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
registered trademarks of the copyright holders.
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.
For patent information, see www.gemapowdercoating.com/patents or
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

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

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

Rev. 00 02/21
OptiCenter OC09 Safety

11
Safety
Basic safety instructions
–This product is built to the latest specification and conforms to the
recognized technical safety regulations and is designed for the
normal application of powder coating.
–Any other use is considered non-compliant. The manufacturer shall
not be liable for damage resulting from such use; the user bears sole
responsibility for such actions. 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. The
standard "Machine safety" must also be observed.
–Unauthorized modifications to the product exempt the manufacturer
from any liability from resulting damage.
–The relevant accident prevention regulations, as well as other
generally recognized safety regulations, occupational health and
structural regulations are to be observed.
–Furthermore, the country-specific safety regulations also must be
observed.

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12

Safety OptiCenter OC09
Product specific security regulations
–This product is a constituent part of the equipment and is therefore
integrated in the system's safety concept.
–If it is to be used in a manner outside the scope of the safety
concept, then corresponding measures must be taken.
–The installation work to be done by the customer must be carried out
according to local 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.
►Before working with the device, organize the required documents
and read the section "Safety regulations".
►Work should only be carried out in accordance with the
instructions of the relevant documents.
►Always work with the complete original document.

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OptiCenter OC09 Transport

13
Transport
Introduction This chapter describes special precautions that must be taken during
internal transport of the product if:
–the customer himself must pack, transport and ship the product, in
order to have overhaul and repair work carried out by the
manufacturer
or
–the product must be shipped for disposal (recycling).
Safety rules
Suitable equipment (e.g. a crane) must be used when moving parts that
are sometimes bulky and heavy.
Components being disassembled must be adequately secured before
they are detached.
Requirements on personnel carrying out the
work
Use only technical personnel who are trained in operating the respective
equipment (e.g. a crane).
If there are any uncertainties, please contact Gema Switzerland GmbH.
Packing material
Not necessary for the internal transport. For external transport:
Transport
Data concerning goods to be transported
–The space requirements correspond to the size of the components
plus the packaging
–Weight see "Technical Data"
–Points of attachment, see "Mode of transportation"

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
Transport OptiCenter OC09
Mode of transportation
For short distances/shifts of position within the same room, the product
must be transported using a forklift truck with long forks.
Fig.
1
Transport the unit only in the position according to its intended use.
ATTENTION
Risk of damage
The OptiCenter must not be placed fully in the horizontal position,
since it is not designed for this purpose.
►In case of doubt contact Gema Switzerland GmbH!
Loading, transferring the load, unloading
Suitable lifting equipment is to be used for all procedures.

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OptiCenter OC09 Product description
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15
Product description
Intended use
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.
As a part of the process controlled coating plant, the center is designed
for automatic or semi-automatic operation. It allows quick, manual color
changes, supported by automated cleaning steps. The completely
equipped OptiCenter can include all powder conveying devices, gun and
axis control units, as well as the complete fresh powder dosing.
Fig.
2
Observance of the operating, service and maintenance instructions
specified by the manufacturer is also part of the intended use. This
product should only be used, maintained and started up by trained
personnel, who are informed about and are familiar with the possible
hazards involved.
Any other use is not considered as intended use. The manufacturer is not
responsible for any incorrect use and the risks associated with such
actions are assumed by the user alone!

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
Product description OptiCenter OC09
For a better understanding of the interrelationships in powder coating, it is
recommended that the operating instructions for all other components be
read as well, so as to be familiar with their functions too.
Field of application
The powder management center is suitable for use in plants with a closed
powder circuit:
Conveying
–Precision conveying from the integrated powder container
(OptiHopper) to the applicators
–Recovered powder is returned to the system
Optional:
–Fresh powder directly from the (original) powder bag
–Fresh powder directly from the (original) powder box
–Powder directly from the large-volume powder container (60 or 100
liters)
–Fresh powder from a Gema fresh powder system
–Powder level monitoring by level sensor(s)
Cleaning
–Automatic internal cleaning of suction tubes, powder conveyors,
powder hoses and guns
–Manual cleaning of the OptiHopper is supported with automated
cleaning steps and fixed built-in suction unit
–Supply of the recovered powder
–The working environment remains clean
Controlling
–No own exhaust air system –the powder management center does
not have its own exhaust air system and will be therefore connected
directly to the after filter
Reasonably foreseeable misuse
–Operation without the proper training
–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

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OptiCenter OC09 Product description
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17
Technical Data
Electrical data
OptiCenter OC09
Connected load
230 V+E+N
Frequency
50/60 Hz
Protection type
IP54
Approvals
II 3 D
Pneumatic data
OptiCenter OC09
Inlet pressure
min. 6.5 bar
Water vapor content of
compressed air
max. 1.3 g/m³
Oil content of compressed air
max. 0.1 mg/m³
Powder transport
OptiCenter OC09
24 guns
Recovery
OptiFeed powder pump
OptiHopper capacity
60 liters (35 kg)
Compressed air consumption
OptiCenter OC09
Max. compressed air
consumption during cleaning (120
seconds)
200-300 Nm³/h
Coating operation
Fluidization OptiHopper +
AirMover + process air
20 Nm³/h
Consumption per applicator
5 Nm³/h
Example for 10 applicators
70 Nm³/h
Cleaning operation mode
Cleaning OptiFeed hose to
cyclone
120 Nm³/h
Cleaning conveying hose to an
applicator
30 Nm³/h
Example for 6 applicators (for
group size = 6)
180 Nm³/h

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
Product description OptiCenter OC09
Dimensions
OptiCenter OC09
24 guns
Area*
(width x depth)(mm)
1900 x 1700
Overall height (mm)
2100 (2250 - OptiFeed
connection)
Weight(kg)
OptiCenter base weight
460
loaded*
765
* with electrostatic and system control
Sound pressure level
OptiCenter OC09
Normal operation
75 dB(A)
Cleaning operation mode
for a short time up to
95 dB(A)
The sound pressure level was measured while the unit was in operation;
measurements were taken at the most frequent operator positions and at
a height of 1.7 m from the ground.
The specified value is applicable only for this product itself and does not
take into account external noise sources or cleaning impulses.
The sound pressure level may vary, depending on the product
configuration and space constraints.
Rating plate
Fig.
3
: Rating plate
Fields with a gray background contain contract-specific data!

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OptiCenter OC09 Product description

19
Design and function
Overall view
fig.
4
: Structure
1 Control unit/operating panel
2 Emergency stop button
3 OptiHopper fluidizing
4 OptiHopper
5 Powder bag fixation
6 Powder bag cone with
vibrator
7 Gun and axes control units
8 OptiFlow injectors
9 Suction unit (not shown)
Touch Panel
All necessary operating procedures are activated by the Touch Panel.
Fig.
5
:

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
Product description OptiCenter OC09
Compressed air indicators
fig.
6
:
Gema default values after installation
30Q1
0.5 bar
AirMover (normal operation)
30Q3
3 bar
OptiHopper fluidizing air
33Q2
2 bar
Powder hopper fluidizing air
33Q1
2 bar
Fluid/suction unit fluidizing air
OptiHopper
The OptiHopper provides the following features:
–Conditioning and fluidization of the coating powder
–Extraction/removal of excess free-floating powder particles and the
fluidization air back into the powder circuit by means of ring injector
(AirMover)
–Cleaning of the ring injector (AirMover) and the connected powder
hose with compressed air pulses for powder recovery
–Manual emptying the residual powder
–Manual cleaning supported by automated cleaning steps and fixed
built-in suction unit
Optional:
–Monitoring and control of the powder level
fig.
7