Gema OptiFeed 4.0 PP07 Operating Instructions Manual
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Gema OptiFeed 4.0 PP07 Operating Instructions Manual

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Rev. 00
1017 576
Operating instructions and Spare parts list
Powder pump
OptiFeed 4.0 (PP07)
Translation of the original operating instructions

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Summary of Contents for Gema OptiFeed 4.0 PP07

  • Page 1 Rev. 00 1017 576 Operating instructions and Spare parts list Powder pump OptiFeed 4.0 (PP07) Translation of the original operating instructions...
  • Page 2 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.

  • Page 3: Table Of Contents

    Rev. 00 12/21 Table of contents About these instructions General information ....................7 Keeping the Manual ....................7 Safety symbols (pictograms) ................... 7 Structure of Safety Notes ................8 Presentation of the contents ................... 8 Figure references in the text ..............8 Software version .....................
  • Page 4 Rev. 00 12/21 Connection instructions ..................31 System integration with CAN bus ............31 System integration with PLC ..............32 Stand alone system integration with start/stop function (e.g. fresh powder system) ....................33 Start-up Preparation for start-up ..................35 Basic conditions ..................35 Basic information ..................
  • Page 5 Rev. 00 12/21 Appearance of errors ................65 Troubleshooting guide ..................65 Decommissioning / Storage Shutdown ......................69 If in disuse for several days ..............69 Storage conditions ....................69 Hazard notes .................... 69 Type of storage ..................69 Storage duration ..................69 Space requirements .................

  • Page 7: About These Instructions

    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.

  • Page 8: Structure Of Safety Notes

    Rev. 00 12/21 ENVIRONMENT Indicates a potentially harmful situation which, if not avoided, may have harmful consequences for the environment. MANDATORY NOTE Information which must be observed. NOTICE Useful information, tips, etc. Structure of Safety Notes Every note consists of 4 elements: –...

  • Page 9: Safety

    If this product is to be used for other purposes or other substances outside of our guidelines then Gema Switzerland GmbH should be consulted.

  • Page 10: Product Specific Security 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 the instructions may result in damage to property and personal injury if relevant safety information is not observed.

  • Page 11: Product Description

    Rev. 00 12/21 Product description Intended use The product is intended exclusively for the conveying of coating powder between plant components (e.g. powder hoppers, fresh powder systems, sieves). Fig. 1 Observance of the operating, service and maintenance instructions specified by the manufacturer is also part of the intended 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.

  • Page 12: Versions

    Rev. 00 12/21 Versions The powder pump is available in two versions. PP07 PP07-S Input voltage 24 VDC 100 - 240 VAC – Power pack integrated Application system-integrated standalone Control* by higher-level locally by controller operating elements Parameter settings* by higher-level locally by controller / locally operating...

  • Page 13: Electrical Data

    Rev. 00 12/21 Electrical data OptiFeed 4.0 PP07 PP07-S Nominal input voltage 24 V DC ±10% 100–240 V AC ±10% Connected load 20 W 20 VA – Frequency 50/60Hz Protection type IP54 +10 °C – +40 °C Temperature range (+50 °F – +104 °F) Temperature class T6 (85 °C max.

  • Page 14: Sound Pressure Level

    Rev. 00 12/21 Sound pressure level OptiFeed 4.0 Normal operation < 55 dB(A) Cleaning operation mode < 67 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.

  • Page 15: Design And Function

    Rev. 00 12/21 Design and function Overall view fig. 3 Suction side Pinch valve Conveyance side Powder chambers with filter elements and fluidized Connections adapters Operating elements Threaded sleeve Conveyance side Suction side connection connection Product description • 15 OptiFeed 4.0 (PP07)

  • Page 16: Operating Elements

    Rev. 00 12/21 Operating elements Display Fig. 4: Display Designation Function Pinch valve pressure indicator (display in bar) Negative pressure (vacuum) indicator (Suction power) Pump operating status indicator: – Standby mode – Pumping (flashes) Maintenance status indicator After-conveying indicator Backpressure indicator (display in bar) Conveying direction indicator 16 •...
  • Page 17 Rev. 00 12/21 Input keys Fig. 5: Input keys Designation Function Selection key – The displayed value is activated in order to be set – The displayed menu can be accessed Back key – Back to previous menu or confirm the set value –...

