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Rev. 03 01/21

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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

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

Decommissioning / Storage

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

Introduction ........................................................................................................... 47

Requirements on personnel carrying out the work .................................. 47

Disposal regulations ................................................................................ 47

Materials .................................................................................................. 47

Disassembly of component groups ...................................................................... 47

Spare parts list

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

Содержание OptiSpray AP01.1-E

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

Страница 2: ... 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 tra...

Страница 3: ...ical 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 rinsi...

Страница 4: ... 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 I...

Страница 5: ...Rev 03 01 21 OptiSpray AP01 1 E Table of contents 5 ...

Страница 6: ......

Страница 7: ...l 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 WARNI...

Страница 8: ...f 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...

Страница 9: ... 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 liab...

Страница 10: ...ed 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 th...

Страница 11: ...ptiStar 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 manufac...

Страница 12: ...ably 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 d...

Страница 13: ...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 ...

Страница 14: ...Rev 03 01 21 14 Product description OptiSpray AP01 1 E Rating plate fig 2 ...

Страница 15: ...ements 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 man...

Страница 16: ...y 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 diff...

Страница 17: ...ir 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 ...

Страница 18: ...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 pr...

Страница 19: ...e 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 ...

Страница 20: ...Rev 03 01 21 20 Product description OptiSpray AP01 1 E ...

Страница 21: ...either in an OptiCenter OC03 E or OC05 E Powder management center 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 ...

Страница 22: ...manufacturer Just a few cables and hoses must be connected fig 7 Connecting guide 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 hopper ...

Страница 23: ... 23 Connect grounding cable to the booth or the suspension arrangement Check ground connections with Ohm meter and ensure 1 MOhm or less The compressed air must be free of oil and water Close the unused connections with the provided dust protection caps ...

Страница 24: ...Rev 03 01 21 24 Assembly Connection OptiSpray AP01 1 E ...

Страница 25: ...ressed air supply available Powder preparation and powder quality Basic information The adherence of the following principles leads to a successful start up of the Application pump The suction distance is to be kept as short as possible Basically the powder transport with the Application pump works with every powder type which can be fluidized If the powder is for example humid or contaminated wit...

Страница 26: ...Rev 03 01 21 26 Start up OptiSpray AP01 1 E ...

Страница 27: ...itched on and off by the pump control see the corresponding operating manual Switching on and off the rinsing procedure The rinsing procedure is switched on and off by the pump control see the corresponding operating manual For a better understanding of the interrelationships in powder coating it is recommended to read completely the operating instructions of the control unit and the powder gun so...

Страница 28: ...Rev 03 01 21 28 Operation OptiSpray AP01 1 E ...

Страница 29: ...e the manufacturer s liability for any resulting damage Regular careful cleaning and maintenance extends the service life of the product and ensures long lasting uniform coating quality The parts to be replaced during maintenance work are available as spare parts For further information see chapter Spare parts list General information The product is designed to require a minimum of maintenance ...

Страница 30: ... are avoided Pinch valve diagnostic The pinch valve diagnostic is to be carried out in order to maintain the coating quality or after the error message H89 is displayed The prerequisites for the diagnostic Exhaust at suction and conveyance side must be present and in operation Powder hopper must be empty Cleaning program completed The pinch valve diagnostic is to start after the cleaning program h...

Страница 31: ...he rinsing procedure can be started and stopped only externally via control unit or plant control The Application pump must be cleaned at least once per shift Periodic checks The periodic checks include examining all connecting cables and hoses The corresponding parts should be replaced immediately if any damage to cables or hoses is discovered All plugs must be properly tightened ...

Страница 32: ...ized specialist Improper tampering can result in serious danger for user and equipment Replacing the pinch valve hoses and filter elements Before dismantling changing the filter elements it is necessary to clean the Application pump in both directions by using the rinsing program Required spare parts AP01 1 E Service set Gema order no 1015 436 fig 8 1 Filter element 2 Pinch valve hose 3 Fluid bloc...

Страница 33: ...01 21 OptiSpray AP01 1 E Maintenance Repairs 33 Required Tools fig 9 1 Dismantling tool Order number 1012 909 2 Open ended wrench 16 mm 3 Allen key size 4 mm 4 Allen key size 3 mm Pump disassembly 1 2 3 4 5 6 ...

Страница 34: ...ect inserted pinch valve hose causes malfunctions It is imperative to consider the position of the lens shaped opening Make sure that the positioning tabs are set correctly 6 ATTENTION Broken pinch valve hose may cause the clogging of the fluid blocking plate Clean or replace the corresponding fluid blocking plate ...

