Gema OptiFeed B FPS19 Quick guide

En
Translation of the original operating instructions
Operating instructions and spare parts list
OptiFeed B FPS19
Fresh powder system

V 04/13
Documentation OptiFeed B FPS19
© Copyright 2010 Gema Switzerland GmbH
All rights reserved.
This publication is protected by copyright. Unauthorized copying is
prohibited by law. No part of this publication may be reproduced,
photocopied, translated, stored on a retrieval system or transmitted in
any form or by any means for any purpose, neither as a whole nor
partially, without the express written consent of Gema Switzerland
GmbH.
OptiFlex, OptiTronic, OptiGun, EasyTronic, EasySelect, EasyFlow,
OptiStar, OptiSelect, OptiFlow and SuperCorona are registered
trademarks of Gema Switzerland GmbH.
OptiMatic, OptiMove, OptiMaster, OptiPlus, PowerClean, Precise Charge
Control (PCC), OptiSpray, MultiTronic 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
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 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 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.
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 04/13
OptiFeed B FPS19 Table of contents •1
Table of contents
General safety regulations 3
Safety symbols (pictograms) ...................................................................................3
Conformity of use ....................................................................................................8
Product-specific safety measures ...........................................................................8
OptiFeed B FPS19 Fresh powder system..................................................8
About this manual 9
General information.................................................................................................9
Product description 11
Field of application ................................................................................................11
Utilization ..................................................................................................12
Reasonably foreseeable misuse ..............................................................12
Technical data .......................................................................................................12
Electrical data...........................................................................................12
Pneumatic data ........................................................................................12
Conveying performance/powder output ...................................................13
Dimensions...............................................................................................13
Processible powders ................................................................................13
Design and function...............................................................................................14
General view ............................................................................................14
Scope of delivery...................................................................................................15
OptiFeed B FPS19 ...................................................................................15
Accessories (Option) ................................................................................15
Typical properties - Characteristics of the functions .............................................15
Processing the powder directly from the original powder manufacturer's
container...................................................................................................15
Start-up 17
Preparation for start-up .........................................................................................17
Basic conditions .......................................................................................17
Set-up ....................................................................................................................17
Initial start-up 19
Operation...............................................................................................................20
Powder hose rinsing.................................................................................21
Color change .........................................................................................................22
General information..................................................................................22
Shutdown...............................................................................................................23
Cleaning and maintenance 25
Daily maintenance.................................................................................................25
Weekly maintenance .............................................................................................25
If in disuse for several days...................................................................................25
Cleaning ................................................................................................................26
Cleaning the fluidizing/suction unit...........................................................26

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2 •Table of contents OptiFeed B FPS19
Maintenance and cleaning of the filter unit ........................................................... 26
Replacing the filter element ..................................................................... 26
Troubleshooting 27
General information .............................................................................................. 27
Spare parts list 29
Ordering spare parts ............................................................................................. 29
OptiFeed B FPS19 Fresh powder system – Spare parts ..................................... 30
OptiFeed B FPS19 Fresh powder system – Spare parts ..................................... 31
Fluidizing/suction unit............................................................................................ 32
Fluidizing/suction unit - spare parts ......................................................................33
OptiFeed B FPS19 – Pneumatic group ................................................................ 34

V 04/13
OptiFeed B FPS19 General safety regulations •3
General safety regulations
This chapter sets out the fundamental safety regulations that must be
followed by the user and third parties using OptiFeed B FPS19 Fresh
powder system.
These safety regulations must be read and understood before the
OptiFeed B FPS19 is put into operation.
Safety symbols (pictograms)
The following warnings with their meanings can be found in the Gema
operating instructions. The general safety precautions must also be
followed 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
equipment
INFORMATION!
Useful tips and other information

