1011 520 En

Operating instructions and spare parts list

Monocyclone
EZ04

Translation of the original operating instructions

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Documentation EZ04 Monocyclone

© Copyright 2004-2016 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
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.Gall
Switzerland
Phone: +41-71-313 83 00
Fax.: +41-71-313 83 83
E-mail: info@gema.eu.com
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Table of contents
About this instructions 3
General information ................................................................................................ 3
Keeping the Manual ................................................................................................ 3
Safety symbols (pictograms)................................................................................... 3
Presentation of the contents ................................................................................... 4

Safety 5
Basic safety instructions ......................................................................................... 5
Product specific security regulations ...................................................................... 5

Product description 7
Intended use ........................................................................................................... 7
Reasonably foreseeable misuse ............................................................................. 7
Design and function ................................................................................................ 7
Technical Data ........................................................................................................ 9

Assembly notes 11
Set-up and assembly ............................................................................................ 11
Space requirement for delivery unit ...................................................................... 12

Preparation for start-up 13

Important notes ..................................................................................................... 13

Dense phase conveyor 15

General information .............................................................................................. 15

Color change 17
Procedure.............................................................................................................. 17

Interval 19
Checkpoints and references ................................................................................. 19
Maintenance / repair of NW15 pinch valves ......................................................... 20
Maintenance – sieve insert ................................................................................... 23
Monocyclone sealing ............................................................................................ 24

Cleaning 25
Cleaning of the connection sleeves ...................................................................... 25
Cleaning the sieve ................................................................................................ 26
Cyclone cleaning granules .................................................................................... 27

Decommissioning, storage 29
Introduction ........................................................................................................... 29

EZ04 Table of contents • 1

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Storage conditions ................................................................................................ 29

Shut-down............................................................................................................. 31
Maintenance during storage ................................................................................. 32
Return to service .................................................................................................. 32

Packing, transport 33
Introduction ........................................................................................................... 33
Packing material ................................................................................................... 33
Transport .............................................................................................................. 33

Troubleshooting guide 35
Problem fixing ....................................................................................................... 35

Spare parts list 37

Ordering spare parts ............................................................................................. 37
Delivery unit .......................................................................................................... 38
Sieve insert ........................................................................................................... 39
Powder transport .................................................................................................. 40
Powder transport connection ................................................................................ 41

Table of contents • 2 EZ04

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About this instructions

General information
This operating manual contains all important information you will need to
work with the EZ04. 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 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
operating instructions. The general safety precautions must also be
followed as well as the regulations in the relevant operating instructions.

DANGER
Indicates a hazardous situation which,
if not avoided, will result in death or serious injury.

WARNING
Indicates a potentially hazardous situation which,
if not avoided, could result in death or serious injury.

CAUTION
Indicates a potentially hazardous situation which,
if not avoided, could result in minor or moderate injury.

EZ04 About this instructions • 3

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ATTENTION
Indicates a potentially harmful situation which,
if not avoided, the equipment or something in its surrounding may be
damaged.

ENVIRONMENT
Indicates a potentially harmful situation which,
if not avoided, may have harmful consequences for the environment.

MANDATORY NOTE
Information which must be observed.

NOTE
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."

4 • About this instructions EZ04

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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.

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!

EZ04 Safety • 5
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WARNING
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.

6 • Safety EZ04
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Product description

Intended use
The EZ04 Monocyclone (as a matter of principle a centrifugal cyclone)
separates the coating powder from the booth exhaust air.
Observance of the operating, service and maintenance instructions
specified by the manufacturer is also part of conformity of use. This
product should only be used, maintained and started up by trained
personnel, who are informed about and are familiar with the possible
hazards involved.
Any other use is considered non-compliant. The manufacturer is not
responsible for any incorrect use and the risks associated with such
actions are assumed by the user alone!
For a better understanding of the interrelationships in powder coating, it is
recommended that the operating instructions for all other components be
read as well, so as to be familiar with their functions too!

Reasonably foreseeable misuse

– Operation without the proper training
– Use of enameled powder
– Use with insufficient compressed air quality

Design and function

The volume of exhaust air, depending on the booth size, the number of
guns etc. is created by a fan fitted after the monocyclone and a filter
separator. The powder/air mixture arrives at the cyclone through the
ducting and the tangential air input. Now the powder is set in rotation,
separated from the air by the centrifugal force and isolated around the
cyclone wall. The exhaust air rises up through the central immersion tube
in the cyclone and arrives at the filter separator. Herein, the residual
powder is retained and the cleaned air is returned into the workshop
environment.