Страница 35: ...nzine light lye or acid or a cleaning agent 1 2 3 ATTENTION Incorrectly assembled parts may cause malfunctions or defects The assembly takes place in reverse order The tightening torques are to be observed when assembling The process zone has to be pressed against a planar surface and assembled on it 4 5 6 7 Operate the Application pump with powder at least 1 2 hour after replacing the filter elem...

Страница 36: ... personnel Before dismantling changing the solenoid valves it is necessary to clean the Application pump in both directions by using the rinsing program Required Tools fig 10 1 Side cutter 2 Phillips screwdriver PH0 3 Hexagon screwdriver 4 mm 4 Hexagon screwdriver 3 mm 5 Hexagon screwdriver 2 5 mm Required spare parts AP01 Solenoid valve Gema order no V1 Suction pinch valve 1009 936 V2 Conveying p...

Страница 37: ...Rev 03 01 21 OptiSpray AP01 1 E Maintenance Repairs 37 Replacing the solenoid valves 1 2 3 ...

Страница 38: ...Rev 03 01 21 38 Maintenance Repairs OptiSpray AP01 1 E 4 5 6 ...

Страница 39: ...Rev 03 01 21 OptiSpray AP01 1 E Maintenance Repairs 39 7 8 9 The assembly takes place in reverse order a ...

Страница 40: ...1 1 E Replacing the Application pump in an OptiCenter 1 Remove the powder from the system 2 Start the cleaning program rinse in both directions 3 Depressurize vent OptiCenter 4 Next steps are described in the corresponding OptiCenters operating manual ...

Страница 41: ...ation Service life of the pinch valve has expired defective Change the pinch valve check the pneumatic system for defects and replace if necessary Service life of the filter element runs off clogged Replace the filter element Application pump conveys irregularly or too little powder Pinholing in the powder container powder will not be fluidized well Adjust the fluidization correctly Hose backpress...

Страница 42: ...t clearance OptiSpray AP01 1 E Incident Causes Corrective action Transport air offset C3 not adapted to powder output Adapt transport air offset C3 see operating manual OptiStar CG12 CP or CG11 P section Correction values ...

Страница 43: ...ocking plate Start the pinch valve diagnostic Diagnosis OK no yes Replace V1 V2 pinch valve solenoid valves Start the pinch valve diagnostic Diagnosis OK no Start the pinch valve diagnostic Diagnosis OK no yes yes Use a replacement pump Start the pinch valve diagnostic Diagnosis OK no yes Send in the defective pump for repair Failure in the control unit or outside of the pump Start the pinch valve...

Страница 44: ...Rev 03 01 21 44 Fault clearance OptiSpray AP01 1 E ...

Страница 45: ...der conveying see therefore the corresponding user manuals 3 Turn off the compressed air main supply Storage conditions Hazard notes There is no danger to personnel or the environment if the unit is stored properly Type of storage For safety reasons the product should only be stored in a horizontal position Storage duration If the physical conditions are maintained the unit can be stored indefinit...

Страница 46: ...ments Storage must be inside a dry building at a temperature between 5 and 50 C Do not expose to direct sunlight Maintenance during storage Maintenance schedule No maintenance schedule is necessary Maintenance works During long term storage periodically perform a visual check ...

Страница 47: ...operly at the end of its service life When disposing of the product the applicable local and regional laws directives and environmental regulations must be complied with Materials The materials must be sorted according to material groups and taken to the appropriate collection points Disassembly of component groups WARNING Live components Risk of fatal injury from electric shock if touched Only tr...

Страница 48: ...Rev 03 01 21 48 Disposal OptiSpray AP01 1 E ...

Страница 49: ...8 15 mm When ordering cable or hose material the required length must also be given The spare part numbers of this bulk stock is always marked with an Wearing parts are always marked with a All dimensions of plastic hoses are specified with the external and internal diameter Example Ø 8 6 mm 8 mm outside diameter o d 6 mm inside diameter i d ATTENTION Use of non original Gema spare parts When usin...

Страница 50: ...lete without pos 14 1010 305 14 Body complete for pos 13 1015 457 15 Nut with kink protection M20x1 Ø 15 mm 1019 721 16 Elbow connection 1013 313 17 Allen cylinder screw M5x20 mm 222 950 18 Allen cylinder screw M4x12 mm 216 275 19 O ring Ø 10x2 mm 243 000 20 Plug 1013 315 21 O ring Ø 16x2 mm 1007 794 22 Suction tube 1013 317 23 O ring Ø 6x1 mm 217 115 24 Connection plug 200 859 25 Screw in nipple ...

