FPS16 Fresh powder system

Transcription

1 En Operating instructions and spare parts list FPS16 Fresh powder system Translation of the original operating instructions

2 Documentation FPS16 Fresh powder system Copyright 2005 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. MagicCompact, MagicCylinder, MagicPlus, MagicControl, OptiFlex, OptiControl, OptiGun, OptiSelect, OptiStar and SuperCorona are registered trademarks of Gema Switzerland GmbH. OptiFlow, OptiCenter, OptiMove, OptiSpeeder, OptiFeed, OptiSpray, OptiSieve, OptiAir, OptiPlus, OptiMaster, MultiTronic, EquiFlow, Precise Charge Control (PCC), Smart Inline Technology (SIT) and Digital Valve Control (DVC) 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 For patent information, see or Printed in Switzerland Gema Switzerland GmbH Mövenstrasse St.Gallen Switzerland Phone: Fax.: info@gema.eu.com

3 Table of contents General safety regulations 3 Safety symbols (pictograms)... 3 Proper use... 3 Product-specific safety measures... 4 FPS16 Fresh powder system... 4 About this manual 5 General information... 5 Function description 7 Field of application... 7 FPS16 Fresh powder system overview... 7 Versions... 7 Technical data 9 FPS16 Fresh powder system... 9 Conveying performance... 9 Electrical data... 9 Pneumatic data Dimensions Container specifications (big bag) Equipment description 11 FPS16 Fresh powder system structure Support Lifting device for large containers Fluidizing/suction tube Lifting device for fluidizing/suction tube Vibrating plate Control unit Powder pump FPS16 Fresh powder system function Powder flow detection Operating and display elements Control cabinet Control module Commissioning 17 Electrical allocation Main module inputs Main module outputs Additional module inputs Additional module outputs Pneumatic connection Powder connections FPS16 Table of contents 1

4 Commissioning Parameterization The standard display looks as follows: Parameter input display: Entering and selecting a menu option Powder flow detection Overview Procedure description Adjusting the threshold values Container change / color change / cleaning 25 Container change Color change Cleaning Maintenance 27 General information Troubleshooting 29 General information Spare parts list 31 Ordering spare parts FPS16 Fresh powder system spare parts list FPS16 Fresh powder system spare parts Fluidizing/suction tube Fluidizing/suction tube Control unit Control unit Pinch valve Table of contents FPS16

5 General safety regulations Safety symbols (pictograms) This chapter sets out the fundamental safety regulations that must be followed by the user and third parties using FPS16 Fresh powder system. These safety regulations must be read and understood before the FPS16 Fresh powder system is put into operation. The following warnings with their meanings can be found in the Gema Switzerland operating instructions. The general safety precautions must also be followed as well as the regulations in the operating instructions. DANGER! Danger due to electrically live 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 equipment INFORMATION! Useful tips and other information Proper use The FPS16 Fresh powder system is state of the art equipment that conforms to the recognized technical safety regulations and is designed for normal powder coating applications. 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 the FPS16 is to be used for other purposes or other substances outside of our guidelines then Gema Switzerland GmbH should be consulted. Observance of the operating, service and maintenance instructions specified by the manufacturer is also part of conformity of use. The FPS16 should only be used, maintained and started up by trained FPS16 General safety regulations 3

6 personnel, who are informed about and are familiar with the possible hazards involved. Start-up (i.e. the execution of a particular operation) is forbidden until it has been established that the FPS16 has been set up and wired according to the guidelines for machinery (2006/42 EG). EN (machine safety) must also be observed. Unauthorized modifications to the FPS16 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. Explosion protection II 3D Protection type IP54 Product-specific safety measures Installation work performed by the customer must be carried out according to local regulations. All components must be grounded according to the local regulations before start-up. Due to accident risk and depending on the placement of the fresh powder system, the safety barriers have to be placed in accordance to the local regulations. The big bag equipped with antistatic loops is grounded via the FPS suspension plate. Grounding resistance should be checked regularly and should not exceed 10 8 ohm. If the big bag is detached from the suspension plate, ensure that it is appropriately grounded, as friction charging may occur during transferring processes. FPS16 Fresh powder system The FPS16 is a constituent part of the system and is thus integrated into the safety system of the plant. If it is to be used in a manner outside the scope of the safety concept, then corresponding measures must be taken. NOTE: For further information, see the more detailed Gema safety regulations! 4 General safety regulations FPS16