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4 •General safety regulations OptiFeed B FPS19
The OptiFeed B FPS19 Fresh powder system is state of the art
equipment that conforms to the recognized technical safety regulations
and is designed for normal powder coating applications.
Any other use is considered non-compliant. 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 before OptiFeed B FPS19 Fresh powder system is used for
any other purposes or substances beyond those indicated here.
Observance of the operating, service and maintenance instructions
specified by the manufacturer is also part of conformity of use.
The relevant accident prevention regulations, as well as other generally
recognized safety regulations, occupational health and structural
regulations are to be observed.
Furthermore, the country-specific safety regulations also must be
observed.
Additional safety and operation notices can be found on the
accompanying CD or on the homepage www.gemapowdercoating.com.
Start-up is forbidden until it has been established that the OptiFeed B
FPS19 Fresh powder system has been set up and wired according to the
EU guidelines for machinery.
Unauthorized modifications to the OptiFeed B FPS19 Fresh powder
system exempt the manufacturer from any liability from resulting
damages or accidents.
The operator must ensure that all users have received appropriate
training for powder spraying equipment and are aware of the possible
sources of danger.
Any operating method, which will negatively influence the technical safety
of the powder spraying equipment, is to be avoided.
General
dangers
General
information

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OptiFeed B FPS19 General safety regulations •5
For your own safety, only use accessories and attachments listed in the
operating instructions. 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.
The connecting cables between the control unit and the spray gun must
be installed so as to eliminate the possibility of damage during the
operation. Please observe the local safety regulations!
The plug connections between the powder spraying equipment and the
mains should only be removed when the power supply is switched off.
All maintenance activities must take place when the powder spraying
equipment is switched off.
The powder coating equipment may not be switched on until the booth is
in operation. If the booth stops, the powder coating device must switch off
too.
The control units for the spray guns must be installed and used in zone
22. Spray guns are allowed in zone 21.
Only original Gema OEM parts are guaranteed to maintain the explosion
protection rating. If damages occur related to the use of spare parts from
other manufacturers, all relevant warranty or compensation claims are
void!
Conditions leading to dangerous levels of dust concentration in the
powder spraying booths or in the powder spraying areas must be
avoided. There must be sufficient technical ventilation available, to
prevent a dust concentration of greater than 50% of the lower explosion
limit (UEG = max. permissible powder/air concentration). If the UEG is
not known, then a value of 10 g/m³ should be considered (see EN
50177).
All unauthorized conversions and modifications to the electrostatic
spraying equipment are forbidden for safety reasons.
The safety devices may not be dismantled or put out of operation.
Mandatory operational and workplace notices from the operating
company must be written in a comprehensible manner in the language of
equipment operators and posted in a suitable place.
Electrical
danger
Explosion hazard

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6 •General safety regulations OptiFeed B FPS19
Powder lying on the floor around the powder spraying equipment is a
potentially dangerous source of slipping. Booths may be entered only in
the places designed for this purpose.
Static charges
Static charges can have the following consequences: Charges to people,
electric shocks, sparking. Proper grounding must be in place to prevent
objects from becoming charged.
Grounding
All electrically conductive parts found within 5 meters around each booth
opening, and in particularly the objects to be coated, must be grounded.
The grounding resistance of each object must amount to maximally 1
MOhm. This resistance must be checked/tested regularly when starting
work.
The condition of the work piece attachments, as well as the hangers,
must guarantee that the work pieces remain grounded. The appropriate
measuring devices must be kept ready in the workplace, in order to
check the grounding.
The floor of the coating area must conduct electricity (normal concrete is
generally conductive).
The supplied grounding cable (green/yellow) must be connected to the
grounding screw of the Fresh powder system. The grounding cable must
have a good metallic connection with the coating booth, the recovery unit
and the conveyor chain, respectively with the suspension arrangement of
the objects.
Smoking and igniting fire are forbidden in the entire vicinity of the system!
No work that could potentially produce sparks is allowed!
Slip hazard
Observe the
grounding
re
g
ulations
Fire and smoke
prohibition

