Gema OptiCenter OC09 Operating Instructions And Spare Parts List Download Page 3

Page: 3 / 112

Rev. 00 02/21

OptiCenter OC09

Table of contents

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Table of contents

About these instructions

General information ................................................................................................ 7

Keeping the Manual ................................................................................................ 7

Safety symbols (pictograms) ................................................................................... 7

Structure of Safety Notes ........................................................................... 8

Software version ..................................................................................................... 8

Presentation of the contents ................................................................................... 9

Figure references in the text ...................................................................... 9

Safety

Basic safety instructions ....................................................................................... 11

Product specific security regulations .................................................................... 12

Transport

Introduction ........................................................................................................... 13

Safety rules .............................................................................................. 13

Requirements on personnel carrying out the work .................................. 13

Packing material.................................................................................................... 13

Transport ............................................................................................................... 13

Data concerning goods to be transported ................................................ 13

Mode of transportation ............................................................................. 14

Loading, transferring the load, unloading ................................................ 14

Product description

Intended use ......................................................................................................... 15

Field of application ................................................................................... 16

Reasonably foreseeable misuse ........................................................................... 16

Technical Data ...................................................................................................... 17

Electrical data .......................................................................................... 17

Pneumatic data ........................................................................................ 17

Powder transport ...................................................................................... 17

Compressed air consumption .................................................................. 17

Dimensions .............................................................................................. 18

Sound pressure level ............................................................................... 18

Rating plate .............................................................................................. 18

Design and function .............................................................................................. 19

Overall view.............................................................................................. 19

Touch Panel ............................................................................................. 19

Compressed air indicators ....................................................................... 20

OptiHopper ............................................................................................... 20

Suction unit .............................................................................................. 21

Level sensors kit** (OptiHopper) ............................................................. 21

Cleaning hose .......................................................................................... 22

OptiFeed kit** ........................................................................................... 22

Powder bag cone ..................................................................................... 22

Vibrating trolley** ..................................................................................... 23

Powder hopper** ...................................................................................... 23

Ultrasonic sieve system US07-1** ........................................................... 24

Summary of Contents for OptiCenter OC09

Page 1: ...Rev 00 1017 579 EN Operating instructions and Spare parts list Powder management system OptiCenter OC09 Translation of the original operating instructions ...

Page 2: ...f 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 trade...

Page 3: ...material 13 Transport 13 Data concerning goods to be transported 13 Mode of transportation 14 Loading transferring the load unloading 14 Product description 15 Intended use 15 Field of application 16 Reasonably foreseeable misuse 16 Technical Data 17 Electrical data 17 Pneumatic data 17 Powder transport 17 Compressed air consumption 17 Dimensions 18 Sound pressure level 18 Rating plate 18 Design a...

Page 4: ...erating modes 34 Coating 34 Cleaning color change operating mode 34 Configuration 35 Settings 35 User levels and access 35 Functions available at user level 36 CAN bus 36 General 36 User administration 36 Status display 36 Login 36 Log out 40 Change user 40 User profile 40 Diagnostic 49 Operating data 50 Checking the software version 51 Assembly Connection 53 Set up 53 Grounding of the powder mana...

Page 5: ...0 Cleaning procedure 70 Cleaning the recovery system 77 Cleaning and maintenance of the operating panel 78 Periodic checks 78 Repair work 79 Repairs 79 SD card data backup 79 Fault clearance 81 Error messages 81 Troubleshooting guide 81 Decommissioning Storage 85 Shutdown 85 If in disuse for several days 85 Storage conditions 85 Storage duration 85 Type of storage 85 Space requirements 85 Physical...

Page 6: ...tics 97 Main air supply 98 OptiHopper pneumatic distributor 99 OptiHopper Fluidization 100 Pressure regulators pool 101 Pneumatic manifold Cleaning 102 Ring Injector Airmover Pinch Valve 103 Powder hopper PH60 OC 104 PH100 OC Powder Hopper 105 LC01 Level sensor 106 Vibration trolley 107 Monocyclone Powder transport 108 Monocyclone Powder transport connection 109 Pneumatics ES AS 110 ...

Page 7: ... instructions describe all equipment and functions of this OptiCenter Please note that your OptiCenter may not be equipped with all the described functions Optional equipment is marked by double asterisks 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 inst...

Page 8: ...ul consequences for the environment MANDATORY NOTE Information which must be observed 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 Software ...

Page 9: ...se instructions 9 Presentation of the contents Figure references in the text Figure references are used as cross references in the descriptive text Example The high voltage H created in the gun cascade is guided through the center electrode ...

Page 10: ...Rev 00 02 21 10 About these instructions OptiCenter OC09 ...

Page 11: ...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 liabi...

