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Gema OptiCenter All-in-One OC11 Operating Instructions And Spare Parts List

Powder management system
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EN
Rev. 00
1027 031
Operating instructions and Spare parts list
Powder management
system
OptiCenter All-in-One
OC11
Translation of the original operating instructions

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Summary of Contents for Gema OptiCenter All-in-One OC11

  • Page 1 Rev. 00 1027 031 Operating instructions and Spare parts list Powder management system OptiCenter All-in-One OC11 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 Switzerland 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

    Sound pressure level ................22 Rating plate ....................23 Structure ........................ 24 Overall view....................24 Function description ....................25 OptiCenter All-in-One OC11 ..............25 Field of application ................... 25 OptiControl (CM41) .................. 27 Emergency stop button ................28 Status lights....................28 Sliding door to OptiSpray .................
  • Page 4 In-/Outputs ....................65 Process monitoring .................. 67 MultiColor switch function test ..............68 Assign gun group ..................69 Statistics ....................... 70 Operating data ..................70 Configuration ......................71 Configuration and parameters ..............71 4 • Table of contents OptiCenter All-in-One OC11...
  • Page 5 Activating the scale in OptiControl (CM41) ..........136 Recording powder volume ..............139 Switching off the OptiCenter (after each working day) ........143 Maintenance / Repairs General information .................... 145 OptiCenter maintenance ..................146 Table of contents • 5 OptiCenter All-in-One OC11...
  • Page 6 Pneumatic distributor – complete ............... 174 Valve plate – complete ..................175 Equipment ......................176 MultiColor switch – complete ................177 PH100 Powder Hopper ..................178 PH60 Powder Hopper ..................179 LC01 Level sensor ....................180 6 • Table of contents OptiCenter All-in-One OC11...
  • Page 7 Rev. 00 11/24 Index Table of contents • 7 OptiCenter All-in-One OC11...

  • Page 9: Other Applicable Documents

    Rev. 00 09/23 OptiSpray All-in-One (CG26-CP) QR-Code Manual Revision Powder pump Rev. 01 05/23 OptiFeed 4.0 (PP07) QR-Code Manual Revision Ultrasonic sieve system V 03/19 US07 QR-Code Manual Revision Monocyclone Rev. 00 01/22 EZ05 Other applicable documents • 9 OptiCenter All-in-One OC11...
  • Page 10 Rev. 00 11/24 10 • Other applicable documents OptiCenter All-in-One OC11...

  • Page 11: About These Instructions

    General information This operating manual contains all the important information that is needed to operate the OptiCenter All-in-One OC11. It will safely guide you through the start-up process and give you references and tips for the optimal use when working with your powder coating system.

  • Page 12: Structure Of Safety Notes

    ► Prevention of the danger Software version This document describes the operation of the product OptiCenter All-in- One OC11 with software version starting from 1.2.40***. See chapter "Checking the software version" on page 92. 12 • About these instructions OptiCenter All-in-One OC11...

  • Page 13: Presentation Of The Contents

    (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)." About these instructions • 13 OptiCenter All-in-One OC11...
  • Page 14 Rev. 00 11/24 14 • About these instructions OptiCenter All-in-One OC11...

  • Page 15: Safety

    If this product is to be used for other purposes or other 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.

  • Page 16: Product Specific Security Regulations

    – It must be ensured, 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.

  • Page 17: Transport

    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 external transport: See chapter "Storage conditions"...

  • Page 18: Mode Of Transportation

    The OptiCenter must not be placed 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 19: Product Description

    The powder management center is designed for easy and clean handling of the coating powder and is operated via a touch panel. The center will only operate in combination with Gema powder conveyors, which are designed to convey coating powder to the spray guns.

  • Page 20: Reasonably Foreseeable Misuse

    Use of moist powder – Insufficient fluidization at the suction point – Use with insufficient compressed air quality – Input pressure too low – Use in connection with unauthorized coating devices or components 20 • Product description OptiCenter All-in-One OC11...

  • Page 21: Technical Data

    1.3 g/m³ 4 (dew point ≤ 3 °C) or Class 5 (dew point ≤ 7 °C) Residual content 0.1 mg/m³ Class Gema Switzerland GmbH recommends compressed air quality according to ISO 8573-1 class 3.4.2. Product description • 21 OptiCenter All-in-One OC11...

  • Page 22: Technical Ventilation

    Rev. 00 11/24 Technical ventilation OptiCenter All-in-One OC11 36 guns Exhaust air volume during 1400 Nm³/h cleaning Preferably, only one exhaust air unit should be in operation during cleaning. The exhaust air duct must have a nominal width of 150 mm and a wall thickness of at least 1.0 mm.

  • Page 23: Rating Plate

    Rev. 00 11/24 Rating plate Fig. 3: Nameplate (example) Fields with a gray background contain contract-specific data! Product description • 23 OptiCenter All-in-One OC11...

  • Page 24: Structure

    Status light Powder bag fixation Sliding door to OptiSpray 10 Fluidizing/suction lance Technical ventilation 11 Powder cone complete Display and adjustment of 12 Cleaning hose (not shown) fluidization OptiSpeeder 13 Slider (not shown) 24 • Product description OptiCenter All-in-One OC11...

  • Page 25: Function Description

    Function description OptiCenter All-in-One OC11 Fig. 5: OptiCenter All-in-One OC11 The OptiCenter All-in-One OC11 powder management center combines OptiSpray All-in-One pump technology for precise control of the application and powder handling process with a fast color change function. The system with dual OptiSpeeder powder containers...
  • Page 26 Rev. 00 11/24 Controling – No own exhaust air system – the powder management center does not have its own exhaust air system and will be therefore connected directly to a filter 26 • Product description OptiCenter All-in-One OC11...

  • Page 27: Opticontrol (Cm41)

    Selection of cleaning programs – Quick cleaning program or cleaning program with maximum powder recirculation from the powder circuit Further information on the control panel See chapter "Touch panel / operating panel" on page 53. Product description • 27 OptiCenter All-in-One OC11...

