Gema OptiCenter OC06 Operating Instructions And Spare Parts List Download

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Rev. 00

1011 544

Operating instructions and Spare parts list

Powder management

system

OptiCenter OC06

Translation of the original operating instructions

Summary of Contents for OptiCenter OC06

Page 1: ...Rev 00 1011 544 EN Operating instructions and Spare parts list Powder management system OptiCenter OC06 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: ... Cleaning color change operating mode 35 Configuration 35 Settings 35 User levels and access 35 Functions available at user level 36 User administration 36 Status display 36 Login 36 Log out 39 Change user 40 User profile 40 Diagnostic 49 Operating hours 50 Assembly Connection 51 Set up 51 Grounding of the powder management center 51 Compressed air supply 52 Start up 53 Preparation for start up 53...

Page 5: ...ing panel 88 Periodic checks 88 Repair work 89 Repairs 89 SD card data backup 89 Fault clearance 91 Error messages 91 Troubleshooting guide 91 Decommissioning Storage 95 Decommissioning 95 If in disuse for several days 95 Storage conditions 95 Storage duration 95 Type of storage 95 Space requirements 95 Physical requirements 96 Hazard notes 96 Maintenance during storage 96 Maintenance schedule 96 ...

Page 6: ... 111 OptiSpeeder Fluidization 112 Pressure regulators pool 113 Compressed air supply CG22 C 114 Pneumatic manifold Cleaning 115 Pinch valves distributor RP FP 116 Powder hopper PH60 OC 117 PH100 OC Powder Hopper 118 LC01 Level sensor 119 Vibration trolley 120 Monocyclone Powder transport 121 Monocyclone Powder transport connection 122 Pneumatics ES AS05 123 ...

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: ...not avoided may have harmful 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 Preventi...

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 04 19 10 About these instructions OptiCenter OC06 ...

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: ...s all powder conveyors 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 by trained personnel who are informed about and are familiar with the possible hazards involved Any other use is ...

Page 16: ...the system or target container Powder level monitoring by level sensor s Cleaning Automatic internal cleaning of suction tubes powder conveyors powder hoses and guns Supply of the recovered powder Closed powder circuit no powder escaping during coating or cleaning procedure This prevents powder loss and the workplace and the environment remain clean Reasonably foreseeable misuse Operation without ...

Page 17: ...port OptiCenter OC06 24 guns 36 guns Recovery max 3 5 kg min OptiSpeeder capacity 6 kg 9 kg Compressed air consumption OptiCenter OC06 Max compressed air consumption during cleaning 120 seconds 300 400 Nm h Coating operation Fluidization OptiSpeeder AirMover process air 15 Nm h Consumption per applicator 5 Nm h Example for 10 applicators 65 Nm h Cleaning operation mode Cleaning OptiSpeeder 120 Nm ...

Page 18: ...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 product con...

Page 19: ... 1 Control unit operating panel 2 Emergency stop button 3 OptiSpeeder fluidization 4 OptiSpeeder 5 Powder bag fixation 6 Powder bag cone with vibrator 9 Gun control unit All in One 10 Powder hopper venting connection Touch Panel All necessary operating procedures are activated by the Touch Panel Fig 5 ...

Page 20: ... 2 bar Powder hopper fluidizing air 30Q1 2 bar Fluid suction unit fluidizing air OptiSpeeder The OptiSpeeder offers the following automatic functions Conditioning and fluidization of the coating powder Emptying the residual powder Cleaning using patented Gema Airjet procedure Monitoring and control of the powder level Extraction removal of excess free floating powder particles and fluidizing air F...

Page 21: ...p connection Fig 9 Ultrasonic sieve system US07 The US07 Ultrasonic sieve system with the corresponding Ultrasonic sieve generator is used for the ultrasonic supported sieving of coating powder It is exclusively used inside the OptiSpeeder powder hopper In addition to the standard version a version with a sieve cover connection for external powder supply is also available The system is delivered f...

