Gema OptiCenter OC04 Guide

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

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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,
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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
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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
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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 Swit-
zerland GmbH makes no representations or warranties with respect to the
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publication and make changes to its content without prior notice.
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www.gemapowdercoating.com.
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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 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

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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

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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

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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

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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!

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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

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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!