Страница 51: ...Rev 03 01 21 OptiSpray AP01 1 E Spare parts list 51 OptiSpray AP01 1 E spare parts fig 11 Item Tightening torque Nm 1 4 4 greased 4 3 1 greased 7 4 4 greased 17 3 1 18 0 5 ...

Страница 52: ... 14 1010 305 14 Body complete for pos 13 1015 457 15 Nut with kink protection M20x1 Ø 15 mm 1019 721 16 Elbow connection 1013 313 17 Allen cylinder screw M5x20 mm 222 950 18 Allen cylinder screw M4x12 mm 216 275 19 O ring Ø 10x2 mm 243 000 20 Plug 1013 315 21 O ring Ø 16x2 mm 1007 794 22 Suction tube 1013 317 23 O ring Ø 6x1 mm 217 115 24 Connection plug 200 859 25 Screw in nipple 1 8 Ø 8 mm 1010 ...

Страница 53: ...Rev 03 01 21 OptiSpray AP01 1 E Spare parts list 53 OptiSpray Twin AP01 1 E spare parts fig 12 Item Tightening torque Nm 1 4 4 greased 4 3 1 greased 7 4 4 greased 17 3 1 18 0 5 ...

Страница 54: ...blue 103 497 1 6 Plastic tube Ø 8 6 mm green 103 519 2 5 Connecting cable 12 pins 1 5 m 1000 991 Connecting cable 12 pins 2 2 m 393 398 Connecting cable 12 pins 5 m 1000 975 Connecting cable 12 pins 10 m 1000 976 Connecting cable 12 pins 15 m 1000 977 Connecting cable 12 pins 20 m 1000 978 Please indicate length fig 13 Connecting material ...

Страница 55: ...4 mm 103 144 3 Screw in nipple M7 Ø 6 mm 1008 699 Connector complete incl pos 4 8 and 9 1011 627 4 Connector 1011 638 5 Fluidizing tube 1005 262 6 O ring Ø 13x1 5 mm 1009 943 7 Adaptor piece complete incl pos 6 1011 625 8 Hose connection complete incl pos 9 1011 632 9 O ring Ø 9x1 5 mm 1011 637 Please indicate length Wearing part fig 14 Diffuser OptiGun GA03 E ...

Страница 56: ...w in nipple M7 Ø 6 mm 1008 699 Connector complete incl pos 4 9 and 10 1011 627 4 Connector 1011 638 5 Fluidizing tube 1005 262 6 O ring Ø 13x1 5 mm 1009 943 7 O ring Ø 12x1 5 mm 1000 822 8 Adaptor piece complete incl pos 6 and 7 1019 533 9 Hose connection complete incl pos 10 1011 632 10 O ring Ø 9x1 5 mm 1011 637 Please indicate length Wearing part fig 15 Diffuser OptiSelect Pro GM04 E ...

Страница 57: ...w in nipple M7 Ø 6 mm 1008 699 Connector complete incl pos 4 9 and 10 1011 627 4 Connector 1011 638 5 Fluidizing tube 1005 262 6 O ring Ø 13x1 5 mm 1009 943 7 O ring Ø 12x1 5 mm 1000 822 8 Adaptor piece complete incl pos 6 and 7 1011 626 9 Hose connection complete incl pos 10 1011 632 10 O ring Ø 9x1 5 mm 1011 637 Please indicate length Wearing part fig 16 Diffuser OptiSelect GM03 E ...

Страница 58: ......

Страница 59: ... Maintenance during storage 46 Maintenance interval monitoring 19 Maintenance of the dense phase pump 30 Maintenance schedule 30 O Operation 27 Overall view 15 P Periodic checks 31 Pictograms 7 Pin assignment 17 Pinch valve diagnostic 30 Pneumatic data 12 Powder hose rinsing 18 Powder hoses 15 Powder output reference values 13 Preparation for start up 25 Presentation of the contents 8 Product desc...

Страница 60: ...Rev 03 01 21 60 Index OptiSpray AP01 1 E Storage conditions 45 Switching on and off Conveying procedure 27 Rinsing procedure 27 T Technical Data 12 Typical characteristics 18 W Wearing parts 30 ...

Страница 61: ......

Страница 62: ...Rev 03 ...

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