Gema PH300 Guide

Rev. 00 1017 583 EN
Operating instructions and Spare parts list
Powder hopper
PH300
Translation of the original operating instructions

Rev. 00 01/22
Documentation PH300
© Copyright 2017 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) und
SuperCorona 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.
For the latest information about Gema products, visit
www.gemapowdercoating.com.
For patent information, see www.gemapowdercoating.com/patents or
www.gemapowdercoating.us/patents.
Printed in Switzerland
Gema Switzerland GmbH
Mövenstrasse 17
9015 St.Gallen
Switzerland
Phone:[phone]
Fax.: [phone]
E-mail: [email protected]

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PH300 Table of contents
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3
Table of contents
About these instructions 5
General information ................................................................................................5
Keeping the Manual................................................................................................5
Safety symbols (pictograms)...................................................................................5
Presentation of the contents...................................................................................6
Figure references in the text......................................................................6
Safety 7
General information ................................................................................................7
Basic safety instructions .........................................................................................7
Product specific security regulations ......................................................................8
Product description 9
Intended use ...........................................................................................................9
Reasonably foreseeable misuse..............................................................10
Structure................................................................................................................10
Overall view..............................................................................................10
Compressed air indicators....................................................................................11
Feed Control Hood................................................................................................11
Principle of operation............................................................................................12
Technical Data......................................................................................................12
Powder transport......................................................................................12
Electrical data ..........................................................................................12
Pneumatic data........................................................................................13
Dimensions ..............................................................................................13
Processible powders................................................................................13
Sound pressure level...............................................................................13
Rating plate..............................................................................................14
Additional equipment / options..............................................................................14
Assembly / Connection 15
Set-up....................................................................................................................15
Connecting the powder hopper.............................................................................15
Connecting the supply ..........................................................................................15
Connecting the electrics...........................................................................15
Connecting the pneumatic system...........................................................16
Grounding of the fresh powder hopper.................................................................16
Start-up 17
Cleaning the interior of the powder hopper...........................................................17
Filling the powder hopper......................................................................................17
Setting the fluidization..............................................................................18
Start-up inspection................................................................................................19
Operation 21
Safety....................................................................................................................21

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Table of contents PH300
Product contamination through foreign matter........................................ 21
Preparing for production....................................................................................... 21
Ending production................................................................................................. 21
Decommissioning / Storage 23
Introduction........................................................................................................... 23
Requirements on personnel carrying out the work.................................. 23
Storage conditions................................................................................................ 23
Hazard notes........................................................................................... 23
Type of storage........................................................................................ 23
Storage duration...................................................................................... 23
Space requirements ................................................................................ 23
Physical requirements............................................................................. 23
Shut-down............................................................................................................. 24
Putting out of service............................................................................... 24
Maintenance during storage................................................................................. 24
Maintenance schedule............................................................................. 24
Maintenance works.................................................................................. 24
Maintenance / Repairs 25
General information.............................................................................................. 25
Securing against unexpected start-up..................................................... 25
Explosion protection................................................................................ 25
Pressurized pneumatics system.............................................................. 26
Cleaning................................................................................................................ 26
Cleaning the interior of the powder hopper............................................. 26
Interval.................................................................................................................. 27
Daily maintenance................................................................................... 27
Wearing parts.......................................................................................... 27
Fault clearance 29
Securing against unexpected start-up..................................................... 29
Explosion protection................................................................................ 29
Pressurized pneumatics system.............................................................. 29
Faults.................................................................................................................... 30
Disposal 31
Introduction........................................................................................................... 31
Requirements on personnel carrying out the work.................................. 31
Disposal regulations................................................................................ 31
Materials.................................................................................................. 31
Spare parts list 33
Ordering spare parts............................................................................................. 33
PH300 Fresh powder hopper ............................................................................... 34
Pneumatic unit...................................................................................................... 35
Fluidized container ............................................................................................... 36

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PH300 About these instructions
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5
About these instructions
General information
This operating manual contains all the important information which you
require for the working with the PH300. 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 PH300
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.
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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PH300 Safety
•
7
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.
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.

