Gema OptiCenter OC04 Operating Instructions And Spare Parts List Download | Manualshive

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Summary of Contents for OptiCenter OC04

Page 1: ...1011 505 En Translation of the original operating instructions Operating instructions and spare parts list Powder management center OptiCenter OC04 ...

Page 2: ...demarks 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 con cerned approve of or are bound in any form by this manual We have en deavored to retain the preferred spelling of the trademarks and registered trademarks of the copyright holders To the best of our kno...

Page 3: ...e 12 Technical Data 12 Powder transport 12 Electrical data 12 Pneumatic data 12 Dimensions 13 Processible powders 13 Sound pressure level 13 Rating plate 13 Design and function 15 Overall view 15 Compressed air indicators 16 Powder container 17 PS07 Sieve machine option 17 Principle of operation 18 Powder circuit 18 Start up 19 Set up and assembly 19 Preparation for start up 19 Compressed air supp...

Page 4: ...mmissioning storage 39 Introduction 39 Safety rules 39 Requirements on personnel carrying out the work 39 Storage conditions 39 Storage duration 39 Space requirements 39 Physical requirements 39 Hazard notes 40 Shut down 40 Decommissioning 40 Cleaning 40 Disassembly attachment of transport safety devices 40 Packing 40 Identification 40 Maintenance during storage 40 Maintenance schedule 40 Maintena...

Page 5: ...der container complete 49 Powder container Fluidizing plate 50 Powder container Level sensor 51 OptiCenter Pneumatics 52 Main air supply 53 Powder container Pneumatic manifold 54 Shuttle valves pool 55 Powder container pneumatics 56 Monocyclone Powder transport 57 Monocyclone Powder transport connection 58 ...

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Page 7: ...se of the equipment could damage the machine or cause it to malfunction Possible consequences minor injuries or damage to equip ment INFORMATION Useful tips and other information Intended use The OptiCenter OC04 is built to the latest specification and con forms to the recognized technical safety regulations and is de signed for the normal application of powder coating Any other use is considered ...

Page 8: ... 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 Protection type II 3 D IP54 Product specific safety information General information The OptiCenter O...

Page 9: ...e operating instructions of the plant control unit before starting up the plant In addition all further equipment specific operating instructions e g the OptiFlex and all additional components should also be read To obtain practice in operating the plant it is absolutely essential to start the operation according to the operating instructions Also later on they serve as a useful aid on possible ma...

Page 10: ...er be valid NOTE We point out that the customer himself is responsible for the safe operation of the equipment Gema Switzerland GmbH is in no way responsible for any resulting damage By carrying out repairs the powder management center must be discon nected from the mains according to the local safety regulations NOTE Only original Gema spare parts should be used The use of spare parts from other ...

Page 11: ...s booth axis gun control unit powder gun or powder injector should be referenced to their enclosed 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 orga...

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Page 13: ...ck color change Utilization The OptiCenter OC04 powder management center is suitable for use in multiple color plants as well as in single color plants As a part of the process controlled coating plant the powder management center is laid out for semi automatic operation Conveyance Processing the powder directly from the integrated powder con tainer manual powder filling Integrated electrical and ...

Page 14: ...point Operation without the proper training Technical Data Powder transport OptiCenter OC04 Conveying performance average value per gun 200 g min Recovery max 3 5 kg min Electrical data OptiCenter OC04 Connected load 1x230 V Frequency 50 60 Hz Protection type IP54 Pneumatic data OptiCenter OC04 Inlet pressure min 6 5 bar Compressed air consumption during coating operation 15 Nm h Compressed air co...

Page 15: ... 75 dB A Cleaning operation mode for a short time up to 95 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 the powder management center itself and does not take into account external noise sources or cleaning impulses The sou...

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Page 17: ...powder container vent 2 Emergency stop push button 8 Hand lever for exhaust air 3 Illuminated push button switches 9 Hand lever for emptying of the powder container 4 Injectors 10 Waste connection 5 Powder container 11 Hose cleaning connection 6 Pneumatic parts 12 Recovery powder connection 13 Lighting 13 8 4 9 10 11 1 12 2 5 7 3 6 6 ...