Page 22: ...e operating instructions of the ultrasonic sieve system Vibrating trolley Powder feed directly from the original powder manufacturer s container Use up to max 12 guns Can be swiveled for easy powder emptying Fluidizing suction lance Fresh powder pump connection Recovery powder pump connection Fig 11 ...

Page 23: ...uitable for metallic powders Level sensor optionally available When using the powder hopper the venting hose must be connected to the connector and the ball valve 10 must be open during the entire operation Is there no powder hopper the ball valve must be closed Powder recovery system Optional powder return into the powder bag cone or into the powder hopper or into the extraction system Plug posit...

Page 24: ...r unit Powder feed to guns from the OptiSpeeder CAN bus capable gun control units mounted outside the OptiCenter Full integration into the cleaning procedure of the OptiCenter For manual coating tasks Up to 2 injector units can be used for optimum cleaning performance rinsing Supply of conveying air and supplementary air by the gun control unit Supply of the pinch valve air and rinsing air through...

Page 25: ...ith the fluidizing suction lance and then fed to the OptiSpeeder 9 The fluidized powder is sucked in by the conveyors and fed through the powder hoses to the guns spray nozzles 8 The powder which does not adhere to the workpieces will be absorbed 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 integra...

Page 26: ...4 19 26 Product description OptiCenter OC06 1 Booth 2 Cyclone separator 3 Sieve 4 Dense phase conveyor 5 After filter 6 Waste container 7 OptiCenter 8 Automatic powder guns 9 OptiSpeeder 10 Exhaust air ducting ...

Page 27: ...ilter and is fed directly back into the workshop environment Touch panel operating panel Typical characteristics Powder coating in 2 operating modes Cleaning in cleaning 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 plan...

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: ...nically 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 MagicControl CM40 Climate 0 50 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 bac...

Page 30: ...play elements Fig 19 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: ...ed 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 with powder recovery Cleaning operation mode Coating without powder recovery spray to waste container Main menu OptiCenter OFF Press and...

Page 33: ...sive Cleaning quick Cleaning adjustable procedure Overview of cleaning times Cleaning ON Cleaning OFF Empty OptiSpeeder Blow off OptiSpeeder Clean powder hoses Clean fresh powder pump Meaning of the colors Gray background present but not active Orange background active state ...

Page 34: ...the powder which does not adhere to the object Utilization of this operating mode Long coating with the same powder In order to increase the coating quality after a color change the function Automatic change from coating without recovery to coating with recovery can be used See chapter Parameter description on page 54 Coating without powder recovery spray to waste container There is no powder reco...

Page 35: ...re switching off the plant The higher the requirement for cleanliness the higher the time expenditure will be During cleaning 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 c...

Page 36: ...1 user 2 user 3 User level 0 1 2 3 4 User groups Administ rator Service Supervis or Operator Painter The panel can be used without 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 User administration Status display The login status is displayed in the corresponding bar User logged in Use...

Page 37: ... Fig 22 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 23 Login Main page not logged in 2 The screen switches to the next page ...

Page 38: ...24 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 25 Login User input 4 Enter user name and confirm by pressing RET 5 Press the Password key ...

Page 39: ...enter OC06 Touch panel operating panel 39 Fig 26 Login Password input 6 Enter password and confirm by pressing RET Fig 27 7 Press the key The following screen is displayed Fig 28 Log out The user can log out in two ways ...

Page 40: ...n 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 29 2 Press the key The following page is displayed ...

Page 41: ... Touch panel operating panel 41 Fig 30 Settings 3 Press the key The following page is displayed Fig 31 4 Press the User key A keyboard opens to enter the name of the new user Fig 32 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 34 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 36 2 Press the User key A keyboard opens to enter the user name to be deleted ...

