Rev. 001024 608

ENPowder coating plant
Gema

Translation of the original operating instructions

Rev. 00 04/23

Documentation Gema

© Copyright 2017 Gema Switzerland GmbHAll rights reserved.
This publication is protected by copyright. Unauthorized copying isprohibited by law. No part of this publication may be reproduced,
photocopied, translated, stored on a retrieval system or transmitted in anyform or by any means for any purpose, neither as a whole nor partially,
without the express written consent of Gema Switzerland GmbH.
Gema, EquiFlow, MagicCompact, MagicCylinder, OptiCenter, OptiFlex,OptiGun, OptiSelect, OptiStar, OptiStar All-in-One and PowerBoost areregistered trademarks of Gema Switzerland GmbH.
ClassicLine, ClassicStandard, ClassicOpen, DVC (Digital Valve Control),GemaConnect, MagicControl, MagicPlus, MonoCyclone, MRS,MultiColor, MultiStar, OptiAir, OptiControl, OptiColor, OptiFeed, OptiFlow,
OptiHopper, OptiMove, OptiSieve, OptiSpeeder, OptiSpray, PCC (PreciseCharge Control), RobotGun, SIT (Smart Inline Technology) andSuperCorona are registered trademarks of Gema Switzerland GmbH.
All other product names are trademarks or registered trademarks of theirrespective holders.
Reference is made in this manual to different trademarks or registeredtrademarks. Such references do not mean that the manufacturers
concerned approve of or are bound in any form by this manual. We haveendeavored to retain the preferred spelling of the trademarks, andregistered trademarks of the copyright holders.
To the best of our knowledge and belief, the information contained in thispublication 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 information regarding patents, seewww.gemapowdercoating.com/patents or
www.gemapowdercoating.us/patents.
Printed in Switzerland
Gema Switzerland GmbH
Mövenstrasse 179015 St.Gallen
Switzerland
Phone: +41-71-313 83 00
Email: info@gema.eu.com

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Table of contents
About these instructions

5Keeping the Manual ................................................................................................ 5
Safety symbols (pictograms)................................................................................... 5
Structure of Safety Notes ........................................................................... 6Safety

7General information ................................................................................................ 7
Individual safety regulations for the operating firm and/or operating
personnel ................................................................................................. 11
A summary of the directives and standards............................................. 12

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Table of contents • 3

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About these instructions

Keeping the Manual
Please keep this Manual ready for later use or if there should be anyqueries.

Safety symbols (pictograms)
The following warnings with their meanings can be found in the Gemainstructions. The general safety precautions must also be followed as wellas the regulations in the relevant instructions.
DANGER
Indicates a hazardous situation which, if not avoided, will result in deathor serious injury.

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

CAUTION
Indicates a hazardous situation which, if not avoided, could result inminor or moderate injury.
ATTENTION
Indicates a potentially harmful situation. If not avoided, the equipment orsomething 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.

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NOTICE
Useful information, tips, etc.

Structure of Safety Notes
Every note consists of 4 elements:–Signal word–

Nature and source of the danger–

Possible consequences of the danger–Prevention of the danger
SIGNAL WORD

Nature and source of the hazard!
Possible consequences of the danger► Prevention of the danger

6 • About these instructions

Gema

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SafetyGeneral information
This chapter provides the user and third parties who operate this productwith all essential safety regulations, the adherence to which is imperative.
These safety regulations must be read and understood in their entirety
before the product is put into operation.
The standards and guidelines applied during the development,
manufacture and configuration are described in the EC declaration ofconformity and in the manufacturer’s declaration.
WARNING
Working without instructions
Working without instructions or with individual pages from theinstructions 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 theinstructions of the relevant documents.
► Always work with the complete original document.
WARNING
These general safety regulations must be read and understood in
all cases prior to start-up!

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General information
This product is built to the latest specification and conforms to therecognized technical safety regulations and is designed for the normal
application of powder coating.
Any other use is not considered as intended use. The manufacturer
shall not be liable for damage resulting from such use; the user bears
sole responsibility for such actions. Gema Switzerland GmbH must beconsulted prior to any use of this product for any purposes orsubstances other than those indicated in our guidelines.
Observance of the operating, service and maintenance instructions
specified by the manufacturer is also part of the intended use.
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 beobserved.
Additional safety and operation notices can be found on the homepage
www.gemapowdercoating.com.

General dangers
Start-up is forbidden until it has been established that the product has
been set up and wired according to the EU guidelines for machinery.
Unauthorized modifications to the product exempt the manufacturer
from any liability from resulting damages or accidents.
The operator must ensure that all users do have the appropriate
training for powder spraying equipment and are aware of the possible
sources of danger.
Any operating method, which will negatively influence the technicalsafety of the powder spraying equipment, is to be avoided.
For your own safety, only use accessories and attachments listed in
the operating instructions. The use of other parts can lead to risk ofinjury. Only original Gema spare parts should be used!
Repairs must only be carried out by specialists or by authorized Gema
service centers. Unauthorized conversions and modifications can leadto injuries and damage to the equipment and invalidate the Gema
Switzerland GmbH guarantee.