EZ04 Product description • 7

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fig. 1:
1 Exit chamber 4 pivoted delivery unit
2 Powder/air entry (from the 5 Powder pump
booth) 6 Air outlet
3 Pinch valve (Dense
phase conveyor)

Delivery unit
The separated powder is removed from the operating cyclone by the
pivoted delivery unit. The delivery unit, consisting of the cyclone
connection, the sieve insert and the dense phase conveyor are pivoted
manually under the cyclone and fitted pneumatically. The separated
powder collects in the lower cone part and is sucked through the open
pinch valve and then transported to the sieve machine or to the powder
hopper.
Consequently, a periodical extraction of powder takes place, which is
regained and fed back to the powder coating circuit.

fig. 2

8 • Product description EZ04

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Security-operation of the delivery unit

The delivery unit is pivoted manually under the cyclone and fitted
pneumatically. The appropriate operation is provided for safety reasons
with a two-hand function.

fig. 3

Technical Data
Exhaust air volume / powder application

Single EZ04- EZ04- EZ04- EZ04- EZ04- EZ04-

cyclone 12000 16000 20000 24000 28000 32000
Exhaust air 11000 14000 18000 22000 26000 29000
volume - - - - - -
m³/h 12000 16000 20000 24000 28000 32000
Powder
removal
Pinch valve NW 15
Conveying
approx. 2.5 kg/min
performance
Compressed
air approx. 4 Nm³/h
consumption
Approvals
II 3D

EZ04 Product description • 9

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Setting values/parameters

Single cyclone EZ04-12000 … EZ04-32000

Pinch valve control
max. 3 bar
pressure
Conveying air
approx. 1 bar
pressure
Transport air
approx. 0.3 bar
pressure
Pinch valve closing
6 sec.
time
Pinch valves
2 sec.
opening time
Conveying air on
0.7 sec.
(delayed)

Dimensions

Single EZ04- EZ04- EZ04- EZ04- EZ04- EZ04-

cyclone 12000 16000 20000 24000 28000 32000
Height
(max.) 4848 5165 5503 5878 6545 7025
mm
Weight
850 1020 1160 1320 1480 1710
kg

Sound pressure level

EZ04
Normal operation < 65 dB(A)
The sound pressure level was measured while the unit was in operation;
measurements were taken at the most frequent operator positions and at
a height of 1.7 m from the ground.
The specified value is applicable only for this product itself and does not
take into account external noise sources or cleaning impulses.
The sound pressure level may vary, depending on the product
configuration and space constraints.

10 • Product description EZ04

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Assembly notes

Set-up and assembly

CAUTION
Danger of injury!
The assembly procedure for setting up the cyclone must be
adapted to the available resources at customer site due to heavy
and bulky parts.
► Pay specially attention to the safety of the assembly personnel!
► In order to guarantee operating safety, all assembly work must be
checked by trained personnel!

Above all, the following points must be observed:

– The angle between the air entry and exit can be freely selected.
– All connecting joints (exit chamber etc.) must be locked
hermetically
– It must be observed that all connecting joints in the ducting and
inside the cyclone etc. are as smooth as possible, so that no
powder can deposit
– In order to ensure the grounding connection from the frame to the
cyclone, a vibration damper must be bypassed with the supplied
grounding cable
– On the section point of the frame feet with their extensions, the
feet must also be connected to one another. Three connection
profiles are supplied for this. The fourth connection point must be
left free for pivoting the delivery unit. The position can be chosen
during assembly, according to local conditions
– The monocyclone must be firmly anchored to the workshop floor
– The ducting must be assembled as tension-free as possible
– The delivery unit is preassembled ready and for mounting
– For monitoring the correct position of the delivery unit, a proximity
switch must be fitted on the cyclone, which gives a signal when
the delivery unit is pivoted and lifted under the cyclone and
releases the plant for operation
– The transport hose must be secured with the supplied steel cable
to the spring hook of the dense phase conveyor, so that no

