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,
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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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3
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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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

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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.

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Product specific safety information
–This product is a constituent part of the equipment and is therefore
integrated in the system's safety concept.
–If it is to be used in a manner outside the scope of the safety
concept, then corresponding measures must be taken.
–The installation work to be done by the customer must be carried out
according to local regulations.
–It must be ensured, that all components are earthed according to the
local regulations before start-up.
–Due to accident risk and depending on the placement of the fresh
powder system, the safety barriers have to be placed in accordance
to the local regulations!
–The big bag equipped with antistatic loops is grounded via the FPS
hang-up plate.
–Grounding resistance should be checked regularly and should not
exceed 108ohm.
–If the big bag is detached from the hang-up plate, ensure that it is
appropriately grounded, as friction charging may occur during
transferring processes.
For further information, see the more detailed Gema safety
regulations.
WARNING
These general safety regulations must be read and understood in
all cases prior to start-up!
General information
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 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.
Observance of the operating, service and maintenance instructions
specified by the manufacturer is also part of the intended 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 homepage
www.gemapowdercoating.com.

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Safety OptiFeed BigBag (FPS16)
General dangers
Start-up is forbidden until it has been established that the product has
been set up and wired according to the EU guidelines for machinery.
Unauthorized modifications to the product exempt the manufacturer
from any liability from resulting damages or accidents.
The operator must ensure that all users do have the 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.
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.
Electrical danger
The connecting cables between the control unit and the spray gun
must be installed in such a way, that they cannot be damaged 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 product may not be switched on until the booth is in operation. If
the booth stops, the product must switch off too.
Explosion hazard
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 by using spare parts from
other manufacturers, the warranty or compensation claim is 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 more 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.
No safety devices should 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.

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OptiFeed BigBag (FPS16) Safety
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Slip hazard
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 suitable for it.
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
Observe the grounding
regulations
All electrically conductive parts found in the workplace of 5 meters
around each booth opening, and particularly the objects to be coated,
have to 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 electrostatic manual powder coating
equipment. 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 open flames
Fire and smoke
prohibition
Smoking and igniting fire are forbidden in the entire vicinity of the
system! No work that could potentially produce sparks is allowed!
Stay for persons with cardiac pacemakers
The stay for persons
with cardiac
pacemakers is forbidden
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!

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Safety OptiFeed BigBag (FPS16)
Photographing with flashlight
Photographing with
flashlight is forbidden
Photographing with flashlight can lead to unnecessary releases and/or
disconnections by safety devices.
Maintenance works
Disconnect from mains
before maintenance
works take place
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 or N95 at minimum
must be worn during any cleaning work.
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.

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OptiFeed BigBag (FPS16) Product description
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Product description
Intended use
The fresh powder system is a powder feeding system and is suited for the
conveying of the coating powder from the large containers (Big Bag) to
the powder coating plant (powder hopper/powder center). The powder
supply takes place continuously from the large container and in
accordance to the consumption in the coating plant. The powder transport
is automatically switched on and off by messages from the level sensor in
the powder container. 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
CAUTION
The use of the equipment must take place in the area defined for it!

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Product description OptiFeed BigBag (FPS16)
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.
Any other use is not considered as intended use. 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.
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

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OptiFeed BigBag (FPS16) Product description
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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
Vibrator connection and
performance
3 x 220-230 / 380-400 VAC
max. 180 W
Protection type
IP54
Approvals
II 3 D
Pneumatic data
OptiFeed BigBag (FPS16)
Compressed air connection
1/4"
Min. input pressure
6 bar
Max. input pressure
8 bar
Max. compressed air
consumption
0.5 Nm³/h for lifting procedure
12 Nm³/h for each PP0x Powder
pump
0.5 Nm³/h for fluidizing
Max. water vapor content of the
compressed air
1.3 g/m³
Max. oil vapor content of the
compressed air
0.1 mg/m³
Dimensions
OptiFeed BigBag (FPS16)
Width
1670 mm
Height
3885 mm
Depth with large container
1460 mm
Weight (without container)
approx. 340 kg
Max. load
500 kg
Container base area
max. 800 x 1200 mm
Container height incl. loops
1160/1260/1360 mm

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Product description OptiFeed BigBag (FPS16)
Container specifications (big bag)
OptiFeed BigBag (FPS16)
Suspension system
4-point loops
Version
square, no partition walls, with
emptying funnel
Safety factor
min. 5:1 for disposable use
min. 8:1 for reuse
Material incl. suspension loops
conductive, R<108ohm
Conveying performance
OptiFeed BigBag (FPS16)
Conveying performance
3500-5000 g/min for each pump*
(according to the material to be
conveyed, suction and conveying
length, powder preparation etc.)
Conveying line
up to 8 m (5 kg/min conveying
performance)
8-16 m (4 kg/min conveying
performance)
16-25 m (3.5 kg/min conveying
performance)
Hose diameter Transport side
NW 16 mm
Suction line
up to 5 m
Material to be conveyed
Coating powder
Remaining quantity
< 5% of the original container
content*
*) The indicated values are guide values for each pump, possible
deviations are dependent on the powder type and the hose length!
The compressed air consumptions are listed in the corresponding
operating manuals
Environmental conditions
OptiFeed BigBag (FPS16)
Utilization
in the interior
Height
up to 2 000 m
Temperature range
+5 °C - +40 °C
(+41 °F - +104 °F)
Max. surface temperature
+85 °C (+185 °F)
Maximum relative humidity
80 % for temperatures to 31 °C,
linearly decreasing to 50 %
relative humidity at 40 °C
Environment
not for wet environment
Degree of pollution of the
intended environment
2 (in accordance with DIN EN
61010-1)

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OptiFeed BigBag (FPS16) Product description
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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.
The specified value during normal operation is applicable only for this
product itself and does not take into account external noise sources or
cleaning impulses.
The specified value during cleaning operation requires the wearing of ear
protection.
The sound pressure level may vary, depending on the product
configuration and space constraints.
Rating plate
Fig.
2

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Product description OptiFeed BigBag (FPS16)
Structure
Overall view
Fig.
3
: Structure
1 Fluidizing/suction unit
2 Control
3 Powder pump
4 Support
5 Vibrating plate
6 Lifting device for
container
7 Lifting device for
fluidizing/suction unit