Electrical danger
The connecting cables between the control unit and the spray gun
must be installed in such a way, that they cannot be damaged during
the operation. Please observe the local safety regulations!
The plug connections between the powder spraying equipment and themains should only be removed when the power supply is switched off.
All maintenance activities must take place when the powder spraying
equipment is switched off.
The product may not be switched on until the booth is in operation. If
the booth stops, the product must switch off too.

8 • Safety

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Explosion hazard
The control units for the spray guns must be installed and used in zone
22. Spray guns are allowed in zone 21.
Only original Gema OEM parts are guaranteed to maintain theexplosion protection rating. If damages occur by using spare parts fromother manufacturers, the warranty or compensation claim is void!
Conditions leading to dangerous levels of dust concentration in thepowder spraying booths or in the powder spraying areas must beavoided. There must be sufficient technical ventilation available, toprevent a dust concentration of more than 50% of the lower explosion
limit (UEG = max. permissible powder/air concentration). If the UEG is
not known, then a value of 10 g/m³ should be considered (see EN50177).
All unauthorized conversions and modifications to the electrostatic
spraying equipment are forbidden for safety reasons.
No safety devices should be dismantled or put out of operation.
Mandatory operational and workplace notices from the operatingcompany must be written in a comprehensible manner in the languageof equipment operators and posted in a suitable place.

Danger due to compressed air
Uncontrolled release of strong compressed air containing powder cancause hearing, eye and skin damage.

Slip hazard
Powder lying on the floor around the powder spraying equipment is apotentially dangerous source of slipping. Booths may be entered onlyin the places suitable for it.

Static charges
Static charges can have the following consequences: Charges to people,electric shocks, sparking. Proper grounding must be in place to prevent
objects from becoming charged.

GroundingObserve the grounding
regulations

Gema

All electrically conductive parts found in the workplace of 5 meters
around each booth opening, and particularly the objects to be coated,have to be grounded. The grounding resistance of each object must
amount to maximally 1 MOhm. This resistance must be checked/tested
regularly when starting work.
The condition of the work piece attachments, as well as the hangers,
must guarantee that the work pieces remain grounded. The
appropriate measuring devices must be kept ready in the workplace, inorder to check the grounding.
The floor of the coating area must conduct electricity (normal concrete
is generally conductive).
The supplied grounding cable (green/yellow) must be connected to thegrounding screw of the electrostatic manual powder coatingequipment. The grounding cable must have a good metallic connection

Safety • 9Rev. 00 04/23

with the coating booth, the recovery unit and the conveyor chain,respectively with the suspension arrangement of the objects.

Smoking and open flamesFire and smoke
prohibition

Smoking and igniting fire are forbidden in the entire vicinity of thesystem! No work that could potentially produce sparks is allowed!

Stay of persons with active implants
The stay for persons
with active implants isforbidden

In general, all persons with active implants (e.g. with cardiac
pacemakers, neurostimulators, insulin pumps, etc.) must not be inareas where strong high voltage and electromagnetic fields aregenerated. Persons with active implants should not enter areas withpowder spraying installations in operation!

Photographing with flashlight
Photographing withflashlight is forbidden

Photographing with flashlight can lead to unnecessary releases and/ordisconnections by safety devices.

Maintenance works
Disconnect from mains
before maintenanceworks take place

10 • Safety

Disconnect the plugs and secure against restart before the machines
are opened for maintenance or repair!
Verify by means of a voltmeter that the parts are deenergized!
The plug connections between the powder spraying equipment and themains should only be removed when the power supply is switched off.

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As far as it is necessary, the operating firm must ensure that theoperating personnel wear protective equipment (e.g. hearing, eye,respiratory protection etc.).
A dust mask corresponding to filter class FFP2 or N95 at minimum
must be worn during any cleaning work, as powder can enter therespiratory tract in an uncontrolled manner and cause breathingdifficulties.
The operating personnel must wear electrically conductive, steel-toe
footwear (e.g. ESD shoes).
The operating personnel should hold the gun with bare hands. If gloves
are worn, these must also conduct electricity.

Individual safety regulations for the operating
firm and/or operating personnel

Gema–

Any operating method, which will negatively influence the technicalsafety of the powder spraying equipment, is to be avoided.

–

The operator should care about no non-authorized personnel works
on the powder spraying equipment (e.g. this also includes using theequipment for non-conform work).

–

For dangerous materials, the employer has to provide an operating
instructions manual for specifying the dangers arising for humans
and environment by handling dangerous materials, as well as thenecessary preventive measures and behavior rules. The operating
instructions manual has to be written in an understandable form andin the language of the persons employed, and has to be announced
in a suitable place in the working area.

