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Cleaning and maintenance

OptiSpray DPP01

Maintenance set

The wearing parts to be replaced during the OptiSpray DPP01 Dense
phase pump maintenance, are available in two maintenance sets (see
the spare parts list). One set contains 2 filter elements, the other set con-
tains 8 pinch valves.

Replacing the filter elements

Attention!
Before dismantling/changing the filter elements, it is necessary to
clean the dense phase pump in both directions by using the local
cleaning keys T1 and T2!

Required spare parts - 2 filter elements (spare parts set)

1.

2.

3.

4.

5.

6.

Special tool

Braided sleeve

4 mm

5 mm

1005 058

1005 270

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Содержание OptiSpray DPP01

Страница 1: ...En Translation of the original operating instructions Operating instructions and spare parts list OptiSpray DPP01 Dense phase pump ...

Страница 2: ...marks 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 know...

Страница 3: ...al 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...

Страница 4: ...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 ...

Страница 5: ... 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 r...

Страница 6: ... 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 ...

Страница 7: ...ing 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 ...

Страница 8: ......

Страница 9: ...e 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 ...

Страница 10: ...uge 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...

Страница 11: ...put 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...

Страница 12: ... 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 ...

Страница 13: ...ill 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 compres...

Страница 14: ...V 03 13 12 Technical data OptiSpray DPP01 Dimensions OptiSpray DPP01 Height 360 mm Width 210 mm Depth 160 mm Weight 11 9 kg ...

Страница 15: ...se 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 ...

Страница 16: ...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...

Страница 17: ...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 ...

Страница 18: ...ing 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 t...

Страница 19: ...rolling 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 Backpre...

Страница 20: ...he 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 cle...

Страница 21: ...sponding operating manual Switching on and off the rinsing procedure The rinsing procedure is switched on and off by the CG09 P Control unit see the corresponding operating manual Manual switching on and off the rinsing proce dure on the pump By pressing the corresponding key depending on the desired rinsing di rection the rinsing procedure will be started The powder chambers are cleaned thoroughl...

Страница 22: ...ll be displayed This consists of following influences Adjusted transport air volume Filter elements resistance Powder quantity to be transported Internal diameter and length of the conveying hose By correct operation this value ranges between 0 3 and max 1 0 bar The backpressure may not exceed 1 2 bar Hot Coating 1 8 bar OptiSpray DPP01 shutdown The OptiSpray DPP01 Dense phase pump is switched off...

Страница 23: ...e device The activated test mode is indicated by the illuminated STA TUS and ERROR displays The test steps are activated in sequence by pressing the key T1 for ap prox 1 sec After test step 3 the dense phase pump returns to normal operation by pressing the key T1 again Test step Purpose Notes 1 Leak tightness test Preparation Close tightly the dense phase pump input and output remove the injector ...

Страница 24: ......

Страница 25: ...ally Maintenance of the OptiSpray DPP01 Dense phase pump The OptiSpray DPP01 Dense phase pump is designed in such a way that only a minimum maintenance is required Daily maintenance Clean the dense phase pump with a dry cloth and check the connection points of the powder hoses Replace the powder hoses if necessary Rinse the dense phase pump in conveying direction and in suction direc tion by using...

Страница 26: ...are parts list One set contains 2 filter elements the other set con tains 8 pinch valves Replacing the filter elements Attention Before dismantling changing the filter elements it is necessary to clean the dense phase pump in both directions by using the local cleaning keys T1 and T2 Required spare parts 2 filter elements spare parts set 1 2 3 4 5 6 Special tool Braided sleeve 4 mm 5 mm 1005 058 1...

Страница 27: ...d maintenance 25 7 8 9 10 Note The assembly takes place in reverse order By assembling the Y piece do not tighten the screws too strong 11 12 Replacing the pinch valves Required spare parts 4 pinch valve hoses NW 7 5 spare parts set 1 2 ...

Страница 28: ...aintenance OptiSpray DPP01 3 4 5 6 7 8 Attention When cleaning the acryl pinch valve bodies do not use alcohol ac etone benzol or other solvents For cleaning use benzine light lye or acid acryl glass cleaner or a cleaning agent ...

Страница 29: ...V 03 13 OptiSpray DPP01 Cleaning and maintenance 27 Service position Service position The front plate can be opened and swiveled in service position by loosing the six screws ...