Page 12: ...d that all components are earthed according to the local regulations before start up For further security information see the more detailed Gema safety regulations WARNING Working without instructions Working without instructions or with individual pages from the instructions may result in damage to property and personal injury if relevant safety information is not observed Before working with the...

Page 13: ...ving 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...

Page 14: ...ruck with long forks Fig 1 Transport the unit only in the position according to its intended use ATTENTION Risk of damage The OptiCenter 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 ...

Page 15: ... manual color changes supported by automated cleaning steps The completely equipped OptiCenter can include all powder conveying devices gun and axis control units as well as the complete fresh powder dosing Fig 2 Observance of the operating service and maintenance instructions specified by the manufacturer is also part of the intended use This product should only be used maintained and started up ...

Page 16: ...e large volume powder container 60 or 100 liters Fresh powder from a Gema fresh powder system Powder level monitoring by level sensor s Cleaning Automatic internal cleaning of suction tubes powder conveyors powder hoses and guns Manual cleaning of the OptiHopper is supported with automated cleaning steps and fixed built in suction unit Supply of the recovered powder The working environment remains...

Page 17: ...m Powder transport OptiCenter OC09 24 guns Recovery OptiFeed powder pump OptiHopper capacity 60 liters 35 kg Compressed air consumption OptiCenter OC09 Max compressed air consumption during cleaning 120 seconds 200 300 Nm h Coating operation Fluidization OptiHopper AirMover process air 20 Nm h Consumption per applicator 5 Nm h Example for 10 applicators 70 Nm h Cleaning operation mode Cleaning Opt...

Page 18: ... 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 this product itself and does not take into account external noise sources or cleaning impulses The sound pressure level may vary depending on the...

Page 19: ...Control unit operating panel 2 Emergency stop button 3 OptiHopper fluidizing 4 OptiHopper 5 Powder bag fixation 6 Powder bag cone with vibrator 7 Gun and axes control units 8 OptiFlow injectors 9 Suction unit not shown Touch Panel All necessary operating procedures are activated by the Touch Panel Fig 5 ...

Page 20: ... the following features Conditioning and fluidization of the coating powder Extraction removal of excess free floating powder particles and the fluidization air back into the powder circuit by means of ring injector AirMover Cleaning of the ring injector AirMover and the connected powder hose with compressed air pulses for powder recovery Manual emptying the residual powder Manual cleaning support...

Page 21: ...r housing and components with additional brush head Can be enabled or disabled at any time on the TouchPanel The extracted powder is transported to the after filter the suction power is increased by additional AirMover fig 8 Level sensors kit OptiHopper The kit provides the following features Two level sensors for monitoring the levels full and low The sensors are cleaned with compressed air pulse...

Page 22: ...n be connected instead of the air gun in the OptiCenter fig 10 OptiFeed kit For filling the OptiHopper with fresh powder using a powder pump Always used in conjunction with the powder bag cone or vibrating trolley fig 11 Powder bag cone Capacity up to 25 kg Can be swiveled for easy powder emptying Fluidizing suction lance Fresh powder pump connection Recovery powder pump connection Fig 12 ...

Page 23: ...mp connection Fig 13 Powder hopper Fig 14 For larger quantities of one powder type Capacity 60 or 100 liters Connection point for fluidizing suction lance Connection point for external powder supply Connection point for recovered powder Fluidized with venting connector Suitable for metallic powders Level sensor optionally available When using the powder hopper the venting hose must be connected to...

Page 24: ...are available 140 µm 200 µm 300 µm 500 µm and 1180 µm The sieve configuration and sieve selection are done on the Touch Panel fig 15 For additional information please see the operating instructions of the ultrasonic sieve system Sieve machine PS07 1 The sieve machine is used for the vibration supported sieving of coating powder and can be equipped with different mesh sizes and sieve covers see sep...

Page 25: ...is no displacer 11 kg of powder is required to start the coating process Powder feed to guns Powder feed to guns from powder bag cone or original powder container Use up to max 2 guns Fluid suction lance s Not included in the cleaning procedure of the OptiCenter For manual simple coating tasks Fig 18 Level sensor For level detection in the powder bag cone or in the powder hopper Height adjustable ...

Page 26: ...clone separator 2 The separated powder is cleaned by passing it through the integrated sieve 3 and fed back into the OptiHopper 9 by the dense phase conveyor 4 where it is prepared again for coating operation fig 20 Powder flow in the plant 1 Booth 2 Cyclone separator 3 Screen 4 Dense phase conveyor 5 After filter 6 Waste container 7 OptiCenter 8 Automatic powder guns 9 OptiHopper 10 Exhaust air d...

Page 27: ...ng mode User administration and language management Configuration and parameter data management Alarm handling Diagnostic functions Operating data acquisition Storage of operating data on SD cards Data exchange with higher level plant controls option 7 0 display with symbol elements TFT color screen with touch screen function CAN bus technology Multilingual version ...