Page 44: ... Fig 37 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 38 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 OC06 Touch panel operating panel 45 Fig 39 Change user password 1 In the Settings menu press the key The following page is displayed Fig 40 2 Press the Password key A keyboard opens to enter the last password used Fig 41 ...

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 42 2 Press the key The following page is displayed ...

Page 47: ...the key The following page is displayed Fig 44 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 04 19 48 Touch panel operating panel OptiCenter OC06 Fig 45 2 Press the key The following page is displayed Fig 46 3 Press the LANGUAGE key The following page is displayed Fig 47 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 48 2 Press the key The following page is displayed Fig 49 Inputs 3 Press the key The following page is displayed ...

Page 50: ...ed Fig 51 Automatic The productive plant utilization coating time Waste mode Total productive time in operating mode Coating without recovery waste Spray mode Total productive time in operating mode Coating with recovery spray Cleaning mode Total productive time in operating mode Cleaning Number of color changes Number of color changes ...

Page 51: ... 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 52: ...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 53 Compressed air supply The other pressure regulators of the system are preset at the factory according to the pneumatic diagram ...

Page 53: ...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 54: ...f 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 SD card in its packaging for protection Parameter...

Page 55: ...lling level OptiSpeeder Setting the desired powder filling level in the OptiSpeeder 55 100 3441 Filling level Hysteresis Hysteresis of the powder level 5 10 3442 Time until start of powder recovery after color change In coating mode with powder recovery spray the recovery powder is first fed into the after filter after a color change and then into the OptiSpeeder after the set time has elapsed in ...

Page 56: ...powder For large production batches of the same color metallic or effect powders can cause color changes if less than 50 of the applied powder adheres to the object In order to maintain the quality of the coating some of the recovery powder can be removed from the system and substituted with fresh powder 0 100 ...

Page 57: ...al check is to be performed without powder Starting the OptiCenter 1 Turn the main switch to the ON position The control starts the operating system the PLC control and the operating software to the main page Fig 54 Main page not logged in 2 Press the symbol in the login status bar to log in with a user name and password ...

Page 58: ...very Coating without powder recovery spray to waste container Cleaning operation mode 4 Set all other plant components to the correct operating mode for more information see the relevant operating instructions If some plant components are not yet ready for operation a message will be displayed Coating with powder recovery spray 1 2 3 If a US sieve has already been configured insert and close the O...

Page 59: ...ing capacity Set US sieve parameters correctly 4 The fluidization of the suction lance switches on The vibrator switches on and runs at intervals US sieve switches on 5 The OptiSpeeder is filled until the filling level is reached The vibrator switches off 6 The extraction system is switched off by default but can be manually switched on and off as needed 7 Open the OptiSpeeder cover and visually c...

Page 60: ...cting 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 OptiSpeeder dry operation Insert US sieve into the OptiSpeeder ATTENTION Clogging of the US sieve The US sieve can become clogged if it has not been configured in the configuration menu and is still inserted in the OptiSpeeder ...

Page 61: ...ng can now commence If an error message is displayed correct the error and acknowledge the error message so that the coating process continues Powder recovery in the powder hopper To use this function parameter 3413 must be set and the optional powder recovery system extension must be installed See chapter Parameter description on page 54 If the customer works with powder that tends to segregate t...

Page 62: ...nal fresh powder supply to the powder hopper or fill the powder hopper manually 7 Press the key to start coating 8 Adjust the fluidization of the powder hopper on the corresponding manometer and check visually This function can be deactivated at any time The recovered powder is then fed directly back into the OptiSpeeder Press or Screen selection If the customer uses more than one screen the OptiC...

Page 63: ...OptiSpeeder after the set time has elapsed in the event of increased quality requirements after a color change Parameter 3442 is used to set an automatic change from coating without recovery waste to coating with recovery spray A pinch valve distributor is used to feed the recovery powder to the after filter during the adjustable time period After the time set in parameter 3442 has elapsed the rec...