  • Page 18: Menu Structure

    Rev. 00 12/21 Menu structure ➔ Menu level System parameters Correction values Parameters (System Parameters) (Correction Values) (Parameters) P00-P13 C0, C1, C2, C3, C4, C5 Pre-conveying duration (Pre convey) After-conveying duration (Post convey) Duty cycle interval operation (T-On) Period duration of interval operation (T-Int) Menu level...

  • Page 19: Connections

    Rev. 00 12/21 Connections Compressed air hoses / cables fig. 6: Connections – Compressed air hoses / cables (PP07) Connection Description Mains / PLC 2.1 Power supply connection (24 VDC) AUX 2.3 CAN bus connection (IN) AUX 2.4 CAN bus connection (OUT) AUX 2.5 Pressure sensor signal (backpressure) connection Compressed air connection...
  • Page 20 Rev. 00 12/21 PP07 Pin assignment Mains / PLC 2.1 connection 24 VDC Start Cleaning 24 V – OUT Keyboard lock PE grounding CAN IN plug with 4 pins (AUX 2.3) Ground 24 VDC CAN high CAN low Enclosure – shield CAN OUT socket with 4 pins (AUX 2.4) Ground 24 VDC...

  • Page 21: Powder Hoses

    Rev. 00 12/21 Vibrator connection (AUX 2.2) – PE grounding Level sensor connection (level sensor AUX 2.6) 24 VDC Signal IN – – – PE grounding Powder hoses A 16/23 mm-diameter powder hose is connected to the suction side and to the conveyance (output) side. –...

  • Page 22: Typical Properties - Characteristics Of The Functions

    Rev. 00 12/21 Typical properties – Characteristics of the functions Conveying direction The conveying (flow) direction of the powder pump is factory-preset in the direction of the arrow (see picture). If the powder has to flow in the opsite direction, the conveying direction may be changed. To change the conveying direction, see chapter "System parameters"...

  • Page 23: Level Sensor Delay

    – This source is provided if the PP07 comes supplied as part of a Gema system (e.g. with OptiCenter)! When the automatic cleaning function is activated by an external control unit, the powder pump is cleaned automatically according to the cleaning program setting.

  • Page 24: Powder Fluidization

    The equipment required for this should be ordered in consultation with Gema Customer Service. – To ensure that the function of the powder pump is not impaired, the compressed air consumption at the fluidizing air connection must not be too high, i.e.

  • Page 25: Keyboard Lock

    0.1 – 10 million of pumping cycles Pinch valves (complete) Warning limit at 20% remaining service life Default 3.0 (changes only in consultation with Gema) 0.1 – 999 days free, e.g. filter elements No warning limit, only alarm display at the end e.g.

  • Page 26: Principle Of Operation

    Rev. 00 12/21 Principle of operation Suction procedure In powder chamber A, a vacuum (negative pressure) is produced. The powder chamber is closed at the output side by a pinch valve (1). This vacuum aspirates the coating powder in the powder chamber. A fine- porous filter element (2) in the powder chamber separates the powder.

  • Page 27: Correction Values

    Rev. 00 12/21 Correction values The correction values are used to optimally adapt the powder pump to the suction and conveying distance. The correction values can be set and requested manually or via the CAN bus. See chapter "Correction values" on page 48. Product description •...
  • Page 28 Rev. 00 12/21 28 • Product description OptiFeed 4.0 (PP07)

  • Page 29: Assembly / Connection

    Rev. 00 12/21 Assembly / Connection Set-up The pump is used to transport fresh powder as well as recovered powder or waste powder. The powder pump must be mounted vertically. Horizontal mounting will result in poor powder transport performance. ATTENTION Surrounding temperature too high –...

