Gema OptiFeed B Guide

En
Operating instructions and spare parts list
OptiFeed B
Fresh powder system
(FPS18 type)
II 3 D
Translation of the original operating instructions

V 04/07
Documentation OptiFeed B Fresh powder system
©Copyright 2006 ITW Gema AG
All rights reserved.
This publication is protected by copyright. Unauthorized copying is pro-
hibited by law. No part of this publication may be reproduced, photocop-
ied, 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 ITW Gema AG.
OptiFlex, OptiTronic, OptiGun, EasyTronic, EasySelect, OptiFlow and
SuperCorona are registered trademarks of ITW Gema AG.
OptiStar, OptiMatic, OptiMove, OptiMaster, OptiPlus, MultiTronic and
Gematic are trademarks of ITW Gema AG.
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 con-
cerned approve of or are bound in any form by this manual. We have en-
deavored to retain the preferred spelling of the trademarks, and regis-
tered 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 issue. ITW Gema AG
makes no representations or warranties with respect to the contents or
use of this publication, and reserves the right to revise this publication
and make changes to its content without prior notice.
Printed in Switzerland
ITW Gema AG
Mövenstrasse 17
9015 St. Gallen
Switzerland
Phone: [phone]
Fax.: [phone]
E-Mail: [email protected]
Homepage: www.itwgema.ch

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OptiFeed B Fresh powder system Table of contents •1
Table of contents
General safety regulations 3
Safety symbols (pictograms)...................................................................................3
Conformity of use....................................................................................................3
Technical safety regulations for stationary electrostatic powder spraying
equipment ...............................................................................................................4
General information ...................................................................................4
Safety conscious working ..........................................................................5
Individual safety regulations for the operating firm and/or operating
personnel ...................................................................................................5
Notes on special types of hazard...............................................................6
Safety requirements for electrostatic powder coating................................7
A summary of the rules and regulations ....................................................8
Product specific security measures ......................................................................10
About this manual 11
General information ..............................................................................................11
Function description 13
Field of application ................................................................................................13
OptiFeed B Fresh powder system ........................................................................13
General information .................................................................................13
Function ...................................................................................................14
Fluidizing the coating powder ..................................................................14
Mechanical structure.............................................................................................15
OptiFeed B scope of delivery................................................................................15
Accessory.................................................................................................15
Technical data 17
OptiFeed B Fresh powder system ........................................................................17
Electrical data ..........................................................................................17
Pneumatical data .....................................................................................17
Conveying performance/powder output...................................................17
Dimensions ..............................................................................................18
Start-up 19
OptiFeed B Fresh powder system ........................................................................19
General information .................................................................................19
Preparing the powder container...............................................................19
Powder fluidization...................................................................................19
Functional check ......................................................................................20
Powder hose rinsing ................................................................................20
Color change 21
General procedure ................................................................................................21

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2 •Table of contents OptiFeed B Fresh powder system
Maintenance 23
OptiFeed B Fresh powder system........................................................................ 23
Daily maintenance ................................................................................... 23
Weekly maintenance ............................................................................... 23
Longer standstill of the fresh powder system.......................................... 23
Cleaning the fluidizing/suction unit .......................................................... 23
Troubleshooting 25
Problem fixing....................................................................................................... 25
Spare parts list 27
Ordering spare parts............................................................................................. 27
OptiFeed B Fresh powder system - spare parts list ............................................. 28
OptiFeed B Fresh powder system - spare parts................................................... 29
OptiFeed B Fresh powder system - fluidizing/suction unit ................................... 30
OptiFeed B Fresh powder system - filter unit ....................................................... 31

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OptiFeed B Fresh powder system General safety regulations •3
General safety regulations
This chapter sets out the fundamental safety regulations that must be fol-
lowed by the user and third parties using the OptiFeed B Fresh powder
system.
These safety regulations must be read and understood before the
OptiFeed B Fresh powder system is used.
Safety symbols (pictograms)
The following warnings with their meanings can be found in the ITW
Gema operating instructions. The general safety precautions must also
be followed as well as the regulations in the operating instructions.
DANGER!
Danger due to live electricity or moving parts. Possible consequences:
Death or serious injury
WARNING!
Improper use of the equipment could damage the machine or cause it to
malfunction. Possible consequences: minor injuries or damage to equip-
ment
INFORMATION!
Useful tips and other information
Conformity of use
1. The OptiFeed B Fresh powder system is built to the latest speci-
fication and conforms to the recognized technical safety regula-
tions. It is designed for the normal application of powder coating.
2. Any other use is considered as non-conform. The manufacturer
is not responsible for damage resulting from improper use of this
equipment; the end-user alone is responsible. If the OptiFeed B
Fresh powder system is to be used for other purposes or other
substances outside of our guidelines then ITW Gema AG should
be consulted.
3. Observance of the operating, service and maintenance instruc-
tions specified by the manufacturer is also part of conformity of

