Gema OptiFeed BigBag Operating Instructions Manual
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Gema OptiFeed BigBag Operating Instructions Manual

Fresh powder system
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Rev. 00
1017 588
Operating instructions and Spare parts list
Fresh powder system
OptiFeed BigBag (FPS16)
Translation of the original operating instructions

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Summary of Contents for Gema OptiFeed BigBag

  • Page 1 Rev. 00 1017 588 Operating instructions and Spare parts list Fresh powder system OptiFeed BigBag (FPS16) 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

    Processing the powder directly from the original powder manufacturer's container ....................24 Fluidizing the coating powder ..............24 Powder flow detection ................24 Start-up Set-up ........................25 Connection ....................25 Electrical allocation ....................25 Table of contents • 3 OptiFeed BigBag (FPS16)
  • Page 4 Repair work ......................44 Fault clearance Software error diagnostics ..................47 General information ................. 47 Help codes ....................47 Appearance of errors ................49 Troubleshooting guide ..................49 Disposal Introduction ......................53 4 • Table of contents OptiFeed BigBag (FPS16)
  • Page 5 Ordering spare parts ..................... 55 FPS16 Fresh powder system – spare parts list ............ 56 FPS16 Fresh powder system – spare parts ............57 Fluidizing/suction unit .................... 58 Fluidizing/suction unit .................... 59 Table of contents • 5 OptiFeed BigBag (FPS16)

  • Page 7: About These Instructions

    General information This operating manual contains all the important information which you require for the working with the OptiFeed BigBag (FPS16). It will safely guide you through the start-up process and give you references and tips for the optimal use when working with your powder coating system.

  • Page 8: Structure Of Safety Notes

    Figure references in the text Figure references are used as cross references in the descriptive text. Example: "The high voltage (H) created in the gun cascade is guided through the center electrode." 8 • About these instructions OptiFeed BigBag (FPS16)

  • Page 9: Safety

    ► Before working with the device, organize the required documents and read the section "Safety regulations". ► Work should only be carried out in accordance with the instructions of the relevant documents. ► Always work with the complete original document. Safety • 9 OptiFeed BigBag (FPS16)

  • Page 10: Basic Safety Instructions

    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 11: Product Specific Safety Information

    Any other use is not considered as intended use. The manufacturer shall not be liable for damage resulting from such use; the user bears sole responsibility for such actions. Gema Switzerland GmbH must be consulted prior to any use of this product for any purposes or substances other than those indicated in our guidelines.
  • Page 12 The use of other parts can lead to risk of injury. Only original Gema spare parts should be used! Repairs must only be carried out by specialists or by authorized Gema service centers. Unauthorized conversions and modifications can lead to injuries and damage to the equipment and invalidate the Gema Switzerland GmbH guarantee.
  • Page 13 As a general rule for all powder spraying installations, persons with The stay for persons pacemakers should never enter high voltage areas or areas with with cardiac electromagnetic fields. Persons with pacemakers should not enter pacemakers is forbidden areas with powder spraying installations! Safety • 13 OptiFeed BigBag (FPS16)
  • Page 14 The operating personnel must wear electrically conductive, steel-toe footwear (e.g. ESD shoes). The operating personnel should hold the gun with bare hands. If gloves are worn, these must also conduct electricity. 14 • Safety OptiFeed BigBag (FPS16)

  • Page 15: Product Description

    The powder is aspirated in pulses by a vacuum, and subsequently transported with conveying air. The fresh powder system will also operate in combination with the OptiFeed PP07 powder pump or other Gema models with suitable connections. Please contact Gema if you have any further queries. Fig. 1...

  • Page 16: Reasonably Foreseeable Misuse

    Reasonably foreseeable misuse – Operation without the proper training – Use with insufficient compressed air quality and grounding – Use in connection with unauthorized coating equipment or components – Incorrect coating powder 16 • Product description OptiFeed BigBag (FPS16)

  • Page 17: Technical Data

    Rev. 00 03/22 Technical Data Electrical data OptiFeed BigBag (FPS16) Nominal input voltage 3 x 400 VAC / 24 VDC Frequency 50 / 60 Hz Fluctuations of the power supply ± 10 % Connected load 140 VA 3 x 220-230 / 380-400 VAC...

  • Page 18: Container Specifications (Big Bag)

    Rev. 00 03/22 Container specifications (big bag) OptiFeed BigBag (FPS16) Suspension system 4-point loops square, no partition walls, with Version emptying funnel min. 5:1 for disposable use Safety factor min. 8:1 for reuse Material incl. suspension loops conductive, R<10 Conveying performance...

