Gema OptiCenter OC04 Guide

1011 505 En
Translation of the original operating instructions
Operating instructions and spare parts list
Powder management
center
OptiCenter OC04

V 04/17
Documentation – OptiCenter OC04
© Copyright 2008 Gema Switzerland GmbH
All rights reserved.
This publication is protected by copyright. Unauthorized copying is prohib-
ited 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.
MagicCompact, MagicCylinder, MagicPlus, MagicControl, OptiFlex, Opti-
Control, OptiGun, OptiSelect, OptiStar and SuperCorona are registered
trademarks of Gema Switzerland GmbH.
OptiFlow, OptiCenter, OptiMove, OptiSpeeder, OptiFeed, OptiSpray, Op-
tiSieve, OptiAir, OptiPlus, OptiMaster, MultiTronic, EquiFlow, Precise
Charge Control (PCC), Smart Inline Technology (SIT) and Digital Valve
Control (DVC) 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 con-
cerned approve of or are bound in any form by this manual. We have en-
deavored 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 Swit-
zerland 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 information regarding patents, visit
www.gemapowdercoating.com/patents or
www.gemapowdercoating.us/patents.
Printed in Switzerland
Gema Switzerland GmbH
Mövenstrasse 17
9015 St.Gallen
Switzerland
Phone: +41-71-313 83 00
Fax.: +41-71-313 83 83

V 04/17
OptiCenter OC04 Table of contents •1
Table of contents
General safety regulations 5
Safety symbols (pictograms)...................................................................................5
Intended use ...........................................................................................................5
Product specific safety information .........................................................................6
General information ...................................................................................6
Installation..................................................................................................7
Grounding ..................................................................................................7
Operating the equipment ...........................................................................7
Inspection...................................................................................................7
Repairs.......................................................................................................8
About this manual 9
General information ................................................................................................9
Product description 11
Field of application ................................................................................................11
Utilization..................................................................................................11
Reasonably foreseeable misuse..............................................................12
Technical Data ......................................................................................................12
Powder transport......................................................................................12
Electrical data ..........................................................................................12
Pneumatic data ........................................................................................12
Dimensions ..............................................................................................13
Processible powders................................................................................13
Sound pressure level ...............................................................................13
Rating plate ..............................................................................................13
Design and function ..............................................................................................15
Overall view..............................................................................................15
Compressed air indicators .......................................................................16
Powder container .................................................................................................. 17
PS07 Sieve machine (option) ...............................................................................17
Principle of operation ............................................................................................18
Powder circuit...........................................................................................18
Start-up 19
Set-up and assembly ............................................................................................19
Preparation for start-up .........................................................................................19
Compressed air supply ............................................................................19
Grounding of the powder management center ........................................20
Operation 21
Push button switches ............................................................................................21
Push button functions ..............................................................................21
Operating modes ..................................................................................................23
General information .................................................................................23
Coating without powder recovery (spray to waste)..................................23

V 04/17
2 •Table of contents OptiCenter OC04
Coating with powder recovery ................................................................. 23
Cleaning / color change (clean)............................................................... 23
Coating operation 25
Before switching on .............................................................................................. 25
Starting up the OptiCenter OC04 ......................................................................... 25
Start-up.................................................................................................... 25
Switching off the OptiCenter OC04 (after each work day) ................................... 27
Cleaning / color change 29
Cleaning operating mode ..................................................................................... 29
Cleaning procedure ................................................................................. 29
Coating after the cleaning........................................................................ 32
Settings 33
Troubleshooting 35
General information .............................................................................................. 35
Maintenance 37
Daily after longer working interruptions and at the end of shift ............................ 37
Check weekly........................................................................................................ 37
Decommissioning, storage 39
Introduction........................................................................................................... 39
Safety rules.............................................................................................. 39
Requirements on personnel carrying out the work.................................. 39
Storage conditions................................................................................................ 39
Storage duration ...................................................................................... 39
Space requirements ................................................................................ 39
Physical requirements ............................................................................. 39
Hazard notes ........................................................................................... 40
Shut-down............................................................................................................. 40
Decommissioning .................................................................................... 40
Cleaning................................................................................................... 40
Disassembly/attachment of transport safety devices .............................. 40
Packing .................................................................................................... 40
Identification ............................................................................................ 40
Maintenance during storage................................................................................. 40
Maintenance schedule............................................................................. 40
Maintenance works.................................................................................. 40
Return to service .................................................................................................. 41
Commissioning following storage............................................................ 41
Packing, transport 43
Introduction........................................................................................................... 43
Safety rules.............................................................................................. 43
Requirements on personnel carrying out the work.................................. 43
Packing material ................................................................................................... 44
Transport .............................................................................................................. 44
Data concerning goods to be transported ............................................... 44
Mode of transportation............................................................................. 44
Loading, transferring the load, unloading ................................................ 45