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4 •General safety regulations OptiFeed B Fresh powder system
use. The OptiFeed B Fresh powder system should only be used,
maintained and started up by trained personnel, who are in-
formed about and are familiar with the possible hazards involved.
4. Start-up (i.e. the execution of a particular operation) is forbidden
until it has been established that the OptiFeed B Fresh powder
system has been set up and wired according to the guidelines for
machinery (98/37 EG). EN 60204-1 (machine safety) must also
be observed.
5. Unauthorized modifications to OptiFeed B Fresh powder system
exempts the manufacturer from any liability from resulting dam-
age.
6. The relevant accident prevention regulations, as well as other
generally recognized safety regulations, occupational health and
structural regulations are to be observed.
7. Furthermore the country-specific safety regulations must be ob-
served.
Explosion protection Protection type Temperature class
II 3 D IP54 T6
Technical safety regulations for stationary electro-
static powder spraying equipment
General information
The powder spraying equipment from ITW Gema is designed with safety
in mind and is built according to the latest technological specifications.
This equipment can be dangerous if it is not used for its specified pur-
pose. Consequently it should be noted that there exists a danger to life
and limb of the user or third party, a danger of damage to the equipment
and other machinery belonging to the user and a hazard to the efficient
operation of the equipment.
1. The powder spraying equipment should only be started up and
used once the operating instructions have been carefully studied.
Improper use of the controlling device can lead to accidents, mal-
function or damage to the control itself.
2. Before every start-up check the equipment for operational safety
(regular servicing is essential)!
3. Safety regulations BGI 764 and VDE regulations DIN VDE 0147,
Part 1, must be observed for safe operation.
4. Safety precautions specified by local legislation must be ob-
served.
5. The plug must be disconnected before the machine is opened for
repair.
6. The plug and socket connection between the powder spraying
equipment and the mains network should only be taken out when
the power is switched off.
7. The connecting cable between the controlling device and the
spray gun must be set up so that it cannot be damaged during

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OptiFeed B Fresh powder system General safety regulations •5
operation. Safety precautions specified by local legislation must
be observed!
8. Only original ITW-Gema spare parts should be used, because
the explosion protection will also be preserved that way. Damage
caused by other parts is not covered by guarantee.
9. If ITW-Gema powder spraying equipment is used in conjunction
with machinery from other manufacturers then their safety regu-
lations must also be taken into account.
10. Before starting work familiarize yourself with all installations and
operating elements, as well as with their functions! Familiariza-
tion during operation is too late!
11. Caution must be exercised when working with a powder/air mix-
ture! A powder/air mixture in the right concentration is flammable!
Smoking is forbidden in the entire plant area!
12. 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!
WARNING!
We emphasize that the customer himself is responsible for the safe
operation of equipment. ITW-Gema is in no way responsible for any
resulting damages!
Safety conscious working
Each person responsible for the assembly, start-up, operation, service
and repair of powder spraying equipment must have read and under-
stood the operating instructions and the "Safety regulations"-chapter. The
operator must ensure that the user has had the appropriate training for
powder spraying equipment and is aware of the possible sources of dan-
ger.
The control units for the spray guns must only be set up and used in zone
22. The spray guns are permitted in the zone 21 created by them.
The powder spraying equipment should only be used by trained and au-
thorized personnel. This applies to modifications to the electrical equip-
ment, which should only be carried out by a specialist.
The operating instructions and the necessary closing down procedures
must be followed before any work is carried out concerning the set-up,
start-up, operation, modification, operating conditions, mode of operation,
servicing, inspection or repairs.
The powder spray equipment can be turned off by using the main switch
or failing that, the emergency shut-down. Individual components can be
turned off during operation by using the appropriate switches.
Individual safety regulations for the operating
firm and/or operating personnel
1. Any operating method which will negatively influence the techni-
cal safety of the powder spraying equipment is to be avoided.
2. The operator should care about no non-authorized personnel
works on the powder spraying equipment (e.g. this also includes
using the equipment for non-conform work).