EZ04 Assembly notes • 11

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uncontrolled movement can take place by revertive rinsing and

thereby endangering personnel
– The connecting hoses of the delivery unit control and of the
dense phase conveyor are to be laid out that way that the delivery
unit can be pivoted for cleaning without disconnecting the hose
connections.
– The delivery unit and the cyclone must be closed tightly during
operation. The gaskets of the cyclone and of the swivel frame are
to be examined regularly

Space requirement for delivery unit

Swiveling out the delivery unit needs at least 800 mm swiveling area. This
place may not be closed or blocked and is used also for operation,
cleaning and maintenance.

fig. 4

12 • Assembly notes EZ04

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Preparation for start-up

Important notes
ATTENTION
Damage to the booth or to the ducting
Foreign objects in the booth or in the ducting can cause damages
to the plant!
► The start-up should be done only by trained personnel!

Before the start-up the following points are to be checked:

− Are all screw connections on the cyclone and on other plant units
firmly tightened?
− Is the ducting and the interior of the cyclone cleaned properly?
− The tube and hose connections, are they properly connected?
− Are there no foreign objects (e.g. screws, small parts etc.) in the
booth, the cyclone or the ducting?
− Is the filter unit completely assembled?
− Are all plant units grounded?
− Is the delivery unit connected correctly? Does the two-hand
function (security-operation) of the delivery unit works correctly?
− Is the transport hose connected correctly on the exhaust side?
− Are the settings for the dense phase conveyor correct?

The plant may be put into operation after all these points are
checked and any faults are corrected!

EZ04 Preparation for start-up • 13

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Dense phase conveyor

General information
The dense phase conveying is suited for the transport of the recovered
powder to the powder container/hopper in the powder center. This
transport principle permits a very careful and dust-free powder transport
because the air requirement and the transport speed are very low.
This version with powder pump is the standard dense phase conveyor,
which is normally delivered with the cyclone and the delivery unit.

fig. 5

EZ04 Dense phase conveyor • 15

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Color change

Procedure
The following points are to be observed at color changes:
1. In order to save time and powder at a color change, the cleaning
should be made in the flow direction of the powder. But cleaning the
powder guns and the booth should be done first. During this phase,
the powder can be transported back into the powder hopper or the
powder container with the dense phase conveyor
2. The filter unit is detached from the cyclone. By aspirating additional
air on the cyclone lower part, the powder separation now is void and
all resulting powder is fed to the After Filter
3. Procedure at an extreme color change or with increased
requirements:
– Blow off the exhaust air ducting between the booth and the
cyclone with compressed air
– Let soak in the compressed air hose without nozzle in the
ducting at the air exhaust while the exhaust is operating
– The turbulences which are caused thereby will detach the
powder in the ducting. After that, the powder is transported to
the cyclone and discharged
4. After switching off the dense phase conveyor, the transport hose is
now flushed with compressed air from the exhaust side and cleaned
in this way
5. While the delivery unit is slowly being swiveled away from the
cyclone, the cone of the delivery unit is blown out and the generated
dust is sucked up into the cyclone
6. Now the inside wall of the cyclone is cleaned with the air nozzle
7. The cleaning of the immersion tube is done with a special cleaning
head (see therefore "Cleaning of the connection sleeves")
8. Now the cleaning of the cyclone, the delivery unit and the ducting is
completed

EZ04 Color change • 17

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Interval

Checkpoints and references

In order to guarantee a trouble-free operation, the following points should
be checked regularly during an operation break:

ATTENTION
Scratches on the surfaces
Scratches on the surface lead to increased powder sintering and
thus to increased cleaning effort.
► All cleaning work should be carried out without scratching.

Points to check Possible causes

Check for powder depositing in increased deposition indicates a
the booth and in the suction tube reduction of the exhaust air and a
and clean change in the powder
Check the cyclone for powder increased sintering indicates
sintering increased exhaust air and
changes in the powder
Check for powder depositing in Depositing indicates higher
the delivery unit powder development or reduced
conveying performance
Check for sintering in the increased sintering indicates
transport hose ageing of the hose or changes in
the powder
Check the cleanliness of the Accumulations of powder indicate
cyclone exterior leakages in the coating area
Check the grounding connections
of the plant units
Check the gaskets of the delivery Defective gaskets greatly
unit and the sieve insert decrease the efficiency of the
cyclone

EZ04 Interval • 19
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Maintenance / repair of NW15 pinch valves

General specifications
– Carry out maintenance and repair work only when the control
pressure has been released.
– The system must be shut off and depressurized.
– The control pressure line must be disconnected from the pinch
valve.
– The power supply to the attachments (e.g. on the pressure switch)
must be disconnected.
– It is important to ensure that there is not any potentially explosive
atmosphere.
– Precautions must be taken (e.g. personal protective equipment) if
dangerous substances may escape whilst carrying out maintenance
work on the pinch valve.