Page 64: ...ached The coating is correctly set when the powder collection unit under the cyclone does not overfill This must be set with parameter 3460 Fig 56 See chapter Parameter description on page 54 Ratio of fresh powder recovery powder For large production batches of the same color metallic or effect powders can cause color changes if less than 50 of the applied powder adheres to the object The proporti...

Page 65: ...duction batches of the same color To achieve this the following is recommended Use of gap control Dense optimized object suspension Well maintained and adjusted application equipment 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 th...

Page 66: ...ff The vibrator switches off 3 Clean the OptiCenter See chapter Cleaning on page 71 4 Turn the main switch to the OFF position the interior lighting goes out Replacing the 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 ...

Page 67: ... another container or dispose of it 12 If an error message appears correct the error and acknowledge it to ensure that the coating process continues to run Color change 1 Clean the OptiCenter See chapter Cleaning on page 71 2 3 4 5 Insert the cleaned OptiSpeeder cover with US sieve if already configured ...

Page 68: ...TH the US sieve The US sieve can become clogged if it has not been configured in the configuration menu and is inserted in the OptiSpeeder Insert the OptiSpeeder cover WITHOUT US sieve 6 7 Select the desired operating mode 8 Do not coat before the set powder level has been reached The OptiSpeeder is now filled with powder If an error message is displayed correct the error and acknowledge the error...

Page 69: ...ermitted 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 quality The parts to be replaced during maintenance work are available as spare parts For further information see chapter Spare parts list ...

Page 70: ...es 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 10 Pinch hose in pinch valve OptiSpeeder emptying Replace Every 2 years 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 ...

Page 71: ...tection 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 OptiSpeeder cover is not closed properly Check that the cover fits properly Check that the lock is properly engaged The lock tension has been set at the factory and must not be changed under any circumstances ATTENTION Damage to t...

Page 72: ...Rev 00 04 19 72 Maintenance Repairs OptiCenter OC06 3 4 Select the desired cleaning mode 5 Exhaust air starts automatically 6 7 8 9 10 11 ...

Page 73: ...d at any time by pressing the stop button 14 15 The pinch valve below the OptiSpeeder opens and the powder in the OptiSpeeder flows into the powder bag 16 The process step is complete when the key looks like this The key can be pressed once again if necessary This is a sign that the next cleaning step will be activated 17 ...

Page 74: ...splayed after approx 180 seconds for intensive cleaning and approx 30 seconds for quick cleaning 22 The powder hoses are cleaned and the powder is transported to the booth The powder is conveyed from the booth The corresponding cleaning program is displayed on the OptiStar control units 23 The process step is complete once this symbol is displayed The key can be pressed once again if necessary Oth...

Page 75: ...splayed Any individual step can be repeated as needed by pressing the corresponding key again Only the selected cleaning step is carried out 26 Visually check the inside of the OptiSpeeder if necessary clean with compressed air gun 27 Booth cleaning can now be started Activate the corresponding command on the MagicControl control unit 28 Clean the OptiCenter 29 Open the monocyclone ...

Page 76: ...ne slowly away and at the same time clean it off with the air gun 34 Clean the inside of the cyclone with the cleaning wand 35 Reconnect the sieve machine and funnel to the cyclone 36 If a new color is to be used See chapter Color change on page 67 OTHERWISE 37 To switch the OptiCenter to stand by mode press and hold the key for 2 seconds 38 Store the powder properly Cleaning with recovery in the ...

Page 77: ...Rev 00 04 19 OptiCenter OC06 Maintenance Repairs 77 3 4 Select the desired cleaning mode 5 Exhaust air starts automatically 6 7 8 9 Ensure that the recovery hose is connected to the powder hopper ...

Page 78: ...system is already connected and that the ball valve is open 11 12 Press Start If necessary the cleaning process can be interrupted at any time by pressing the stop button 13 14 The pinch valve below the OptiSpeeder opens and the powder in the OptiSpeeder flows into the powder hopper ...

