Gema PS02 Guide

Rev. 00 1024 619 EN
Operating instructions and Spare parts list
Powder sieve machine
PS02
Translation of the original operating instructions

Rev. 00 08/23
Documentation PS02
© Copyright 2019 Gema Switzerland GmbH
All rights reserved.
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without the express written consent of Gema Switzerland GmbH.
Gema, EquiFlow, MagicCompact, MagicCylinder, OptiCenter, OptiFlex,
OptiGun, OptiSelect, OptiStar, OptiStar All-in-One and PowerBoost are
registered trademarks of Gema Switzerland GmbH.
ClassicLine, ClassicStandard, ClassicOpen, DVC (Digital Valve Control),
GemaConnect, MagicControl, MagicPlus, MonoCyclone, MRS,
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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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PS02 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
Structure of Safety Notes...........................................................................6
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
Sieve vibration motor...............................................................................11
Double sieve with cleaning effect ............................................................11
Technical Data......................................................................................................12
Versions...................................................................................................12
Electrical data ..........................................................................................12
Sieve performance...................................................................................12
Sieves ......................................................................................................12
Sound pressure level...............................................................................13
Assembly / Connection 15
Set-up....................................................................................................................15
Grounding of the sieve machine..............................................................15
Grounding of the sieve insert...................................................................15
Seating of the clamp ring.........................................................................16
Installing the double sieve insert..............................................................16
Connecting the powder sieve machine.................................................................16
Connecting the supply ..........................................................................................16
Connecting the electrics...........................................................................16
Connecting the pneumatic system...........................................................16
Start-up 17
Cleaning the interior of the sieve machine............................................................17
Start-up inspection................................................................................................17
Operation 19
Safety....................................................................................................................19
Product contamination through foreign matter.........................................19
Preparing for production .......................................................................................19

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Table of contents PS02
Operation..............................................................................................................20
Ending production.................................................................................................20
Decommissioning / Storage 21
Introduction...........................................................................................................21
Requirements on personnel carrying out the work..................................21
Storage conditions................................................................................................21
Hazard notes...........................................................................................21
Type of storage........................................................................................21
Storage duration......................................................................................21
Space requirements ................................................................................21
Physical requirements.............................................................................21
Shut-down.............................................................................................................22
Decommissioning....................................................................................22
Maintenance during storage.................................................................................22
Maintenance schedule.............................................................................22
Maintenance works..................................................................................22
Maintenance / Repairs 23
General information..............................................................................................23
Safety....................................................................................................................23
Securing against unexpected start-up..................................................................23
Explosion protection................................................................................23
Pressurized pneumatics system..............................................................24
Cleaning................................................................................................................24
Cleaning the interior of the sieve machine..............................................25
Dirt removal .............................................................................................26
Interval..................................................................................................................26
Daily maintenance...................................................................................26
Repairing the sieve mesh........................................................................26
Wearing parts..........................................................................................27
Fault clearance 29
Safety....................................................................................................................29
Securing against unexpected start-up..................................................................29
Explosion protection................................................................................29
Pressurized pneumatics system..............................................................29
Troubleshooting....................................................................................................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
PS02 –Spare parts list.........................................................................................34
PS02 –spare parts...............................................................................................35

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PS02 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 PS02. 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 PS02
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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PS02 Safety
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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 PS02
–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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PS02 Product description
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9
Product description
Intended use
The powder sieve machine is only intended for sieving powder which is
used for coating. The powder sieve machine’s sieving capacity is
supported by the sieve vibration motor. Depending on customer
specifications, the powder is fed in by powder pumps or dense phase
conveyor.
Fig.
1
: Powder sieve machine PS02
The powder sieve machine is certified for using in the following
zone, if powder hoses are used, which grounding resistance is
less than 1 MOhm!
Explosion protection
Zone
II 3 D
22
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

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Product description PS02
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
–Incorrectly assembled individual parts
–Use with insufficient compressed air quality
–Operation without the proper training
Structure
Overall view
Fig.
2
1 Hose connection
2 Screen
3 Clamp ring
4 Support
5 Screen base
6 Vibrator
7 Sieve cover
8 Connecting hose
9 Interruption switch
10 Ventilation

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PS02 Product description
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Sieve vibration motor
The sieve vibration motor supports the sieve performance of the powder
sieve machine. After activating the powder coating system, it will run
continuously until the entire system is either deactivated or switched into
cleaning mode.
Double sieve with cleaning effect
Double sieves consist of two parts, the wire net with large mesh width on
the lower side, and the wire net with fine mesh on the upper side.
fig.
3
: Double sieve
1 fine sieve mesh
2 large mesh supporting sieve
3 sieve assistance
Both sieve frames are fitted together, so that the inlying rings cannot be
lost. By using this filter assistance, the sieve mesh on the lower surface is
constantly cleaned and the clogging danger is substantially reduced.
According to experience, it is well-known that blockages are caused by
the powder accumulation on the lower surface of the sieve.