7 About this manual General information This operating manual contains all important information which you require for the working with the FPS16 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 booth, gun control unit, and gun or powder injector should be referenced to their corresponding documents. DANGER: Working without operating instructions Working without operating instructions or with individual pages from the operating 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. FPS16 About this manual 5

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9 Function description Field of application The FPS16 Fresh powder system is built exclusively for electrostatic coating with organic powders. Any other use is considered non-compliant. The manufacturer is not responsible for any incorrect use, and any associated risks are assumed by the user alone. FPS16 Fresh powder system overview The FPS16 Fresh powder system is suited for supplying the powder coating equipment with powder from large containers (Big Bag). The powder supply takes place continuously from the large container and in accordance to the consumption in the coating plant. The powder transport is switched on and off by messages from the level sensor in the powder container. The powder is aspirated in pulses by a vacuum, and subsequently transported with conveying air. Versions The FPS16 Fresh powder system is available either with one or with two powder pumps (FPS16-2). The FPS16-2 version permits a powder transport from the large powder container to two different destinations. FPS16-1 FPS16-2 FPS16 Function description 7

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11 Technical data FPS16 Fresh powder system Conveying performance FPS16 Conveying performance Conveying line Hose diameter Transport side Suction line Material to be conveyed Remaining quantity g/min for each pump* (according to the material to be conveyed, suction and conveying length, powder preparation etc.) up to 8 m (5 kg/min conveying performance) 8-16 m (4 kg/min conveying performance) m (3.5 kg/min conveying performance) NW 16 mm up to 5 m Coating powder < 5% of the original container content* * The indicated values are guide values; possible deviations are dependent on the powder type and the large container (BigBag) geometry! Electrical data FPS16 Power supply Frequency 3x400 VAC 24 VDC 50/60 Hz FPS16 Technical data 9

12 Pneumatic data FPS16 Compressed air Compressed air consumption Max. water vapor content Max. oil vapor content Dimensions FPS16 Weight Max. load Container base area Container height incl. loops 5-8 bar max. 0.5 Nm³/h for lifting procedure max. 12 Nm³/h for each PP0x Powder pump max. 0.5 Nm³/h for fluidizing 1,3 g/m³ 0,1 mg/m³ approx. 340 kg 500 kg max. 800 x 1000 mm 1160/1260/1360 mm Container specifications (big bag) FPS16 Suspension system Version Safety factor Material incl. suspension loops 4-point loops square, no partition walls, with emptying funnel min. 5:1 for disposable use min. 8:1 for reuse conductive, R<10 8 ohm 10 Technical data FPS16

13 Equipment description FPS16 Fresh powder system structure The FPS16 Fresh powder system consists of: fig. 1: Structure 1 Fluidizing/suction tube 2 Control unit 3 Powder pump 4 Support 5 Vibrating plate 6 Lifting device for container 7 Lifting device for fluidizing/suction tube FPS16 Equipment description 11