Page 79: ...l be activated 16 17 The OptiSpeeder is cleaned the powder from the OptiSpeeder is transported to the booth 18 The powder is conveyed from the booth 19 The process is complete once this symbol is displayed after approx 180 seconds for intensive cleaning and approx 30 seconds for quick cleaning 20 The powder hoses are cleaned and the powder is transported to the booth The powder is conveyed from th...

Page 80: ...y Otherwise the next cleaning step is activated 22 The following screen is displayed The fresh powder pump is cleaned 23 Booth cleaning can now be started Activate the corresponding command on the MagicControl control unit The resulting powder is fed into the powder hopper 24 Once the booth has been cleaned reposition the recovery hose in the cleaning position 25 The cleaning of the recovery hoses...

Page 81: ...p is carried out 27 Visually check the inside of the OptiSpeeder if necessary clean with compressed air gun 28 Clean the OptiCenter 29 Open the monocyclone ATTENTION Sieve damage The sieve can be damaged when backwashing the transport hose Swing out the sieve completely during this cleaning step 30 Slowly swing out the sieve and clean it with the air gun 31 Press the button on the monocyclone The ...

Page 82: ...er to stand by mode press and hold the key for 2 seconds 38 Store the powder properly Cleaning with recovery in the powder bag To use this function parameter 3413 must be set and the optional powder recovery system extension must be installed See chapter Parameter description on page 54 See chapter Color change on page 67 The powder circuit could contain more than 20 kg of powder Be sure to estima...

Page 83: ...0 04 19 OptiCenter OC06 Maintenance Repairs 83 5 Exhaust air starts automatically 6 7 8 9 10 11 12 13 Press Start If necessary the cleaning process can be interrupted at any time by pressing the stop button ...

Page 84: ...in the OptiSpeeder flows into the powder bag 16 The process step is complete when the key looks like this The key can be pressed once again if necessary This is a sign that the next cleaning step will be activated 17 18 19 Connect the extraction system and open the ball valve 20 Connect the recovery hose to the cover ...

Page 85: ...s step is complete once this symbol is displayed after approx 180 seconds for intensive cleaning and approx 30 seconds for quick cleaning 25 The powder hoses are cleaned and the powder is transported to the booth The powder from the booth is fed via the cyclone into the powder bag The corresponding cleaning program is displayed on the OptiStar control units 26 The process is complete once this sym...

Page 86: ...ate the corresponding command on the MagicControl control unit The powder is fed into the powder bag 29 Once the booth has been cleaned reposition the GK coupling in the cleaning position 30 The cleaning of the recovery hoses starts automatically sensor monitored 31 The process is complete when this screen is displayed Any individual step can be repeated as needed by pressing the corresponding key...

Page 87: ... button on the monocyclone The cleaning process is started 37 Compressed air pulses blow through the hose from the OptiCenter to the cyclone The process can be manually stopped and resumed by the operator 38 Swing the funnel on the cyclone slowly away and at the same time clean it off with the air gun 39 Clean the inside of the cyclone with the cleaning wand 40 Reconnect the sieve machine and funn...

Page 88: ...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 89: ...ened 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 Technical Manual Some operating systems do not d...

Page 90: ...Rev 00 04 19 90 Maintenance Repairs OptiCenter OC06 ...

Page 91: ...bleshooting guide Fault Cause Corrective action No extraction in the OptiCenter Incorrect operating mode selected Select correct operating mode Corresponding valve in the valve pool defective or dirty Check function at corresponding output see also Pneumatic diagram replace if necessary Exhaust air flap does not move Check for movement or replace No AirMover function in the OptiSpeeder Ring inject...