  • Page 28: Emergency Stop Button

    Red: OptiCenter is in alarm mode and shows a fault or error. NOTICE Uncontrolled discharge of powder-air mixture. Do not open the OptiSpeeder when the status is “Blue” (cleaning active). 28 • Product description OptiCenter All-in-One OC11...

  • Page 29: Sliding Door To Optispray

    Rev. 00 11/24 Sliding door to OptiSpray The sliding doors (left/right) can be opened at the handles to provide access to the application pumps (OptiSpray). Fig. 9: Sliding doors (left/right) Product description • 29 OptiCenter All-in-One OC11...

  • Page 30: Technical Ventilation

    Slider closed Slider open State Description Increases the exhaust air supply in the lower area of Closed the OptiCenter. Same exhaust air supply in the lower and upper Open areas of the OptiCenter. 30 • Product description OptiCenter All-in-One OC11...

  • Page 31: Optispeeder Indicator Fluidization

    Fig. 12: Example - Optimal fluidization of the powder in the OptiSpeeder Check the powder level visually. – The fill level in the OptiSpeeder is undercut --> See chapter "Fault clearance" on page 149. Product description • 31 OptiCenter All-in-One OC11...

  • Page 32: Optispeeder

    Output Coating with recovery - powder can be reused Level sensor high Long Batch: For larger powder quantities in the OptiSpeeder Level sensor Short Batch: For small powder deep quantities in the OptiSpeeder 32 • Product description OptiCenter All-in-One OC11...
  • Page 33 The OptiSpeeder offers the following automatic functions: – Conditioning and fluidization of the coating powder – Emptying the residual powder – Cleaning using patented Gema-AirWave procedure – Monitoring and control of the powder level – Extraction/removal of excess free-floating powder particles and fluidizing air –...

  • Page 34: Blow Gun

    Fig. 16: Blow gun (example) Equipped with several nozzle openings to protect the user and an antistatic hose package. 34 • Product description OptiCenter All-in-One OC11...

  • Page 35: Cleaning Hose

    This is essential to ensure that the powder is removed evenly and reliably. Fig. 18: Fluidizing/suction lance – Powder conveying from powder containers – Powder feed from powder bag cone – Powder conveying from vibration trolleys Product description • 35 OptiCenter All-in-One OC11...

  • Page 36: Powder Bag Cone Complete

    Fig. 19: Powder bag cone complete – Capacity up to 25 kg – Can be swiveled for easy powder emptying – Fluidizing/suction lance – Fresh powder pump connection – Recovery powder pump connection 36 • Product description OptiCenter All-in-One OC11...

  • Page 37: Multicolor Switch

    Fig. 21: Functional principle of gun grouping The assignment of the gun groups to the respective OptiSpeeder can be selected in the Configuration menu under “Configure gun group”. See chapter "Configuration" on page 71. Product description • 37 OptiCenter All-in-One OC11...

  • Page 38: Powder Bag Cone With Weighing Function

    Fig. 22: Powder cone with weighing function – Load capacity of over 100 kg – Can be swiveled for easy powder emptying – Fluidizing/suction unit – Fresh powder pump connection – Recovery powder pump connection 38 • Product description OptiCenter All-in-One OC11...

  • Page 39: Airmover-Set

    Rev. 00 11/24 Airmover-Set** The powder hopper can be vented using the Airmover-Set. This prevents powder escaping from the powder hopper. The connection of the Airmover-Set is shown in the pneumatic diagram. Fig. 23: Airmover-Set Product description • 39 OptiCenter All-in-One OC11...

  • Page 40: Level Sensor

    Rev. 00 11/24 Level sensor** Fig. 24: Level sensor – For level detection in the powder bag cone or in the powder hopper – Height adjustable – Fluidized in the measuring range 40 • Product description OptiCenter All-in-One OC11...

  • Page 41: Ultrasonic Sieve System Us07

    The sieve configuration and sieve selection are done on the Touch Panel. Fig. 25: Ultrasonic sieve system For additional information, please see the operating instructions of the ultrasonic sieve system! See chapter "Other applicable documents" on page 9. Product description • 41 OptiCenter All-in-One OC11...

  • Page 42: Powder Hopper

    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. 42 • Product description OptiCenter All-in-One OC11...

  • Page 43: Principle Of Operation

    (5). The after filter separates the powder into a waste container (6), which is positioned directly under the filter elements and is very easy to empty. The cleaned air then exits the filter and is fed directly back into the workshop environment. Product description • 43 OptiCenter All-in-One OC11...

  • Page 44: Powder Cycle "Recycling

    (5). The after filter separates the powder into a waste container (6), which is positioned directly under the filter elements and is very easy to empty. The cleaned air then exits the filter and is fed directly back into the workshop environment. 44 • Product description OptiCenter All-in-One OC11...

  • Page 45: Operating Modes

    • Enables the handling and color change of two different colors in a parallel process. This ensures a color change in 60 seconds without interrupting operation Product description • 45 OptiCenter All-in-One OC11...
  • Page 46 Rev. 00 11/24 Use of this coating type: – If highest coating quality is required No cabin cleaning required. 46 • Product description OptiCenter All-in-One OC11...

  • Page 47: Mode - Parallel

    • The OptiSpeeder B forms the redundantly available powder source. The assignment of the powder source is controlled via the gun group. The assignment of the powder source is controlled via the gun group. See chapter "Configuration" on page 71. Product description • 47 OptiCenter All-in-One OC11...

  • Page 48: Mode - Cleaning

    After switching on the plant, if very high quality is required on initial coating application – Before every color change – Before switching off the plant During cleaning, no objects may be present in the booth and no objects may enter the booth. 48 • Product description OptiCenter All-in-One OC11...

  • Page 49: Parameter Description

    3442 has elapsed, the recovery powder is fed back into the powder circuit. Fig. 31: Starting recovery after a color change [3442] The delay time can be set in the parameter list in the Configuration menu. See chapter "Configuration" on page 71. Product description • 49 OptiCenter All-in-One OC11...