Page 18: ...V 04 17 16 Product description OptiCenter OC04 Compressed air indicators DR1 Powder container fluidizing air DR2 Level sensor fluidizing air DR2 DR1 ...

Page 19: ...kg powder approx 60 liters fluid ized powder and can be equipped with up to 30 OptiFlow IG06 P injec tors PS07 Sieve machine option The PS07 sieve machine is used for the vibration supported sieving of coating powder and can be equipped with different mesh sizes see sepa rate operating instructions If necessary the sieve machine is manually switched on and off with the relevant push button ...

Page 20: ...dhere to the workpieces will be ab sorbed by the exhaust air of the booth 1 and separated from the air in the cyclone separator 2 The separated powder is cleaned by passing it through the integrated sieve 3 and fed back into the OptiCenter by the dense phase conveyor 4 where it is prepared again for coating operation Powder flow in the plant 1 Booth 6 Refuse container 2 Cyclone separator 7 OptiCen...

Page 21: ...es such as an enameling furnace or electromagnetic sources such as a control cabinet After unpacking and installing the OptiCenter is to be anchored to the floor with the supplied steel bolts Preparation for start up Compressed air supply NOTE The compressed air must be free of oil and water The OptiCenter requires a connection to a sufficient dimensioned com pressed air circuit In order to ensure...

Page 22: ...he OptiCenter must be grounded according to the general local safety regulations The grounding of the powder management center must be checked regularly A corresponding connection point at the OptiCenter is reserved for the po tential equalization Potential equalization connection point ...

Page 23: ...tronically Incor rect operation can lead to personal injuries or damage to the Opti Center itself The user must be fully aware of all the process steps Push button switches Push button functions 1 Powder pump ON OFF RP Turns the powder pump ON OFF RP recovery powder The light indicates that the pump is in operation During the cleaning process this push button switch must be OFF so that the RP hose...

Page 24: ...nation Can only be activated when push button switch 1 is OFF flashes Blinking Requiring confirmation that the RP hose is in the cleaning position not recovery or spray to waste position ON Steady illumination RP hose is cleaned by purg ing intermittently 4 Sieve machine Turns the sieve machine ON OFF The light indicates that the Powder sieve machine is in operation ...

Page 25: ...lows the coating with recovery of the powder which does not adhere to the object Utilization of this operating mode Long time coating operation with the same powder and high coating quality with minimal powder loss Immediate coating following a powder change with not so high demands on quality and the smallest possible of powder loss Cleaning color change clean This operating mode enables the user...

Page 26: ...peration OptiCenter OC04 Utilization of this operating mode After switching on the equipment if very high quality is required on initial coating application Before every color change Before switching off the plant ...

Page 27: ...according the following steps 1 Switch on the booth see also the booth operating instructions 2 Switch the powder management center with the main switch the interior lighting switches on 3 Select desired coating mode on the OptiCenter Coating with or without powder recovery Connect the recovery hose manually Coating with powder recovery spray Coating without powder recovery spray to waste 4 Switch...

Page 28: ...oud capable of causing respiratory prob lems Adjust the fluidization correctly 7 Set the powder container aeration with the hand lever Turn the hand lever to the stop so that the dust cloud is drawn slightly backwards The stop can be set on the OptiCenter rear side 8 Set the level sensor fluidizing air with the corresponding pres sure regulator The powder fluidization depends on the powder type th...

Page 29: ...om absorbing moisture during the night which can cause no or uneven fluidization The following steps must be taken to switch off the powder center 1 Check if all the workpieces have been coated 2 Clean the OptiCenter thoroughly in order to avoid powder accumula tion see therefore in chapter Cleaning Color change WARNING Empty powder container 3 Switch off the powder management center at the main s...

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Page 31: ...r a short time up to 95 db A occurring during the cleaning process may cause hearing damage Do not approach the OptiCenter unless absolutely necessary Wear adequate hearing protectors e g ear muffs per EN 352 1 WARNING If no safety glasses are worn when cleaning the OptiCenter then the dust that is stirred up from the coating powder can cause eye irrita tions Safety glasses must be worn during any...