  • Page 19: Sound Pressure Level

    Rev. 00 03/22 Sound pressure level OptiFeed BigBag (FPS16) Normal operation < 70 dB(A) Cleaning operation mode > 85 dB(A) (for a short time) 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 20: Structure

    Rev. 00 03/22 Structure Overall view Fig. 3: Structure Fluidizing/suction unit Vibrating plate Control Lifting device for container Powder pump Lifting device for Support fluidizing/suction unit 20 • Product description OptiFeed BigBag (FPS16)

  • Page 21: Versions

    The fluidizing/suction unit can be lifted manually by a cable and can be fixed in this position by hooking-in the final loop. The fluidizing/suction unit is lifted only during the change of the large container. Product description • 21 OptiFeed BigBag (FPS16)

  • Page 22: Vibrating Plate

    – As soon as the level sensor of the powder container detects “empty”, the powder transport and the vibrating plate switch on automatically 22 • Product description OptiFeed BigBag (FPS16)

  • Page 23: Control Module

    The laterally attached powder pump sucks the powder, if required, by the fluidizing/suction unit and ensures the transport to the powder container in the coating plant. All information about the powder pump can be found in the corresponding enclosed documentation! Product description • 23 OptiFeed BigBag (FPS16)

  • Page 24: Scope Of Delivery

    If the powder shortage will not be reset by the up/down procedure during a defined time, an alarm message for the operating personnel will be released. 24 • Product description OptiFeed BigBag (FPS16)

  • Page 25: Start-Up

    Electrical allocation ATTENTION: The equipment and the vibrating plate are necessarily to be grounded with the ground connection! ► As ground conductor, use a copper cable with a cross-section of at least 4 mm²! Start-up • 25 OptiFeed BigBag (FPS16)

  • Page 26: Main Module Inputs

    Additional module outputs Output Description Conveying ON - pump 1 Conveying ON - pump 2 Pinch valve – preventing excess air suction of pump 1 Pinch valve – preventing excess air suction of pump 2 26 • Start-up OptiFeed BigBag (FPS16)

  • Page 27: Pneumatic Connection

    Fluid air P min = 0.5 bar Compressed air supply of pinch valves (FPS16-2 version only) P max. = 3.0 bar Powder connections The powder hose must be connected according to the corresponding powder pump(s). Start-up • 27 OptiFeed BigBag (FPS16)

  • Page 28: Initial Start-Up

    If a malfunction occurs, see the troubleshooting guide, as well as the Powder pump operating manual! Fig. 8 The remainder of the start-up procedure for the Powder pump is explicitly described in the corresponding operating instructions (chapter "Initial start-up" and "Daily start-up")! 28 • Start-up OptiFeed BigBag (FPS16)

  • Page 29: Preparing The Powder Box

    Standard display not to be used Set parameter not to be used not to be used Parameter input display Block number The value set at Parameter Time The value set at Parameter Time Current time Start-up • 29 OptiFeed BigBag (FPS16)

  • Page 30: Entering And Selecting A Menu Option

    B2 Edit appears. Move Quit the program mode with the ESC key and return to the normal display The control unit continues to process the program in the "Parameterization" operating mode! 30 • Start-up OptiFeed BigBag (FPS16)

  • Page 31: Powder Flow Detection

    If the pressure decreases under a defined threshold value, the powder container is lowered to the floor and lifted again, so that the craters can be loosen. Start-up • 31 OptiFeed BigBag (FPS16)
  • Page 32 Craters in the powder container / container empty Fig. 10: Craters in the powder Threshold value down container / container (variable) empty Threshold value not Pump reached - Powder flow not OK Backpressure in the powder hose 32 • Start-up OptiFeed BigBag (FPS16)

  • Page 33: Procedure Description

    Functional check Turn on the vibrator switch Activate the powder transport (manually or by an external, superordinated control unit) The fluidizing air and the vibration must be in operation Start-up • 33 OptiFeed BigBag (FPS16)
  • Page 34 Rev. 00 03/22 34 • Start-up OptiFeed BigBag (FPS16)

  • Page 35: Operation • 35

    ► A dust mask corresponding to filter class FFP2 or N95 at minimum must be worn during any cleaning work. A great deal of air is required for the cleaning procedure! ► Make sure that 6 bar is always available! Operation • 35 OptiFeed BigBag (FPS16)

  • Page 36: Operation

    The powder hose rinsing enables the cleaning of the powder hoses and the filter elements in the powder pump. For further information, see the OptiFeed PPxx Powder pump operating manual! 36 • Operation OptiFeed BigBag (FPS16)

  • Page 37: Color Change

    Activate cleaning mode (see OptiFeed 4.0 operating manual) – The automated cleaning procedure is started Clean the entire equipment with compressed air • Connect powder hose to the fluidizing/suction unit • Prepare the equipment with new powder for start-up Operation • 37 OptiFeed BigBag (FPS16)
  • Page 38 Rev. 00 03/22 38 • Operation OptiFeed BigBag (FPS16)

  • Page 39: Decommissioning / Storage

    There are no special requirements concerning distance to neighboring equipment. Physical requirements Storage must be inside a dry building at a temperature between +5 and +50 °C. Do not expose to direct sunlight. Decommissioning / Storage • 39 OptiFeed BigBag (FPS16)