  • Page 50: Delay Freshpowder Demand

    This must with parameter 3460 be set Fig. 32: Delay freshpowder demand [3460] The delay time can be set in the parameter list in the Configuration menu. See chapter "Configuration" on page 71. 50 • Product description OptiCenter All-in-One OC11...

  • Page 51: Ratio Of Fresh Powder / Recovery Powder

    To achieve this, the following is recommended: – Use of gap control – Dense, optimized object suspension – Well maintained and adjusted application equipment Product description • 51 OptiCenter All-in-One OC11...
  • Page 52 Rev. 00 11/24 The ratio of fresh and recovery powder can be set in the parameter list in the Configuration menu. See chapter "Configuration" on page 71. 52 • Product description OptiCenter All-in-One OC11...

  • Page 53: Touch Panel / Operating Panel

    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 Touch panel / operating panel • 53 OptiCenter All-in-One OC11...

  • Page 54: Technical Data

    1024 x 600 pixels (WXGA) ≈ 16.7 million (color depth 24 Bit) Number of colors Display surface 154 x 90 mm Operation Multifinger touch Front screen Anti reflex coated, scratch-proof 54 • Touch panel / operating panel OptiCenter All-in-One OC11...

  • Page 55: Connections

    The rating place contains the following information: – Type designation – Version – Required power supply – Serial no. – Arrangement of interfaces and operating elements Fig. 34: Rating plate Touch panel / operating panel • 55 OptiCenter All-in-One OC11...

  • Page 56: Design And Function

    Acquisition of the actuation of the operating elements shown on the display. Operated by touch using fingers. Slot for SD card SD card slot Exits the visualization program CTRL button 56 • Touch panel / operating panel OptiCenter All-in-One OC11...

  • Page 57: Connections And Interfaces

    RS-485, not galvanically isolated, SUB-D COM2 connector 9-pin CAN1, not galvanically isolated, SUB-D connector 9-pin MSTB plug connector, 3-pin Power supply SDSC or SDHC according to SDA SD card slot specification 2.0 Touch panel / operating panel • 57 OptiCenter All-in-One OC11...

  • Page 58: Sd Card

    “autoexec.bat” files, for example. – When copying the data, make sure that all data is visible and copied. – If in doubt, contact your IT department. 58 • Touch panel / operating panel OptiCenter All-in-One OC11...

  • Page 59: Can Bus

    The wiring and topology of the CAN network is specified in the electrical diagram. CAN bus network 1 CAN bus network 2 Fig. 37: System integration with CAN BUS Touch panel / operating panel • 59 OptiCenter All-in-One OC11...

  • Page 60: User Levels And Access

    Access is only possible after entering the appropriate password. Certain functions are available depending on the user level, which is defined in advance. The software has 5 user levels as standard predefined by Gema: – User level 0 (admin) –...

  • Page 61: Menu Structure

    The settings and information levels can be accessed via the Navigation toolbar Level navigation toolbar. Setting and Settings can be made and information viewed at these levels. Level information levels Touch panel / operating panel • 61 OptiCenter All-in-One OC11...

  • Page 62: Symbols

    Detection for larger powder quantities in the OptiSpeeder low: Detection for small powder quantities in the OptiSpeeder Mode-dependent bar (left working area) Navigation bar (right work area) Mode-dependent bar (right working area) 62 • Touch panel / operating panel OptiCenter All-in-One OC11...

  • Page 63: Meaning Of The Colors

    = present, but not active Orange background = active state Gray background (hatched) = locked function Orange background (hatched) = locked function Orange background = active working area Gray background = inactive working area Touch panel / operating panel • 63 OptiCenter All-in-One OC11...

  • Page 64: Function Keys

    Cleaning ON Cleaning OFF Empty OptiSpeeder Blow off OptiSpeeder Clean fresh powder Clean powder hoses pump US sieve ON/OFF Fluidize OptiHopper Suction ON/OFF Back key Mode: Sequential Mode: Parallel 64 • Touch panel / operating panel OptiCenter All-in-One OC11...

  • Page 65: Diagnostics

    All assigned inputs and outputs can be activated and deactivated at this level. Press the key. Press the key. Press the key (inputs/outputs). – The following page is displayed: Fig. 40: Inputs Touch panel / operating panel • 65 OptiCenter All-in-One OC11...
  • Page 66 Rev. 00 11/24 ► Press the – The following page is displayed: Fig. 41: Outputs ► Press the – The following page is displayed: Fig. 42: Valves pool 66 • Touch panel / operating panel OptiCenter All-in-One OC11...

  • Page 67: Process Monitoring

    The current operating mode is displayed schematically and the process can be tracked in real time. Press the key. Press the key. Press the key (function) – The following page is displayed: Fig. 43: Process illustration Touch panel / operating panel • 67 OptiCenter All-in-One OC11...

  • Page 68: Multicolor Switch Function Test

    • Remove the lid and check whether there is any powder inside is located. Observe protective measures! Press the key. Press the key. Press the key (MultiColor switch test) – The following page is displayed: Fig. 44: MultiColor switch function test 68 • Touch panel / operating panel OptiCenter All-in-One OC11...

  • Page 69: Assign Gun Group

    OptiSpeeder A Assign gun group Press the key. Press the key. Press the key (MultiColor switch Gun group) – The following page is displayed: Suction (aktive) Fig. 45: Assign gun group Touch panel / operating panel • 69 OptiCenter All-in-One OC11...

  • Page 70: Statistics

    Total productive time in operating mode Mode Cleaning Cleaning Number of color Number of color changes changes Number of times the pinch valve is switched Number of cycles on and off during operation. 70 • Touch panel / operating panel OptiCenter All-in-One OC11...

  • Page 71: Configuration

    – The following page is displayed: Fig. 47: Configuration– parameters Use the key to scroll down the list (configuration). Press the required configuration or parameter setting. – Configuration: Activate/deactivate – Parameterization: Make settings Touch panel / operating panel • 71 OptiCenter All-in-One OC11...

  • Page 72: Assign Gun Group

    (adhesive) on each individual OptiSpray pump. Press the key. Press the key. Press the key (MultiColor switch). – The following page is displayed: Fig. 48: Configure gun group 72 • Touch panel / operating panel OptiCenter All-in-One OC11...