  • Page 30: Assembly Guide

    Rev. 00 12/21 Assembly guide The powder pump is mounted with 4 M6 screws on the back. Fig. 9: Drilling pattern PP07 If the PP07 powder pump is to replace a type PP06 powder pump without any mechanical rework, the corresponding adapter plate can be used (order no.

  • Page 31: Connection Instructions

    Rev. 00 12/21 Connection instructions The powder pump(s) are supplied ready for use by the manufacturer. Just a few cables and hoses must be connected. Depending on the system integration, different connection options may be selected. System integration with CAN bus fig.

  • Page 32: System Integration With Plc

    Rev. 00 12/21 System integration with PLC fig. 12: Connection instructions PP07 – overview Signal cable (backpressure) Compressed air hose Signal cable Powder pump Connect grounding cable to ground potential! ► Check ground connections with Ohm meter and ensure 0.1 Ohm or less! The compressed air must be free of oil and water! Close the unused connections with the provided dust protection caps!

  • Page 33: Stand Alone System Integration With Start/Stop Function (E.g. Fresh Powder System)

    Rev. 00 12/21 Stand alone system integration with start/stop function (e.g. fresh powder system) fig. 13: Connection instructions PP07-S – overview Compressed air hose 10 Level sensor cable Powder pump 11 Mains cable (start/stop signal) Vibrator cable Connect grounding cable to ground potential! ►...
  • Page 34 Rev. 00 12/21 34 • Assembly / Connection OptiFeed 4.0 (PP07)

  • Page 35: Start-Up

    Rev. 00 12/21 Start-up Preparation for start-up Basic conditions When starting up the powder pump, the following basic conditions, which have an influence on the powder transport, must be considered: – Correct hose layout – Maximum length of the conveying distance –...
  • Page 36 Rev. 00 12/21 Set the corresponding system parameter value with the key. Select parameter values according to the following table Description Values Display 0: Off Level sensor delay 1: On 0: P in = 6.0 bar 6.0 bar Inlet pressure 1: P in = 7.0 bar 7.0 bar 2: P in = 8.0 bar...
  • Page 37 Rev. 00 12/21 Description Values Display 0: 20 kbit/s 1: 50 kbit/s 2: 100 kbit/s 100k 3: 125 kbit/s 125k CAN Baud rate 4: 250 kbit/s 250k 5: 500 kbit/s 500k 6: 800 kbit/s 800k 7: 1 Mbit/s CAN Node ID 1-127 0: Forward Forward...
  • Page 38 Rev. 00 12/21 System parameter P08 (cleaning direction) This parameter can be used to set the cleaning direction in the opposite direction to the conveying direction. This only affects cleaning programs that clean in one direction (Remote R2 and Manual M1). P09 system parameter (REMOTE cleaning program) Automatic cleaning (cleaning program) is defined by the system parameters P09.
  • Page 39 Rev. 00 12/21 P10 system parameter (MANUAL cleaning program) Manual cleaning (cleaning program) is defined by the system parameter P10. The cleaning program is initiated manually. For more information, see chapter "Manually starting/stopping the cleaning procedure and reversing the cleaning direction" on page 47. Program M1 P10=1 –...

  • Page 40: Can Bus

    Rev. 00 12/21 CAN bus General The powder pump is a simple CANopen slave. It operates in a network with a central control unit (Master). Communication takes place exclusively between the Master and the Slaves. The following functions are available via the CAN bus: –...
  • Page 41 Rev. 00 12/21 CAN bus cable – plug assignment Fig. 15: CAN bus cable Signal Color white +24 VDC brown CAN H green CAN L yellow Start-up • 41 OptiFeed 4.0 (PP07)

  • Page 42: Determining Device Address (Node-Id) And Baud Rate

    Rev. 00 12/21 Determining device address (Node-ID) and Baud rate Each device (user), which operates on the CAN network, must have an individual user address (Node-ID) assigned. The Baud rate setting enables the transmission speed setting. The Baud rate value may be set by editing the system parameter P05, and the Node ID value may be set by editing the system parameter P06.