V 04/17
OptiCenter OC04 Table of contents •3
Spare parts list 47
Ordering spare parts .............................................................................................47
OptiCenter.............................................................................................................48
Powder container – complete ...............................................................................49
Powder container – Fluidizing plate......................................................................50
Powder container – Level sensor..........................................................................51
OptiCenter – Pneumatics......................................................................................52
Main air supply ...................................................................................................... 53
Powder container – Pneumatic manifold ..............................................................54
Shuttle valves pool................................................................................................55
Powder container pneumatics...............................................................................56
Monocyclone – Powder transport .........................................................................57
Monocyclone – Powder transport connection.......................................................58


V 04/17
OptiCenter OC04 General safety regulations •5
General safety regulations
This chapter sets out the fundamental safety regulations that must be fol-
lowed by the user and third parties using the OptiCenter OC04.
These safety regulations must be read and understood before the Opti-
Center OC04 is put into operation.
Safety symbols (pictograms)
The following warnings with their meanings can be found in the Gema
Switzerland operating instructions. The general safety precautions must
also be followed as well as the regulations in the operating instructions.
DANGER!
danger due to live electricity or moving parts. Possible consequences:
Death or serious injury
ATTENTION!
improper use of the equipment could damage the machine or cause it to
malfunction. Possible consequences: minor injuries or damage to equip-
ment
INFORMATION!
Useful tips and other information
Intended use
−The OptiCenter OC04 is built to the latest specification and con-
forms to the recognized technical safety regulations and is de-
signed for the normal application of powder coating.
−Any other use is considered non-compliant. The manufacturer is
not responsible for any incorrect use and the risks associated
with such actions are assumed by the user alone. If the OptiCen-
ter OC04 is to be used for other purposes or other substances
outside of our guidelines then Gema Switzerland GmbH should
be consulted.
−Observance of the operating, service and maintenance instruc-
tions specified by the manufacturer is also part of conformity of
use. The OptiCenter OC04 should only be used, maintained and

V 04/17
6 •General safety regulations OptiCenter OC04
started up by trained personnel, who are informed about and are
familiar with the possible hazards involved.
−Start-up (i.e. the execution of a particular operation) is forbidden
until it has been established that the OptiCenter OC04 has been
set up and wired according to the guidelines for machinery
(2006/42 EG). EN 60204-1 (machine safety) must also be ob-
served.
−Unauthorized modifications to the OptiCenter OC04 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.
Explosion protection Protection type
II 3 D IP54
Product specific safety information
General information
The OptiCenter OC04 is a constituent part of the system and is thus inte-
grated into the safety system of the plant.
If it is to be used in a manner outside the scope of the safety concept,
then corresponding measures must be taken.
NOTE:
For further information, see the more detailed Gema safety regula-
tions!