  • Page 73: Settings

    Icon Setting Create user Password change Delete users Search users Set date / time Increase the brightness of the touch panel Reducing the brightness of the touch panel Network features Touch panel / operating panel • 73 OptiCenter All-in-One OC11...
  • Page 74 Rev. 00 11/24 Icon Setting Can only be activated or deactivated. Shut down: Switches the touch panel off System: Additional setting options Restart the OptiControl View system information (software version) Change language 74 • Touch panel / operating panel OptiCenter All-in-One OC11...

  • Page 75: User Administration

    Fig. 50: 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 Touch panel / operating panel • 75 OptiCenter All-in-One OC11...

  • Page 76: Login Procedure

    Select the desired user profile and confirm by pressing the Fig. 52: Login – User selection Alternatively, the user can enter their own name directly by pressing the User key 76 • Touch panel / operating panel OptiCenter All-in-One OC11...
  • Page 77 Enter user name and confirm by pressing ENTER Press the Password key Fig. 54: Login – Password Enter password and confirm by pressing ENTER Fig. 55: Login – Password input Touch panel / operating panel • 77 OptiCenter All-in-One OC11...

  • Page 78: Log-Out

    143.) – By pressing 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. 78 • Touch panel / operating panel OptiCenter All-in-One OC11...

  • Page 79: User Profile

    "Functions available at user level" on page 60. Create user Press the – The following page is displayed: Fig. 58: Create user Press the – The following page is displayed: Fig. 59: Settings Touch panel / operating panel • 79 OptiCenter All-in-One OC11...
  • Page 80 Fig. 60: New user Press the “User” key – A keyboard opens to enter the name of the new user. Fig. 61: User name Enter user name Press the ENTER key to confirm 80 • Touch panel / operating panel OptiCenter All-in-One OC11...
  • Page 81 Press the “New password” key – A keyboard opens to enter a password for the new user. Fig. 63: Generate new password 10. Enter password 11. Press the ENTER key to confirm Touch panel / operating panel • 81 OptiCenter All-in-One OC11...

  • Page 82: Delete Users

    The new user now appears in the list of available users and can be deleted or changed at any time. Delete users Press the – The following page is displayed: Fig. 65: Navigation bar Press the – The following page is displayed: 82 • Touch panel / operating panel OptiCenter All-in-One OC11...
  • Page 83 Fig. 66: Settings Press the key. – The following page is displayed: Fig. 67: Delete users Press the “User” key. – A keyboard opens to enter the user name to be deleted. Touch panel / operating panel • 83 OptiCenter All-in-One OC11...
  • Page 84 Rev. 00 11/24 Fig. 68: Search users Enter the user name to be deleted. Press the ENTER key to confirm. 84 • Touch panel / operating panel OptiCenter All-in-One OC11...

  • Page 85: Change User Password

    Press the ENTER key to confirm 10. Press the – The following page is displayed: Fig. 70: User successfully deleted Change user password Press the key. – The following page is displayed: Touch panel / operating panel • 85 OptiCenter All-in-One OC11...
  • Page 86 Rev. 00 11/24 Fig. 71: Navigation bar Press the key. – The following page is displayed: Fig. 72: Settings 86 • Touch panel / operating panel OptiCenter All-in-One OC11...
  • Page 87 Press the ENTER key to confirm. 10. Press the “Confirm password” key. – A keyboard opens and the new password must be entered again. 11. Press the ENTER key to confirm. 12. Press the key. Touch panel / operating panel • 87 OptiCenter All-in-One OC11...
  • Page 88 Press the – The following page is displayed: Fig. 75: Navigation bar Press the – The following page is displayed: Fig. 76: Settings Press the – The following page is displayed: 88 • Touch panel / operating panel OptiCenter All-in-One OC11...

  • Page 89: User Language

    The selected language is loaded each time you log in. Press the The following page is displayed: Fig. 78: Navigation bar Press the – The following page is displayed: Touch panel / operating panel • 89 OptiCenter All-in-One OC11...
  • Page 90 Rev. 00 11/24 Fig. 79: Select desired language 90 • Touch panel / operating panel OptiCenter All-in-One OC11...
  • Page 91 Press the LANGUAGE key – The following page is displayed: Fig. 80: Change language Select desired language – The change takes effect immediately and the control switches to the previous page Touch panel / operating panel • 91 OptiCenter All-in-One OC11...

  • Page 92: Checking The Software Version

    Rev. 00 11/24 Checking the software version Press the Press the Press the – The following page with the actual software version is displayed: Fig. 81: Project info 92 • Touch panel / operating panel OptiCenter All-in-One OC11...

  • Page 93: Assembly / Connection

    ► Ground all metal parts of the OptiCenter in accordance with the general local regulations. ► Check grounding regularly. A corresponding connection point at the rear of the OptiCenter is reserved for the potential equalization. Assembly / Connection • 93 OptiCenter All-in-One OC11...

  • Page 94: Compressed Air Supply

    In order to ensure correct operation, the main pressure regulator must be set to a pressure of 6 bar. Fig. 83: Compressed air supply The other pressure regulators of the system are preset at the factory according to the pneumatic diagram. 94 • Assembly / Connection OptiCenter All-in-One OC11...

  • Page 95: Start-Up

    At the suction point, a homogeneous fluidization must be ensured, so that no air ducts (craters) can be formed – The connecting hose between the AirMover and the booth should be as short as possible. An additional AirMover must be installed from 7 Start-up • 95 OptiCenter All-in-One OC11...

  • Page 96: Sd Card

    Removing SD card Push the SD card all the way into the SD card slot. Pull the SD card out of the SD card slot. Store the SD card in its packaging for protection. 96 • Start-up OptiCenter All-in-One OC11...

  • Page 97: Operation

    ► The ventilation system must be turned on for all cleaning work! ► 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! Operation • 97 OptiCenter All-in-One OC11...
  • Page 98 Damage to the sieve mesh tension When using an ultrasonic sieve**, the sieve mesh tension is damaged during cleaning! ► The OptiSpeeder must only be cleaned with the cover on WITHOUT a US sieve. 98 • Operation OptiCenter All-in-One OC11...

