Gema OptiCenter OC09 Guide

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

Rev. 00 02/21
Documentation OptiCenter OC09
© Copyright 2021 Gema Switzerland GmbH
All rights reserved.
This publication is protected by copyright. Unauthorized copying is
prohibited by law. No part of this publication may be reproduced,
photocopied, translated, stored on a retrieval system or transmitted in any
form or by any means for any purpose, neither as a whole nor partially,
without the express written consent of Gema Switzerland GmbH.
Gema, EquiFlow, MagicCompact, MagicCylinder, OptiCenter, OptiFlex,
OptiGun, OptiSelect and OptiStar are registered trademarks of Gema
Switzerland GmbH.
ClassicLine, ClassicStandard, ClassicOpen, DVC (Digital Valve Control),
GemaConnect, MagicControl, MagicPlus, MonoCyclone, MRS,
MultiColor, MultiStar, OptiAir, OptiControl, OptiColor, OptiFeed, OptiFlow,
OptiHopper, OptiMove, OptiSieve, OptiSpeeder, OptiSpray, PCC (Precise
Charge Control), RobotGun, SIT (Smart Inline Technology) und
SuperCorona are trademarks of 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
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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.
For the latest information about Gema products, visit
www.gemapowdercoating.com.
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www.gemapowdercoating.us/patents.
Printed in Switzerland
Gema Switzerland GmbH
Mövenstrasse 17
9015 St.Gallen
Switzerland
Phone:[phone]
Fax.: [phone]
E-mail: [email protected]

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OptiCenter OC09 Table of contents
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3
Table of contents
About these instructions 7
General information ................................................................................................7
Keeping the Manual................................................................................................7
Safety symbols (pictograms)...................................................................................7
Structure of Safety Notes...........................................................................8
Software version .....................................................................................................8
Presentation of the contents...................................................................................9
Figure references in the text......................................................................9
Safety 11
Basic safety instructions .......................................................................................11
Product specific security regulations ....................................................................12
Transport 13
Introduction ...........................................................................................................13
Safety rules..............................................................................................13
Requirements on personnel carrying out the work..................................13
Packing material....................................................................................................13
Transport...............................................................................................................13
Data concerning goods to be transported................................................13
Mode of transportation.............................................................................14
Loading, transferring the load, unloading ................................................14
Product description 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 and function..............................................................................................19
Overall view..............................................................................................19
Touch Panel.............................................................................................19
Compressed air indicators.......................................................................20
OptiHopper...............................................................................................20
Suction unit ..............................................................................................21
Level sensors kit** (OptiHopper) .............................................................21
Cleaning hose..........................................................................................22
OptiFeed kit**...........................................................................................22
Powder bag cone.....................................................................................22
Vibrating trolley** .....................................................................................23
Powder hopper**......................................................................................23
Ultrasonic sieve system US07-1**...........................................................24

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Table of contents OptiCenter OC09
Sieve machine PS07-1**......................................................................... 24
Displacer**............................................................................................... 25
Powder feed to guns**............................................................................. 25
Level sensor** ......................................................................................... 25
Principle of operation............................................................................... 26
Touch panel / operating panel 27
Typical characteristics.......................................................................................... 27
Technical Data...................................................................................................... 28
System..................................................................................................... 28
Electrical data.......................................................................................... 28
Dimensions.............................................................................................. 28
Display..................................................................................................... 28
Connections............................................................................................. 29
Environmental conditions ........................................................................ 29
Rating plate ............................................................................................. 29
Design and function.............................................................................................. 30
Operating and display elements.............................................................. 30
Connections and interfaces..................................................................... 31
Symbols................................................................................................... 32
Meaning of the colors.............................................................................. 33
Operating modes.................................................................................................. 34
Coating .................................................................................................... 34
Cleaning/color change operating mode................................................... 34
Configuration........................................................................................... 35
Settings.................................................................................................... 35
User levels and access......................................................................................... 35
Functions available at user level............................................................. 36
CAN bus ............................................................................................................... 36
General.................................................................................................... 36
User administration............................................................................................... 36
Status display.......................................................................................... 36
Login........................................................................................................ 36
Log-out..................................................................................................... 40
Change user............................................................................................ 40
User profile .............................................................................................. 40
Diagnostic............................................................................................................. 49
Operating data......................................................................................... 50
Checking the software version ............................................................................. 51
Assembly / Connection 53
Set-up................................................................................................................... 53
Grounding of the powder management center..................................................... 53
Compressed air supply............................................................................ 54
Start-up 55
Preparation for start-up......................................................................................... 55
Basic conditions....................................................................................... 55
Basic information..................................................................................... 55
Inserting the SD card............................................................................................ 56
Inserting SD card..................................................................................... 56
Removing SD card .................................................................................. 56
Parameter description .......................................................................................... 56
Operation 59
Operation.............................................................................................................. 59
Starting the OptiCenter......................................................................................... 59