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OptiFeed B FPS19 General safety regulations •7
As a general rule for all powder spraying installations, persons with
pacemakers should never enter high voltage areas or areas with
electromagnetic fields. Persons with pacemakers should not enter areas
with powder spraying installations!
Photographing with flashlight can lead to unnecessary releases and/or
disconnections by safety devices.
Disconnect the plugs before the machines are opened for maintenance
or repair.
The plug connections between the powder spraying equipment and the
mains should only be removed when the power supply is switched off.
As far as it is necessary, the operating firm must ensure that the
operating personnel wear protective clothing (e.g. facemasks).
A dust mask corresponding to filter class FFP2 at minimum must be worn
during any cleaning work.
The operating personnel must wear electrically conductive, steel-toe
footwear (e.g. leather soles).
The operating personnel should hold the gun with bare hands. If gloves
are worn, these must also conduct electricity.
These general safety regulations must
be read and understood in all cases
prior to start-up!
The stay for persons
with cardiac pacemakers
is forbidden
Photographing with
flashlight is
forbidden
Disconnect from
mains before
maintenance works
take place

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8 •General safety regulations OptiFeed B FPS19
Conformity of use
1. The OptiFeed B FPS19 Fresh powder system is state of the art
equipment that conforms to the recognized technical safety
regulations and is designed for normal powder coating
applications.
2. Any other use is considered non-compliant. 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 before OptiFeed B FPS19 Fresh
powder system is used for any other purposes or substances
beyond those indicated here.
3. Observance of the operating, service and maintenance
instructions specified by the manufacturer is also part of
conformity of use. The OptiFeed B FPS19 Fresh powder system
should only be used, maintained and started up by trained
personnel informed and familiar with the possible hazards
involved.
4. Start-up (i.e. operation of its intended use) is not allowed until it
has been established that the OptiFeed B FPS19 Fresh powder
system has been installed and wired according to the EU
Machinery Directive (2006/42/EC). EN 60204-1 (machine safety)
must also be observed.
5. Unauthorized modifications to the OptiFeed B FPS19 Fresh
powder system exempt the manufacturer from any liability from
resulting 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 also must be
observed.
Explosion protection Protection type
II 3D IP54
Product-specific safety measures
- Installation work performed by the customer must be carried
out according to local regulations.
- All components must be grounded according to the local
regulations before start-up.
OptiFeed B FPS19 Fresh powder system
The OptiFeed B FPS19 is a constituent part of the system and is thus
integrated into the safety system of the plant.
If it is to be used in a manner outside the scope of the safety concept,
then corresponding measures must be taken.
Note:
For further security information, see the more detailed Gema safety
regulations!

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OptiFeed B FPS19 About this manual •9
About this manual
General information
This operating manual contains all important information required to work
with the OptiFeed B FPS19 Fresh powder system. It will safely guide you
through the start-up process and give you references and tips for the
optimal use of your new powder coating system.
Information about the functionality of the individual system components -
booth, gun control unit, manual gun or powder injector - should be
referenced to their enclosed corresponding documents.

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OptiFeed B FPS19 Product description •11
Product description
Field of application
The OptiFeed B FPS19 Fresh powder system (with powder box) is
exclusively intended for electrostatic coating using organic powders (For
more on this please also review chapter "Technical Data").
Any other use is considered non-compliant. The manufacturer is not
responsible for any incorrect use and the risks associated with such
actions are assumed by the user alone!
For a better understanding of the interrelationships in powder coating, it
is recommended that the operating instructions for all other components
be read as well, so as to be familiar with their functions too!
OptiFeed B FPS19 Fresh powder system