Page 28: ...0 0 VDC effective Reverse voltage protection yes Protection yes internal inaccessible melting fuse Electrical insulation no Current consumption max 21 6 W 24 VDC Switch on current max 1 A2 s Dimensions Touch Panel Mechanical dimensions 196 x 135 x 51 mm Window 183 x 122 mm Display Touch Panel Technology Projected Capacitive Touch PCT Screen diagonal 7 0 Resolution 1024 x 600 pixels WXGA Number of ...

Page 29: ...vanically isolated SUB D connector 9 pin CAN CAN1 not galvanically isolated SUB D connector 9 pin SD card slot SDSC or SDHC according to SDA specification 2 0 Environmental conditions Touch Panel Climate 10 40 C 10 95 relative humidity not condensing Vibration shock drop test Vibration IEC 60068 2 6 Shock IEC 60068 2 27 Drop test IEC 60068 2 31 Rating plate A rating place is attached to the back o...

Page 30: ...play elements Fig 22 Front and back Designation Description 1 Display touch sensor Operating and display elements Acquisition of the actuation of the operating elements shown on the display Operated by touch using fingers 2 SD card slot Slot for SD card 3 CTRL button Exits the visualization program ...

Page 31: ...6 LAN1 10 100 Mbps 3 USB host USB 2 0 not galvanically isolated plug type A full power 500 mA 4 USB device USB 2 0 not galvanically isolated plug type B 5 COM1 RS 232 not galvanically isolated SUB D connector 9 pin 6 COM2 RS 485 not galvanically isolated SUB D connector 9 pin 7 CAN CAN1 not galvanically isolated SUB D connector 9 pin 8 Power supply MSTB plug connector 3 pin 9 SD card slot SDSC or ...

Page 32: ...he screen Do not use any pointed or sharp objects e g knife Only activate the touch panel with your finger or a stylus When wearing gloves ensure that these are clean They must not be covered with abrasive dust or sharp particles The function keys are distributed on the user interface Coating operation Cleaning operation mode Main menu OptiCenter OFF Press and hold 2 seconds US sieve ON OFF Vibrat...

Page 33: ...f cleaning times Cleaning ON Cleaning OFF Suction unit ON OFF Collecting powder Cleaning the ring injector AirMover Cleaning the powder hoses in direction to the guns Cleaning the powder hoses in direction to the pumps Fluidizing the OptiHopper Meaning of the colors Gray background present but not active Orange background active state ...

Page 34: ...very spray The powder is recovered in this coating mode the powder which does not adhere to the object is fed back into the powder circuit Operating mode Coating without powder recovery into a waste container spray to waste There is no powder recovery in this coating mode the powder which does not adhere to the object is fed directly to the waste The recovery hose must be plugged in manually conne...

Page 35: ...eaning no objects may be present in the booth and no objects may enter the booth Configuration This operating mode allows logged in operators to make certain configurations on the OptiCenter and to change parameters Settings This operating mode allows logged in operators to make certain settings on the control unit or to read information User administration Operator and system language Brightness ...

Page 36: ...ut any limitation Level for trained Gema personnel Configuration possible Plant parameters can be modified If no user is logged on to the panel operation is locked CAN bus General The control is a CAN master system Together with CAN slave participants it forms the network The wiring and topology of the CAN network is specified in the electrical diagram User administration Status display The login ...

Page 37: ... Fig 25 Login Log in by user selection Log in by entering user name Enter user password Confirm Cancel Login status User logged in User logged out Login procedure 1 Press the Select key Fig 26 Login Main page not logged in 2 The screen switches to the next page ...

Page 38: ...27 Login User selection 3 Select the desired user profile and confirm by pressing the key Alternatively the user can enter their own name directly by pressing the User key Fig 28 Login User input 4 Enter user name and confirm by pressing RET 5 Press the Password key ...

Page 39: ...Rev 00 02 21 OptiCenter OC09 Touch panel operating panel 39 Fig 29 Login Password input 6 Enter password and confirm by pressing RET Fig 30 7 Press the key The following screen is displayed Fig 31 ...

Page 40: ...ressing the symbol in the log in status bar User is logged off Change user The change of user takes place by logging out and in User profile Depending on user rights individual functions and settings may not be accessible and are locked See chapter Functions available at user level on page 36 Create user 1 Press the key The following page is displayed Fig 32 2 Press the key The following page is d...

Page 41: ... Touch panel operating panel 41 Fig 33 Settings 3 Press the key The following page is displayed Fig 34 4 Press the User key A keyboard opens to enter the name of the new user Fig 35 5 Enter user name 6 Press the RET key to confirm ...

Page 42: ...able user groups Select the desired group using the arrow keys Press the MARK key the selected group is marked with Press the RET key to confirm 9 Press the New password key A keyboard opens to enter a password for the new user Fig 37 10 Enter password 11 Press the RET key to confirm 12 Press the Confirm password key A keyboard opens and the password for the new user must be entered again ...