  • Page 99: Starting The Opticenter

    Fig. 84: Main page (not logged in) 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 75. Operation • 99 OptiCenter All-in-One OC11...

  • Page 100: Coating With Powder Recovery (Spray) - Sequential Mode

    Overview neutral state OptiControl (CM41) In the neutral state, the operator is free to decide which work area (OptiSpeder A or B) to start with. Fig. 85: Neutral state in “Sequential” mode - ready for operation 100 • Operation OptiCenter All-in-One OC11...

  • Page 101: Powder Preparation

    The US sieve can become clogged if it has not been configured in the configuration menu and is still inserted in the OptiSpeeder (operation without or with insufficient sieving capacity). ► Set US sieve parameters correctly Operation • 101 OptiCenter All-in-One OC11...

  • Page 102: Starting The Coating Process (Spray)

    – The OptiSpeeder is filled until the filling level is reached – The vibrator switches off 2. Coating can now commence. If an error message is displayed, correct the error and acknowledge the error message so that the coating process continues. 102 • Operation OptiCenter All-in-One OC11...

  • Page 103: Changing Color (Spray)

    – US sieve** switches on (if available) – The OptiSpeeder is filled until the filling level is reached – The vibrator switches off 4. After cleaning, the second working area will be active and can be coated. Operation • 103 OptiCenter All-in-One OC11...

  • Page 104: Coating Without Powder Recovery (Waste) - Sequential Mode

    Overview neutral state OptiControl (CM41) In the neutral state, the operator is free to decide which work area (OptiSpeder A or B) to start with. Fig. 86: Neutral state in “Sequential” mode - ready for operation 104 • Operation OptiCenter All-in-One OC11...

  • Page 105: Powder Preparation

    The US sieve can become clogged if it has not been configured in the configuration menu and is still inserted in the OptiSpeeder (operation without or with insufficient sieving capacity). ► Set US sieve parameters correctly Operation • 105 OptiCenter All-in-One OC11...

  • Page 106: Starting The Coating Process (Waste)

    – The OptiSpeeder is filled until the filling level is reached – The vibrator switches off 2. Coating can now commence. If an error message is displayed, correct the error and acknowledge the error message so that the coating process continues. 106 • Operation OptiCenter All-in-One OC11...

  • Page 107: Changing Color (Waste)

    – US sieve** switches on (if available) – The OptiSpeeder is filled until the filling level is reached – The vibrator switches off 4. After cleaning, the second working area will be active and can be coated. Operation • 107 OptiCenter All-in-One OC11...

  • Page 108: Quick Switching From Sequential To Parallel Mode

    The quick switchover function only works in standby mode when all cleaning in both working areas has been completed. 1. Press the key. 2. Automatic switching to parallel mode. – Symbol indicates parallel mode – The switch to parallel mode has been made 108 • Operation OptiCenter All-in-One OC11...

  • Page 109: Coating - Parallel Mode

    In the neutral state, the operator is free to choose: 1. Parallel coating with and without powder recovery 2. Parallel coating without powder recovery Fig. 87: Neutral state in “sequential” mode – ready for operation Operation • 109 OptiCenter All-in-One OC11...

  • Page 110: Starting The Coating Process (Spray/Waste)

    – OptiSpeeder A (left) = coating with powder recovery – OptiSpeeder B (right) = coating without powder recovery If an error message is displayed, correct the error and acknowledge the error message so that the coating process continues. 110 • Operation OptiCenter All-in-One OC11...

  • Page 111: Screen Selection

    –See chapter "Parameter description" on page 49. Press the key. Press the key. – The following page is displayed: Fig. 88: Press the key (Powder Mgmt). – The following page is displayed: Fig. 89: Operation • 111 OptiCenter All-in-One OC11...
  • Page 112 Select configured mesh size and activate with ON. Fig. 90: Select sieve Press the back key twice in succession. Configuration with save. – The selected mesh size remains active until the system is switched on again. 112 • Operation OptiCenter All-in-One OC11...

  • Page 113: Replace Powder Bag

    Rev. 00 11/24 Replace powder bag Check visually the powder level in the bag cone. Hold the full powder bag ready. Switch on the extraction if it is has not been switched on already. Operation • 113 OptiCenter All-in-One OC11...

  • Page 114: Working Interruptions Or Coating Breaks

    Check if all the workpieces have been coated Press the key for 2 seconds – The Coating menu is closed and switches back to the main menu – The level control is switched off – The vibrator switches off 114 • Operation OptiCenter All-in-One OC11...

  • Page 115: Cleaning

    Only the selected cleaning step is carried out. 1. End the coating procedure. 2. To exit Coating mode, press and hold the key for 2 seconds. 3. Place the powder bag centered under the OptiSpeeder. Operation • 115 OptiCenter All-in-One OC11...
  • Page 116 9. To carry out the complete cleaning (incl. recycling), continue with the cyclone cleaning. 10. Clean the cyclone. – See chapter "Cleaning the cyclone" page 133. 116 • Operation OptiCenter All-in-One OC11...
  • Page 117 11. Cleaning is complete and is indicated by two blue points 12. Press and hold the button for 2 seconds to switch the inactive work area to standby mode. 13. Coating can now be carried out in the active working area. Operation • 117 OptiCenter All-in-One OC11...