General principles for the maintenance/repair of

the pinch valves
Damaged sleeves, connections and joints as well as protection and safety
settings must be repaired immediately or replaced with original spare
parts.
The pinch valve must not be used until the proper function of the plant
has been fully restored.
– Use only original assembly paste and no adhesive, grease or oil!
– Do not use any sharp or pointed objects during assembly to avoid
damage to the sleeve/valve!
– Assembly aids or kits can be ordered.
Assembly aid: assembly paste MP200, order no. 1006 265

Structure of the pinch valves NW15

fig. 6
1 Enclosure 4 Pinch valve sleeve
2 Screws 5 Pressure zone ring
3 Socket end cover / flange

20 • Interval EZ04
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Dismantling
1. Place the pinch valve facing
upwards and hold it tightly on
the body.
2. Loosen the screws crossways
with a ratchet (T30 Torx bit).
3. Then turn the pinch valve and
also loosen all screws
crossways.

4. Lift both socket end covers off

the valve unit. Use a slot
screwdriver to do this if
necessary.

5. Push or pull the sleeve

through the pressure zone
rings out of the body.
– This is made easier by
using assembly paste
(MP200) as lubrication
between the sleeve and
pressure zone ring.

6. Clean all individual parts afterwards and check the parts for damage
as well as for ageing and porosity. Replace damaged parts.
7. Replace the body following two assemblies to ensure the thread
strength.

Assembly

1. Slide both pressure zone rings

including the sealing ring into the body.

2. Apply a thin layer of assembly paste

(MP200) to the outside of one end of
the sleeve.

EZ04 Interval • 21
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3. Slide the coated end of the sleeve

through the first pressure zone ring
into the body until the sleeve through
the second pressure zone ring is flush
with the bottom edge of the body.

4. Apply enough assembly paste

(MP200) to both ends of the sleeve
and to the cone of the socket end
cover.

5. Position the valve unit with one hand

and hold it firmly.
6. Insert the socket end cover diagonally
into the sleeve with your other hand
and push in the socket end cover.

7. Align the socket end cover with the

screw holes flush with the holes in the
body.
8. Insert the screws into the designated
holes.

9. Push and hold the socket end cover

and tighten the screws crossways with
a ratchet until the socket end cover is
sitting on the body.
– Check all screws have an
adequate tightening torque (max. 4
Nm).
10. Turn the valve unit 180° and position it
again.

11. Repeat the process for the second socket end cover.
12. Check the function of the pinch valve by closing the pinch valve with
minimal control pressure. Make sure that it closes correctly to form a
lip shape.

Disposal
Pinch valves can be recycled. The environmental guidelines in force at
the operator's location are applicable for the disposal.

22 • Interval EZ04
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Maintenance – sieve insert

Clothing the sieve mesh
It takes place according to the following steps:

CAUTION
Danger of injury!
Overhanging wires can cause injuries.
► Always work with gloves on!

1. Place the Supporting ring on the workbench.

2. Lay the sieve mesh on the supporting ring (pay attention that the
mesh is evenly standing out)
3. Apply the clamping ring, align the supporting ring and the clamping ring
holes
4. At one hole, puncture the sieve mesh with a sharp object (e.g. awl)
and screw in a screw
5. Stretch the sieve mesh on the opposite side with combination pliers,
puncture the sieve mesh and insert the screw
6. Turn the sieve 90°, stretch the sieve mesh again with combination
pliers, puncture the sieve mesh and insert a screw
7. Stretch the sieve mesh on the opposite side with combination pliers,
puncture the sieve mesh and insert the screw
8. Stretch the sieve mesh at each intermediate hole with combination
pliers, puncture the sieve mesh and insert the screw
9. Fit the additionally grounding spring with two screws
10. Cut away the surplus mesh with a sharp knife, and remove the
overhanging wires with a grinding wheel

fig. 7
1 Supporting ring 4 Grounding spring
2 Clamp ring 5 Screw
3 Sieve mesh

EZ04 Interval • 23
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In order to achieve a good sieve-performance make sure that the

sieve mesh is stretched uniformly tight!