–

The operator is obliged to check the powder spraying equipment atleast once per shift for externally visible damage and defects, and toreport any changes (including the operating characteristics) that
affect safety immediately.

–

The operating enterprise has to ensure that GEMA electrostatic
spraying equipment is only operated in perfect condition.

–

As far as it is necessary, the operating firm must ensure that theoperating personnel wear protective clothing (e.g. facemasks).

–

The operating firm must guarantee cleanliness and an overview ofthe workplace with suitable instructions and checks in and aroundthe powder spraying equipment.

–

No safety devices should be dismantled or put out of operation. If thedismantling of a safety device for set-up, repair or servicing isnecessary, reassembly of the safety devices must take place
immediately after the maintenance or repair work is finished. All
maintenance activities must take place when the powder spraying
equipment is switched off. The operator must train and commit theresponsible personnel to this.

–Activities, such as checking powder fluidization or checking the highvoltage spray gun etc., must be carried out with the powder spraying
equipment switched on.

Safety • 11

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A summary of the directives and standards
The Gema products were built according to the current state of the art.
The products are subject to the European directives and complie with thefollowing standards.
The products are suitable for the intended purpose and can be used inthe appropriate areas.
For further information, also refer to the enclosed Declaration ofConformity.

European directives RL
EG-RL
2006/42/EU

Machinery

EG-RL
2014/34/EU

Equipment and Protective Systems in Potentially
Explosive Atmospheres (ATEX)

EG-RL
2014/30/EU

Electromagnetic compatibility

EG-RL
2014/35/EU

Low Voltage Directive

EN European standards

12 • Safety

EN ISO 12100

Safety of machinery – General principles for design –Risk assessment and risk reduction

EN ISO 8007934

Explosive atmospheres – Part 34: Application ofquality systems for Ex product manufacture

EN ISO 9001

Quality Management Systems – Requirements

EN 1127-1

Explosive atmospheres – Explosion prevention andprotection - Part 1: Basic Concepts and Methodology

EN 1953

Atomizing and spraying equipment for coating
materials – Safety requirements

EN ISO13849-1

Safety of machinery – Safety-related parts of controlsystems – Part 1: General principles for design

EN 14462

Surface treatment equipment – Noise test code forsurface treatment equipment including its ancillaryhandling equipment – Accuracy grades 2 and 3EN 16985

Spray booths for organic coating material – Safety
requirements

EN 50050-2

Electrostatic hand-held spraying equipment – Safety
requirements
Part 2: Electrostatic hand-held spraying equipment

EN 50177

Stationary electrostatic application equipment for
ignitable liquid coating material - Safety requirements

EN 55011

Industrial, scientific and medical equipment - Radiofrequency disturbance characteristics – Limits andmethods of measurement

EN 60079:-0

Explosive atmospheres – Part 0: Equipment –General requirements

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EN 60079-10

Explosive atmospheres – Part 10-2: Classification ofareas – Explosive dust atmospheres

EN 60079-31

Explosive atmospheres – Part 31: Equipment dust
ignition protection by enclosure "t"

EN 60204-1

Safety of Machinery – Electrical Equipment ofMachines – Part 1: General requirements

EN 60529

Degrees of protection provided by enclosures (IPCode)EN 61000-3-2

Electromagnetic compatibility (EMC) – Part 3-2:
Limits – Limits for harmonic current emissions(equipment input current <= 16 A per phase)

EN 61000-3-3

Electromagnetic compatibility (EMC) – Part 3-3:
Limits – Limitation of voltage changes, voltage
fluctuations and flicker in public low-voltage supply
systems, for equipment with rated current <= 16 A
per phase and not subject to conditional connection

EN 61000-4-4Electromagnetic compatibility (EMC) – Part 4-4:
Testing and measurement techniques – Electricalfast transient/burst immunity test

EN 61000-6-1

Electromagnetic compatibility (EMC) – Part 6-1:
Generic standards – Immunity standard forresidential, commercial and light-industrial
environments

EN 61000-6-2

Electromagnetic compatibility (EMC) – Part 6-2:
Generic standards – Immunity standard for industrial
environments

EN 61000-6-3

Electromagnetic compatibility (EMC) – Part 6-3:Generic standards – Emission standard forequipment in residential environments, commercial
and light-industrial environments

Recognized safety-related regulations
764 / DGUVInformation
209-052

Gema

Electrostatic coating
Trade Union information concerning health andsafety during work (BGI)

Safety • 13

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Index
A
About these instructions ..................................... 5
G
Guidelines, European....................................... 12S
Safety................................................................. 7
Safety symbols .................................................. 5Standards, European....................................... 12

P
Pictograms ......................................................... 5Gema

Safety • 15

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