Gema OptiFeed 4.0 PP07 User manual

Rev. 00 1017 576 EN
Operating instructions and Spare parts list
Powder pump
OptiFeed 4.0 (PP07)
Translation of the original operating instructions

Rev. 00 12/21
Documentation OptiFeed 4.0 (PP07)
© Copyright 2020 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]

Rev. 00 12/21
OptiFeed 4.0 (PP07) Table of contents
•
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
Software version .....................................................................................................8
Safety 9
Basic safety instructions .........................................................................................9
Product specific security regulations ....................................................................10
Product description 11
Intended use .........................................................................................................11
Versions...................................................................................................12
Reasonably foreseeable misuse...........................................................................12
Technical Data......................................................................................................12
Processible powders................................................................................12
Electrical data ..........................................................................................13
Pneumatic data........................................................................................13
Powder output (reference values)............................................................13
Dimensions ..............................................................................................13
Sound pressure level...............................................................................14
Rating plate..............................................................................................14
Design and function..............................................................................................15
Overall view..............................................................................................15
Operating elements..................................................................................16
Menu structure.........................................................................................18
Connections.............................................................................................19
Powder hoses ..........................................................................................21
Scope of delivery ..................................................................................................21
Available accessories ...........................................................................................21
Typical properties –Characteristics of the functions............................................22
Conveying direction .................................................................................22
Powder hose emptying ............................................................................22
Powder hose cleaning..............................................................................22
Level sensor delay...................................................................................23
Powder fluidization...................................................................................24
Interval operation.....................................................................................24
Monitoring of the wear parts....................................................................24
Keyboard lock ..........................................................................................25
Principle of operation...............................................................................26
Correction values.....................................................................................27
Assembly / Connection 29
Set-up....................................................................................................................29
Assembly guide.....................................................................................................30

Rev. 00 12/21
4
•
Table of contents OptiFeed 4.0 (PP07)
Connection instructions........................................................................................ 31
System integration with CAN bus............................................................ 31
System integration with PLC................................................................... 32
Stand alone system integration with start/stop function (e.g. fresh powder
system).................................................................................................... 33
Start-up 35
Preparation for start-up......................................................................................... 35
Basic conditions....................................................................................... 35
Basic information..................................................................................... 35
System parameters .............................................................................................. 35
Entering the system parameters ............................................................. 35
CAN bus ............................................................................................................... 40
General.................................................................................................... 40
Hardware................................................................................................. 40
Determining device address (Node-ID) and Baud rate........................... 42
Operation 43
Operation.............................................................................................................. 43
Conveying parameters ......................................................................................... 43
After-conveying length............................................................................. 44
Starting and stopping the conveying procedure...................................... 45
Starting and stopping the cleaning procedure......................................... 45
Interval operation..................................................................................... 45
Manual operation.................................................................................................. 46
Switching on the powder pump............................................................... 46
Manually starting/stopping the conveying procedure.............................. 46
Manually starting/stopping the cleaning procedure and reversing the
cleaning direction..................................................................................... 47
Correction values.................................................................................................. 48
Entering the correction values................................................................. 48
Adjustment of the suction and conveying parameters ......................................... 50
Conveying pressure adjustment (C0)...................................................... 50
Suction power adjustment (C1)............................................................... 50
Guide values for the adjustment of the suction and conveying parameters50
Procedure monitoring (CHK)................................................................... 51
Checking the software version / INFO menu........................................................ 51
Monitoring of the wear parts................................................................................. 53
Memory Reset...................................................................................................... 54
Maintenance / Repairs 55
General information.............................................................................................. 55
Maintenance......................................................................................................... 56
Maintenance based on monitoring of the wear parts.............................. 56
Maintenance schedule............................................................................. 56
Daily maintenance................................................................................... 57
Cleaning................................................................................................................ 58
Cleaning the powder pump (color change) ............................................. 58
Periodic checks .................................................................................................... 58
Repair work........................................................................................................... 59
Replacing the pinch valves and filter elements....................................... 59
Pump disassembly .................................................................................. 60
Fault clearance 63
Software error diagnostics.................................................................................... 63
General information................................................................................. 63
Help codes............................................................................................... 63

Rev. 00 12/21
OptiFeed 4.0 (PP07) Table of contents
•
5
Appearance of errors...............................................................................65
Troubleshooting guide ..........................................................................................65
Decommissioning / Storage 69
Shutdown..............................................................................................................69
If in disuse for several days .....................................................................69
Storage conditions ................................................................................................69
Hazard notes............................................................................................69
Type of storage........................................................................................69
Storage duration ......................................................................................69
Space requirements.................................................................................69
Physical requirements..............................................................................70
Maintenance during storage .................................................................................70
Maintenance schedule.............................................................................70
Maintenance works..................................................................................70
Disposal 71
Introduction ...........................................................................................................71
Requirements on personnel carrying out the work..................................71
Disposal regulations.................................................................................71
Materials...................................................................................................71
Disassembly of component groups.......................................................................71
Spare parts list 73
Ordering spare parts.............................................................................................73
OptiFeed 4.0 (PP07/PP07-S)................................................................................74
OptiFeed 4.0 (PP07) –spare parts.......................................................................75
Pneumatic group...................................................................................................76
Hose connections ....................................................................................76
Pneumatic group...................................................................................................77
Powder chamber...................................................................................................78
Powder chamber –spare parts.............................................................................79
Protective filter holder...........................................................................................80
Connecting material..............................................................................................81

Rev. 00 12/21
OptiFeed 4.0 (PP07) About these instructions
•
7
About these instructions
General information
This operating manual contains all the important information you require
for the working with both OptiFeed 4.0 versions (PP07 and PP07-S). It will
safely guide you through the start-up process and provide you with
references and tips for optimum use of 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.

Rev. 00 12/21
8
•
About these instructions OptiFeed 4.0 (PP07)
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."
Software version
This document describes the operation of the product OptiFeed 4.0
(PP07) with software version starting from 0.10.1.

Rev. 00 12/21
OptiFeed 4.0 (PP07) Safety
•
9
Safety
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.

Rev. 00 12/21
10
•
Safety OptiFeed 4.0 (PP07)
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!
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.