Page 43: ...to confirm 14 Press the key The new user now appears in the list of available users and can be deleted or changed at any time Delete users 1 In the Settings menu press the key The following page is displayed Fig 39 2 Press the User key A keyboard opens to enter the user name to be deleted ...

Page 44: ... Fig 40 3 Enter the user name to be deleted 4 Press the RET key to confirm OR 5 Press the key A corresponding dialog opens Fig 41 6 Select the user to be deleted using the arrow keys 7 Press the RET key to confirm 8 Press the key The following page is displayed ...

Page 45: ...er OC09 Touch panel operating panel 45 Fig 42 Change user password 1 In the Settings menu press the key The following page is displayed Fig 43 2 Press the Password key A keyboard opens to enter the last password used Fig 44 ...

Page 46: ...Enter the new password 7 Press the RET key to confirm 8 Press the Confirm password key A keyboard opens and the new password must be entered again 9 Press the RET key to confirm 10 Press the key Search users This function is used to display all created and active users 1 Press the key The following page is displayed Fig 45 2 Press the key The following page is displayed ...

Page 47: ...the key The following page is displayed Fig 47 User language The user language is part of the user profile and can be changed to one of the pre installed languages if required The selected language is loaded each time you log in 1 Press the key The following page is displayed ...

Page 48: ...0 02 21 48 Touch panel operating panel OptiCenter OC09 Fig 48 2 Press the key The following page is displayed Fig 49 3 Press the LANGUAGE key The following page is displayed Fig 50 4 Select desired language ...

Page 49: ...9 The change takes effect immediately and the control switches to the previous page Diagnostic 1 Press the key The following page is displayed Fig 51 2 Press the key The following page is displayed Fig 52 Inputs 3 Press the key The following page is displayed ...

Page 50: ...g mode total The productive plant utilization coating time Coating mode with recovery Total productive time in operating mode Coating with recovery spray Mode paint waste Total productive time in operating mode Coating without recovery waste Cleaning mode Total productive time in operating mode Cleaning Number of color changes Number of color changes ...

Page 51: ... 00 02 21 OptiCenter OC09 Touch panel operating panel 51 Checking the software version 1 Push the button 2 Push the button 3 Push the button The following page with the actual software version is displayed ...

Page 52: ...Rev 00 02 21 52 Touch panel operating panel OptiCenter OC09 ...

Page 53: ... locations with an ambient temperature of between 10 C and 40 C i e never next to heat sources such as an enameling furnace or electromagnetic sources such as a control cabinet Grounding of the powder management center DANGER Missing or incorrect grounding A poor or missing ground connection can be dangerous to the operator Ground all OptiCenter metal parts in accordance with general local regulat...

Page 54: ...e free of oil and water The OptiCenter requires a connection to a sufficiently dimensioned compressed air circuit In order to ensure correct operation the main pressure regulator must be set to a pressure of 6 bar Fig 56 Compressed air supply The other pressure regulators of the system are preset at the factory according to the pneumatic diagram ...

Page 55: ...paration and powder quality Basic information Compliance with the following principles will result in successful start up The OptiCenter works with all types of powders that can be fluidized If the powder is for example humid or contaminated with other materials then the conveying can be negatively influenced or does not work at all At the suction point a homogeneous fluidization must be ensured s...

Page 56: ... with the power switched off Before switching off make sure that no software is writing data on to the SD card Inserting SD card SD cards are protected against incorrect insertion 1 Do not use force when inserting 2 Push the SD card into the slot until it clicks into place Removing SD card 1 Push the SD card all the way into the SD card slot 2 Pull the SD card out of the SD card slot 3 Store the S...

Page 57: ...ult settings for an internal fresh powder system 0 1 3408 Fresh powder system extern Activates typical limits and default settings for an external fresh powder system 0 1 3409 Vacuum cleaner 0 1 3410 Second OptiCenter OptiCenter is configured as the second OptiCenter in a MultiColor MCS01 system 0 1 3412 Operating mode spray manual 0 1 3414 level sensor 0 1 3417 Sieve PSxx Activates typical limits...

Page 58: ...pped for safety reasons overfill protection and an error message is triggered 2 0 10 0 min 3465 Supervision Fresh powder demand FPS If in automatic mode the powder level set in parameter 3440 is not reached after the set time has elapsed the powder feed of fresh and recovery powder is stopped for safety reasons overfill protection and an error message is triggered 0 3 5 0 min 3471 Extend sieve 15 ...

Page 59: ...arts the operating system the PLC control and the operating software to the main page fig 57 Main page not logged in 2 Press the symbol in the login status bar to log in with a user name and password The user does not have to be logged in to operate the OptiCenter with its basic functions More about the login procedure see chapter Login on page 36 After logging in the following functions are avail...