Page 92: ...OC Replace pinch hose Pinch valve defective mono cyclone Replace pinch hose No cleaning or insufficient cleaning of the powder hoses Corresponding valve in the valve pool defective or dirty Check function at corresponding output see also Pneumatic diagram replace if necessary Insufficient emptying of the OptiSpeeder during cleaning Corresponding valve in the valve pool defective or dirty Check fun...

Page 93: ...e Replace Cable broken Replace Conveying problem with recovery powder pump Powder pump does not function properly Pump defective See corresponding operating manual OptiFeed PP06 Hose clogged Check the recovery system Check level sensor see above Check the cyclone funnel for powder abrasion Contact Gema Service Overpressure recovery powder pump Powder pump is switched off Hose clogged or connected ...

Page 94: ...ise contact a Gema service center Powder alert in OptiSpeeder Powder warning flashlight activated Check the powder bag otherwise powder shortage Powder shortage in OptiSpeeder Powder bag empty chain conveyor stops flashlight activated Replace powder bag CAN bus malfunction No communication with CM40 CM41 Switch on higher level control unit CM40 CM41 CAN bus participant defective Contact Gema Servi...

Page 95: ...torage 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 position Sp...

Page 96: ... 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 97: ...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 98: ...Rev 00 04 19 98 Decommissioning Storage OptiCenter OC06 ...

Page 99: ...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 100: ...s 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 101: ... 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...

Page 102: ...C gun control unit see corresponding operating manual 4 OptiSpeeder see corresponding spare parts list 5 Powder supply see corresponding spare parts list 6 Rubber buffer Ø 35x40 mm 211 664 6 1 End position 1018 740 10 Powder transport see corresponding spare parts list 11 OptiFeed PP06 Powder pump see corresponding operating manual For all other electric components see also the Spare parts list in...

Page 103: ...rews 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 59 ...

Page 104: ...332 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 60 ...

Page 105: ...sponding spare parts list 3 Pinch valve DN32 G 1 1 4 complete 1007 648 4 Sealing plug not shown 1008 085 5 Pinch valve DN15 complete 1018 025 6 Pinch valves distributor RP complete see corresponding spare parts list 7 Pinch valves distributor FP complete see corresponding spare parts list 8 AirMover NW40 complete see corresponding spare parts list 1008 066 fig 61 ...

Page 106: ...arts list OptiCenter OC06 OptiSpeeder Cover 1 Handle 1018 039 2 O ring Ø 21x3 mm 214 981 3 Support 1008 064 4 Screw M6x16 mm 216 410 5 Plug 1018 032 6 Gasket 24P 1018 023 Gasket 36P 1018 737 7 X ring 1018 069 Wear part Fig 62 ...

Page 107: ...018 038 2 Sensor sleeve nut 1018 713 3 O ring Ø 12x1 5 mm 261 416 4 Sensor 1017 591 5 Throttle valve Ø 4 M5x0 8 mm 1005 634 6 Sensor rinsing 1018 049 7 O ring Ø 15x1 5 mm 261 564 8 O ring Ø 28x2 5 mm 263 842 Wear part After replacement open the throttle valve until the compressed air begins to flow then open it further by one turn Fig 63 ...

Page 108: ...sket 24P 1018 022 Gasket 36P 1018 736 3 Fastening plate 24P 1018 016 Fastening plate 36P 1018 731 4 Allen cylinder screw M6x20 mm 216 429 5 Elbow joint 1 8 Ø 8 mm 251 372 6 Pinch valve DN32 G 1 1 4 complete 1007 648 7 Pinch valve hose NW32 1007 647 8 O ring Ø 33x3 mm 244 252 9 O ring Ø 40x3 mm 225 053 10 Connector 1007 571 11 Elbow joint 1 4 Ø 8 mm 254 029 Wearing part fig 64 ...

Page 109: ... 066 6 Pinch valve see corresponding spare parts list 7 Pressure regulators pool see corresponding spare parts list 8 Valves pool see corresponding pneumatic diagram 1019 190 9 Pneumatic manifold 2 see corresponding spare parts list 10 Vacuum filter Ø 10 mm 1004 946 11 Pneumatic manifold 1 see corresponding spare parts list 12 Main air supply see corresponding spare parts list 13 Fluidization Opti...