14 Support The fresh powder system support is formed by three wall elements and the crossbeam for the lifting devices. The wall elements must be installed on the floor, so that the stability under load can be ensured. The crossbeam can be installed, depending on the container, on three different heights. Lifting device for large containers The lifting device for large containers consists of the suspension plate and two pneumatic cylinders. The operation and the control take place by the attached control cabinet. Fluidizing/suction tube The fluidizing/suction tube enables the loosening of the powder in the container, and aspirates the powder for the powder pump. Lifting device for fluidizing/suction tube The fluidizing/suction tube can be lifted manually by a cable and can be fixed in this position by hooking-in the final loop. The fluidizing/suction tube is lifted only during the change of the large container. Vibrating plate When using the vibrating plate, the constant powder transport is guaranteed. The vibrating plate is hung on the suspension plate by means of two spring hooks and is then laid loosely onto the Big Bag. The vibrating operation is started automatically every time the suction is switched on. However, the vibration can be manually switched on and off using an additional switch, and a light indicates the condition. Control unit All operation and control elements for the FPS16 Fresh powder system are implemented in the laterally attached control unit. Powder pump The laterally attached powder pump aspirates the powder, if required, by the fluidizing/suction tube and ensures the transport to the powder container in the coating plant. Please observe the operating manual of the corresponding powder pump! 12 Equipment description FPS16

15 FPS16 Fresh powder system function In the starting position of the FPS16 Fresh powder system, the fluidizing/suction tube is lifted up and the lifting cylinders for the large container are lowered. The large powder container is now put into the support by a pallet lifting truck. All four lifting loops are hung up to the bolts; an unintentional hangout will be prevented by the existing rubber straps. The large powder container is opened now, and the fluidizing/suction tube is slowly lowered into the powder. Now press the Conveying ready key on the control unit and the powder transport will be switched on, according to requirement. The lifting procedure of the container is now also automatically switched on by reaching the max. lifting weight (adjustable depending on cylinder pressure). Powder flow detection The powder transport is monitored by the powder flow detection during the conveying procedure. If during a powder requirement by the level sensor no or too little powder flows through the conveying line within a defined time, this will be recognized by the installed sensor. This powder shortage actuates an up/down procedure of the powder container (Big Bag). This procedure will be automatically interrupted when the Powder shortage signal resets, otherwise constantly repeated during a defined time. If the powder shortage will not be reset by the up/down procedure during a defined time, an alarm message for the operating personnel will be released. FPS16 Equipment description 13

16 Operating and display elements Control cabinet The control cabinet contains the following operating elements: , 3, 4 fig. 2: View Control cabinet Pos. Function Description 1 Main switch The complete control unit is disconnected from the mains with the main switch 2 Conveying ready The powder transport readiness takes place by pressing the Conveying ready key The readiness is indicated by the indicator lamp (pos. 6) Therewith, the lifting up of the large container will be started. Depending on the weight in the large container, the lifting up takes place after the powder discharge, if the weight of the container is smaller than the adjusted lifting power of the pneumatic cylinders As soon as the level sensor of the powder container detects empty, the powder transport and the vibrating plate switch on automatically 3 Cleaning By pressing the Cleaning key, the rinsing procedure of the powder pump will be started. The suction unit must be lifted manually and can be blown off with compressed air and can be cleaned (Attention large dust formation possible!) 4 Conveying off By pressing the Conveying off key, the powder conveying procedure will be interrupted and the large powder container lowers immediately. 5 Big Bag empty This red indicator lamp illuminates, if the powder flow sensor does not detect powder during a defined time. Now the large powder container must be checked by the operating personnel and probably be changed 14 Equipment description FPS16

17 Control module fig. 3: Control module 1 Power pack 2 Main module 3 Additional module FPS16 Equipment description 15

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19 Commissioning Electrical allocation WARNING: The equipment and the vibrating plate are necessarily to be grounded with the ground connection! As ground conductor, use a copper cable with a cross-section of at least 4 mm²! Main module inputs Entry I1 Description External interlocking/automatic operating mode must be operated with switch control unit is ready for operation. Powder box will be lifted I2 External fresh powder requirement (pump 1) I3 External fresh powder requirement (pump 2) I4 I5 I6 Activate cleaning mode Reserve Reserve I7 Analog input 0-10 V / pressure sensor for pump 1 I8 Analog input 0-10 V / pressure sensor for pump 2 Main module outputs Output Q1 Q2 Q3 Q4 Description Main solenoid valve Solenoid valve lift cylinder Warning lamp no powder Potential-free contact no powder (max. voltage 230 VAC) FPS16 Commissioning 17

