Subscribe to Our Youtube Channel
Related Manuals for Gema OptiCenter OC04
Summary of Contents for Gema OptiCenter OC04
- Page 1 1011 505 Operating instructions and spare parts list Powder management center OptiCenter OC04 Translation of the original operating instructions...
- Page 2 To the best of our knowledge and belief, the information contained in this publication was correct and valid on the date of publication. Gema Swit- zerland GmbH makes no representations or warranties with respect to the contents or use of this publication, and reserves the right to revise this publication and make changes to its content without prior notice.
-
Page 3: Table Of Contents
Grounding of the powder management center ........20 Operation Push button switches .................... 21 Push button functions ................21 Operating modes ....................23 General information ................. 23 Coating without powder recovery (spray to waste) ........23 Table of contents • 1 OptiCenter OC04... - Page 4 Coating operation Before switching on ....................25 Starting up the OptiCenter OC04 ................. 25 Start-up ....................25 Switching off the OptiCenter OC04 (after each work day) ........27 Cleaning / color change Cleaning operating mode ..................29 Cleaning procedure ................. 29 Coating after the cleaning................
- Page 5 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 Table of contents • 3 OptiCenter OC04...
-
Page 7: General Safety Regulations
General safety regulations This chapter sets out the fundamental safety regulations that must be fol- lowed by the user and third parties using the OptiCenter OC04. These safety regulations must be read and understood before the Opti- Center OC04 is put into operation. -
Page 8: Product Specific Safety Information
Product specific safety information General information The OptiCenter OC04 is a constituent part of the system and is thus inte- grated into the safety system of the plant. If it is to be used in a manner outside the scope of the safety concept, then corresponding measures must be taken. -
Page 9: Installation
For this reason, the operating manual must always be available at the equipment. Should difficulties arise, however, your Gema service center is always ready to assist. Inspection... -
Page 10: Repairs
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 manufacturers will invalidate the Gema guarantee conditions! 8 •... -
Page 11: About This Manual
General information This operating manual contains all important information which you re- quire for the working with the OptiCenter OC04. It will safely guide you through the start-up process and give you references and tips for the op- timal use of your new powder coating system. -
Page 13: Product Description
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. -
Page 14: Reasonably Foreseeable Misuse
Use of moist powder − Insufficient fluidization at the suction point − Operation without the proper training − Technical Data Powder transport OptiCenter OC04 Conveying performance (average value per 200 g/min. gun) Recovery max. 3.5 kg/min. Electrical data OptiCenter OC04... -
Page 15: Dimensions
V 04/17 Dimensions with OptiCenter OC04 OC04 with AS10 AS10+ICS02 Base area 1140 x 1500 1700 x 1500 2600 x 1500 (width x depth) (mm) Overall height (mm) 2100 (2270 – PP06 connection) Weight (kg) approx. 300 (without AS and ICS) -
Page 17: Design And Function
V 04/17 Design and function Overall view OptiCenter OC04 – layout Main switch Hand lever for powder container vent Emergency stop push Hand lever for exhaust air button Illuminated push button Hand lever for emptying of the powder switches container Injectors "Waste"... -
Page 18: Compressed Air Indicators
V 04/17 Compressed air indicators Powder container fluidizing air Level sensor fluidizing air 16 • Product description OptiCenter OC04... -
Page 19: Powder Container
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. Product description • 17 OptiCenter OC04... -
Page 20: Principle Of Operation
Principle of operation Powder circuit During the typical OptiCenter OC04 (7) operation the powder is filled into the powder container and fluidized. The fluidized powder is aspirated by the injectors and fed through the powder hoses to the guns/spray nozzles (8). -
Page 21: Start-Up
The OptiCenter requires a connection to a sufficient dimensioned com- pressed air circuit. In order to ensure a perfect operation, a pressure of 6 bar must be ad- justed with the main pressure regulator. Compressed air supply Start-up • 19 OptiCenter OC04... -
Page 22: Grounding Of The Powder Management Center
The 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 20 • Start-up OptiCenter OC04... -
Page 23: Operation
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 cleaning can be activated Operation • 21 OptiCenter OC04... - Page 24 (not recovery or spray to waste position) Steady illumination - RP hose is cleaned (by purg- ing intermittently) Sieve machine Turns the sieve machine ON/OFF − The light indicates, that the Powder sieve machine is in operation − 22 • Operation OptiCenter OC04...
-
Page 25: Operating Modes
The cleaning of the components is partially automated, however, some of them must be cleaned manually. The Cleaning operating mode can only be initiated when the plant clean- ing mode is stopped, namely by pressing the corresponding push button. Operation • 23 OptiCenter OC04... - Page 26 V 04/17 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 − 24 • Operation OptiCenter OC04...
-
Page 27: Coating Operation
− plant units and ensure it, if necessary Check the compressed air supply − Starting up the OptiCenter OC04 Start-up The start-up takes place according the following steps: Switch on the booth (see also the booth operating instructions) Switch the powder management center with the main switch the interior lighting switches on −... - Page 28 Turn on the recovery powder pump, if necessary 10. Select desired operating mode (AUTOMATIC or MANUAL) on the booth control unit (see therefore the corresponding operating manu- 11. Start the coating procedure 26 • Coating operation OptiCenter OC04...