  • Page 118: Cleaning Process (Spray) - Sequential Mode

    Only the selected cleaning step is carried out. 1. End the coating procedure. 2. To exit Coating mode, press and hold the key for 2 seconds. 3. Place the powder bag centered under the OptiSpeeder. 118 • Operation OptiCenter All-in-One OC11...
  • Page 119 – The fresh powder pump is cleaned. 8. Visually check the interior of the OptiSpeeder and clean with a compressed air gun and/or cleaning hose if necessary. 9. Clean the OptiCenter and booth. 10. Clean the cyclone. Operation • 119 OptiCenter All-in-One OC11...
  • Page 120 12. Press and hold the button for 2 seconds to switch the inactive work area to standby mode. 13. Coating can now be carried out in the active working area. 14. Store the powder properly. 120 • Operation OptiCenter All-in-One OC11...
  • Page 121 (powder collection) manually. 1. End the coating procedure. 2. To exit Coating mode, press and hold the key for 2 seconds. 3. Place the powder bag centered under the OptiSpeeder. Operation • 121 OptiCenter All-in-One OC11...
  • Page 122 – The pinch valve below the OptiSpeeder A opens and the powder in the OptiSpeedervA flows into the powder bag.. – The process step runs continuously until the operator stops this process step manually. 8. Stop process step 1. 122 • Operation OptiCenter All-in-One OC11...
  • Page 123 14. Clean the OptiCenter and booth. 15. Clean the cyclone. – See chapter "Cleaning the cyclone" page 133. 16. Cleaning is complete and is indicated by two blue points Operation • 123 OptiCenter All-in-One OC11...
  • Page 124 Rev. 00 11/24 17. Press and hold the button for 2 seconds to switch the inactive work area to standby mode. 124 • Operation OptiCenter All-in-One OC11...

  • Page 125: Cleaning Sequence (Spray/Waste) - Parallel Mode

    Cleaning sequence spray (working area 1) 1. End the coating procedure. 2. To exit Coating mode, press and hold the key for 2 seconds. 3. Position the powder bag in the center under the OptiSpeeder. Operation • 125 OptiCenter All-in-One OC11...
  • Page 126 9. Visually check the inside of the OptiSpeeder and clean if necessary using the compressed air gun and/or cleaning hose. 10. Clean the OptiCenter and the cabin. 11. Clean the cyclone. 126 • Operation OptiCenter All-in-One OC11...
  • Page 127 13. To switch inactive to standby mode, press and hold the key for 2 seconds. Cleaning sequence waste (working area 2) 1. Switch to working area 2. 2. Position the powder bag in the center under the OptiSpeeder. 3. Activate cleaning. Operation • 127 OptiCenter All-in-One OC11...
  • Page 128 – See chapter "Cleaning the cyclone" page 133. 10. The cleaning is complete and is indicated by two blue dots 11. To switch inactive to standby mode, press and hold the key for 2 seconds. 128 • Operation OptiCenter All-in-One OC11...
  • Page 129 When the cleaning sequence is controlled manually, the operator must stop the cleaning process (powder collection) manually. 1. End the coating procedure. 2. To exit Coating mode, press and hold the key for 2 seconds. Operation • 129 OptiCenter All-in-One OC11...
  • Page 130 – The powder is collected. – The pinch valve below the OptiSpeeder A opens and the powder in the OptiSpeeder A flows into the powder bag. – The process step runs continuously until the operator stops it manually. 130 • Operation OptiCenter All-in-One OC11...
  • Page 131 – The fresh powder pump is cleaned. 13. Visually check the inside of the OptiSpeeder and clean if necessary using the compressed air gun and/or cleaning hose. 14. Clean the OptiCenter and the cabin. Operation • 131 OptiCenter All-in-One OC11...
  • Page 132 – See chapter "Cleaning the cyclone" page 133. 16. The cleaning is complete and is indicated by two blue dots 17. To switch inactive to standby mode, press and hold the key for 2 seconds. 132 • Operation OptiCenter All-in-One OC11...

  • Page 133: Cleaning The Cyclone

    22. Swing the funnel on the cyclone slowly away and, at the same time, clean it off with the air gun. 23. Press the button on the cyclone again. – The cleaning process ends. Operation • 133 OptiCenter All-in-One OC11...
  • Page 134 24. Clean the inside of the cyclone with the cleaning wand. 25. Reconnect the sieve and funnel to the cyclone. For additional information, please see the operating instructions for the EZ05 monocyclone! See chapter "Other applicable documents" on page 9. 134 • Operation OptiCenter All-in-One OC11...

  • Page 135: Batch Management

    Batch management is used to record the consumed powder, divided into production batches. The recorded consumption data is continuously updated and then processed in table form in MagicControl 4.0 (CM40). Function keys Scale Record weight Subtract weight Set to zero Operation • 135 OptiCenter All-in-One OC11...

  • Page 136: Activating The Scale In Opticontrol (Cm41)

    MagicControl 4.0 (CM40). – Batch management has been started in MagicControl (CM40). Press the key. Press the key. Press the key (Powder Mgmt). – The following page is displayed: Fig. 91: Configuration – parameterization 136 • Operation OptiCenter All-in-One OC11...
  • Page 137 Tap on the scale (3425). – The following page is displayed: Fig. 92: Activating the scale Tap the key. Tap the key twice in succession. – The following page is displayed: Fig. 93: Save configuration Operation • 137 OptiCenter All-in-One OC11...
  • Page 138 Rev. 00 11/24 Press the key to save your selection. – The following page is displayed: Fig. 94: Scale activated – The symbol appears on the main screen. 138 • Operation OptiCenter All-in-One OC11...

  • Page 139: Recording Powder Volume

    1. Tap the key. – The following page is displayed: Fig. 95: Scale mode - working area 1 2. Place fresh powder in the cone. Fig. 96: Placing fresh powder - working area 1 Operation • 139 OptiCenter All-in-One OC11...
  • Page 140 Fig. 98: Scale mode - working area 2 6. Tap the key. – The weight of the powder volume is entered in the MagicControl 4.0 (CM40). 7. Back to the scale in the active working area. 140 • Operation OptiCenter All-in-One OC11...
  • Page 141 – This step can be done once or with each additional supply of fresh powder. 14. For a new batch, start with step 5 for pre-entering. 15. The recorded batches are displayed in the overview page in MagicControl 4.0 (CM40). Operation • 141 OptiCenter All-in-One OC11...
  • Page 142 Rev. 00 11/24 Fig. 100: Chronological listing of batches produced 142 • Operation OptiCenter All-in-One OC11...