Страница 30: ...ndard Operation Hot Coating Operation 1 Injector Vacuum 3 5 bar 3 5 bar 2 Pinch valve Transport 2 4 bar 3 0 bar 3 Pinch valve Cleaning 5 0 bar 5 0 bar Indicator BACK PRESSURE 0 3 1 0 bar 0 3 1 8 bar Checking the injector set pressure The set pressure can be checked by simple disconnecting switching of the pneumatic hose 1 2 Checking the injector set pressure 1 2 3 ...

Страница 31: ... gram 3 so it can be determined if the con trol or the dense phase pump is defective Compressed air supply failed or pressure too low Check the compressed air source ensure an air pressure of 7 10 bar check the pressure gauge of the local pres sure regulator No transport air present Check the hose connec tion of the control unit to the dense phase pump Check the compressed air supply No fluidizati...

Страница 32: ...clogged clean or replace it Filter elements are clogged clean or re place them Sintering in Y piece or hose connection clean Filter elements tend to clogging Run the rinsing program in conveying and in suc tion direction replace the filter elements Powder hoses tend to clogging due to sintering Clean or replace the powder hoses Oil or water in the sys tem Ensure that oil or water will be separated...

Страница 33: ... block diagram DPP01 VALVE BOARD X2 L N PE V V POWER SUPPLY F1 2AT 2 1 1 2 A B C D E F G 2 2 H J K L M X1 1 2 PE X4 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 S1 1 2 3 4 5 6 7 8 9 12p Adapter OptiSpray DPP01 block diagram Mains connection Solenoid valves Control cable connection ...

Страница 34: ...P01 pneumatic diagram Pumps Pinch valves Transport air TL Control unit Vacuum injector Powder aspiration IN Pinch valves Buffer volume Hose connections Air ducts in the distribution block Powder output OUT Pressure injector Press pinch valve Cleaning Air supply 6 bar Press pinch valve Pumping ...

Страница 35: ...mp Ø 18 15 mm When ordering cable or hose material the required length must also be indicated The spare part numbers of this yard meter ware is always marked with an The wear parts are always marked with a All dimensions of plastic hoses are specified with the external and inter nal diameter Example Ø 8 6 mm 8 mm outside diameter o d 6 mm inside diameter i d WARNING Only original Gema spare parts ...

Страница 36: ...onnection 4 5 mm 1005 474 18 O ring Ø 8x1 5 mm 248 878 19 Washer Ø 6 4 11x1 6 mm 1005 254 20 Allen cylinder screw M6x20 mm 216 429 21 Nut with kink protection M12x1 mm Ø 8 mm 201 316 22 Powder hose suction side Ø 4 5 mm not shown 1005 454 23 Maintenance set 1 2 x filter elements 3 µm complete 1005 257 24 Maintenance set 2 8 x pinch valves with Short instructions not shown 1005 256 25 Hose connecti...

Страница 37: ...V 03 13 OptiSpray DPP01 Spare parts list 35 OptiSpray DPP01 Spare parts OptiSpray DPP01 Dense phase pump spare parts 21 18 17 20 19 16 5 2 24 4 3 13 15 25 26 23 27 22 ...

Страница 38: ...er supply extension 12 m 1002 637 3 Connecting cable 12 pins 1 5 m 1000 991 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 4 Connector NW5 1 8 i 200 859 5 Connection sleeve 1 8 Ø 6 mm 233 412 OptiSpray DPP01 rear view 3 2 5 4 1 ...

Страница 39: ...V 03 13 OptiSpray DPP01 Spare parts list 37 OptiSpray DPP01 inside rear view 1 Power pack 24 VDC 1003 100 2 Filter plate 1004 846 OptiSpray DPP01 inside rear view 2 1 ...

Страница 40: ...front view 1 Electronics board complete 1004 171 2 Pressure gauge 1 9 bar 1005 827 3 Pressure regulator 0 5 7 bar 1005 177 4 Solenoid valve MHA2 1004 317 5 Solenoid valve MHA3 1004 318 6 Vacuum suction nozzle 1005 251 OptiSpray DPP01 inside front view 4 2 5 4 1 5 6 4 3 ...

Страница 41: ...V 03 13 OptiSpray DPP01 Spare parts list 39 ...

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