Repairing the sieve insert

Small holes in the sieve mesh can be filled with 2-components adhesive.

Monocyclone sealing
In order to achieve a good cyclone-performance it is very important that
the delivery unit is tightly closed during the operation. In order to ensure a
trouble-free operation, three gaskets are intended in accordance with
following drawing:

fig. 8
1 Cyclone cone 4 Swivel frame
2 Seal 1 on the cyclone 5 Seal 2 and 3 on the
3 Sieve insert swivel frame
6 Delivery unit cone

Part Item Function

Seal 1 on the lower cyclone seals between cyclone cone
cone flange and sieve insert or delivery unit
cone
Seal 2 on top of the swivel seals between sieve insert and
frame swivel frame
Seal 3 bottom of the swivel seals between swivel frame and
frame delivery unit cone

The gaskets are always to be checked during the start-up as well

during the operation.
► Replace damaged gaskets immediately!
– Leakages on the cyclone site will greatly decrease the
efficiency of the cyclone, i.e. it goes more powder in the
After Filter than into the recuperation.

24 • Interval EZ04
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Cleaning

Cleaning of the connection sleeves

The cleaning of the cyclone takes place with the provided cleaning wand.
It is composed of two blast pipes with the following features:

Cleaning of the clean gas connecting piece

fig. 9
1 Tube 1 4 Ball valve 2
2 Tube 2 5 Guiding plate
3 Ball valve 1

The blow off lance is connected to the clean gas connecting piece, tube 1
inside, tube 2 outside. By turning on the compressed air on ball valve 2,
the cleaning air for the outside diameter is turned on and the clean gas
pipe is blown through on the entire level at once. During the blowing

EZ04 Cleaning • 25
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process, the lance is now conducted manually throughout the entire clean
gas pipe thus cleaning the entire connecting sleeve. Tube 1 in the inside
of the tube, prevents the blowing nozzle from being pushed off during
cleaning.
The guiding plate must be cleaned according to the same principle.

Cleaning of the inlet connection sleeve

By using the tube 1 and the compressed air at ball valve 1, individual
ranges in the cyclone can be blown off purposefully.

In order to provide as much compressed air as possible during

cleaning, only one ball valve should be opened for each cleaning
process!

The following points are to be considered for the further maintenance and
the care of the cyclone:

Item Cleaning and/or Remarks

check cycle
Collecting Daily Blow off with compressed air
funnel inside – by using some powder
types some sintering can
develop, these will be
cleaned with suitable
cleaning agents
Cyclone cone Daily Blow off with compressed air
inside – by using some powder
types some sintering can
develop, these will be
cleaned with suitable
cleaning agents
Cyclone outside monthly Clean from outside, avoid
dust deposits

ATTENTION
Risk of damaging and clogging
It must be observed, that no cleaning agents or solvents get into
the pinch valve of the dense phase conveyor!
► The cleaning agent must evaporate completely; it must not come
in contact with the coating powder!

Cleaning the sieve

The sieve must be cleaned when the sieve meshes are clogged/dirty
because of powder agglomerations. For this purpose the sieve is to keep
immersed in solvent, until all contaminations can be removed. Thereafter
blow off the sieve and let the solvent evaporate for approx. 1 day, until the
sieve is dried completely. It must be observed, that solvent must not come
in contact with the coating powder!

26 • Cleaning EZ04
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Cyclone cleaning granules

Order number: 269 115 Delivery unit: 4 kg
– The solid powder agglomerations inside the Cyclone can be
removed with the aid of these Cleaning granules.
– Each cleansing process requires approximately 4 kg (8.82 lb = one
delivery unit). Depending on how it is interspersed with powder, the
granules can be reused for several cleaning processes.
– It is recommended to clean the cyclone once a month.
– The cleaning granules must be stored in a cool, dry space.
– It is advisable to adhere to the following cleaning procedure:

Avoid heat, sparks etc. during all work!