  • Page 43: Operation

    Rev. 00 12/21 Operation Operation During the initial commissioning of the device, the functional check must be performed without powder! Conveying parameters The powder pump has no programs, only 4 parameters are available for powder transport. The parameters may be shown and set via the display. Changes via the display are stored in the EEPROM.

  • Page 44: After-Conveying Length

    Rev. 00 12/21 Set the corresponding value with the key. Select values according to the following table Default Name / Icon Description Range value Pre convey Pre-conveying duration 1 … 16 (Cycles) Post convey After-conveying duration 4 … 32 (Cycles) T-On 1 …...

  • Page 45: Starting And Stopping The Conveying Procedure

    Rev. 00 12/21 Starting and stopping the conveying procedure The conveying procedure is switched on and off either manually or by an external Control unit (see the corresponding operating manual). Starting and stopping the cleaning procedure The cleaning procedure is switched on and off either manually or by an external Control unit (see the corresponding operating manual).

  • Page 46: Manual Operation

    Rev. 00 12/21 Manual operation When installing or starting up the pump for the first time, it is recommended to carry out a function check without powder! Switching on the powder pump Switch on the powder pump with the ON/OFF switch. –...

  • Page 47: Manually Starting/Stopping The Cleaning Procedure And Reversing The Cleaning Direction

    ► The powder hoses on the suction and conveyance side must be mounted and held in the direction of an appropriately dimensioned suction unit (such as Gema Classic Open booth) (targeted discharge of the compressed air energy). ► Wear appropriate protective equipment.

  • Page 48: Correction Values

    They may be set and requested manually or via the CAN bus. ATTENTION Incorrectly set correction values may lead to poor conveying results The plant was optimally set by the Gema service engineer at the first start-up. ► Changes of correction values may only be made by Gema trained personnel.
  • Page 49 Rev. 00 12/21 Select correction values according to the following table Correction Default Description Range value value 2.0 – 5.0 Conveying pressure desired value (bar) 1 – 4 Vacuum Suction power 2.5 – 4.0 Pinch valve pressure desired value for pumping (bar) 3.0 –...

  • Page 50: Adjustment Of The Suction And Conveying Parameters

    Rev. 00 12/21 Adjustment of the suction and conveying parameters The adjustment is carried out using the correction values C0 (conveying pressure) and C1 (suction power). Conveying pressure adjustment (C0) Recommendation: – Do not fall below 2 bar, this can lead to cloggings –...

  • Page 51: Procedure Monitoring (Chk)

    Rev. 00 12/21 Procedure monitoring (CHK) The CHK (backpressure) indicator is used for process monitoring. If the powder hose clogs, then the pressure increases noticeably! The value is shown on the local display. The corresponding signal is output at the connection 2.5 and can be used for further control tasks. When the unit is operating properly, i.e., powder is supplied correctly to the pump in normal operation, a pressure peak between 0.3-1.0 bar should be generated!
  • Page 52 Rev. 00 12/21 Press to switch to the corresponding display – The current software version and other information are displayed. 52 • Operation OptiFeed 4.0 (PP07)

  • Page 53: Monitoring Of The Wear Parts

    – Wear part number 1 (pinch valves) is displayed. The displayed default value (pumping cycles) is activated ex works and may only be changed in consultation with Gema. – The high resolution number of pumping cycles is displayed in the INFO menu.

  • Page 54: Memory Reset

    Rev. 00 12/21 The count down timer is then activated and runs only during the pumping process If the selected service life is exceeded, the symbol appears on the display. This does not affect the pumping process. If the service life has expired and maintenance has become necessary, the corresponding wear part must be replaced and the respective service life must be reset (see chapter "Reset the service life"...

  • Page 55: Maintenance / Repairs

    Rev. 00 12/21 Maintenance / Repairs ATTENTION Any unauthorized modifications and alterations to the product are not permitted for safety reasons and exclude 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! –...

  • Page 56: Maintenance

    Rev. 00 12/21 Maintenance Maintenance based on monitoring of the wear parts The powder pump indicates it is time for maintenance by changing the maintenance indicator from . If the recommended operating life is exceeded (e.g. pinch valve), the indicator changes to Icon Status Condition/Action...

