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Summary of Contents for ITW Gema OptiCenter OC01
- Page 1 Operating instructions and spare parts list OptiCenter OC01 Powder management center 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 issue. ITW Gema 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.
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Page 3: Table Of Contents
Preparation for start-up ..................17 Compressed air supply ................17 Grounding of the powder management center ........18 Operation Push buttons ......................19 Operating modes ....................20 General information ................. 20 Table of contents 1 OptiCenter OC01... - Page 4 Coating without powder recovery (spray waste) ..........26 Replacing the powder bag ..................27 Switching off the OptiCenter OC01 (after each work day) ........28 Cleaning / color change Cleaning operating mode ..................29 ...
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Page 5: General Safety Regulations
2. Any other use is considered as non-conform. The manufacturer is not responsible for any incorrect use, the risk for this is assumed by the user alone. If the OptiCenter OC01 is to be used for other purposes or other substances outside of our guidelines then ITW Gema GmbH should be consulted. -
Page 6: Product Specific Security Measures
II 3 D Product specific security measures General information The OptiCenter OC01 is part of the plant and therefore integrated in the safety concept of the plant. For the use outside of the safety concept, corresponding measures must be taken. -
Page 7: Installation
For this reason, the operating manual must always be available at the equipment. Should difficulties arise, however, your ITW Gema service center is always ready to assist. Inspection check... -
Page 8: Repairs
By carrying out repairs, the powder management center must be disconnected from the mains, according to the local safety regulations! Note: Only original ITW Gema spare parts should be used! The use of spare parts from other manufacturers will invalidate the ITW Gema guarantee conditions! 6 ... -
Page 9: About This Manual
- booth, axis, gun control unit, powder gun or powder injector - should be referenced to their enclosed corresponding documents. Software version This document describes the operation of the control of the OptiCenter OC01 powder management center with software version 2_1a. About this manual 7 OptiCenter OC01... -
Page 11: Product Description
As a part of the process controlled coating plant, the powder management center is laid out for fully automatic operation. Utilization The OptiCenter OC01 powder management center is suitable for use in plants with a completely closed powder circuit: Conveying... -
Page 12: Reasonably Foreseeable Misuse
After Filter Reasonably foreseeable misuse Use of moist powder Insufficient fluidization at the suction point Operation without the proper training Technical data Powder transport OptiCenter OC01 Conveying performance 230 g/Min. Recovery max. 3,5 kg/Min. Electrical data OptiCenter OC01... -
Page 13: Dimensions
V 10/10 Dimensions with OptiCenter OC01 with AS04 AS04+ICS03 Base area 1150 x 1500 1700 x 1500 1700 x 1500 (width x depth) (mm) Overall height (mm) 2100 (2270 - PP06 connection) Weight (kg) env. 400 Processible powders OptiCenter OC01... -
Page 15: Structure And Function
V 10/10 Structure and function General view OptiCenter OC01 - layout Main switch Powder bag cone with vibrator Emergency stop push button Powder bag fixation Control unit/operating panel Gun and axes control units Injectors "Waste" connection OptiSpeeder OptiSpeeder connection Vibrator switch Product description ... -
Page 16: Compressed Air Indicators
Switching on the exhaust air manually Switching on the vibrator Emptying the OptiSpeeder! Cleaning the OptiSpeeder Cleaning the powder hoses Cleaning the powder pumps L1 Hopper full indicator (green) L2 Powder shortage indicator (red) 14 Product description OptiCenter OC01... -
Page 17: Optispeeder
24 or 30 IG06-P OptiFlow injectors. Powder bag cone Capacity up to 25 kg Mobile to allow the powder to be emptied easily Fluidizing/suction lance Fresh powder pump connection Recowery powder pump connection Product description 15 OptiCenter OC01... -
Page 18: Principle Of Function
Principle of function Powder circuit During the typical OptiCenter OC01 (7) operation, the powder bag is put in the powder bag cone. The powder is fluidized in the bag with the fluidizing/suction lance and then fed to the OptiSpeeder in the OptiCenter OC01. -
Page 19: Start-Up
The OptiCenter requires a connection to a sufficient dimensioned compressed air circuit. In order to ensure a perfect operation, a pressure of 6 bar must be adjusted with the main pressure regulator. Compressed air supply Start-up 17 OptiCenter OC01... -
Page 20: 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 potential equalization. Potential equalization - connection point 18 Start-up OptiCenter OC01... -
Page 21: Operation
The operation of the powder management center takes place by the push buttons. The push buttons serve to initiate the function commands, which are necessary for the satisfactory operation of the powder management center. Push buttons Operation 19 OptiCenter OC01... -
Page 22: Operating Modes
Utilization of this operating mode: Long time coating operation with the same powder and high coating quality with minimal powder loss Immediate coating following a powder change with minimum demands on quality and the smallest possible of powder loss 20 Operation OptiCenter OC01... -
Page 23: Cleaning / Color Change
The cleaning of the components is partially automated, however, some of them must be cleaned manually. Utilization of this operating mode: After switching on the equipment, if very high quality is required on initial coating application Before every color change Operation 21 OptiCenter OC01... -
Page 25: Coating Operation
V 10/10 Coating operation Before switching on the OptiCenter OC01 Before switching on the OptiCenter, the following points must be observed: Observe the safety regulations Check the grounding of the OptiCenter, the booth and the other plant units and ensure it, if necessary... - Page 26 11. Setting the fluidization 12. Select desired coating mode on the OptiCenter (Coating with or without powder recovery) 13. Select desired operating mode (AUTOMATIC or MANUAL) on the booth control unit (see therefore the corresponding operating manual) 24 Coating operation OptiCenter OC01...