1. Switch off the exhaust air

2. Swivel the delivery unit, and the sieve unit to the side
3. Seal up the delivery unit opening (to the pinch valve)
4. Switch off the dense phase conveyor
5. Pour 4 kg (8.82 lb) cleaning granules into the delivery unit funnel
6. Close the delivery unit while the sieve insert remains swiveled to the
side
7. Switch on the exhaust air
– The turbulences which are caused thereby will start the
cleansing process.
– The cleaning procedure can take 30 minutes to several hours,
depending on the level of sintering.
8. Switch off the exhaust air
9. Swivel the delivery unit to the side as soon as the air flow is slown
down
– If the delivery unit is opened untimely, the cleaning granules are
sucked up into the After filter!
10. Check the cleaning result
– If the cleansing process should go on, then switch the plant on
according to point 6
11. Remove the granules from the delivery unit (e.g. with a small shovel)
– Depending on how it is interspersed with powder, the granules
can be reused again
12. Clean the cyclone and the delivery unit thoroughly
13. Open the delivery unit opening in the pinch valve and switch on the
dense phase conveyor
14. Swivel in the sieve insert and the delivery unit, and close the delivery
unit
15. The plant is now ready for operation

EZ04 Cleaning • 27
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Decommissioning, storage

Introduction
Safety rules
Suitable equipment (e.g. a crane) must be used when moving parts that
are sometimes bulky and heavy.
Components being disassembled must be adequately secured before
they are detached.

Requirements on personnel carrying out the

work
Use only technical personnel who are trained in operating the respective
equipment (e.g. a crane).
If there are any uncertainties, please contact Gema Switzerland GmbH.

Storage conditions
Storage duration
The cyclone unit can be stored indefinitely, so long as corrosion
protection is assured, see regulations/standards.
Store the pinch valve and the spare sleeves dry, dust-free and protected
against ultraviolet radiation at room temperature. As the storage time
increases, the technical properties of the sleeves deteriorate.

Space requirements
The space requirements correspond to the size of the components plus
the packaging.
The load-bearing capacity of the floor should be at least 200 kg/m².
There are no special requirements concerning distance to neighboring
equipment.

EZ04 Decommissioning, storage • 29

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Physical requirements
Storage must be inside a dry building at a temperature between +5 – 60
°C.

Regulations/standards
For storage and transport:
– A desiccant bag (silica gel) approx. 300 g (8 units/bag, DIN 55473)
must be placed in all ducting and cyclones.
– These bags must not be placed directly onto the steel surface, i.e.
place plastic film or styrofoam underneath and, if necessary, stick
the bag to the plastic film.

– Cyclone < 22 000 m³/h: 3 bags

– Cyclone > 22 000 m³/h: 4 bags
– Tube < 3 m: 1 bag
– Tube > 3 m: 2 bags
Long-term storage periods (> 4 months) or for sea freight transport
– Only spray cyclones with Panolin ARC fluid W 25.
– All openings of the ducting and cyclones must be sealed with PE film
(at least 120 µm thick) or VCI film (Cortec VCI-126 quality) in order
to prevent external air and ambient influences. Affix and seal this film
with stretch film (approx. 100 mm wide).

Hazard notes
The safety data sheets of the corrosion protection agent used must be
observed.
There is no danger to personnel or the environment if the unit is stored
properly.

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Shut-down
Decommissioning
Before starting any kind of work, the whole plant must be disconnected
from the supply (current/compressed air).
The fire suppression components connected to the cyclone/ducting are to
be dismantled/removed according to the instructions of the fire detection
system supplier.

Cleaning
Remove the contamination from the outside of all components.
The cyclone and ducting must be thoroughly cleaned internally of
sintering and contamination.

Preservation
Ensure corrosion protection in accordance with section "Regulations and
standards".

Disassembly/attachment of transport safety

devices
Storage in upright position:
1. Secure moving parts of the delivery unit
2. Secure the delivery unit to the cyclone frame, or remove the delivery
unit and pack it separately
3. To save space, the delivery unit and the lower part of the cyclone
frame (yellow) can be removed and packed separately. When lifting,
observe the instructions in the "Transport" section.