  • Page 40: Maintenance During Storage

    No maintenance plan for the equipment is necessary. • The equipment fitted with powder pump (OptiFeed 4.0) must be serviced after a long standstill period (≥ 1 year) Maintenance works During long-term storage, periodically perform a visual check. 40 • Decommissioning / Storage OptiFeed BigBag (FPS16)

  • Page 41: Maintenance / Repairs

    – The parts to be replaced during maintenance work are available as spare parts. These parts can be found in the appropriate spare parts list! Maintenance / Repairs • 41 OptiFeed BigBag (FPS16)

  • Page 42: Interval

    Check the grounding connections with the coating booth, the suspension devices of the work pieces, or the conveyor chain If in disuse for several days Separate from power mains Clean the coating equipment Turn off the main compressed air supply 42 • Maintenance / Repairs OptiFeed BigBag (FPS16)

  • Page 43: Maintenance Of The Filter Unit

    Unscrew the filter glass on the filter unit Remove the complete filter element Fig. 11: Symbol image for maintenance of a filter element Replace the filter element Clean the filter glass on the inside and install it again Maintenance / Repairs • 43 OptiFeed BigBag (FPS16)

  • Page 44: Cleaning

    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 equipment and may result in loss of warranty! 44 •...

  • Page 45: Fault Clearance

    "Software error diagnostics" on page 47. Problem/error/malfunction Cause Procedures/remedy Vibration not running Vibration motor not connected Connect the cables or defective Replace the vibration motor Fluidization not running Compressed air not present Ensure the compressed air supply Fault clearance • 45 OptiFeed BigBag (FPS16)
  • Page 46 (see associated operating Powder hose clogged Clean the powder hose manual) Powder not present Replace the powder box Pinholing will not be solved Contact an Gema service center Insufficient conveying Fluidizing/suction unit not performance of the powder lowered pump (see associated...

  • Page 47: Software Error Diagnostics

    BUS OFF condition. otherwise contact Gema Permanent CAN bus error service No power supply or cable is not connected. High error rate when The CAN controller changes into Contact Gema Service transmitting/receiving ERROR_PASSIVE condition Fault clearance • 47 OptiFeed BigBag (FPS16)
  • Page 48 (insufficient air volume flow) Contact Gema Service Pressure regulator Vacuum value out of tolerance Contact Gema Service vacuum Pressure regulator PV air Actual pressure PV supply out of Contact Gema Service supply tolerance 48 • Fault clearance OptiFeed BigBag (FPS16)

  • Page 49: Appearance Of Errors

    – Hose backpressure is greater Powder hose is clogged or than 1.0 bar bent (clean or replace it) – Filter elements (powder chamber/pinch valve hose) are clogged (clean or replace them) Fault clearance • 49 OptiFeed BigBag (FPS16)
  • Page 50 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 Indicator on powder pump be present at connection 2.1: PP07 does not light up = +24 VDC;...
  • Page 51 Rev. 00 03/22 Incident Causes Corrective action pump control or corresponding Powder pump is not Replace the defective valve valve is defective conveying, indicator flashing Fault clearance • 51 OptiFeed BigBag (FPS16)
  • Page 52 Rev. 00 03/22 52 • Fault clearance OptiFeed BigBag (FPS16)

  • Page 53: 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 54 Rev. 00 03/22 54 • Disposal OptiFeed BigBag (FPS16)

  • Page 55: 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 • 55 OptiFeed BigBag (FPS16)

  • Page 56: Fps16 Fresh Powder System - Spare Parts List

    Grounding cable – complete with clamp 1009 284 Powder hose – Ø 23/16 mm 1010 040* * Please indicate length For all other electric/pneumatic components, see also the Spare parts list in the enclosed wiring/ pneumatic diagram! 56 • Spare parts list OptiFeed BigBag (FPS16)

  • Page 57: Fps16 Fresh Powder System - Spare Parts

    Rev. 00 03/22 FPS16 Fresh powder system – spare parts Fig. 13: Spare parts Spare parts list • 57 OptiFeed BigBag (FPS16)

  • Page 58: Fluidizing/Suction Unit

    103 756* Hose connection – complete (incl. pos. 14) 1023 156# O-ring – Ø 20x2 mm 1017 809# Powder hose – Ø 23/16 mm 1010 040*# * Please indicate length # Wear parts 58 • Spare parts list OptiFeed BigBag (FPS16)

  • Page 59: Fluidizing/Suction Unit

    Rev. 00 03/22 Fluidizing/suction unit Fig. 14: FPS16 Fresh powder system – fluidizing/suction unit Spare parts list • 59 OptiFeed BigBag (FPS16)
  • Page 61 Spare parts list ..........55 Fault clearance ..........45 Start-up ............25 Figure references in the text ......8 Storage ............39 Intended use ............ 15 Technical Data ..........17 Maintenance ............. 41 Spare parts list • 61 OptiFeed BigBag (FPS16)
  • Page 62 Rev. 00...

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