Page 60: ...e coating the OptiHopper must first be filled with powder The level is reached when the fluidized powder is 20 mm above the air suction openings Manual filling is provided as standard Optional fresh powder systems and level sensors allow automatic filling The optional displacer can be used for processing small quantities of powder less than 11 kg see chapter Displacer on page 25 Coating With powde...

Page 61: ... size If there are several mesh sizes the corresponding menu appears for selecting the mesh size used ATTENTION Overheating of the US sieve The US sieve can break if it has already been configured in the configuration menu and is not inserted in the OptiHopper dry operation Insert US sieve into the OptiHopper ATTENTION Clogging of the US sieve The US sieve can become clogged if it has not been con...

Page 62: ...rrectly if the powder does not escape and is slightly removed If necessary adjust again on the appropriate pressure regulator 7 Coating can now commence If an error message is displayed correct the error and acknowledge the error message so that the coating process continues Screen selection If the customer uses more than one screen the OptiCenter panel displays a relevant choice of mesh sizes Onl...

Page 63: ... as needed Set parameter no 3412 to 1 See chapter Parameter description on page 56 1 2 3 Delay fresh powder demand In coating mode with powder recovery spray fresh powder is also fed into the OptiHopper after the set time has elapsed in addition to the recovery powder until the powder level is reached again ...

Page 64: ...is must be set with parameter 3460 fig 58 See chapter Parameter description on page 56 Working interruptions or coating breaks If the coating process is interrupted for a longer period of time the system should be brought into an economical state 1 Check if all the workpieces have been coated 2 Press the key for 2 seconds The Coating menu is closed and switches back to the main menu The level cont...

Page 65: ...pter Cleaning on page 69 4 Turn the main switch to the OFF position the interior lighting goes out Replace powder bag 1 Check visually the powder level in the bag cone 2 Hold the full powder bag ready 3 Switch this on if it is has not been switched on already 4 5 6 7 8 9 10 ...

Page 66: ...ing process continues to run Color change To perform a color change proceed as follows 1 End the coating procedure 2 Clean the OptiCenter See chapter Cleaning procedure on page 70 3 Fill the cleaned OptiHopper with new color See chapter Filling the OptiHopper on page 60 4 Select the desired operating mode If an error message is displayed correct the error and acknowledge the error message so that ...

Page 67: ...ntenance work are available as spare parts These parts can be found in the appropriate spare parts list ATTENTION Any unauthorized modifications and alterations to the product are not permitted for safety reasons and exclude the manufacturer s liability for any resulting damage Regular careful cleaning and maintenance extends the service life of the product and ensures long lasting uniform coating...

Page 68: ...e 1 x annually 7 Filter element check valves injectors Replace 1 x annually 8 Hose lines and fittings Check 1 x annually 9 All electrical screw and clamp connections Check if firmly fitted 1 x annually The specified intervals are based on operation of 8 hours per day The service life of the components depends heavily on the service duration the powder quality and the quality of the air supply Chec...

Page 69: ...ccurring during the cleaning process may cause hearing damage Do not approach the OptiCenter unless absolutely necessary Wear adequate hearing protection e g ear muffs per EN 352 1 A great deal of air is required for the cleaning procedure Make sure that 6 bar is always available ATTENTION Powder can escape if the OptiHopper cover is not closed properly Check that the cover fits properly ATTENTION...

Page 70: ...ng the powder hoses in direction to the pumps The following functions are available for fine cleaning Strong fluidization of the fluidization plate Suction unit Cleaning Times All cleaning steps are time controlled However the factory set values can be individually adjusted according to the requirements for cleanliness 1 In cleaning mode press the key 2 Adjust cleaning time s Cleaning procedure 1 ...

Page 71: ...Rev 00 02 21 OptiCenter OC09 Maintenance Repairs 71 3 4 Select the desired cleaning mode 5 Exhaust air starts automatically 6 Remove and clean all powder contacting components see example below 7 8 9 10 ...

Page 72: ...ide where to collect the powder from the booth Variant 1 in the OptiHopper Variant 2 transferred to the waste Variant 3 in the optional powder hopper Variant 4 in the optional powder cone bag For variants 2 3 and 4 the recovery hose must be replugged before starting Option Destination 1 2 3 ...

Page 73: ...sary 15 Press Start If necessary the cleaning process can be interrupted at any time by pressing the stop button The powder is collected in the OptiHopper This step can be stopped by the operator when no more powder is returned 16 Press Cleaning of the ring injector AirMover and the connected powder hose with compressed air pulses starts automatically 17 The automatic process step is complete when...

Page 74: ... wall parking position 23 Lift the white OptiHopper covers clean them and place them in the parking position rear panel parking position ATTENTION Large dust formation possible If the OptiCenter is operated without the appropriate equipment hearing protection safety goggles and if not cleaned with the exhaust air switched on the compressed air containing powder can cause hearing damage eye damage ...