Storage in horizontal position:

The cyclone assembly must be disassembled into its individual parts.
1. Remove the delivery unit
2. Remove the cone insert
3. Remove the exit chamber
4. Remove the cyclone frame
5. Put aside cyclone cylinder

Packing
A suitably stable pallet, big enough, must be used. To prevent damage to
the components, collisions with other parts must be prevented.
It is definitely not recommended to stack the individual parts! Should this
nonetheless be planned, the packaging must be made robust enough to
protect the cyclone parts against additional forces.

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Identification
Apply the label "Protect from dampness and moisture" on the product
and the packaging.

Maintenance during storage

Maintenance schedule
For longer storage periods (> 1 year) check the anti-corrosion measures
periodically.

Maintenance works
If any deficiencies in the anti-corrosion protection measures are found,
these must be eliminated.

Return to service
Removing the preservation
All ducting and cyclones must be cleaned internally i.e. free of grease, oil
and dust (bath cleaning, thinner cleaning or “Kärcher” hot/steam
cleaning).

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Packing, transport

Introduction
This chapter describes special precautions that must be taken during
internal transport of the product if:
– the customer himself must pack, transport and ship the product,
such as to have renovations or service work carried out by the
manufacturer
or
– the product must be shipped for disposal (recycling).

Safety rules
Suitable equipment (e.g. a crane) must be used when moving parts that
are sometimes bulky and heavy.
Components being disassembled must be adequately secured before
they are detached.

Requirements on personnel carrying out the work

Use only technical personnel who are trained in operating the respective
equipment (e.g. a crane).
If there are any uncertainties, please contact Gema Switzerland GmbH.

Packing material
Not necessary for the internal transport. For external transport see
"Storage".

Transport
Data concerning goods to be transported
– The space requirements correspond to the size of the components
plus the packaging
– Weight see "Technical Data"
– Points of attachment, see "Mode of transportation"

EZ04 Packing, transport • 33

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Mode of transportation
For short distances/relocations within the same room, the cyclone must
be transported suspended (e.g. using a crane).

ATTENTION
Risk of damage
The center of gravity can be above the attachment point.
► Tighten straps etc. only to cyclone frame!
► Use the attachment points on the upper part of the cyclone
exclusively for disassembly!




fig. 10

For longer distances or through doors which require a horizontal position

of the cyclone body, disassembly of the cyclone is required (see section
"Storage").

ATTENTION
Risk of damage
The cyclone must not be placed fully in the horizontal position,
since it is not designed for this purpose.
► In case of doubt contact Gema Switzerland GmbH!

Loading, transferring the load, unloading

Suitable lifting equipment is to be used for all procedures.

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Troubleshooting guide

Problem fixing

Problem/error/ma Cause Procedures/remedy

lfunction
Plant cannot be The signal from the Connect the delivery
put into operation delivery unit is not unit to the cyclone
present correctly
Too little exhaust Ducting booth/cyclone Search and repair
air in the booth or cyclone/After Filter the leak(s)
not leak-proof
Delivery unit not Connect the delivery
connected to the unit to the cyclone
cyclone correctly
Contamination on Connection points reseal
the cyclone leaking
external wall
Powder sintering in Quick reacting powder Check the room
the cyclone quality temperature
Air speed too high Check the air volume
Solvents came in Clean the cyclone
contact with powder
Powder remains in Powder accumulation Check the conveying
the delivery unit in the cyclone too large performance
Settings of the dense Check setting values
phase conveyor not / parameters
correct according to
technical data
Continual heavy Spiral air is set too high Guide value approx.
dust generation at 0.3 bar
the exit of the
transport hose
Strong dust Conveying air set too Guide value approx.
generation at the high 1 bar
exit of the transport
hose during
conveying

EZ04 Troubleshooting guide • 35

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Problem/error/ma Cause Procedures/remedy

lfunction
too much powder Sieve clogged up Clean the sieve
in the After Filter Check the powder
removal
Check the seals on
the cyclone and the
delivery unit
Check the air volume
Pinch valve does No control air present Check compressed
not close or not air lines
fully close Check if control air is
Control valve defective present on pinch
valve
Control pressure too Check/replace
low control valve
Check ideal control
Sleeve defective
pressure to be set
Pinch valve does Bleed bore on control Clean
not open or not valve clogged silencer/control air
fully open line
Control valve defective Check/replace
(does not switch) control valve
Sleeve wears out Excessive control Check ideal control
quickly pressure/differential pressure to be set
pressure
Switching Increase switching
(open/closed) too fast time
Turbulence in the Change conveying
conveying line/pinch line or arrangement
valve too close to an of pinch valve
elbow (minimum distance to
elbow)
Pinch valve does not Check ideal control
fully close pressure to be set
Unfavorable operating Change operating
conditions (e.g. conditions
excessive temperature,
operating pressure or
flow speed)
Sleeve quality not Use different sleeve
suitable for pumping quality
medium