  • Page 57: Daily Maintenance

    1 x weekly no action Pinch valves Schedule maintenance Carry out maintenance Reset service life – Pinch valve diagnosis by Gema Service OK = no action Pinch valves NOK = replace Carry out maintenance Reset service life – Filter elements...

  • Page 58: Cleaning

    Rev. 00 12/21 Reinigung Cleaning Cleaning the powder pump (color change) For the preparation of a color change, the pump has to be cleaned. The cleaning procedure may be started and stopped either via external control unit or manually. – The Powder pump must be cleaned at least once per shift! Periodic checks The periodic checks include examining all connecting cables and hoses.

  • Page 59: Repair Work

    Repair work In the event of malfunctions or faults, the product must be checked and repaired at an authorized Gema service location. The repairs must only be performed by an authorized specialist. Improper interventions can result in serious danger for user or the...

  • Page 60: Pump Disassembly

    Rev. 00 12/21 Pump disassembly 60 • Maintenance / Repairs OptiFeed 4.0 (PP07)
  • Page 61 Rev. 00 12/21 The end piece with the O-rings should not be removed because it is pressurized only. Maintenance / Repairs • 61 OptiFeed 4.0 (PP07)
  • Page 62 Rev. 00 12/21 Reset the service life After successful replacement of wear parts, the respective service life must be reset. Example: Pinch Valves (Wear Part No. 1) Hold key down for 3 seconds If necessary, reset the service life of other wear parts Setting the desired service life (in days) 62 •...

  • Page 63: Fault Clearance

    Here is a list of all possible help codes for this powder pump: Code Description Criteria Remedy Power supply: Voltage supply error Mainboard defective Contact Gema Service Mainboard Power pack defective or Contact Gema Service Supply undervoltage overloaded EEPROM (equipment memory): EEPROM error...
  • Page 64 Rev. 00 12/21 Code Description Criteria Remedy Values not correctly EEPROM error Contact Gema Service stored in EEPROM during switching off EEPROM error Contact Gema Service EEPROM verification erroneous CAN bus: The CAN controller changes into Connect the cable, BUS OFF condition.

  • Page 65: Appearance Of Errors

    Rev. 00 12/21 Code Description Criteria Remedy Transport air throttle Lost steps, limit switch defective, Contact Gema Service position lost throttle motor defective Vacuum throttle position Lost steps, limit switch defective, Contact Gema Service lost throttle motor defective Pneumatics: Pressure regulator...
  • Page 66 Oil or water in the system Do not use the pump before ensuring that oil or water will be separated before entering into the pump, otherwise contact Gema No operating voltage The corresponding voltage must be Indicator on powder pump present at connection 2.1: PP07 =...
  • Page 67 Rev. 00 12/21 Incident Causes Corrective action Power pack is defective (PP07- Replace Fuse is defective (PP07-S) Replace Main switch is defective (PP07- Replace The parameter memory test Reset to the default values: Indicator flashes was erroneous Press for 5 seconds Then set parameters, if necessary Powder pump is not No Pump on control signal...
  • Page 68 Rev. 00 12/21 68 • Fault clearance OptiFeed 4.0 (PP07)

  • Page 69: Decommissioning / Storage

    Rev. 00 12/21 Decommissioning / Storage Shutdown End the coating procedure Switch off the powder pump by pressing the ON/OFF switch, or by switching off on the external control unit. – The display will go dark. Cut off the compressed air supply to the powder pump! If in disuse for several days Switch off the plant with the main switch Clean the guns and the components for powder transport (see the...

  • Page 70: Physical Requirements

    Rev. 00 12/21 Physical requirements 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. 70 •...

