Gema OptiFeed BigBag User manual

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

Rev. 00 03/22
Documentation OptiFeed BigBag (FPS16)
© Copyright 2022 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.
Gema, EquiFlow, MagicCompact, MagicCylinder, OptiCenter, OptiFlex,
OptiGun, OptiSelect and OptiStar are registered trademarks of Gema
Switzerland GmbH.
ClassicLine, ClassicStandard, ClassicOpen, DVC (Digital Valve Control),
GemaConnect, MagicControl, MagicPlus, MonoCyclone, MRS,
MultiColor, MultiStar, OptiAir, OptiControl, OptiColor, OptiFeed, OptiFlow,
OptiHopper, OptiMove, OptiSieve, OptiSpeeder, OptiSpray, PCC (Precise
Charge Control), RobotGun, SIT (Smart Inline Technology) and
SuperCorona are registered 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.
For the latest information about Gema products, visit
www.gemapowdercoating.com.
For information regarding patents, see
www.gemapowdercoating.com/patents or
www.gemapowdercoating.us/patents.
Printed in Switzerland
Gema Switzerland GmbH
Mövenstrasse 17
9015 St.Gallen
Switzerland
Phone: [phone]
Email: [email protected]

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OptiFeed BigBag (FPS16) Table of contents
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Table of contents
About these instructions 7
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
Safety 9
General information ................................................................................................9
Basic safety instructions .......................................................................................10
Product specific safety information.......................................................................11
Product description 15
Intended use .........................................................................................................15
Reasonably foreseeable misuse..............................................................16
Technical Data......................................................................................................17
Electrical data ..........................................................................................17
Pneumatic data........................................................................................17
Dimensions ..............................................................................................17
Container specifications (big bag) ...........................................................18
Conveying performance...........................................................................18
Environmental conditions.........................................................................18
Sound pressure level...............................................................................19
Rating plate..............................................................................................19
Structure................................................................................................................20
Overall view..............................................................................................20
Versions...................................................................................................21
Support.....................................................................................................21
Lifting device for large containers............................................................21
Fluidizing/suction unit...............................................................................21
Lifting device for fluidizing/suction unit ....................................................21
Vibrating plate..........................................................................................22
Control......................................................................................................22
Control cabinet.........................................................................................22
Control module.........................................................................................23
Powder pump...........................................................................................23
Scope of delivery ..................................................................................................24
Typical characteristics –properties of the functions.............................................24
Processing the powder directly from the original powder manufacturer's
container ..................................................................................................24
Fluidizing the coating powder..................................................................24
Powder flow detection..............................................................................24
Start-up 25
Set-up....................................................................................................................25
Connection...............................................................................................25
Electrical allocation...............................................................................................25

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Table of contents OptiFeed BigBag (FPS16)
Main module inputs .................................................................................26
Main module outputs...............................................................................26
Additional module inputs.........................................................................26
Additional module outputs.......................................................................26
Pneumatic connection..........................................................................................27
Powder connections.............................................................................................27
Initial start-up........................................................................................................28
Preparing the powder box .......................................................................29
Powder fluidizing .....................................................................................29
Parameterization ..................................................................................................29
Standard display......................................................................................29
Parameter input display...........................................................................29
Entering and selecting a menu option.....................................................30
Powder flow detection ..........................................................................................31
Overview..................................................................................................31
Procedure description..............................................................................33
Adjusting the threshold values ................................................................33
Functional check......................................................................................33
Operation 35
Operation..............................................................................................................36
Powder hose rinsing................................................................................36
Color change...........................................................................................37
Decommissioning / Storage 39
Shutdown..............................................................................................................39
Storage conditions................................................................................................39
Hazard notes...........................................................................................39
Type of storage........................................................................................39
Storage duration......................................................................................39
Space requirements ................................................................................39
Physical requirements.............................................................................39
Maintenance during storage.................................................................................40
Maintenance schedule.............................................................................40
Maintenance works..................................................................................40
Maintenance / Repairs 41
General information..............................................................................................41
Interval..................................................................................................................42
Daily maintenance...................................................................................42
Weekly maintenance...............................................................................42
If in disuse for several days.....................................................................42
Maintenance of the filter unit...................................................................43
Cleaning................................................................................................................44
Periodic checks ....................................................................................................44
Repair work...........................................................................................................44
Fault clearance 45
Software error diagnostics....................................................................................47
General information.................................................................................47
Help codes...............................................................................................47
Appearance of errors...............................................................................49
Troubleshooting guide..........................................................................................49
Disposal 53
Introduction...........................................................................................................53

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OptiFeed BigBag (FPS16) Table of contents
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Requirements on personnel carrying out the work..................................53
Disposal regulations.................................................................................53
Materials...................................................................................................53
Spare parts list 55
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

Rev. 00 03/22
OptiFeed BigBag (FPS16) About these instructions
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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.
Information about the functional mode of the individual system
components should be referenced in the respective enclosed documents.
Keeping the Manual
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.
WARNING
Indicates a hazardous situation which, if not avoided, could result in
death or serious injury.
CAUTION
Indicates a hazardous situation which, if not avoided, could result in
minor or moderate injury.
ATTENTION
Indicates a potentially harmful situation. If not avoided, the equipment or
something in its surrounding may be damaged.

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About these instructions OptiFeed BigBag (FPS16)
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:
–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 high voltage (H) created in the gun cascade is guided through the
center electrode."

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OptiFeed BigBag (FPS16) Safety
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9
Safety
General information
This chapter provides the user and third parties who operate this product
with all essential safety regulations, the adherence to which is imperative.
These safety regulations must be read and understood in their entirety
before the product is put into operation.
The standards and guidelines applied during the development,
manufacture and configuration are described in the EC declaration of
conformity and in the manufacturer’s declaration.
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 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.

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Safety OptiFeed BigBag (FPS16)
Basic safety instructions
–This product is built to the latest specification and conforms to the
recognized technical safety regulations and is designed for the
normal application of powder coating.
–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. If this product is to be used for other
purposes or other 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 liability from resulting damage.
–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.