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Safety PH300
–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.
Product specific security regulations
–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.
For further security information, see the more detailed Gema
safety regulations!

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PH300 Product description
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9
Product description
Intended use
The PH300 fresh powder hopper serves to continually supply powder to
the coating plant.
The fresh powder hopper is suitable for use in single-color systems and,
as part of the process-controlled coating system, is designed for semi-
automatic operation.
Fig.
1
: PH300 Powder Hopper
The powder hopper is certified for using in the following zone, if
powder hoses with conductive strips are used, and the grounding
resistance is less than 1 MOhm!
Explosion protection
Zone
II (2) D
22
Observance of the operating, service and maintenance instructions
specified by the manufacturer is also part of the intended use. This

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Product description PH300
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!
Reasonably foreseeable misuse
–Use of moist or over-tempered powder
–Insufficient fluidization
–Incorrectly assembled individual parts
–Use with insufficient compressed air quality
–Operation without the proper training
Structure
Overall view
Fig.
2
: PH300 –structure
1 Powder pump
2 Fluidizing plate
3 Fluidized container
4 Feed Control Hood
5 Powder filling cover
6 Ventilation
7 Pneumatic unit

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PH300 Product description
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Compressed air indicators
Fig.
3
DR1
Powder hopper fluidizing air
DR2
Compressed air input
Feed Control Hood
The fresh powder hopper has a powder outlet in the plate with a Dense
Phase Conveyor. If the powder hopper is switched off directly after
conveying, the still fluidized powder flows into the opening into the Dense
Phase Conveyor. At the next 'restart' this can lead to clogging, so that the
conveyor hose must be emptied first.
This feed control hood is inserted into the outlet opening. A ring slot
around the outlet opening is created by the hood, so that powder can only
flow slightly. The ring slot setting is, however, very much dependent on
the flow characteristics of the powder and must, therefore, be set
individually.
Because the Feed Control Hood is only a push fit, it can be removed for
setting or cleaning.
Fig.
4

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Product description PH300
Principle of operation
The PH300 fresh powder hopper serves to continually supply powder to
the coating plant. The hopper is fitted with a fluidizing plate, as well as
with a dense phase pump.
As soon as the coating plant is put into operation, the powder hopper is
supplied with compressed air. The ventilation switches on to vent the
hopper. The powder hopper is filled manually with powder, preferably
from 25 kg powder bags. The large surface platform on the hopper for the
powder bag, and the inclined filler plate serve the simple, and dust-free
filling of the hoppers. Resulting dust is sucked up by the ventilation and
can be fed back into the booth or the powder recovery.
Because of additional dust development it is not recommended to
refill during transport cycles.
If powder is now requested through the level sensor of the powder
hopper, the fluidizing air, and the powder pump(s) are switched on. The
powder is moved to the powder hopper, as long as the level sensor still
requests powder.
The fresh powder hopper is not equipped with level monitoring, as the
level sensor in the powder hopper releases a booth alarm as long as the
correct powder level is not reached within the specified time.
Technical Data
Powder transport
PH300
Hose length up to 8 m
6 kg/min
Hose length 8–16 m
4.5 kg/min
Hose length 16–25 m
4 kg/min
Electrical data
PH300
Connected load
1x230 V
Frequency
50/60 Hz
Protection type
IP54

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PH300 Product description
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13
Pneumatic data
PH300
Inlet pressure
min. 6.5 bar / max. 10 bar
Max. compressed air
consumption:
–Fluidization
–Conveying
–Ventilation
approx. 40 Nm³/h
approx. 11 Nm³/h
approx. 2.5 Nm³/h
Max. water vapor content of the
compressed air
max. 1.3 g/m³
Max. oil vapor content of the
compressed air
max. 0.1 mg/m³
Dimensions
PH300
Area
(width x depth)(mm)
1230 x 1210
Overall height (mm)
1500
Weight (kg)
approx. 185
(with two PP07 pumps)
Processible powders
OptiFeed 4.0
Plastic powder
yes
Metallic powder
yes
Enamel powder
yes
Sound pressure level
PH300
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.