20 Additional module inputs Entry Description I1-I4 Reserve Additional module outputs Output Description Q1 Conveying on pump 1 Q2 Conveying on pump 2 Q3 Pinch valve preventing wrong air suction of pump 1 Q4 Pinch valve preventing wrong air suction of pump 2 Pneumatic connection The compressed air must be connected to the control unit input in accordance to the specifications. All compressed air consumers will be supplied by the control unit Description 1 Lift/lower 2 3 Fluidizing air P min = 0,5 bar Compressed air supply of pinch valves (only FPS16-2 version) P max. = 3,0 bar Powder connections The powder hose must be connected according to the corresponding powder pump(s). 18 Commissioning FPS16

21 Commissioning By the start-up of the FPS16 Fresh powder system, the following points are to be observed: 1. Check the grounding of the enclosure 2. Hook in the large container into every four loops 3. Fit the vibrating plate 4. Ensure the grounding of the vibrating plate 5. Check the compressed air supply 6. Check the power supply 7. Switch on the main switch 8. Activate the operating release NOTE: For the adjustment and the operation of the powder transport, the corresponding powder pump documentation must be observed! Parameterization The various time sequences can be easily set and adapted to all plantspecific requirements by the aid of a simple menu control unit. Read carefully this section, before access to a menu option! The standard display looks as follows: not to be used Set parameter not to be used not to be used Parameter input display: Block number The value set at Parameter Time ON The value set at Parameter Time OFF Current time FPS16 Commissioning 19

22 Entering and selecting a menu option Select the Set Param menu with the key. Important: No other menu may be selected; otherwise the program becomes unusable for the control unit! Press OK. The first block B1 appears. Press the key, the block B2 appears. Select Block B2 until B4 with the triangular arrow key. Press OK Select and modify the values with the arrow keys. Done Change Move or or Press OK The values are saved, and the block B2 appears. Quit the program mode with the ESC key and return to the normal display WARNING! The control unit continues to process the program in the "Parameterization" operating mode! 20 Commissioning FPS16

23 Parameterization Block no. (Parameter) B001 B002 B009 B010 Designation Default value Remarks Powder flow measurement delay Cylinder lift/lower cycle Analog threshold values of the pump 1 switch Analog threshold values of the pump 2 switch 2.0 secs. Lift: TH = 30.0 secs. Lower: TL = 50.0 secs. Threshold value down: ON = 150 Threshold value up: OFF = 900 Threshold value down: ON = 250 Threshold value up: OFF = 900 B014 Error message delay T = 50.0 secs. B016 Debouncing of B001 T = 10.0 secs. B017 Debouncing of B014 T = 3.0 secs digits corresponds to 2.5 bar (e.g. 150 = 0.36 bar) 1024 digits corresponds to 2.5 bar (e.g. 150 = 0.36 bar) The pressure monitoring must indicate no powder for a defined duration, until the signal will be evaluated The no powder signal must be present for a defined duration NOTE: For the adjustment and the operation of the powder transport, the corresponding powder pump documentation must be observed! FPS16 Commissioning 21

24 Powder flow detection Overview If craters arise from the suction procedure in the powder container, the powder flow can thereby be influenced negatively. In order to prevent this, a pressure sensor measures the backpressure in the powder hose. If the pressure decreases under a defined threshold value, the powder container is lowered to the floor and lifted again, so that the craters can be loosen. Powder container full Backpressure in the powder hose Threshold value down (variable) Threshold value reached Powder flow OK Pump Powder container full Craters in the powder container/container empty Backpressure in the powder hose Threshold value down (variable) Pump Threshold value not reached Powder flow not OK Craters in the powder container/container empty 22 Commissioning FPS16