-
Page 29: Switching Off The Opticenter Oc04 (After Each Work Day)
V 04/17 Switching off the OptiCenter OC04 (after each work day) NOTE: Before the equipment can be turned off, the contents of the contain- er should be emptied into a powder bag. This will prevent the pow- der from absorbing moisture during the night, which can cause no or uneven fluidization. -
Page 31: Cleaning / Color Change
A great deal of air is required for the cleaning procedure! ► Make sure that 6 bar is always available! Cleaning operating mode Cleaning procedure Plant control (e.g. Magic Control CM30) 1. End the coating procedure 2. Select the cleaning mode. Cleaning / color change • 29 OptiCenter OC04... - Page 32 − 17. Open fully the powder container aeration with hand lever 18. Continue with fine cleaning of the powder container, OptiCenter and booth with compressed air 30 • Cleaning / color change OptiCenter OC04...
- Page 33 23. Open the monocyclone WARNING: The sieve can be damaged when forceful purging through the re- covery hose is started. ► The sieve must be swung out completely during the cleaning process! Cleaning / color change • 31 OptiCenter OC04...
-
Page 34: Coating After The Cleaning
Connect the recovery hose manually to the connection Press the push button, in order to switch on the recovery powder pump 32 • Cleaning / color change OptiCenter OC04... -
Page 35: Settings
V 04/17 Settings WARNING: All OptiCenter settings are set at the factory and may only be modi- fied after consultation with a Gema service center! Settings • 33 OptiCenter OC04... -
Page 37: Troubleshooting
Check the recovery system Powder pump does Check the level sensor not function proper- Check the cyclone funnel for pow- der abrasion Contact a Gema service center Powder recovery Hose clogged or connected in- Check the recovery system and/or con- pump overpressure correctly... - Page 38 Causes Corrective action Push buttons do Control voltage circuit breaker in Check the power panel not respond the electrical panel is tripped Reset the breaker (see enclosed wiring diagram) otherwise contact a Gema service center 36 • Troubleshooting OptiCenter OC04...
-
Page 39: 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 − Maintenance • 37 OptiCenter OC04... -
Page 41: Decommissioning, Storage
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. Storage conditions Storage duration If the physical conditions for metal parts and electronics are maintained, the unit can be stored indefinitely. -
Page 42: Hazard Notes
Apply the label "Protect from dampness and moisture" on the product and the packaging. Maintenance during storage Maintenance schedule No maintenance schedule is necessary. Maintenance works During long-term storage, periodically perform a visual check. 40 • Decommissioning, storage OptiCenter OC04... -
Page 43: Return To Service
V 04/17 Return to service Commissioning following storage Following storage of more than 3 years, the rubber components must be checked and replaced if necessary. Decommissioning, storage • 41 OptiCenter OC04... -
Page 45: Packing, Transport
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. Packing, transport • 43 OptiCenter OC04... -
Page 46: Packing Material
Transport using a crane: use the eye bolts on the roof − Transport using a forklift: remove the lateral panels before the − transport NOTE: Transport the unit only in the position according to its intended use. 44 • Packing, transport OptiCenter OC04... -
Page 47: Loading, Transferring The Load, Unloading
V 04/17 Loading, transferring the load, unloading Suitable lifting equipment is to be used for all procedures. Packing, transport • 45 OptiCenter OC04... -
Page 49: Spare Parts List
Ø 8/6 mm, 8 mm outside diameter (o/d) / 6 mm inside diameter (i/d) ATTENTION! Only original Gema spare parts should be used, because the explo- sion protection will also be preserved that way. The use of spare parts from other manufacturers will invalidate the Gema guarantee conditions! Spare parts list •... -
Page 50: Opticenter
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! 48 • Spare parts list OptiCenter OC04... -
Page 51: Powder Container - Complete
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 Spare parts list • 49 OptiCenter OC04... -
Page 52: Powder Container - Fluidizing Plate
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 50 • Spare parts list OptiCenter OC04... -
Page 53: Powder Container - Level Sensor
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 Spare parts list • 51 OptiCenter OC04... -
Page 54: Opticenter - Pneumatics
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 52 • Spare parts list OptiCenter OC04... -
Page 55: Main Air Supply
1 Pressure regulator/Filter unit – 0.5-8 bar, 1" 1006 547 1010 964 2 Pressure gauge – 0-10 bar, 1/4" 3 Double nipple – 1"-1" 1003 544 4 Ball valve – 1"-1" 1006 065 Spare parts list • 53 OptiCenter OC04... -
Page 56: Powder Container - Pneumatic Manifold
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 54 • Spare parts list OptiCenter OC04... -
Page 57: Shuttle Valves Pool
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 Spare parts list • 55 OptiCenter OC04... -
Page 58: Powder Container Pneumatics
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 56 • Spare parts list OptiCenter OC04... -
Page 59: Monocyclone - Powder Transport
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 Spare parts list • 57 OptiCenter OC04... -
Page 60: Monocyclone - Powder Transport Connection
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 regulator – 3 bar, 1/4" 1005 517 #Wearing part 58 • Spare parts list OptiCenter OC04... - Page 61 V 04/17 Spare parts list • 59 OptiCenter OC04...
Need help?
Do you have a question about the OptiCenter OC04 and is the answer not in the manual?
Questions and answers