommended to read completely the operating instruc-
tions of the control unit and the powder gun, so as to be familiar
with their functions too!
Connection and control
Connection by the Control IN connector
The OptiSpray DPP01 Dense phase pump is connected and controlled
with CG09-P Gun control unit by the Control IN connection.
OptiSpray
DPP01 Dense
phase pump
CG09-P
Gun control

V 03/13
OptiSpray DPP01 Start-up and operation •17
OptiSpray DPP01 - operating elements
LEDs and operating keys
Status LEDs
Power - equipment is switched on
Status - reserved
Error - reserved
Diagnostic LEDs
These LEDs are assigned to the corresponding valves and illuminate
when the valve is activated. If the LED does not or does constantly illu-
minate, a valve or the controlling by the control unit can be defective.
Operating keys
Key T1 - rinsing in conveying direction (in upwards direction)
Key T2 - rinsing in suction direction (in downwards direction)
The cleaning programs can be terminated by pressing any key.
Pressure display
Pinch valve pressure (PINCH VALVES)
This pressure gauge indicates the adjusted pinch valve pressure. This
value is set on 2.4 bar by factory.
Backpressure (BACK PRESSURE)
This pressure gauge serves for the procedure monitoring. In normal op-
eration, the value ranges between 0.3 and max. 1.0 bar.
Power
Status
Error
T1
T2

V 03/13
18 •Start-up and operation OptiSpray DPP01
OptiSpray DPP01 - characteristics
Conveying direction
The OptiSpray DPP01 Dense phase 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 dense phase pump. If color changes take place,
rinsing must be done in conveying and in suction direction.
Manual rinsing for color change preparation
Rinsing in conveying direction is activated by pressing the T1 key.
Rinsing in suction direction is activated by pressing the T2 key.
The cleaning program (controlled by the control unit) takes place with an
external compressed air source in conveying direction.
Attention:
Large dust formation possible!
The suction hose and the conveying hose must be kept in the booth
during the rinsing procedure!
Cleaning programs
The CG09-P Gun control units feature three cleaning programs:
- Powder chamber emptying
- Cleaning the hose to the gun
- Cleaning the hose on the suction side
(For details, see the operating instructions of the corresponding gun con-
trol unit)
Attention:
Large dust formation possible!
The conveying hose and the powder gun must be kept in the booth
during the rinsing procedure!
Maintenance interval monitoring
This function is provided by the CG09-P Control unit.