Page 32: ...nect the recovery hose manually Coating with powder recovery spray Coating without powder recovery spray to waste 10 Press the push button in order to switch on the recovery powder pump the push button lamp illuminates 11 Press the push button in order to clean the powder hoses to the guns 12 Basic booth cleaning can be started now already Activate the corre sponding command on the Magic Control C...

Page 33: ...tion 21 Press the push button again the push button lamp illuminates The powder hose is cleaned the powder is gently purged back wards to the cyclone The process is completed after a certain period of time 22 Close the exhaust air and the powder container aeration with corresponding hand levers NOTE Any individual step can be repeated as needed by pressing the cor responding key again Otherwise th...

Page 34: ...27 Swing the funnel on the cyclone slowly away and at the same time clean it off with the compressed air gun 28 Clean the inside of the cyclone with the cleaning wand 29 Close the sieve and funnel on the cyclone again Coating after the cleaning 1 Connect the recovery hose manually to the connection 2 Fill the powder container with powder 3 Press the push button in order to switch on the recovery p...

Page 35: ...V 04 17 OptiCenter OC04 Settings 33 Settings WARNING All OptiCenter settings are set at the factory and may only be modi fied after consultation with a Gema service center ...

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Page 37: ...nd check it Sensor defective Replace Cable defective Replace Powder recovery pump conveying problem Powder pump does not function proper ly Pump defective see corresponding operating manual OptiFeed PP06 Hose clogged Check the recovery system Check the level sensor Check the cyclone funnel for pow der abrasion Contact a Gema service center Powder recovery pump overpressure Powder pump is switched ...

Page 38: ... OC04 Fault Causes Corrective action Push buttons do not respond Control voltage circuit breaker in the electrical panel is tripped Check the power panel Reset the breaker see enclosed wiring diagram otherwise contact a Gema service center ...

Page 39: ...37 Maintenance Daily after longer working interruptions and at the end of shift WARNING Before switching off the plant the powder container must be emp tied and cleaned Check weekly Check the injector nozzles and replace them if necessary ...

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Page 41: ...a Storage conditions Storage duration If the physical conditions for metal parts and electronics are maintained the unit can be stored indefinitely On the other hand the installed elas tomeric components pinch valve collars O ring seals etc can become brittle over time and crack when put under repeated loads Space requirements The space requirements correspond to the size of the OptiCenter The loa...

Page 42: ...e OptiCenter is to be cleaned according to the instructions in the operating manual Disassembly attachment of transport safety de vices Fasten the powder container cover Packing It is recommended that the OptiCenter is placed on a dimensionally sta ble adequately large palette using a forklift truck with long forks To pre vent damage to the components collisions with other parts must be pre vented...

Page 43: ... 04 17 OptiCenter OC04 Decommissioning storage 41 Return to service Commissioning following storage Following storage of more than 3 years the rubber components must be checked and replaced if necessary ...

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Page 45: ...vice 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 re...

Page 46: ...s of attachment see Mode of transportation Mode of transportation For short distances shifts of position within the same room parts for the booth must be transported using a forklift truck with long forks or a crane Therefore the steel bolts must be loosened first Transport using a crane use the eye bolts on the roof Transport using a forklift remove the lateral panels before the transport NOTE Tr...

Page 47: ...V 04 17 OptiCenter OC04 Packing transport 45 Loading transferring the load unloading Suitable lifting equipment is to be used for all procedures ...

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Page 49: ...ce 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 Only original Gema spare parts sho...

Page 50: ...iner pneumatics see corresponding spare parts list 4 Pneumatics see corresponding spare parts list 5 Roof see corresponding spare parts list 6 Powder transport see corresponding spare parts list 7 OptiFeed PP06 Powder pump see corresponding operating manual NOTE For all other electric components see also the Spare parts list in the enclosed wiring diagram 3 2 6 7 4 5 1 ...