  • Page 143: Switching Off The Opticenter (After Each Working Day)

    The level control is switched off – The vibrator switches off Clean the OptiCenter Turn the key switch on the CM40 to 0. Turn the main switch to the OFF position. – the interior lighting goes out Operation • 143 OptiCenter All-in-One OC11...
  • Page 144 Rev. 00 11/24 144 • Operation OptiCenter All-in-One OC11...

  • Page 145: Maintenance / Repairs

    The parts to be replaced during maintenance work are available as spare parts. See chapter "Spare parts list" on page 159. General information The product is designed to require a minimum of maintenance. Maintenance / Repairs • 145 OptiCenter All-in-One OC11...

  • Page 146: Opticenter Maintenance

    Check the components at the noise source. If no clear cause can be found, contact Gema customer service. Maintenance of the control panel The operating panel is maintenance-free. However, the following work may be necessary: –...

  • Page 147: Wearing Parts

    The periodic checks include examining all connecting cables and hoses. The corresponding parts should be replaced immediately if any damage to cables or hoses is discovered. All plugs must be properly tightened. Maintenance / Repairs • 147 OptiCenter All-in-One OC11...

  • Page 148: Repair Work

    Repair work In the event of malfunctions or faults, the product must be checked and repaired at an authorized Gema service location. The repairs must only be performed by an authorized specialist. Improper interventions can result in serious danger for user or the...

  • Page 149: Fault Clearance

    The causes of these errors must be eliminated, before further procedures can be carried out (refer to troubleshooting guide). If the error has been eliminated, the display returns to the previous menu again. Fault clearance • 149 OptiCenter All-in-One OC11...

  • Page 150: Troubleshooting Guide

    “Pneumatic diagram”), replace if necessary Corresponding valve in the Check function at Insufficient emptying of the valve pool defective or dirty corresponding output (see also OptiSpeeder during cleaning “Pneumatic diagram”), replace if necessary 150 • Fault clearance OptiCenter All-in-One OC11...
  • Page 151 Motor protection switch Q6 has Remove the small Vibrator defective reacted maintenance panel and switch on the motor protection switch again. With repeated Alarms, contact a Gema service center Vibrator defective Replace Cable broken Replace Powder pump does not Conveying problem with...
  • Page 152 Fuse (1 AT) in the WAGO Replace the fuse, otherwise Fuse Fxx defective module A1 defective, control contact a Gema service center unit switches to stand-by mode Powder warning, flashlight Check the powder bag, Powder alert in OptiSpeeder...

  • Page 153: Decommissioning / Storage

    The space requirements correspond to the size of the components plus the packaging. The load-bearing capacity of the floor should be at least 500 kg/m². There are no special requirements for the spacing to adjacent devices Decommissioning / Storage • 153 OptiCenter All-in-One OC11...

  • Page 154: Physical Requirements

    ► Do not expose the operating panel to direct heat radiation from heaters. Observe the ambient conditions when transporting and storing the operating panel. The maximum ambient temperature for storage and transport must not exceed the specified value: 154 • Decommissioning / Storage OptiCenter All-in-One OC11...
  • Page 155 During storage and transport in cold weather, and in the event of extreme temperature differences, ensure that no moisture is deposited on or inside the unit (condensation). If condensation is present, the unit may only be switched on after it is fully dry. Decommissioning / Storage • 155 OptiCenter All-in-One OC11...
  • Page 156 Rev. 00 11/24 156 • Decommissioning / Storage OptiCenter All-in-One OC11...

  • Page 157: Disposal

    Requirements on personnel carrying out the work The disposal of the product is to be carried out by the owner or operator. When disposing of components that are not manufactured by Gema, the instructions in the respective manufacturer’s documentation must be observed.
  • Page 158 ► 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. 158 • Disposal OptiCenter All-in-One OC11...

  • Page 159: Spare Parts List

    Ø 8/6 mm, 8 mm outside diameter (o/d) / 6 mm inside diameter (i/d) WARNING Use of non-original Gema spare parts Use of Non-Gema replacement spare parts may invalidate some or all approval certificates and accreditations; and the user assumes all explosion risks associated with use of these parts. Use of these replacement spare parts may void any and all warranty claims.

  • Page 160: Opticenter Oc11

    Pneumatics – see corresponding spare parts list OptiSpeeder – see corresponding spare parts list Powder supply – see corresponding spare parts list Fluidization pressure regulator – complete 1012742 Fig. 101: OptiCenter OC11 160 • Spare parts list OptiCenter All-in-One OC11...

  • Page 161: Cone Trolley

    Connection plug 4 pins 206466 Weighing cell** 1026567 Cover bushing 1005245 GEKA blind coupling 1002405 GEKA coupling – 3/4" 254339 Cover 1007177 ** optional (cone trolley with scales) Fig. 102: Cone trolley Spare parts list • 161 OptiCenter All-in-One OC11...

  • Page 162: Fluidizing/Suction Unit

    Flow restrictor – ø0.3 mm 338303 O-ring – ø14x1.5 mm (2x) 263486 # O-ring – ø22.1x1.6 mm (2x) 233340 # Foot piece 1005327 Fluidizing ring 1005330 # Wearing part Fig. 103: Fluidizing/suction 162 • Spare parts list OptiCenter All-in-One OC11...

  • Page 163: Optispeeder - Complete

    Cylinder screw – M6x20 mm– 6kt 216429 Pinch valve DN32 G 1¼" 1007648 Screw-in angle G ¼” 254029 Grub screw M6x10 mm – 6kt 234931 # Wearing part Fig. 104: OptiSpeeder – complete Spare parts list • 163 OptiCenter All-in-One OC11...

  • Page 164: Hopper - Complete

    O-ring – ø33x3 mm (1x) 244252 # Cylinder screw – M6x20 mm– 6kt 216429 Flat gasket frame 1024281 Hinge 1018024 Countersunk-head screw – M6x50 mm – 6kt 1002954 # Wearing part Fig. 105: Hopper - complete 164 • Spare parts list OptiCenter All-in-One OC11...