V 04/17
OptiCenter OC04 General safety regulations •7
Installation
The services and facilities to be provided by the customer should be in-
stalled according to local regulations.
Grounding
Check the grounding of the booth and the powder management center
before every start-up. The grounding connection is customer specific and
is fitted on the booth base, on the cyclone and on the powder manage-
ment center. Also make sure that the workpieces, and all other systems
are properly grounded.
Operating the equipment
In order to be able to operate the equipment safely, it is necessary to be
familiar with the safety regulations, the operational characteristics and
functioning of the various plant units.
For this purpose, read the safety notes, this operating manual and the
operating instructions of the plant control unit, before starting up the plant.
In addition, all further equipment-specific operating instructions, e.g. the
OptiFlex and all additional components should also be read.
To obtain practice in operating the plant, it is absolutely essential to start
the operation according to the operating instructions. Also, later on, they
serve as a useful aid on possible malfunctions or uncertainty and will
make many enquiries unnecessary. For this reason, the operating manual
must always be available at the equipment.
Should difficulties arise, however, your Gema service center is always
ready to assist.
Inspection
Before switching on the booth, check the following points (where applica-
ble):
−No foreign material in the central suction unit in the booth and in
the powder suction
−Sieve machine is connected to the cyclone separator, the clamp
is tightly locked
−Pneumatic conduction and powder hose are connected to the
dense phase conveyor

V 04/17
8 •General safety regulations OptiCenter OC04
Repairs
Repairs must be carried out by trained personnel only. Unauthorized con-
versions and modifications can lead to injuries and damage to the equip-
ment. The Gema Switzerland GmbH guarantee would no longer be valid.
NOTE:
We point out that the customer himself is responsible for the safe
operation of the equipment! Gema Switzerland GmbH is in no way
responsible for any resulting damage.
By carrying out repairs, the powder management center must be discon-
nected from the mains, according to the local safety regulations!
NOTE:
Only original Gema spare parts should be used! The use of spare
parts from other manufacturers will invalidate the Gema guarantee
conditions!

V 04/17
OptiCenter OC04 About this manual •9
About this manual
General information
This operating manual contains all important information which you re-
quire for the working with the OptiCenter OC04. It will safely guide you
through the start-up process and give you references and tips for the op-
timal use of your new powder coating system.
Information about the function mode of the individual system components
- booth, axis, gun control unit, powder gun or powder injector - should be
referenced to their enclosed corresponding documents.
DANGER:
Working without operating instructions
Working without operating instructions or with individual pages
from the operating 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 on "Safety regulations".
►Work should only be carried out in accordance with the instructions in
the relevant documents.
►Always work with the complete original document.


V 04/17
OptiCenter OC04 Product description •11
Product description
Field of application
The OptiCenter OC04 Powder management center is conceived for sim-
ple and clean handling of the coating powder. It enables a semi-
automated cleaning procedure and consequently a quick color change.
Utilization
The OptiCenter OC04 powder management center is suitable for use in
multiple color plants as well as in single color plants.
As a part of the process controlled coating plant, the powder management
center is laid out for semi-automatic operation.
Conveyance
−Processing the powder directly from the integrated powder con-
tainer (manual powder filling)
−Integrated electrical and pneumatic control units
−Powder level monitoring by level sensor (option)

V 04/17
12 •Product description OptiCenter OC04
Cleaning
−Automatic internal cleaning of the injectors, powder hoses and
guns
−Supply of the recovered powder
−The workplace and the environment remain clean
−No own exhaust system - the powder management center does
not have its own exhaust system and will be therefore connected
directly to the After Filter
Reasonably foreseeable misuse
−Use of moist powder
−Insufficient fluidization at the suction point
−Operation without the proper training
Technical Data
Powder transport
OptiCenter OC04
Conveying performance (average value per
gun) 200 g/min.
Recovery max. 3.5 kg/min.
Electrical data
OptiCenter OC04
Connected load 1x230 V
Frequency 50/60 Hz
Protection type IP54
Pneumatic data
OptiCenter OC04
Inlet pressure min. 6.5 bar
Compressed air consumption during coating
operation 15 Nm³/h
Compressed air consumption during cleaning
(incl. powder container and guns) 350 Nm³/h
Compressed air consumption during cleaning
of the PP06 hose to the cyclone 120 Nm³/h
Water vapor content of compressed air max. 1.3 g/m³
Oil content of compressed air max. 0.1 mg/m³