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Product description PH300
Rating plate
Fig.
5
Additional equipment / options
–Level sensor (see corresponding documentation)
–Vibrating sieve (see corresponding documentation)

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PH300 Assembly / Connection
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15
Assembly / Connection
Set-up
The fresh powder hopper is used in combination with powder coating
plants.
Installation work to be done by the customer must be carried out
according to local safety regulations!
NOTICE
Surrounding temperature too high
–Install the product only in locations with an ambient temperature
of between +10 °C and +40 °C, i.e. never next to heat sources
(such as an enameling furnace) or electromagnetic sources (such
as a control cabinet).
–All hose connections should be as short as possible.
–The venting hose should be laid out without loops so that depositing,
and clogging are prevented.
–Check the hose connections for a good seal, and firm seating
–Check the interlocking, so that the fresh powder hopper only works
when the exhaust system is switched on.
Connecting the powder hopper
The powder hoppers delivered by the manufacturer are ready for
operation. Just a few hoses must be connected additionally.
Connecting the supply
Connecting the electrics
Only locally authorized specialists may install and inspect the electrical
elements of the machine.
In the event of customizations, the wiring diagram may differ.

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Assembly / Connection PH300
Connecting the pneumatic system
The compressed air must be free of oil and water!
The fresh powder hopper requires a connection to a sufficiently
dimensioned compressed air circuit.
In order to ensure correct operation, the main pressure regulator must be
set to a pressure of 6 bar.
Fig.
6
: Compressed air supply
Grounding of the fresh powder hopper
DANGER
Missing or incorrect grounding
A poor or missing ground connection can be dangerous to the
machine operator.
►Ground all metal parts in accordance with general local
regulations.
►Check grounding regularly.
A corresponding connection point at the rear of the container is reserved
for the potential equalization.
Fig.
7
: Potential equalization –connection point

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PH300 Start-up
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17
Start-up
NOTICE
Cross-contamination
For technical reasons, the fluidizing plate consists of porous
material and is therefore able to capture residual amounts of
powder particles.
►Always use the fluidizing plate corresponding with the
processable powder and end product!
Cleaning the interior of the powder hopper
The interior of the powder hopper must be clean before start-up.
1. Clean the interior of the powder hopper. See chapter "Cleaning the
interior of the powder hopper" on page 26.
–The interior of the powder hopper is clean.
Filling the powder hopper
The powder hopper is filled manually via the open filling cover. Depending
on the strength of the fluidization, powder can flow out.
CAUTION
Large dust formation possible.
Respiratory problems.
►Wear protective clothing and eye protection!
CAUTION
Foreign objects.
Contamination by foreign objects.
►Ensure that no foreign objects can fall into the powder hopper
during manual filling!
1. Open the cover

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Start-up PH300
2. Fill with powder.
3. Close the filling cover.
Setting the fluidization
The powder fluidization depends on the powder type, the air humidity and
the ambient temperature. Fluidizing starts by switching on the system
1. Connect the quick release coupling to the fluidizing air connection of
the powder hopper
2. Adjust the fluidizing air on the pneumatic/fluidizing unit.
3. Check fluidization of the powder in the powder hopper
–The powder should "boil" only slightly, but regularly
CAUTION
Large dust formation possible!
If the fluidization has been incorrectly adjusted, then the coating
powder can create a dust cloud capable of causing respiratory
problems.
►Adjust the fluidization correctly.
4. Check whether everything is functioning correctly

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PH300 Start-up
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Start-up inspection
No.
Inspection
✓
1
All screw connections are tight.
2
Power levels are correct. See chapter "Filling the
powder hopper" on page 17.
3
Fluidization air is set correctly.
4
The interior of the powder hopper is clean. See chapter
"Cleaning the interior of the powder hopper" on page
26.
5
The operating manual is stored with the machine close
to the work station.
6
The operator has been told that he is responsible for
instructing the personnel.
7
Assembly and installation have been concluded in
accordance with the operating manual.
8
Electrical and mechanical safety equipment is in perfect
working order.

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Start-up PH300