  • Page 165: Cover Without Sieve - Complete

    Rev. 00 11/24 Cover without sieve - complete Cover without sieve Gasket – 266.07x5.34 mm 1018069 # # Wearing part Fig. 106: Cover without sieve - complete Spare parts list • 165 OptiCenter All-in-One OC11...

  • Page 166: Initiator Holder - Complete

    Air connection Initiator 1005544 O-ring – ø34x2 mm (1x) 1003151 # Screw – M5x12 mm 239941 Proximity switch PNP 1002436 Elbow joint 1009941 # Wearing part Fig. 107: Initiator holder - complete 166 • Spare parts list OptiCenter All-in-One OC11...

  • Page 167: Opticenter - Pneumatics

    Pressure switch – 1 to 10 10 bar 233757 OptiFeed PP07 Powder– see the corresponding operating manual (See chapter "Other applicable documents" on page 9.) Exhaust air recovery - see corresponding spare parts list Fig. 108: OptiCenter – Pneumatics Spare parts list • 167 OptiCenter All-in-One OC11...

  • Page 168: Exhaust Air Waste - Complete

    216410 Cylinder screw M6x20 mm – 6kt 216429 Elbow joint G¼ 254029 Powder Pinch valve DN32 G1¼, see corresponding spare parts list # Wearing part Fig. 109: Exhaust air Waste – complete 168 • Spare parts list OptiCenter All-in-One OC11...

  • Page 169: Exhaust Air Recovery - Complete

    216429 Cylinder screw M6x25 mm – 6kt 216437 Elbow joint G¼ 254029 Powder Pinch valve DN32 G1¼, see corresponding spare parts list # Wearing part Fig. 110: Exhaust air Recovery – complete Spare parts list • 169 OptiCenter All-in-One OC11...

  • Page 170: Exhaust Air Airmover Waste - Complete

    Shut-off damper - 1 ¼ - 1 ¼ 1022314 Pinch valve – DN32 complete, see corresponding spare parts list Hose Powder hose – ø40x48 mm 1005371 # Wearing part Fig. 111: Exhaust air Airmover Waste – complete 170 • Spare parts list OptiCenter All-in-One OC11...

  • Page 171: Pinch Valve - Complete

    Elbow joint G¼ 265691 Pinch valve DN32 – complete 1007648 Cylinder screw – M8x20 mm– 6kt 216496 Pinch valve hose – NW32 1007647 # # Wearing part Fig. 112: Pinch valve DN15 – complete Spare parts list • 171 OptiCenter All-in-One OC11...
  • Page 172 Rev. 00 11/24 Fig. 113: Pinch valve DN15 – pre-assembled Fig. 114: Pinch valve D32 – complete 172 • Spare parts list OptiCenter All-in-One OC11...

  • Page 173: Compressed Air Distributor

    Valve coil - 24VDC 1005119 Solenoid valve – 3/4", NW18 without coil 1005121 Pressure gauge – 0 to 10 bar 1010964 Filter control unit – 0,5 to 8 bar 1006547 Fig. 115: Compressed air distributor Spare parts list • 173 OptiCenter All-in-One OC11...

  • Page 174: Pneumatic Distributor - Complete

    Solenoid valve – NW13.5 without coil 1005120 Pressure gauge – 0 to 10 bar 259179 Pressure regulator – 0.5 to 10 bar 259187 # Wearing part Fig. 116: Pneumatic distributor – complete 174 • Spare parts list OptiCenter All-in-One OC11...

  • Page 175: Valve Plate - Complete

    Non-return valve - ø08-ø08 1005575 Pressure gauge – 0 to 10 bar 259179 DR valve - 1/8I - 1/8A 1002127 Pressure regulator – 1/4" 0.5 to 10 bar 264326 Fig. 117: Valve plate – complete Spare parts list • 175 OptiCenter All-in-One OC11...

  • Page 176: Equipment

    Screw – M4x12 mm, 6rd 1026412 Screw – M5x12 mm, 6kt 257052 OptiSpray (CG26-CP) – complete, see corresponding user manual (See chapter "Other applicable documents" on page 9.) # Wear part Fig. 118: Equipment 176 • Spare parts list OptiCenter All-in-One OC11...

  • Page 177: Multicolor Switch - Complete

    Screw-in nipple – ø6 mm 1025007 O-ring – ø4x2 mm, NBR70 (2x) (not shown) 1004731 # O-ring – ø5x2 mm, NBR70 (1x) (not shown) 1024989 # # Wearing part Fig. 119: MultiColor switch – complete Spare parts list • 177 OptiCenter All-in-One OC11...

  • Page 178: Ph100 Powder Hopper

    Elbow joint – 1/8"-1/8" 237604 Connector – NW5-1/8" 237272 Fluidizing plate PH100 1006017 Rubber profile 1007172* Countersunk Allen screw – M6x50 mm 1002954 Handle 1006013 * Please specify length Fig. 120: PH100 Powder Hopper 178 • Spare parts list OptiCenter All-in-One OC11...

  • Page 179: Ph60 Powder Hopper

    Fluidizing plate PH60-OC 1006012 Rubber profile 1007172* Countersunk Allen screw – M6x50 mm 1002954 Elbow joint – 1/8"-1/8" 237604 Connector – NW5-1/8" 237272 * Please specify length Fig. 121: PH60 Powder Hopper Spare parts list • 179 OptiCenter All-in-One OC11...

  • Page 180: Lc01 Level Sensor

    O-ring – ø38 x 4 mm (1x) 239151 # Plastic pipe - ø6/4SW, EVA AS 1001973* Connecting cable – complete 1009005 # Wearing part * Please specify length Fig. 122: LC01 Level sensor 180 • Spare parts list OptiCenter All-in-One OC11...
  • Page 181 Technical Data ..........21 Intended use ............ 19 Technical ventilation ........22 Transport ............17 Maintenance ........... 145 Maintenance during storage......154 User levels Access ............60 Available functions ........60 Operating and display elements ...... 56 Index • 181 OptiCenter All-in-One OC11...
  • Page 182 Rev. 00 11/24 182 • Table of contents OptiCenter All-in-One OC11...
  • Page 184 Rev. 00...