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Page 27: Coating With Powder Recovery
"Replacing the powder bag" 6. If necessary, switch on the exhaust air manually the button blinks as long as the function is active push again, in order to terminate this operating mode Coating operation 25 OptiCenter OC01... -
Page 28: Coating Without Powder Recovery (Spray Waste)
The OptiSpeeder is now filled with powder. Coating can now commence 6. If necessary, replace the powder bag, see also "Replacing the powder bag" push again, in order to terminate this operating mode 26 Coating operation OptiCenter OC01... -
Page 29: Replacing The Powder Bag
2. Hold the full powder bag ready Switch on 4. Empty the used powder bag with the residual powder into another container or dispose of it push again, in order to switch off the exhaust air Coating operation 27 OptiCenter OC01... -
Page 30: Switching Off The Opticenter Oc01 (After Each Work Day)
V 10/10 Switching off the OptiCenter OC01 (after each work day) Note: Before the equipment can be turned off, the contents of the container (OptiSpeeder) must be emptied into the cone. If this is not done, the powder can escape from the container unhindered. -
Page 31: Cleaning / Color Change
4. Adjust the movement axes to the cleaning position, so that the guns can be cleaned from the inside. OptiCenter 5. Push , to end the coating procedure 6. Push , the exhaust air is switched on Cleaning / color change 29 OptiCenter OC01... - Page 32 V 10/10 12. Push the button illuminates for approx. 40 seconds 13. The pinch valve below the OptiSpeeder opens and the powder in the OptiSpeeder flows into the powder bag 30 Cleaning / color change OptiCenter OC01...
- Page 33 22. Basic booth cleaning can be started now already. Activate the corresponding command on the Magic Control CM-10 NOTE! If you do not want this powder to be recovered, connect the recovery hose to the waste connection. Cleaning / color change 31 OptiCenter OC01...
- Page 34 The button can be pressed once again if necessary. If a button flashes, this is a sign that the next cleaning phase needs to be activated. Recovery hose 29. Clean the OptiCenter 32 Cleaning / color change OptiCenter OC01...
- Page 35 35. Open the monocyclone Attention: In order to avoid damage to the sieve when blowing through the transport hose, make sure that the sieve is swung out completely during the cleaning process! Cleaning / color change 33 OptiCenter OC01...
- Page 36 39. Swing the funnel on the cyclone slowly away and, at the same time, clean it off with the compressed air gun 40. Clean the inside of the cyclone with the cleaning lance 41. Close the sieve and funnel on the cyclone again 34 Cleaning / color change OptiCenter OC01...
- Page 37 The OptiSpeeder is now filled with powder. 48. Keep the guns switched on until the first hangers have passed. 49. Push again the button , in order to terminate this operating mode Recovery hose 51. Push the button Cleaning / color change 35 OptiCenter OC01...
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Page 39: Messages
- Pump defective - see corresponding operating manual OptiFeed PP06 - Hose clogged Check the recovery system - Check the level sensor (see also Error message no. 03) - Check the cyclone funnel for powder abrasion Messages 37 OptiCenter OC01... - Page 40 V 10/10 Display Description Activity - Contact an ITW Gema service center Powder recovery pump Powder pump is switched off overpressure - Hose clogged or connected Check the recovery system and/or incorrectly connect correctly - Pressure sensor at the OptiFeed...
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Page 41: Maintenance
Daily after longer working interruptions and at the end of shift WARNING Before switching off the plant, the OptiSpeeder must be emptied and cleaned Check weekly Check the injector nozzles and replace them, if necessary Maintenance 39 OptiCenter OC01...
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