V 04/17
OptiCenter OC04 Product description •13
Dimensions
OptiCenter OC04 OC04 with AS10 with
AS10+ICS02
/05
Base area
(width x depth) (mm) 1140 x 1500 1700 x 1500 2600 x 1500
Overall height (mm) 2100 (2270 – PP06 connection)
Weight (kg) approx. 300 (without AS and ICS)
Processible powders
OptiCenter OC04
Plastic powder yes
Metallic powder yes
Sound pressure level
OptiCenter OC04
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 the powder management center
itself and does not take into account external noise sources or cleaning
impulses.
The sound pressure level may vary, depending on the powder manage-
ment center configuration and space constraints.
Rating plate
NOTE:
Fields with a gray background contain contract-specific data!


V 04/17
OptiCenter OC04 Product description •15
Design and function
Overall view
OptiCenter OC04 – layout
1 Main switch 7 Hand lever for powder container vent
2 Emergency stop push
button
8 Hand lever for exhaust air
3 Illuminated push button
switches
9 Hand lever for emptying of the powder
container
4 Injectors 10 "Waste" connection
5 Powder container 11 Hose cleaning connection
6 Pneumatic parts 12 Recovery powder connection
13 Lighting
13
8
4
9
10
11
1
12
2
5
7
3
6
6

V 04/17
16 •Product description OptiCenter OC04
Compressed air indicators
DR1 Powder container fluidizing air
DR2 Level sensor fluidizing air
DR2
DR1

V 04/17
OptiCenter OC04 Product description •17
Powder container
The powder container is suited for the preparation and fluidization of the
coating powder.
The powder container can contain 25 kg powder (approx. 60 liters fluid-
ized powder) and can be equipped with up to 30 OptiFlow IG06-P injec-
tors.
PS07 Sieve machine (option)
The PS07 sieve machine is used for the vibration supported sieving of
coating powder and can be equipped with different mesh sizes (see sepa-
rate operating instructions).
If necessary, the sieve machine is manually switched on and off with the
relevant push button.

V 04/17
18 •Product description OptiCenter OC04
Principle of operation
Powder circuit
During the typical OptiCenter OC04 (7) operation the powder is filled into
the powder container and fluidized. The fluidized powder is aspirated by
the injectors and fed through the powder hoses to the guns/spray nozzles
(8). The powder, which does not adhere to the workpieces, will be ab-
sorbed by the exhaust air of the booth (1) and separated from the air in
the cyclone separator (2).
The separated powder is cleaned by passing it through the integrated
sieve (3) and fed back into the OptiCenter by the dense phase conveyor
(4), where it is prepared again for coating operation.
Powder flow in the plant
1 Booth 6 Refuse container
2 Cyclone separator 7 OptiCenter
3 Sieve 8 Automatic guns
4 OptiFeed PP06 Powder pump 9 Powder container
5 After Filter 10 Exhaust air ducting
1
3
4
2
5
6
7
8
9
10
Table of contents
Other Gema Paint Sprayer manuals

Gema
Gema OptiGun GA03-P User manual

Gema
Gema OptiFlex 2 F User manual

Gema
Gema OptiFlex Pro B User manual

Gema
Gema OptiGun GA03 Guide

Gema
Gema OptiFlex Pro B Guide

Gema
Gema OptiFlex Pro F Guide

Gema
Gema OptiFlex Pro B Spray Guide

Gema
Gema OptiFlex Pro BN Guide

Gema
Gema OptiFlex 2 B User manual

Gema
Gema OptiFlex Pro BN User manual
Popular Paint Sprayer manuals by other brands

Titan
Titan LX-75 instruction sheet

WAGNER
WAGNER ProSpray 23 operating manual

SNOWJOE
SNOWJOE SUNJOE SJ-APS-2G Operator's manual

Casotti
Casotti AQUILOTTO 1 SIDE FC8 Instruction for the installation and the adjustment

Garland
Garland FUM 105 W instruction manual

Kwazar
Kwazar HYDRA SUPER CLEANING PRO Plus owner's manual