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12 •Product description OptiFeed B FPS19
Utilization
The OptiFeed B FPS19 Fresh powder system conveys fluidized coating
powder dust free from a powder container to the place of destination.
Note:
The use of the OptiFeed B FPS19 Fresh powder system must take
place in the area defined for it!
Reasonably foreseeable misuse
- Operation without the proper training
- Use with insufficient compressed air quality and grounding
- Use in connection with unauthorized coating devices or
components
Technical data
Electrical data
OptiFeed B FPS19
Nominal input voltage 100-240 VAC
Frequency 50 -60 Hz
Connected load 120 VA
Vibrator connection and performance 110-230 VAC
max. 100 VA
Temperature range 0 °C - +40 °C
(+32 °F - +104 °F)
Max. surface temperature 120 °C (+248 °F)
Approvals II 3 D IP54 120 °C
Pneumatic data
OptiFeed B FPS19
Max. input pressure 8 bar
Min. input pressure 6 bar
Max. water vapor content of the compressed
air 1.3 g/m³
Max. oil vapor content of the compressed air 0.1 mg/m³
Air consumption (complete system) 8-11 Nm³/h
Air consumption (transport) 2-5 Nm³/h

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OptiFeed B FPS19 Product description •13
Conveying performance/powder output
OptiFeed B FPS19
Powder hose length 0-8 m 5000 g/min
Powder hose length 8-16 m 4000 g/min
Powder hose length 16-25 m 3500 g/min
Powder pump OptiFeed PP06 type
Dimensions
OptiFeed B FPS19
Width 460 mm
Depth 710 mm
Height 1700 mm
Weight 54 kg
Processible powders
OptiFeed B FPS19
Plastic powder yes
Metallic powder yes
Enamel powder yes
(with OptiFeed PP06-E only)
Note:
For further information, see the OptiFeed PP06 Powder pump
operating manual!

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14 •Product description OptiFeed B FPS19
Design and function
General view
OptiFeed B FPS19 Fresh powder system - Structure
AS Suction side 5 Fluidizing/suction unit
FS Transport side 6 Filter unit
1 OptiFeed PP06 Powder pump 7 Vibrating table
2 Power pack 8 Swivel wheel
3 Pressure regulator for fluidizing air 9 Rubber wheel
4 Fluidizing air connection 10 Swivel arm with guide
sleeve
OptiFeed PP06 Powder pump
All information about the OptiFeed PP06 Powder pump will be found in
the corresponding enclosed documentation!
1
10
4
5
3
8
9
6
7
AS
2
FS

V 04/13
OptiFeed B FPS19 Product description •15
Power pack
Switch position
I
Switch on the vibrator manually
0
Vibrator OFF
II Vibrator is switched on via an
external signal
0
PP06 Powder pump OFF
I PP06 Powder pump ON
Scope of delivery
OptiFeed B FPS19
- mobile trolley
- vibrating table with a fluidizing/suction unit
- OptiFeed PP06 Powder pump
- Pneumatic hoses and connection cable
- Special cable jack for the connection of an external control
signal
- Power pack with power supply cable
- Operating manual
- Short instructions
Accessories (Option)
- LM02 Level sensor
Typical properties - Characteristics of the functions
Processing the powder directly from the original
powder manufacturer's container
The OptiFeed B FPS19 Fresh powder system allows for powder to be
processed directly out of the original powder manufacturer's container. A
titled vibrating floor has been included to ensure that the powder
container empties itself completely.

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OptiFeed B FPS19 Start-up •17
Start-up
Preparation for start-up
Basic conditions
When starting up the OptiFeed B FPS19 Fresh powder system, the
following general conditions impacting the coating results must be taken
into consideration:
- Fresh powder system is set up properly
- Powder pump correctly connected
- Corresponding power and compressed air supply available
- Powder preparation and powder quality
Set-up
The OptiFeed B FPS19 Fresh powder system should always be set up
vertically on a flat surface.
WARNING:
The Fresh powder system must not under any circumstances be set
up near a heat source (such as an enameling furnace) or an
electromagnetic source (such as a control cabinet).
Note:
Use clamp to connect grounding cable to the cabin or the
suspension arrangement. Check ground connections with Ohm
meter and ensure 1 MOhm or less!
Note:
The compressed air must be free of oil and water!