Gema PH300 Operating Instructions And Spare Parts List Download Page 4

Page: 4 / 38

Rev. 00 01/22

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Table of contents

PH300

Product contamination through foreign matter ........................................ 21

Preparing for production ....................................................................................... 21

Ending production ................................................................................................. 21

Decommissioning / Storage

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

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

Securing against unexpected start-up ..................................................... 29

Explosion protection ................................................................................ 29

Pressurized pneumatics system .............................................................. 29

Faults .................................................................................................................... 30

Disposal

Introduction ........................................................................................................... 31

Requirements on personnel carrying out the work .................................. 31

Disposal regulations ................................................................................ 31

Materials .................................................................................................. 31

Spare parts list

Ordering spare parts ............................................................................................. 33

PH300 Fresh powder hopper ............................................................................... 34

Pneumatic unit ...................................................................................................... 35

Fluidized container ............................................................................................... 36

Summary of Contents for PH300

Page 1: ...Rev 00 1017 583 EN Operating instructions and Spare parts list Powder hopper PH300 Translation of the original operating instructions ...

Page 2: ...a 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...

Page 3: ...0 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 pneum...

Page 4: ...chedule 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 F...

Page 5: ...ep 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 Indicate...

Page 6: ...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 ...

Page 7: ...egulations 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 manu...

Page 8: ...s 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...

Page 9: ...rt 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 manufacture...

Page 10: ... 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 con...

Page 11: ... 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 m...

Page 12: ... 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 ...

Page 13: ...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 fo...

Page 14: ...Rev 00 01 22 14 Product description PH300 Rating plate Fig 5 Additional equipment options Level sensor see corresponding documentation Vibrating sieve see corresponding documentation ...

Page 15: ...ol 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 manufacture...

Page 16: ...sure 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 fo...

Page 17: ...an 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...

Page 18: ...o 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 Adj...

Page 19: ...terior 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 ...

Page 20: ...Rev 00 01 22 20 Start up PH300 ...

Page 21: ...ies Only use products and materials that are approved for the explosion hazard 1 Switch on the plant 2 Switch on fluidization 3 After a prolonged shutdown of the system or before a product change clean the interior of the powder hopper See chapter Cleaning the interior of the powder hopper on page 26 Ending production 1 Empty the powder hopper 2 In the event of impurities clean the powder hopper C...

Page 22: ...Rev 00 01 22 22 Operation PH300 ...

Page 23: ...ironment if the unit is stored properly Type of storage For safety reasons the product should only be stored in a vertical position Storage duration If the physical conditions are maintained the unit can be stored indefinitely Space requirements The space requirements correspond to the size of the product There are no special requirements concerning distance to neighboring equipment Physical requi...

Page 24: ... reactivation 2 Empty the powder hopper completely 3 Clean the interior of the powder hopper See chapter Cleaning the interior of the powder hopper on page 26 Maintenance during storage Maintenance schedule No maintenance schedule is necessary Maintenance works During long term storage periodically perform a visual check ...

Page 25: ...as spare parts These parts can be found in the appropriate spare parts list General information The product is designed to require a minimum of maintenance Securing against unexpected start up The machine starting unexpectedly may cause injuries to persons working on the machine 1 Set the safety switch to 0 and lock it 2 Remove the key and keep it with you Explosion protection Lack of maintenance ...

Page 26: ...e If no safety glasses are worn when cleaning the product then the dust that is stirred up from the coating powder can cause eye irritations Safety glasses must be worn during any cleaning work Cleaning the interior of the powder hopper Apart from these instructions please also observe the generally valid product specific hygiene information from the manufacturer 1 Open the cover 2 Remove powder r...

Page 27: ...e Repairs 27 Interval Daily maintenance Clean the outside of the powder hopper with a dry cloth Check hose connections Wearing parts Wearing parts replaced during maintenance can be individually purchased refer to spare parts list ...

Page 28: ...Rev 00 01 22 28 Maintenance Repairs PH300 ...

Page 29: ... a lack of ignition protection can lead to explosions Do not modify the machine Do not use potentially explosive products operational material or cleaning liquids Maintain and clean the machine correctly Only use original spare parts Pressurized pneumatics system The pressurized pneumatics system may trigger dangerous situations 1 Disconnect the compressed air supply before working on the pneumati...

Page 30: ...Fluidizing in the fresh powder hopper not switched on Switch on fluidization Too little fluidizing air Adjust the fluidizing air correctly Powder pump defective See operating manual of the powder pump The powder is not fluidized Compressed air not present Connect the equipment to the compressed air Fluidizing air is set too low Adjust the fluidizing air correctly Powder discharges from the fresh p...

Page 31: ... the instructions in the respective manufacturer s documentation must be observed Disposal regulations The product must be disassembled and disposed of properly at the end of its service life When disposing of the product the applicable local and regional laws directives and environmental regulations must be complied with Materials The materials must be sorted according to material groups and take...

Page 32: ...Rev 00 01 22 32 Disposal PH300 ...

Page 33: ...ose material the required length must also be given The spare part numbers of this bulk stock is always marked with an The wearing parts are always marked with a marked All dimensions of plastic hoses are specified with the external and internal diameter Example Ø 8 6 mm 8 mm outside diameter o d 6 mm inside diameter i d WARNING Use of non original Gema spare parts When using the spare parts from ...

Page 34: ... powder hopper 1 PPxx OptiFeed powder pump see applicable operating manual 2 Pneumatic unit see corresponding spare parts list 3 Fluidized container see corresponding spare parts list 4 Fluidizing plate 365 009 Please indicate length Wearing part Fig 8 ...

Page 35: ... R F unit 0 8 bar 1 4 incl pos 8 and 9 1008 236 8 Filter cartridge 20 µm 1008 239 9 Condensate container with drain valve 1008 238 10 Pressure gauge 0 10 bar 1 8 259 179 11 Plug 1 8 203 297 12 Elbow joint 1 4 1 4 222 674 13 T piece 1 4 1 4 1 4 227 269 14 Screw in nipple 1 4 Ø 8 mm 245 933 15 Double nipple 1 2 1 4 202 738 16 Adapter nipple 1 4 1 2 253 995 20 Plastic tube Ø 8 6 mm anti static 103 75...

Page 36: ...06 256 4 Elbow joint 1 4 Ø 8 mm 254 029 5 Cap screw M4x12 mm 216 798 6 Throttle valve 1 8 1 8 1002 127 7 Screw in nipple 1 8 Ø 8 mm 240 087 8 Base piece 1006 655 9 O ring Ø 64x3 mm NBR70 255 335 10 Gasket 395 439 11 GEKA coupling with grommet Ø 16 mm 1003 872 12 Hose clamp 17 25 mm 223 085 13 Powder hose Ø 16 23 mm anti static 1010 040 Wearing part Please indicate length Fig 10 Fluidized container...

Page 37: ...ault clearance 29 Feed Control Hood 11 Figure references in the text 6 G Grounding Potential equalization 16 I Intended use 9 M Maintenance 25 O Operation 21 P Pictograms 5 Pneumatic data 13 Powder transport 12 Presentation of the contents 6 Principle of operation 12 Product description 9 Product specific security regulations 8 R Rating plate 14 Repairs 25 S Safety 7 Safety symbols 5 Set up 15 Sou...

Page 38: ...Rev 00 ...

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