Gema OptiCenter OC08 Guide

Rev. 02 1011 546 EN
Operating instructions and Spare parts list
Powder management
system
OptiCenter OC08
Translation of the original operating instructions

Rev. 02 04/21
Documentation OptiCenter OC08
© Copyright 2019 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 OC08 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
Operating elements .................................................................................. 20
OptiSpeeder ............................................................................................. 20
Cleaning hose .......................................................................................... 21
Powder bag cone ..................................................................................... 21
Vibrating trolley** ..................................................................................... 22
Powder hopper** ...................................................................................... 22
Ultrasonic sieve system US07** .............................................................. 23
Powder recovery system** ....................................................................... 23
Powder feed to guns** ............................................................................. 24

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4•Table of contents OptiCenter OC08
Level sensor** ......................................................................................... 24
Principle of function ................................................................................. 24
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 with powder recovery (spray) ..................................................... 34
Coating without powder recovery (spray to waste container) ................. 34
Manual coating mode .............................................................................. 34
Cleaning/color change operating mode ................................................... 35
Configuration ........................................................................................... 35
Settings .................................................................................................... 35
User levels and access ......................................................................................... 35
Functions available at user level ............................................................. 36
Inserting the SD card ............................................................................................ 36
Inserting SD card ..................................................................................... 36
Removing SD card .................................................................................. 37
CAN bus ............................................................................................................... 37
General .................................................................................................... 37
User administration ............................................................................................... 37
Status display .......................................................................................... 37
Login ........................................................................................................ 37
Log-out ..................................................................................................... 40
Change user ............................................................................................ 40
User profile .............................................................................................. 40
SD card – data backup ............................................................................ 49
Diagnostic ............................................................................................................. 49
Operating hours ....................................................................................... 50
Checking the software version ............................................................................. 51
Disassembly of component groups ...................................................................... 52
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

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OptiCenter OC08 Table of contents •5
Operation 59
Operation .............................................................................................................. 59
Starting the OptiCenter ......................................................................................... 59
Coating with powder recovery (spray) .................................................................. 60
Coating without powder recovery (spray to waste container) ............................... 62
Powder recovery in the powder hopper** ................................................ 63
Screen selection ...................................................................................... 64
Manual coating ...................................................................................................... 65
Starting recovery after a color change (waste/spray) ........................................... 67
Delayed fresh powder request .............................................................................. 68
Ratio of fresh powder / recovery powder .............................................................. 69
Level OptiSpeeder ................................................................................................ 70
100% Adjustment (Teach 100%) .......................................................................... 70
Prerequisite .............................................................................................. 70
Procedure ................................................................................................. 70
Working interruptions or coating breaks ............................................................... 73
Switching off the OptiCenter (after each working day) ......................................... 73
Replacing the powder bag .................................................................................... 73
Color change ............................................................................................ 75
Maintenance / Repairs 77
General information .............................................................................................. 77
OptiCenter maintenance ....................................................................................... 78
Maintenance schedule ............................................................................. 78
Check for unusual noises ......................................................................... 78
Wearing parts ........................................................................................... 78
Cleaning ................................................................................................................ 79
Cleaning procedure (standard) ................................................................ 79
Cleaning with recovery in the powder hopper** ....................................... 84
Cleaning with recovery in the powder bag ............................................... 90
Cleaning and maintenance of the operating panel .................................. 96
Periodic checks ..................................................................................................... 96
Repair work ........................................................................................................... 97
Repairs ..................................................................................................... 97
SD card – data backup ............................................................................ 97
Fault clearance 99
Error messages ..................................................................................................... 99
Troubleshooting guide .......................................................................................... 99
Decommissioning / Storage 103
Shutdown ............................................................................................................ 103
If in disuse for several days ................................................................... 103
Storage conditions .............................................................................................. 103
Storage duration .................................................................................... 103
Type of storage ...................................................................................... 103
Space requirements ............................................................................... 103
Physical requirements ............................................................................ 104
Hazard notes .......................................................................................... 104
Maintenance during storage ............................................................................... 104
Maintenance schedule ........................................................................... 104
Maintenance works ................................................................................ 104
Storage and transport of the operating panel ........................................ 104
Disposal 107
Introduction ......................................................................................................... 107

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6•Table of contents OptiCenter OC08
Requirements on personnel carrying out the work ................................ 107
Disposal regulations .............................................................................. 107
Materials ................................................................................................ 107
Disassembly of component groups .................................................................... 107
Spare parts list 109
Ordering spare parts ........................................................................................... 109
OptiCenter OC08 ................................................................................................ 110
Cone trolley ......................................................................................................... 111
Fluidizing/suction unit ......................................................................................... 112
OptiSpeeder – complete ..................................................................................... 113
OptiSpeeder – Cover .......................................................................................... 114
OptiSpeeder – rod level sensor .......................................................................... 115
OptiSpeeder – Level sensor (capacitive) ........................................................... 116
OptiSpeeder – Level sensor (capacitive) ........................................................... 117
OptiSpeeder – Ultrasonic sensor (Option) ......................................................... 118
OptiSpeeder – Fluidizing plate ........................................................................... 119
OptiCenter – Pneumatics ................................................................................... 120
Main air supply.................................................................................................... 121
OptiSpeeder – Pneumatic manifold .................................................................... 122
OptiSpeeder – Fluidization ................................................................................. 123
Pressure regulators pool .................................................................................... 124
Pneumatic manifold Cleaning ............................................................................. 125
Pinch valves distributor (RP/FP)......................................................................... 126
Powder hopper PH60-OC ................................................................................... 127
PH100-OC Powder Hopper ................................................................................ 128
LC01 Level sensor .............................................................................................. 129
Vibration trolley ................................................................................................... 130
Shuttle valves pool ............................................................................................. 131
Monocyclone – Powder transport ....................................................................... 132
Monocyclone – Powder transport connection .................................................... 133
WRS kit (Powder switch) .................................................................................... 134
Pinch valves distributor (WRS/SAT) ................................................................... 135
Pneumatics ES (AS..) ......................................................................................... 136

Rev. 02 04/21
OptiCenter OC08 About these instructions •7
About these instructions
General information
This operating manual contains all the important information which you
require for the working with the OptiCenter OC08. 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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8•About these instructions OptiCenter OC08
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 OC08
with software version starting from 1.4.12.
See chapter "Checking the software version" on page 51.

Rev. 02 04/21
OptiCenter OC08 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."

Rev. 02 04/21
10 •About these instructions OptiCenter OC08