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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 OptiGun GA03 automatic powder gun
Serial number 1234 5678
– Order no. 203 386, 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)

ATTENTION
Use of non-original Gema spare parts
When using the spare parts from other manufacturers the
explosion protection is no longer guaranteed. If any damage is
caused by this use all guarantee claims become invalid!
– Only original Gema spare parts should be used!

EZ04 Spare parts list • 37

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Delivery unit
1 Seailing ring – Ø 42/55x2 mm 267 686
2 Clamping piece – Ø 40 mm 355 291
3 Counter plate 392 405
4 Snap ring – I45 256 420
5 Allen grub screw – M6x10 mm 234 931
6 Dense phase conveyor – complete (see "Powder transport")
7 Sieve insert – complete (see "Sieve insert")
8 Foam rubber profile – 40x10 mm (indicate cyclone size/-type!) 105 163*
9 Foam rubber profile – 30x10 mm (indicate cyclone size/-type!) 100 870*
* Please indicate length

fig. 11

For all other electric and pneumatic components, see also the
Spare parts list in the enclosed wiring or pneumatic diagram!

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Sieve insert
Sieve insert complete – 600 μm (pos. 1, 2, 3, 4, 5) 392 499#
Sieve insert complete – 400 μm (pos. 1, 2, 3.1, 4, 5) 395 340#
Sieve insert complete – 2000 μm (pos. 1, 2, 3.2, 4.1, 5.1) 1012 799#

1 Supporting ring 392 472

2 Clamp ring 392 480
3 Sieve mesh – 600 μm 105 180#
3.1 Sieve mesh – 400 μm 105 171#
3.2 Sieve mesh – 2000 μm 1012 798#
4 Grounding spring 392 464
4.1 Grounding spring 1012 797
5 Screw 248 568
5.1 Screw 1012 796
# Wearing part

fig. 12

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Powder transport
2 Powder hose – dia. 16/23 mm 1010 040#*
3 Hose clamp – 17-25 mm 223 085
4 OptiFeed PP06 Powder pump – see corresponding operating manual
5 Plastic tube – Ø 6/4 mm 103 144*
6 GEKA coupling with grommet – Ø 16 mm 1003 872
7 Fluidizing unit – complete, see corresponding spare parts list 1005 507#
8 Allen cylinder screw – M8x20 mm 265 241
9 Gasket 395 439
10 Hexagon shakeproof nut – M8 244 449
# Wearing part

2 3

10

8
4
7

5
6

fig. 13

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Powder transport connection

Powder transport connection – complete (pos. 1-13, incl. fixing screws) 1008 846
1 Funnel piece 1005 502
1.1 Gasket for pos. 1 395 439#
Fluidizing unit – complete (pos. 2-6) 1005 507
2 Connector 1005 504
Fluidizing tube set (incl. pos. 3, 4, 5) 720 006
3 Fluidizing tube 1005 505#
4 O-ring – Ø 17x3 mm 242 489#
5 O-ring – Ø 26x2 mm 246 549#
6 Locking piece 1005 506
7 Connecting piece 1005 503
8 GEKA coupling – 1"-IG 1000 854
9 Pinch valve DN15 – complete, incl. pos. 9.1 1006 255
9.1 Pinch valve sleeve NW15 1006 256#
10 Elbow joint – 1/8"-dia. 8 mm 224 359
11 Throttle valve – 1/8"-1/8" 1002 127
12 Double nipple – 1/4"-1/8" 242 209
13 Inline regulator – 3 bar, 1/4" 1005 517
# Wearing part

1.1

11
2
12
4
13
3
10
4

6 5

10
9
9.1

8
fig. 14

EZ04 Spare parts list • 41