25 Procedure description If the powder flow measurement of pump 1 or 2 reacts, the analog inputs of the pump 1 or pump 2 are set. This means, that no powder will be fed now (pinholing, powder container is empty or hose is bent). After the elapse of B001, the signal will be transmitted to B002. The powder container is now lowered and lifted again, according to B002 parameters. At the same time, B014 will be activated (error message delay). After the elapse of the set duration, the indicator lamp on the control cabinet door will be activated. At the same time, the potential-free contact is set, which can be evaluated by an external reporting device. Adjusting the threshold values Lower threshold value The lower threshold depends of the length of the conveying distance and the filling by the powder pump. Example: Length of the conveying distance 15 m, default value 150 OK! Length of the conveying distance 5 m, default value approx. 80 adjust! Upper threshold value The upper threshold value limits the correct functionality of the powder transport. The exceeding signifies a malfunction (powder hose is clogged or bent). Example: Default value 900 corresponds to 2.2 bar (suction and conveying procedure of the pump will be influenced) FPS16 Commissioning 23

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27 Container change / color change / cleaning Container change The container change takes place according to the following instructions: 1. Press the Conveying off key, the automatic conveying will be interrupted and the lifting device will be lowered 2. Lift the fluidizing/suction tube by manual lifting device out of the large container 3. Hang out the vibrating plate 4. Hang out the empty container bag and remove it 5. Put the full large container into the support by a pallet lifting truck 6. Hook in the large container with every four loops, open the container on the top and insert the fluidizing/suction tube WARNING: Observe the right position of the safety straps on the bolts! 7. Fit the vibrating plate 8. Press the Conveying ready key 9. Lower the fluidizing/suction tube manually and slowly into the large powder container Color change A color change with a partially emptied large container must take place in same way. In this case, it's important that the partially emptied container is well locked for storage. FPS16 Container change / color change / cleaning 25

28 Cleaning In order to achieve a long-term trouble-free operation of the FPS16 Fresh powder system, it is important that also the environment is kept clean every day. The fresh powder system, as well as the fluidizing/suction tube does not require a special cleaning. NOTE: By cleaning the powder pump, the specific documents are to be observed! 26 Container change / color change / cleaning FPS16

29 Maintenance General information The FPS16 Fresh powder system does not require a special maintenance. However, the following steps are to be observed regularly: 1. Check grounding resistance. The measured value should not exceed 10 8 ohm. Measuring points: suspension bolts > main grounding connection at rear of unit 2. Constant compressed air quality observe the maintenance unit on the compressed air connection 3. Cleanliness of the environment 4. Powder pump maintenance see the corresponding documents 5. Check the fluidizing pads of the fluidizing/suction tube for damage FPS16 Maintenance 27

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31 Troubleshooting General information Fault Causes Fault remedying The large container has not been lifted up Too low or no conveying performance of the powder pump Compressed air not present Lifting force smaller than the weight of the large container No mains voltage present Switch Conveying ready is not switched on Fluidizing/suction tube not lowered Vibrating plate not functioning or NOT SWITCHED ON Fluidizing air not present: - Fluidizing air supply not connected to the suction tube - Fluidizing air supply is bent Too much fluidizing air present Fluidizing/suction tube clogged Connect the compressed air Increase the lifting cylinder pressure Switch on the main switch Check the fuse F1 Switch on Check connection Replace vibrator Adjust the fluidizing air with the pressure regulator in the control cabinet Plug in fluidizing air hose Lay out fluidizing air hose as straight as possible Reduce the fluidizing air with the pressure regulator in the control cabinet Lift the fluidizing/suction tube and clean it FPS16 Troubleshooting 29

32 Fault Causes Fault remedying Observe the connection and the powder pump instructions Powder pump defect No signal for fresh powder requirement Pinch valve defective, excess air suction defective Pinholing will not be solved Repair powder pump Check wiring Check level sensor signal Check/replace pinch valve hose Contact an Gema service center 30 Troubleshooting FPS16