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6 •General safety regulations OptiFeed B Fresh powder system
3. For dangerous materials, the employer has to provide an operat-
ing instructions manual for specifying the dangers arising for hu-
mans and environment by handling dangerous materials, as well
as the necessary preventive measures and behavior rules. The
operating instructions manual has to be written in an under-
standable form and in the language of the persons employed,
and has to be announced in a suitable place in the working area.
4. The operator is under obligation to check the powder spraying
equipment at least once every shift for signs of external damage,
defects or changes (including the operating characteristics)
which could influence safety and to report them immediately.
5. The operator is obliged to check that the powder spraying
equipment is only operated when in satisfactory condition.
6. As far as it is necessary, the operating firm must ensure that the
operating personnel wear protective clothing (e.g. facemasks).
7. The operating firm must guarantee cleanliness and an overview
of the workplace with suitable instructions and checks in and
around the powder spraying equipment.
8. No safety devices should be dismantled or put out of operation. If
the dismantling of a safety device for set-up, repair or servicing is
necessary, reassembly of the safety devices must take place
immediately after the maintenance or repair work is finished. The
powder spraying device must be turned off while servicing is car-
ried out. The operator must train and commit the responsible
personnel to this.
9. Activities such as checking powder fluidization or checking the
high voltage spray gun etc. must be carried out with the powder
spraying equipment switched on.
Notes on special types of hazard
Power
It is necessary to refer once more to the danger of life from high voltage
current if the shut-down procedures are not observed. High voltage
equipment must not be opened - the plug must first be taken out - other-
wise there is danger of electric shock.
Powder
Powder/air mixtures can be ignited by sparks. There must be sufficient
ventilation in the powder coating booth. Powder lying on the floor around
the powder spraying device is a potentially dangerous source of slipping.
Static charges
Static charges can have the following consequences: Charges to people,
electric shocks, sparking. Charging of objects must be avoided - see
"Earthing".
Grounding/Earthing
All electricity conducting parts and machinery found in the workplace (ac-
cording to DIN VDE 0745, part 102) must be earthed 1.5 meters either
side and 2.5 meters around each booth opening. The earthing resistance
must amount to maximally 1 MOhm. The resistance must be tested on a
regular basis. The condition of the machinery surroundings as well as the

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OptiFeed B Fresh powder system General safety regulations •7
suspension gear must ensure that the machinery remains earthed. If the
earthing of the machinery includes the suspension arrangements, then
these must constantly be kept clean in order to guarantee the necessary
conductivity. The appropriate measuring devices must be kept ready in
the workplace in order to check the earthing.
Compressed air
When there are longer pauses or stand-still times between working, the
powder spraying equipment should be drained of compressed air. There
is a danger of injury when pneumatic hoses are damaged and from the
uncontrolled release and improper use of compressed air.
Crushing and cutting
During operation, moving parts may automatically start to move in the
operating area. It must be ensured that only instructed and trained per-
sonnel go near these parts. The operator should ensure that barriers
comply with the local security regulations.
Access under exceptional circumstances
The operating firm must ensure that local conditions are met when re-
pairs are made to the electronic parts or when the equipment is restarted
so that there are additional measures such as barriers to prevent unau-
thorized access.
Prohibition of unauthorized conversions and modifica-
tions to machines
All unauthorized conversions and modifications to electrostatic spraying
equipment are forbidden for safety reasons.
The powder spraying equipment should not be used if damaged, the
faulty part must be immediately replaced or repaired. Only original ITW-
Gema replacement parts should be used. Damage caused by other parts
is not covered by guarantee.
Repairs must only be carried out by specialists or in ITW-Gema work-
shops. Unauthorized conversions and modifications may lead to injury or
damage to machinery. The ITW Gema AG guarantee would no longer be
valid.
Safety requirements for electrostatic powder
coating
1. This equipment is dangerous if the instructions in this operating
manual are not followed.
2. All electrostatic conductive parts, in particular the machinery
within 5 meters of the coating equipment, must be earthed.
3. The floor of the coating area must conduct electricity (normal
concrete is generally conductive).
4. The operating personnel must wear electricity conducting foot-
wear (e.g. leather soles).
5. The operating personnel should hold the gun with bare hands. If
gloves are worn, these must also conduct electricity.
6. The supplied earthing cable (green/yellow) must be connected to
the earthing screw of the electrostatic powder spraying hand ap-
pliance. The earthing cable must have a good metallic connec-