Page 75: ...s possible to the opening 26 Use a scraper to clean the side walls of the OptiHopper so that the suction openings are no longer covered with powder 27 Also clean the fluidizing plate so that there is only a small amount of powder on the surface 28 Press the key The powder hoses are cleaned and the residual is transported to the booth Suction channels in the OptiHopper are rinsed ...

Page 76: ...layed Any individual step can be repeated as needed by pressing the corresponding key again Only the selected cleaning step is carried out Fine cleaning 1 Press the key This key activates deactivates the strong fluidization for fine cleaning 2 Press the key This key is used to activate deactivate the suction unit 3 Visually check the OptiHopper interior clean with the suction unit and or with the ...

Page 77: ...ocess is started 4 Compressed air pulses blow through the hose from the OptiCenter to the cyclone The process can be manually stopped and resumed by the operator 5 Swing the funnel on the cyclone slowly away and at the same time clean it off with the air gun 6 Clean the inside of the cyclone with the cleaning wand 7 Reconnect the sieve machine and funnel to the cyclone 8 If a new color is to be us...

Page 78: ...t use any aggressive or abrasive cleaning agent or solvent Ensure liquids do not enter the operating panel risk of short circuit and no damage is caused to the operating panel Clean the touch screen surface carefully with a clean soft damp cloth Battery The built in battery for buffering the real time clock is maintenance free and designed for a buffer time with the power switched off while mainta...

Page 79: ...ed by the manufacturer or an authorized body Operate the operating panel only with the housing completely closed Use appropriate packaging when transporting SD card data backup The contents of the SD card can be saved on another medium in order to be able to copy them back in case of card damage or data loss Further information can be found in the SD card user manual Some operating systems do not ...

Page 80: ...Rev 00 02 21 80 Maintenance Repairs OptiCenter OC09 ...

Page 81: ...ocedures can be carried out refer to troubleshooting guide If the error has been eliminated the display returns to the previous menu again Troubleshooting guide Fault Cause Corrective action No powder feed from the OptiHopper OptiHopper empty Refill powder manually Powder accumulation on optional level sensor Clean the sensor Readjust the sensor sensitivity Check the fluidizing of the sensor if ne...

Page 82: ...p defective See corresponding operating manual OptiFeed PPxx Pump does not suck in powder Check the cyclone funnel for powder abrasion Check fluidization at the suction point Hose plugged or incorrectly connected overpressure at the OptiFeed PPxx powder pump See corresponding operating manual OptiFeed PPxx No extraction in the OptiCenter Incorrect operating mode selected Select correct operating m...

Page 83: ...f necessary Vibrator defective Motor protection switch Q6 has reacted Remove the small maintenance panel and switch on the motor protection switch again With repeated Alarms contact a Gema service center Vibrator defective Replace Cable broken Replace Valve battery failure Safety equipment F7 has reacted control unit switches to stand by mode Check the 24 VDC Power pack G4 Check the safety equipme...

Page 84: ...Rev 00 02 21 84 Fault clearance OptiCenter OC09 ...

Page 85: ...ain supply 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 elastomeric components pinch valve collars O ring seals etc can become brittle over time and crack when put under repeated loads Type of storage For safety reasons the product should only be stored in a vertical...

Page 86: ... service life of the operating panel Protect the operating panel from direct sunlight or other sources of UV radiation ATTENTION Risk of short circuit In the event of climatic fluctuations ambient temperature or humidity moisture may be deposited on or inside the operating panel If the control panel is subjected to condensation there is a risk of short circuit Never switch on the operating panel w...

Page 87: ...gn the built in components are sensitive to excessive vibrations and or shocks The operating panel must be protected from mechanical loads outside its intended use The operating panel may only be transported in the appropriate packaging and in the correct manner Before recommissioning During storage and transport in cold weather and in the event of extreme temperature differences ensure that no mo...

Page 88: ...Rev 00 02 21 88 Decommissioning Storage OptiCenter OC09 ...

Page 89: ...perly at the end of its service life When disposing of the product the applicable local and regional laws directives and environmental regulations must be complied with Materials The materials must be sorted according to material groups and taken to the appropriate collection points Disassembly of component groups WARNING Live components Risk of fatal injury from electric shock if touched Only tra...

Page 90: ... a risk of explosion due to the lithium battery installed in the operating panel Ensure the operating panel is disposed of properly The recyclable materials should be taken to your local recycling center Operating panels that are no longer required must be disposed of properly in accordance with local regulations ...

Page 91: ...g cable or hose material the required length must also be given The spare part numbers of this bulk stock is always marked with an The wearing parts are always marked with a marked All dimensions of plastic hoses are specified with the external and internal diameter Example Ø 8 6 mm 8 mm outside diameter o d 6 mm inside diameter i d WARNING Use of non original Gema spare parts When using the spare...