Page 110: ...9 110 Spare parts list OptiCenter OC06 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 66 ...

Page 111: ... 5 mm without coil 1005 120 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 8 Adapter 1 8 1 8 259 551 9 Double nipple 1 4 1 8 242 209 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 1017 189 12 Elbow joint 1 4 Ø 8 3 x 1002 614 Wearing part Please indicate length fig 67 ...

Page 112: ...ple 1 8 1 4 265 454 6 Elbow joint 1 8 1 8 237 604 7 Flow restrictor Ø 1 4 mm 404 497 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 Plastic tube Ø 8 6 mm 103 756 13 Screw in nipple 1 4 Ø 6 mm 234 826 14 Plastic tube Ø 6 4 mm 103 144 15 Elbow joint 1 8 Ø 6 mm 251 380 Wearing part Please ...

Page 113: ...6 bar 1 4 264 342 2 Elbow joint 1 4 Ø 8 mm 254 029 3 Pressure gauge 0 10 bar 1 8 259 179 4 Sealing plug 1 4 258 695 5 Elbow joint 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 Plug Ø 8 mm not shown 238 023 fig 69 ...

Page 114: ...supply CG22 C 1 Pressure switch 1 10 bar 1 4 233 757 2 Solenoid valve 3 4 NW18 without coil 1005 121 3 Valve coil 24 VDC 1005 119 4 Pressure gauge 0 10 bar 1 4 1010 964 5 Pressure regulator Filter unit 0 5 8 bar 1 1006 547 6 Hose connector Ø 17 mm 1 2 223 069 fig 70 ...

Page 115: ...ar 1 2 259 187 2 Double nipple 1 4 1 8 242 209 3 Adapter 1 8 1 8 259 551 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 1005 120 7 Valve coil 24 VDC 1005 119 8 Valve cable 3 pins 1007 004 9 Hose connector Ø 17 mm 1 2 223 069 Wearing part fig 71 ...

Page 116: ...ch valve sleeve NW15 1006 256 3 Connecting socket NW15 1018 043 4 Screw Ø 5x26 mm 1006 263 5 O ring Ø 21x3 mm 214 981 6 Screw M6x25 mm 216 437 7 Y distributor 3m 0f 1018 047 8 Socket end cover NW15 m 1018 027 9 Y distributor 2m 1f 1018 060 Powder hose Ø 16 23 mm not shown 1010 040 Wearing part Please indicate length fig 72 ...

Page 117: ...g 3 4 254 339 5 GEKA blind coupling 1002 405 6 Grip 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 OptiSpeeder emptying Ø 40 mm not shown 100 048 Blind cover PH60 OC not...

Page 118: ...p 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 642 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 OptiSpeeder emptying Ø 40 mm not sho...

Page 119: ...Spare parts list 119 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 75 ...

Page 120: ...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 1002 551 10 Double nipple 3 4 3 4 228 028 11 Vibrator 1009 251 Please indicate length fig 76 ...

Page 121: ... 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 77 ...

Page 122: ...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 123: ...r OC06 Spare parts list 123 Pneumatics ES AS05 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 79 ...

Page 124: ......

Page 125: ...tion 51 I Intended use 15 M Maintenance 69 Maintenance during storage 96 O Operating and display elements 30 Operation 57 OptiCenter maintenance 70 Overall view 19 P Periodic checks 88 Pictograms 7 Pneumatic data 17 Powder transport 17 Preparation for start up 53 Presentation of the contents 9 Product description 15 Product specific security regulations 12 R Rating plate 18 29 Reasonably foreseeab...

Page 126: ...Rev 00 ...

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Gema OptiCenter OC06, Operating Instructions And Spare Parts List

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