33 Spare parts list Ordering spare parts When ordering spare parts for powder coating equipment, please indicate the following specifications: Type and serial number of your powder coating equipment Order number, quantity and description of each spare part Example: Type FPS16 Serial number Order no , 1 piece, Clamp Ø 18/15 mm When ordering cable or hose material, the required length must also be given. The spare part numbers of this bulk stock is always marked with an *. Wearing parts are always marked with a #. 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! Only original Gema spare parts should be used, because the explosion protection will also be preserved that way. The use of spare parts from other manufacturers will invalidate the Gema guarantee conditions! FPS16 Spare parts list 31

34 FPS16 Fresh powder system spare parts list FPS16-1 Fresh powder system complete FPS16-2 Fresh powder system complete Fluidizing/suction tube complete (see corresponding spare parts list) 2 Pinch valve (see corresponding spare parts list) 3 Control unit (see corresponding spare parts list) 4 PP0x Powder pump (see the corresponding operating manual) 5 Cylinder Ø 100 mm, stroke=500 mm Adapter nipple 1/2"-1/8" Elbow joint 1/8"-1/8" Check valve 1/8", with fix throttle Rubber strap Roller Sliding bearing Plastic hose Ø 8/6 mm * 13 Pressure sensor bar, G1/2" Pressure sensor cable (for pos. 13, not shown) Wire rope * 15 Steel bolt dowel M10x89 mm Spring hook Round sling Grounding cable complete Vibrator Grounding cable complete with clamp (not shown) A Powder hose Ø 23/16 mm Parts set for FPS16 (not shown), consisting of: Roller Clamp Fluidizing pad 1/8" * Please indicate length 32 Spare parts list FPS16

35 FPS16 Fresh powder system spare parts A fig. 4: Spare parts FPS16 Spare parts list 33

36 Fluidizing/suction tube Fluidizing/suction unit complete Fluidizing ring Fluidizing pad 1/8" Spacer bolt External tube Coupling ring O-ring Ø 35x2 mm O-ring Ø 25x2 mm Connection case, double Hose connection # 10 O-ring Ø 16x2 mm Connector NW5, 1/8" Quick release connection NW5, Ø 8 mm Connection case, single Powder hose Ø 23/16 mm *# * Please indicate length # Wearing parts 34 Spare parts list FPS16

37 Fluidizing/suction tube fig. 5: Fluidizing/suction tube FPS16 Spare parts list 35

38 Control unit 1 Solenoid valve 1/8", NW 5, 24 VDC, complete, consisting of: Solenoid valve 5-1/8" Valve coil 24 VDC R/F unit 1/2", 0-10 bar Pressure gauge 1/8", round, 0-10 bar Double nipple 1/2"-1/2" Adapter 1/2"-1/2" Connection fitting 1/2"-1/2" Lead-through connection Ø 8/8 mm Adjusting elbow Ø 8/8 mm Y-piece Ø mm Plug screw M Locknut M Cable connection M Locknut M Plug screw M Plug cap Ø 8 mm Elbow joint 1/4", Ø 8 mm Y-piece 1/4"-1/4"-1/4" Connection sleeve 1/2"-1/4" Pressure gauge 1/8", round, 0-6 bar Elbow joint 1/4"-1/4" Y-connection fitting 1/4", Ø 8 mm Solenoid valve 1/8", NW 5, 24 VDC, complete, consisting of: Solenoid valve 3-1/8" Valve coil 24 VDC Pressure regulator bar Elbow joint 1/8", Ø 8 mm Control cabinet (empty) Spare parts list FPS16

39 Control unit fig. 6: Control unit FPS16 Spare parts list 37

40 Pinch valve A Pinch valve NW15, complete Powder hose Ø 23/16 mm *# 2 Hose clamp Ø mm Hose connection Ø 17 mm Screw 5x26 mm Pinch valve hose NW # 6 Elbow joint 1/4", Ø 8 mm * Please indicate length # Wearing parts A fig. 7: Pinch valve 38 Spare parts list FPS16

41 FPS16 Spare parts list 39