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8 •General safety regulations OptiFeed B Fresh powder system
tion with the coating booth, the recovery unit and the conveyor
chain and with the suspension arrangement of the objects.
7. The electricity and powder supply to the hand guns must be set
up so that they are fully protected against heat and chemical
damage.
8. The powder coating device may only be switched on once the
booth has been started up. If the booth cuts out then the powder
coating device must be switched off.
9. The earthing of all electricity conducting devices (e.g. hooks,
conveyor chains) must be checked on a weekly basis. The
earthing resistance must amount to maximally 1 MOhm.
10. The control device must be switched off if the hand gun is
cleaned or the nozzle is changed.
11. When working with cleaning agents there may be a risk of haz-
ardous fumes. The manufacturers instructions must be observed
when using such cleaning agents.
12. The manufacturers instructions and the applicable environmental
requirements must be observed when disposing of powder lac-
quer and cleaning agents.
13. If any part of the spray gun is damaged (broken parts, tears) or
missing then it should not be used.
14. 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 ITW-Gema replacement parts should
be used.
15. Repairs must only be carried out by specialists and under no cir-
cumstances should they be carried out in the operating area. The
former protection must not be reduced.
16. 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) (UEG = max. permissible pow-
der/air concentration). If the UEG is not known then a value of 10
g/m³ should be used.
A summary of the rules and regulations
The following is a list of relevant rules and regulations which are to be
observed:
Guidelines and regulations, German professional asso-
ciation
BGV A1 Prevention principles
BGV A3 Electrical equipment and material
BGI 764 Electrostatic coating
BGR 132 Guidelines for the avoidance of the dangers of ignition
due to electrostatic charging (guideline "Static Electric-
ity")
VDMA 24371 Guidelines for electrostatic coating with synthetic pow-
der1)
- Part 1 General requirements
- Part 2 Examples of use

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OptiFeed B Fresh powder system General safety regulations •9
EN European standards
RL94/9/EC The approximation of the laws of the Member States
relating to apparatus and safety systems for their in-
tended use in potentially explosive atmospheres
EN 12100-1
EN 12100-2
Machine safety 2)
EN IEC 60079-0 Electrical equipment for locations where there is danger
of explosion 3)
EN 50 050 Electrical apparatus for potentially explosive atmos-
pheres - electrostatic hand-held spraying equipment 2)
EN 50 053, part 2 Requirements for the selection, installation and use of
electrostatic spraying equipment for flammable materi-
als - hand-held electrostatic powder spray guns 2)
EN 50 177 Stationary electrostatic spraying equipment for flamma-
ble coating powder 2)
EN 12981 Coating plants - spray booths for application of organic
powder coating material - safety requirements
EN 60 529, identi-
cal: DIN 40050
IP-Type protection: contact, foreign bodies and water
protection for electrical equipment 2)
EN 60 204 identi-
cal: DIN VDE 0113
VDE regulations for the setting up of high voltage elec-
trical machine tools and processing machines with
mains voltages up to 1000 V 3)
VDE (Association of German Engineers) Regulations
DIN VDE 0100 Regulations for setting-up high voltage equipment with
mains voltages up to 1000 V 4)
DIN VDE 0105
part 1
part 4
VDE regulations for the operation of high voltage
equipment 4)
General regulations
Supplementary definitions for stationary electrical spray-
ing equipment
DIN VDE 0147
part 1
Setting up stationary electrostatic spraying equipment 4)
DIN VDE 0165 Setting up electrical equipment in locations in areas with
danger of explosion 4)
Sources:
1) Carl Heymanns Verlag KG, Luxemburger Strasse 449, 5000 Köln 41,
or from the appropriate employers association
2) Beuth Verlag GmbH, Burgrafenstrasse 4, 1000 Berlin 30
3) General secretariat, Rue Bréderode 2, B-1000 Bruxelles, or the appro-
priate national committee
4) VDE Verlag GmbH, Bismarckstrasse 33, 1000 Berlin 12