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OptiCenter OC09 Table of contents
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5
Filling the OptiHopper...........................................................................................60
Coating..................................................................................................................60
With powder recovery (spray)..................................................................60
Without powder recovery (spray to waste) ..............................................60
Screen selection ......................................................................................62
Manual coating......................................................................................................62
Delay fresh powder demand.................................................................................63
Working interruptions or coating breaks...............................................................64
Switching off the OptiCenter (after each working day).........................................64
Replace powder bag.............................................................................................65
Color change............................................................................................66
Maintenance / Repairs 67
General information ..............................................................................................67
OptiCenter maintenance.......................................................................................68
Maintenance schedule.............................................................................68
Check for unusual noises.........................................................................68
Wearing parts...........................................................................................68
Cleaning................................................................................................................69
Cleaning Steps.........................................................................................70
Cleaning Times........................................................................................70
Cleaning procedure..................................................................................70
Cleaning the recovery system..................................................................77
Cleaning and maintenance of the operating panel..................................78
Periodic checks.....................................................................................................78
Repair work...........................................................................................................79
Repairs.....................................................................................................79
SD card –data backup ............................................................................79
Fault clearance 81
Error messages.....................................................................................................81
Troubleshooting guide ..........................................................................................81
Decommissioning / Storage 85
Shutdown..............................................................................................................85
If in disuse for several days .....................................................................85
Storage conditions ................................................................................................85
Storage duration ......................................................................................85
Type of storage........................................................................................85
Space requirements.................................................................................85
Physical requirements..............................................................................86
Hazard notes............................................................................................86
Maintenance during storage .................................................................................86
Maintenance schedule.............................................................................86
Maintenance works..................................................................................86
Storage and transport of the operating panel..........................................86
Disposal 89
Introduction ...........................................................................................................89
Requirements on personnel carrying out the work..................................89
Disposal regulations.................................................................................89
Materials...................................................................................................89
Disassembly of component groups.......................................................................89
Spare parts list 91
Ordering spare parts.............................................................................................91

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Table of contents OptiCenter OC09
OptiCenter OC09.................................................................................................. 92
Cone trolley........................................................................................................... 93
Fluidizing/suction unit........................................................................................... 94
OptiHopper –complete......................................................................................... 95
OptiHopper –Fluidization plate............................................................................ 96
OptiCenter –Pneumatics ..................................................................................... 97
Main air supply...................................................................................................... 98
OptiHopper –pneumatic distributor...................................................................... 99
OptiHopper –Fluidization................................................................................... 100
Pressure regulators pool .................................................................................... 101
Pneumatic manifold Cleaning............................................................................. 102
Ring Injector (Airmover) / Pinch Valve ............................................................... 103
Powder hopper PH60-OC................................................................................... 104
PH100-OC Powder Hopper................................................................................ 105
LC01 Level sensor.............................................................................................. 106
Vibration trolley...................................................................................................107
Monocyclone –Powder transport....................................................................... 108
Monocyclone –Powder transport connection ....................................................109
Pneumatics ES (AS..)......................................................................................... 110

Rev. 00 02/21
OptiCenter OC09 About these instructions

7
About these instructions
General information
This operating manual contains all important information which you
require for the working with the OptiCenter OC09. 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.
Information about the functional mode of the individual system
components should be referenced in the respective enclosed documents.
These operating 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
instructions. The general safety precautions must also be followed as well
as the regulations in the relevant instructions.
DANGER
Indicates a hazardous situation which, if not avoided, will result in death
or serious injury.
WARNING
Indicates a hazardous situation which, if not avoided, could result in
death or serious injury.

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About these instructions OptiCenter OC09
CAUTION
Indicates a hazardous situation which, if not avoided, could result in
minor or moderate injury.
ATTENTION
Indicates a potentially harmful situation. If not avoided, the equipment or
something in its surrounding may be damaged.
ENVIRONMENT
Indicates a potentially harmful situation which, if 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
►Prevention of the danger
Software version
This document describes the operation of the product OptiCenter OC09
with software version starting from 1.2.40 xxxx.
See chapter "Checking the software version" on page 51.

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OptiCenter OC09 About these instructions
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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."

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About these instructions OptiCenter OC09