Page 92: ...07 PA Powder injector see corresponding operating manual 4 OptiHopper see corresponding spare parts list 5 Powder supply see corresponding spare parts list 7 Pneumatics ES AS06 see corresponding spare parts list 10 Powder feed see corresponding spare parts list 11 OptiFeed PPxx Powder pump see corresponding operating manual For all other electrical components see also the spare parts list in the e...

Page 93: ...ews 720 001 4 Vibrator motor 220 240 V 1009 251 5 GEKA blind coupling 1002 405 6 Cover 1007 177 7 GEKA coupling 3 4 254 339 8 Cover bushing 1005 245 9 Fluidizing suction unit Ø 28 mm complete 1005 332 10 Tube connection complete incl pos 11 1007 658 11 O ring Ø 16x2 mm 1007 794 12 Quick release connection NW5 Ø 6 mm 200 840 Wear part Please specify length Fig 60 ...

Page 94: ...32 1 Connector NW5 0 1 8 200 859 2 Elbow joint 1 8 1 8 235 733 3 Adapter nipple 1 8 1 8 200 930 4 Flow restrictor Ø 0 3 mm 338 303 Fluidizing ring set incl pos 5 6 7 720 002 5 O ring Ø 22 1x1 6 mm 233 340 6 Fluidizing ring 1005 330 7 O ring Ø 14x1 5 mm 263 486 8 Foot piece 1005 327 Wear part Please specify length Fig 61 ...

Page 95: ...1 Handle 1006 013 2 Sealing plug complete with O ring 1018 773 3 Pinch valve DN32 G 1 1 4 complete see corresponding spare parts list 1007 648 4 Ring injector AirMover complete see corresponding spare parts list 1019 824 5 Grounding cable complete 391 603 6 GEKA coupling 3 4 1002 551 7 GEKA blind coupling 1002 405 fig 62 ...

Page 96: ...mm 262 986 4 Magnet Ø 25 mm 1019 880 5 Plug 1022 153 6 Screw M5x30 mm 1019 883 7 O ring Ø 70x8 mm 1022 038 8 O ring Ø 104x3 mm 1019 887 9 O ring Ø 114x3 mm 1019 888 10 Powder outlet 1019 873 11 Bottom fluidization plate complete 1019 813 12 Fastening plate complete 1019 820 13 Allen cylinder screw M6x20 mm 216 429 14 Elbow joint 1 4 Ø 8 mm 254 029 Wear part fig 63 ...

Page 97: ...sponding spare parts list 8 Valves pool see corresponding pneumatic diagram 1020 470 9 Pneumatic manifold 2 see corresponding spare parts list 10 Vacuum filter Ø 8 mm 1004 946 10 1 Vacuum filter Ø 6 mm 1019 437 11 Pneumatic manifold 1 see corresponding spare parts list 12 Main air supply see corresponding spare parts list 13 Fluidization OptiHopper see corresponding spare parts list 14 Compressed ...

Page 98: ...21 98 Spare parts list OptiCenter OC09 Main air supply 1 Ball valve 1 1 1006 065 2 Pressure regulator Filter unit 0 5 8 bar 1 1006 547 2 Pressure gauge 0 10 bar 1 4 1010 964 4 Plug 1 1019 095 5 Filter unit fig 65 ...

Page 99: ...thout coil incl pos 3 1 1005 120 3 1 Membrane not shown 830 160 4 Valve coil 24 VDC 1005 119 5 Valve cable 3 pins 1006 902 6 Hose connector Ø 17 1 2 223 069 7 Elbow joint 1 8 1 8 237 604 9 Adapter nipple 1 4 1 8 1020 052 10 Pressure regulator 0 5 8 bar 3 8 1017 787 11 Plug 1 4 258 695 12 Elbow joint 3 8 Ø 10 2 x 1020 062 13 Elbow joint 1 4 Ø 8 2 x 1020 054 Wear part Please indicate length fig 66 ...

Page 100: ...ple 1 8 1 4 265 454 6 Elbow joint 1 8 1 8 237 604 7 Flow restrictor Ø 1 9 mm 372 900 8 Screw in nipple 1 8 Ø 8 mm 240 087 9 Double connecting nipple Ø 8 mm 229 326 10 Check valve Ø 8 Ø 8 mm 1005 575 11 Y plug connection Ø 8 2x Ø 8 mm 264 814 12 Elbow joint 1 4 Ø 8 mm 254 029 13 Elbow joint 1 8 Ø 8 mm 253 987 14 Adjusting elbow Ø 8 Ø 8 mm 1001 031 15 Plastic tube Ø 8 6 mm 103 756 Wear part Please i...