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10 •General safety regulations OptiFeed B Fresh powder system
Product specific security measures
- The installation work, to be done by the customer, must be
carried out according to local regulations
- Before starting up the plant, a check must be made that no
foreign objects are in the booth or in the ducting (input and
exhaust air)
- It must be observed, that all components are grounded ac-
cording to the local regulations, before start-up

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OptiFeed B Fresh powder system About this manual •11
About this manual
General information
This operating manual contains all the important information which you
require for the working with the OptiFeed B Fresh powder system. It will
safely guide you through the start-up process and give you references
and tips for the optimal use of your new powder coating system.
Information about the function mode of the individual system components
- reciprocators, booths, powder gun control units, powder guns etc. -
should be referenced to their corresponding documents.

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OptiFeed B Fresh powder system Function description •13
Function description
Field of application
The OptiFeed B Fresh powder system conveys fluidized coating powder
dust free from a powder container to the place of destination.
Note:
The use of the OptiFeed B Fresh powder system must take place in
the areas defined for it!
OptiFeed B Fresh powder system
General information
The OptiFeed B Fresh powder system is equipped with a OptiFeed PP05
powder pump and a fluidizing/suction unit.
OptiFeed B Fresh powder system - overview

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14 •Function description OptiFeed B Fresh powder system
Function
The powder box is placed on the vibrating table of the OptiFeed B Fresh
powder system. The coating powder is sucked in by the OptiFeed PP05
Powder pump through the fluidizing/suction unit. Then, the powder is
transported through the powder hose, which is fastened to the corre-
sponding powder pump connection.
Note:
For further information, see the OptiFeed PP05 Powder pump oper-
ating manual!
Fluidizing the coating powder
The fluidization of the coating powder with fluidizing air improves the
conveying characteristics of the powder. For this purpose, the fluidizing
air is fed into the external tube of the fluidizing/suction unit and exits
through three fluidizing pads at the lower end of the tube. Thereby, the
area around the suction tube is fluidized, the powder obtains fluid-like
characteristics and will be sucked into the tube.
The table vibration causes an even sinking of the powder level and pre-
vents a depositing of residual powder in the corners of the powder box.
That way, the powder can be used entirely (optimum powder utilization).

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OptiFeed B Fresh powder system Function description •15
Mechanical structure
OptiFeed B Fresh powder system - mechanical structure
A Suction side 5 Swivel wheel
B Transport side 6 Rubber wheel
1 Mobile frame with hand rail 7 Compressed air connection
2 OptiFeed PP05 Powder pump 8 Hose holder
3 Fluidizing/suction unit 9 Fluidizing air connection
4 Vibrating table 10 Pressure regulator for fluidiz-
ing air
OptiFeed B scope of delivery
- A mobile trolley with a gun/hose support
- A vibrating table with a fluidizing/suction unit
- An OptiFeed PP05 Powder pump
- Pneumatic hoses and connection cable
- Special cable jack for the connection of an external control
signal
Accessory
- LM02 Level sensor
1
2
3
4
5
6
7
8
A
B
9
10

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16 •Function description OptiFeed B Fresh powder system

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OptiFeed B Fresh powder system Technical data •17
Technical data
OptiFeed B Fresh powder system
Electrical data
OptiFeed B Fresh powder system
Nominal input voltage 100-240 VAC
Frequency 50/60 Hz
Power 120 VA
Protection type IP54
Temperature range +10°C - +40°C
Pneumatical data
OptiFeed B Fresh powder system
Max. input pressure 8 bar
Min. input pressure 6 bar
Air consumption (complete system) 8-11 Nm³/h
Air consumption (transport) 2-5 Nm³/h
Max. water vapor content of the compressed
air 1.3 g/m³
Max. oil vapor content of the compressed air 0.1 mg/m³
Conveying performance/powder output
OptiFeed B Fresh powder system
Powder hose length 0-8 m 5000 g/min
Powder hose length 8-16 m 4000 g/min
Powder hose length 16-25 m 3500 g/min
Powder pump OptiFeed PP05 type

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18 •Technical data OptiFeed B Fresh powder system
Dimensions
OptiFeed B Fresh powder system
Width 690 mm
Depth 800 mm
Height 1310 mm
Weight 60 kg
Max. powder box size (L x W x H) 510 x 480 x 390 mm
Note:
For further information, see the OptiFeed PP05 Powder pump oper-
ating manual!