  • Page 71: Disposal

    Requirements on personnel carrying out the work The disposal of the product is to be carried out by the owner or operator. When disposing of components that are not manufactured by Gema, the instructions in the respective manufacturer’s documentation must be observed.
  • Page 72 Rev. 00 12/21 72 • Disposal OptiFeed 4.0 (PP07)

  • Page 73: Spare Parts List

    When using the spare parts from other manufacturers the explosion protection is no longer guaranteed. If any damage is caused by this use all warrantee claims become invalid! ► Only original Gema spare parts should be used! Spare parts list • 73 OptiFeed 4.0 (PP07)

  • Page 74: Optifeed 4.0 (Pp07/Pp07-S)

    Rev. 00 12/21 OptiFeed 4.0 (PP07/PP07-S) OptiFeed 4.0 powder pump (PP07) – complete (pos. 1-9) 1020 430 OptiFeed 4.0 powder pump (PP07-S) – complete (pos. 1-6, 10-12) 1020 440 Powder chamber – complete (see corresponding spare parts list) Silencer – 1/2" 1006 969 Pneumatic group –...

  • Page 75: Optifeed 4.0 (Pp07) - Spare Parts

    Rev. 00 12/21 OptiFeed 4.0 (PP07) – spare parts Fig. 21: PP07 Fig. 22: PP07-S Spare parts list • 75 OptiFeed 4.0 (PP07)

  • Page 76: Pneumatic Group

    Rev. 00 12/21 Pneumatic group Throttle valve – complete 1016 590 Screw – M3x10 mm 216 739 Solenoid valve – 5/2 AP, 24 V DC 1020 404 Solenoid valve – 2x3/2 AP, 24 V DC 1020 403 Solenoid valve – 5/3 AP, 24 V DC 1020 405 Silencer –...

  • Page 77: Pneumatic Group

    Rev. 00 12/21 Pneumatic group Fig. 23: OptiFeed 4.0 powder pump – pneumatic group Thread size Tightening torque [Nm] M3 (8.8) M4 (8.8) M5 (8.8) G1/8" G1/4" Spare parts list • 77 OptiFeed 4.0 (PP07)

  • Page 78: Powder Chamber

    Rev. 00 12/21 Powder chamber Powder chamber – complete (pos. 1–23) 1019 460 Y-piece 1006 962 Hose clamp – Ø 17–20 mm 1001 729 Powder hose – Ø 16/23 mm 1010 040*# Threaded sleeve 1020 416 Tube connection (without pos. 6) 1020 413 O-ring –...

  • Page 79: Powder Chamber - Spare Parts

    Rev. 00 12/21 Powder chamber – spare parts fig. 24 Thread size Tightening torque [Nm] M5 (8.8) M6 (8.8) G1/8" Spare parts list • 79 OptiFeed 4.0 (PP07)

  • Page 80: Protective Filter Holder

    Rev. 00 12/21 Protective filter holder Filter ring – complete 1020 436 Allen cylinder screw – M4x12 mm 1016 278 Washer – Ø 4.3/9x0.8 mm 215 791 Screw-in nipple – 1/8"-Ø 8 mm 240 087 Screw-in nipple – 1/8"-Ø 6 mm 240 095 Protective filter element –...

  • Page 81: Connecting Material

    Rev. 00 12/21 Connecting material CAN bus cable – 0.5 m 1002 655 CAN bus cable – 4.5 m 387 592 CAN bus cable – 5.5 m 388 521 CAN bus cable – 6.5 m 388 530 CAN bus cable – 10.0 m 1010 407 CAN bus cable –...
  • Page 83 Rev. 00 12/21 Index About these instructions ........7 Inlet pressure ........... 36 Adapter plate ............ 30 Intended use ............ 11 Adjustment of the suction parameters Interval operation ........37, 44 Conveying parameters ......... 50 Duty cycle..........24, 45 After-conveying ........22, 37, 44 Period duration ........
  • Page 84 Rev. 00 12/21 Reasonably foreseeable misuse ..... 12 Start/stop function Repair work ............59 Fresh powder system ........33 Repairs............. 55 Starting and stopping Replacing Cleaning procedure ........45 Filter elements ..........59 Conveying procedure ........45 Pinch valves ..........59 Start-up .............
  • Page 86 Rev. 00...

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