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Product description PS02
Technical Data
Versions
The powder sieve machine is available, depending on sieve cover design,
in three versions.
K-E
K
M
PS02-K-E
PS02-K
PS02-M
Number of connections
1, 2, 4, 6
1, 2, 3
2
Operation
(recommended)
Sieving the coating powder before entering
the powder hopper
Approvals
EEx II 3GD IP65 T120
Electrical data
PS02
Input voltage - vibration motor
3x400 V
3x230 V (with vibrator control)
Frequency
50 Hz
Performance
50 W
Sieve performance
The sieve performance depends on powder type, ageing, grain
distribution, machine set-up etc.
Sieves
Mesh width
Double sieve
Single sieve
200 µm
x
x
250 µm
x
x
265 µm
x
x
300 µm
x
x
315 µm
x
x
400 µm
x
x
500 µm
x
x
750 µm
–
x

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PS02 Product description
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13
Sound pressure level
PS02
Normal operation
< 70 dB(A)
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 is applicable only for this product itself and does not
take into account external noise sources or cleaning impulses.
The sound pressure level may vary, depending on the product
configuration and space constraints.

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Product description PS02

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PS02 Assembly / Connection
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Assembly / Connection
Set-up The powder sieve machine must be installed vertically and secured by
screws (vibration transfer) in order to achieve optimum sieving
performance. A non-secured sieve machine can vibrate strongly and
deliver up to 20% less sieving performance.
Grounding of the sieve machine
During installation, the sieve machine must be grounded in accordance
with local safety regulations. All grounding connections must be checked
regularly.
Grounding of the sieve insert
The grounding of the sieve insert is done by a grounding spring which is
grounded by continuous contact with the sieve cover.
WARNING
Incorrect or no grounding
►Take care to install the sieve correctly!
fig.
4
:
1 Sieve mesh
2 Grounding spring
3 Gasket
4 Clamp ring

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Assembly / Connection PS02
Seating of the clamp ring
ENVIRONMENT
Powder leak
An incorrectly seated clamping ring may cause damage to the
sieve insert seal and powder leaking into the environment.
►Check clamping ring for secure seating!
Installing the double sieve insert
In order to obtain the maximum sieve performance of the powder sieve
machine, the double sieve insert must be correctly installed. The fine
sieve mesh must show upwards and the rough sieve mesh downwards.
ATTENTION
Damage to sieve mesh
The fine-meshed screen may be damaged by careless handling.
►Only hold the sieve insert by the flange!
fig.
5
: Double sieve
1 fine sieve mesh
2 large mesh supporting sieve
3 sieve assistance
Connecting the powder sieve machine
The powder sieve machine is delivered ready-to-use by the manufacturer.
Only a few cables and hoses still have to be connected.
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.
Connecting the pneumatic system
The compressed air must be free of oil and water!

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PS02 Start-up
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Start-up
ATTENTION
Cross-contamination
For technical reasons, the sieve consists of fine-meshed material
and is therefore able to capture residual amounts of powder
particles
►Always use the sieve corresponding with the processable powder
and end product!
Cleaning the interior of the sieve machine
The interior of the sieve machine must be clean before start-up.
1. Clean the interior of the sieve machine. See chapter "Cleaning the
interior of the sieve machine" on page 25.
–The interior of the sieve machine is clean.
Start-up inspection
No.
Inspection
✓
1
All screw connections are tight.
2
The interior of the sieve machine is clean.
3
The operating manual is stored with the machine close
to the work station.
4
The operator has been told that he is responsible for
instructing the personnel.
5
Assembly and installation have been concluded in
accordance with the operating manual.
6
Electrical and mechanical safety equipment is in perfect
working order.

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Start-up PS02

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PS02 Operation
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Operation
Safety
Product contamination through foreign matter
Foreign matter entering the sieve machine through the open cover may
contaminate the powder.
1. Take measures to ensure that foreign matter is unable to enter the
sieve machine.
Preparing for production
DANGER
Explosive atmosphere.
Death or severe injuries.
►Only use products and materials that are approved for the
explosion hazard.
►Stop the machine immediately if you hear unusual noises during
operation.
1. Switch on the plant.
2. After a prolonged shutdown of the system or before a product
change, clean the interior of the sieve machine. See chapter
"Cleaning the interior of the sieve machine" on page 25.

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Operation PS02
Operation
ATTENTION
Clattering or hitting noise.
A loose vibration motor or worn motor bearing may cause
mechanical damage.
►Deactivate the vibration motor immediately!
►Empty the sieve machine and eliminate the cause!
1. Refer to the operating manual of the system control unit.
Ending production
1. Switch off the installation.
2. In the event of impurities, clean the sieve machine.
–Clean the exterior of the sieve machine.
–Clean the interior of the sieve machine.