Page 101: ...ling plug 1 4 258 695 5 Screw in nipple 1 4 Ø 8 mm 265 136 6 Adjusting elbow Ø 8 Ø 8 mm 1001 031 7 Double connecting nipple Ø 8 mm 229 326 8 Check valve Ø 8 Ø 8 mm 1005 575 9 Y connection 3 x Ø 8 mm 251 259 10 Elbow connection Ø 8 Ø 8 mm 230 995 11 Adjusting elbow Ø 8 Ø 8 mm 1005 190 12 Screw in nipple 1 4 Ø 8 mm 600 237 13 Adjusting elbow Ø 6 Ø 6 mm 268 453 Plug Ø 8 mm not shown 238 023 fig 68 ...

Page 102: ...9 187 2 Adapter nipple 1 4 1 8 1020 052 4 Elbow joint 1 8 1 8 237 604 5 Pressure gauge 0 10 bar 1 8 259 179 6 Solenoid valve 1 2 NW13 5 mm without coil incl pos 6 1 1005 120 6 1 Membrane not shown 830 160 7 Valve coil 24 VDC 1005 119 8 Valve cable 3 pins 1007 004 9 Hose connector Ø 17 mm 1 2 223 069 Wear part fig 69 ...

Page 103: ...Pinch Valve 1 Pinch valve NW32 complete 1007 648 2 Pinch valve sleeve NW32 1007 647 3 Elbow joint 1 4 Ø 8 mm 254 029 4 Connector 1019 823 5 O ring Ø 46x3 mm 1019 886 6 Ring injector AirMover complete 1019 824 7 O ring Ø 59x2 mm 1003 352 Wear part Please specify length fig 70 ...

Page 104: ...ing 3 4 254 339 5 GEKA blind coupling 1002 405 6 Handle 1006 013 7 Connector NW5 1 8 237 272 8 Elbow joint 1 8 1 8 237 604 9 Fluidizing plate PH60 OC 1006 012 10 Countersunk Allen screw M6x50 mm 1002 954 15 Level sensor cover 1007 178 16 Cover bushing 1011 499 17 Locknut Ø 40x28xM8 mm 1008 285 18 Rubber profile 1007 172 19 Hose for OptiHopper emptying Ø 40 mm not shown 100 048 Blind cover PH60 OC ...

Page 105: ...ndle 1006 013 7 Connector NW5 1 8 237 272 8 Elbow joint 1 8 1 8 237 604 10 Countersunk Allen screw M6x50 mm 1002 954 12 Cover PH100 OC 1011 497 13 Fluidizing plate PH100 OC 1006 017 15 Level sensor cover 1007 178 16 Cover bushing 1011 499 17 Locknut Ø 40x28xM8 mm 1008 285 18 Rubber profile 1007 172 19 Rubber buffer M40x1 5 mm 248 592 20 Roller 1009 141 21 Hose for OptiHopper emptying Ø 40 mm not s...

Page 106: ...list OptiCenter OC09 LC01 Level sensor 1 LC01 Level sensor complete incl pos 2 1006 089 2 O ring Ø 38 x 4 mm 239 151 3 Plastic tube Ø 6 Ø 4 mm 1001 973 4 Connecting cable complete 371 696 Wearing part Please indicate length fig 73 ...

Page 107: ...ber damper Ø 25x30 mm 232 866 3 Connection plug 206 466 4 Swivel wheel Ø 50 mm 260 606 5 Rubber buffer 15x8 mm not shown 234 915 6 Rubber damper Ø 20x20 mm 248 681 7 Fluidizing suction unit Ø 28 mm complete 1005 332 8 Cover 1009 744 9 GEKA coupling 3 4 254 339 10 Quick connection socket 1005 245 11 Vibrator 1009 251 Please specify length fig 74 ...

Page 108: ... 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 Please indicate length fig 75 ...

Page 109: ...ctor 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 4 Ø 8 mm 224 359 11 Throttle valve 1 8 1 8 1002 127 12 Double nipple 1 4 1 ...

Page 110: ...e parts list OptiCenter OC09 Pneumatics ES AS 1 Solenoid valve 3 4 NW18 without coil 1005 121 1 Valve coil 24 VDC 1005 119 3 Pressure switch 1 10 bar 1 4 PG7 233 757 4 Hose connector Ø 16 mm 1 2 259 268 Wearing part fig 77 ...

Page 111: ...tion 53 I Intended use 15 M Maintenance 67 Maintenance during storage 86 O Operating and display elements 30 Operation 59 OptiCenter maintenance 68 Overall view 19 P Periodic checks 78 Pictograms 7 Pneumatic data 17 Powder transport 17 Preparation for start up 55 Presentation of the contents 9 Product description 15 Product specific security regulations 12 R Rating plate 18 29 Reasonably foreseeab...

Page 112: ...Rev 00 ...

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Gema OptiCenter OC09, Operating Instructions And Spare Parts List

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