Page 51: ...lete incl pos 3 1011 879 3 O ring Ø 22x1 5 mm 231 614 4 Screw M4x8 mm 216 259 5 Grub screw M5x8 mm 214 825 6 Butterfly valve DN32 G 1 1 4 complete 1011 293 7 Cover strip long 1011 745 8 Cover strip short 1011 998 9 Plug cap 1012 026 10 Container cover complete 1012 015 11 Level sensor see corresponding spare parts list Wearing part 6 1 11 7 8 4 10 2 9 3 5 3 4 ...

Page 52: ...uidizing plate 30P complete 1011 832 2 Spacing frame 1011 895 3 Gasket 30P 1011 896 4 Allen cylinder screw M4x12 mm 5 Fastening plate 1011 742 6 Adapter nipple 1 4 1 2 253 995 7 Flow restrictor Ø 2 5 mm complete 652 113 8 Elbow joint 1 8 Ø 8 mm 251 372 9 O ring Ø 80x2 5 mm 10 O ring Ø 95x2 mm 11 Connector 1011 833 Wearing part 1 2 3 6 4 9 11 5 7 10 8 ...

Page 53: ...screw M5x12 mm 239 941 3 O ring Ø 34x2 mm 1003 151 4 Cable for pos 1 not shown 1005 498 Fluidizing plate set incl pos 5 6 7 8 9 720 004 5 Fluidizing plate Ø 44x4 mm 1005 646 6 Gasket Ø 47 5x1 mm 1007 639 7 Compressed air connector 1005 544 8 Throttle valve Ø 4 M5x0 8 mm 1005 634 9 Cap screw M4x35 mm 237 965 10 Support 1005 644 Wearing part 6 1 2 7 9 10 5 3 8 ...

Page 54: ...re parts list 2 Manifold see corresponding spare parts list 3 Shuttle valves pool see corresponding spare parts list 4 Powder container pneumatics see corresponding spare parts list 3 Powder hose dia 16 23 mm 1010 040 5 Compressed air hose Ø 16 4 26 6 mm 105 155 Wearing part Please indicate length 1 3 2 4 ...

Page 55: ... OptiCenter OC04 Spare parts list 53 Main air supply 1 Pressure regulator Filter unit 0 5 8 bar 1 1006 547 2 Pressure gauge 0 10 bar 1 4 1010 964 3 Double nipple 1 1 1003 544 4 Ball valve 1 1 1006 065 2 4 1 3 ...

Page 56: ...valve 1 2 1 2 259 160 4 Hose connector Ø 17 1 2 223 069 5 Solenoid valve 1 2 NW13 5 mm without coil 1005 120 6 Valve coil 24 VDC 1005 119 7 Elbow joint 1 4 Ø 8 3 x 1 mm 1002 614 8 Adapter nipple 1 4 1 2 253 995 9 Double nipple 1 2 1 2 divisible 243 582 10 Double nipple 1 1 divisible 1005 563 11 Hose connector Ø 25 mm 1 1005 856 Wearing part 11 4 1 5 4 3 9 7 2 6 10 9 8 ...

Page 57: ...arts list 55 Shuttle valves pool 1 Solenoid valve 1 2 NW13 5 mm without coil 1005 120 2 Valve coil 24 VDC 1005 119 3 Double nipple 1 2 1 2 divisible 243 582 4 Hose connector Ø 17 mm 1 2 223 069 5 Block 1007 388 Wearing part 1 4 2 3 5 ...

Page 58: ...ainer pneumatics 1 Pressure regulator 0 5 6 bar 1 4 264 342 2 Sealing plug 1 4 258 695 3 Pressure gauge 0 10 bar 1 8 259 179 4 Coupling package 264 350 5 Toggle valve 1012 283 6 Elbow joint 1 4 Ø 8 mm 254 029 7 Elbow joint 1 4 Ø 6 mm 265 691 2 3 1 7 6 5 6 4 ...

Page 59: ... 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 5 7 6 3 8 9 3 4 2 10 ...

Page 60: ...ing 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 NW15 complete incl pos 9 1 1006 255 9 1 Pinch valve sleeve NW15 1006 256 10 Elbow joint 1 4 Ø 8 mm 224 359 11 Throttle valve 1 8 1 8 1002 127 12 Double nipple 1 4 1 8 242 209 13 Inline r...

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