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ITW Gema OptiCenter OC02 Operating Instructions And Spare Parts List

Powder management center
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Operating instructions and spare parts list
OptiCenter OC02
Powder management center
Translation of the original operating instructions

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Summary of Contents for ITW Gema OptiCenter OC02

  • Page 1 Operating instructions and spare parts list OptiCenter OC02 Powder management center Translation of the original operating instructions...
  • Page 2 To the best of our knowledge and belief, the information contained in this publication was correct and valid on the date of issue. ITW Gema 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.

  • Page 3: Table Of Contents

    Preparation for start-up ..................17   Compressed air supply ................17   Grounding of the powder management center ........18 Operation by touch panel     Touch panel/operating panel ................19   Touch keypads ..................20 Table of contents  1 OptiCenter OC02...
  • Page 4   Coating without powder recovery (spray waste) ..........29   Replacing the powder bag ..................31   Switching off the OptiCenter OC02 (after each work day) ........33 Cleaning / color change     Cleaning operating mode ..................35  ...

  • Page 5: General Safety Regulations

    2. Any other use is considered as non-conform. The manufacturer is not responsible for any incorrect use, the risk for this is assumed by the user alone. If the OptiCenter OC02 is to be used for other purposes or other substances outside of our guidelines then ITW Gema GmbH should be consulted.

  • Page 6: Product Specific Security Regulations

    II 3 D Product specific security regulations General information The OptiCenter OC02 is part of the plant and therefore integrated in the safety concept of the plant. For the use outside of the safety concept, corresponding measures must be taken.

  • Page 7: Installation

    For this reason, the operating manual must always be available at the equipment. Should difficulties arise, however, your ITW Gema service center is always ready to assist. Inspection check...

  • Page 8: Repairs

    By carrying out repairs, the powder management center must be disconnected from the mains, according to the local safety regulations! Note: Only original ITW Gema spare parts should be used! The use of spare parts from other manufacturers will invalidate the ITW Gema guarantee conditions! 6 ...

  • Page 9: About This Manual

    - booth, axis, gun control unit, powder gun or powder injector - should be referenced to their enclosed corresponding documents. Software version This document describes the operation of the Touch Panels to control the OptiCenter OC02 powder management center with software version 2_1a. About this manual  7 OptiCenter OC02...

  • Page 11: Product Description

    As a part of the process controlled coating plant, the powder management center is laid out for fully automatic operation. Utilization The OptiCenter OC02 powder management center is suitable for use in plants with a completely closed powder circuit: Conveying...

  • Page 12: Reasonably Foreseeable Misuse

    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 OC02 Conveying performance 230 g/min. Recovery max. 3.5 kg/min. Electrical data OptiCenter OC02...

  • Page 13: Dimensions

    V 10/10 Dimensions with OptiCenter OC02 with AS04 AS04+ICS03 Base area 1150 x 1500 1700 x 1500 1700 x 1500 (width x depth) (mm) Overall height (mm) 2100 (2270 - PP06 connection) Weight (kg) Processible powders OptiCenter OC02 Plastic powder...

  • Page 15: Structure And Function

    V 10/10 Structure and function General view OptiCenter OC02 - layout Main switch Powder bag cone with vibrator Emergency stop push button Powder bag fixation Control unit/operating panel Gun and axes control units Injectors "Waste" connection OptiSpeeder OptiSpeeder connection Vibrator switch Product description ...

  • Page 16: Compressed Air Indicators

    V 10/10 Compressed air indicators AirMover OptiSpeeder fluidizing air Level sensor fluidizing air Valve block supply Fluidizing/suction lance fluidizing air Operating elements Designation Function Touch Panel Hopper full indicator (green) Powder shortage indicator (red) 14  Product description OptiCenter OC02...

  • Page 17: Optispeeder

    Capacity up to 25 kg Mobile to allow the powder to be emptied easily Fluidizing/suction lance Fresh powder pump connection Recovery powder pump connection Touch Panel All necessary operating procedures are activated by the Touch Panel. Product description  15 OptiCenter OC02...

  • Page 18: Principle Of Function

    Principle of function Powder circuit During the typical OptiCenter OC02 (7) operation, the powder bag is put in the powder bag cone. The powder is fluidized in the bag with the fluidizing/suction lance and then fed to the OptiSpeeder in the OptiCenter OC02.

  • Page 19: Start-Up

    The OptiCenter requires a connection to a sufficient dimensioned compressed air circuit. In order to ensure a perfect operation, a pressure of 6 bar must be adjusted with the main pressure regulator. Compressed air supply Start-up  17 OptiCenter OC02...

  • Page 20: Grounding Of The Powder Management Center

    The OptiCenter must be grounded according to the general, local safety regulations. The grounding of the powder management center must be checked regularly. A corresponding connection point at the OptiCenter is reserved for the potential equalization. Potential equalization - connection point 18  Start-up OptiCenter OC02...

  • Page 21: Operation By Touch Panel

    The function parameters are also entered by the control panel. These are set at the factory and, therefore, may only be changed after consultation with an ITW Gema service center. Operating panel Operation by touch panel  19...

  • Page 22: Touch Keypads

    Exit key Note: The designation (labeling) of pictograms is in English only and is used by ITW Gema worldwide for identification of technical support issues. The symbols are designed for the user, who will be guided through the plant by means of pictures. All operation and error messages...

  • Page 23: Key Functions

    Cleaning for color change Key is not activated, until boot is ready For this function, no log-in is necessary Log-in to modify parameters, configuration or change the language Configuration Parameters Language change Operation by touch panel  21 OptiCenter OC02...
  • Page 24 V 10/10 By pressing the Help key, the phone number and the e-mail address of the ITW Gema Helpline will be shown. Attention: The function parameters are set at the factory and may not be changed by the customer! Parameters may only be modified after consultation with an ITW...

  • Page 25: Operating Modes

    If the volume of order is very small Coating with powder recovery This coating mode allows the coating with recovery of the powder, which does not adhere to the object. Utilization of this operating mode: Operation by touch panel  23 OptiCenter OC02...

  • Page 26: Cleaning / Color Change (Clean)

    After switching on the equipment, if very high quality is required on initial coating application Before every color change Service / parameterization (maintenance) This operating mode enables the user to change the operating language. 24  Operation by touch panel OptiCenter OC02...

  • Page 27: Coating Operation

    Check the grounding of the OptiCenter, the booth and the other plant units and ensure it, if necessary Check the compressed air supply Starting up the OptiCenter OC02 Start-up Attention: The keys of the input field should only be pressed with fingertips...
  • Page 28 11. Select the coating type required on the OptiCenter (coating with or without powder recovery) 12. Select desired operating mode (AUTOMATIC or MANUAL) on the booth control unit (see therefore the corresponding operating manual) 26  Coating operation OptiCenter OC02...

  • Page 29: Coating With Powder Recovery (Spray)

    V 10/10 Coating with powder recovery (spray) Recovery hose Coating operation  27 OptiCenter OC02...
  • Page 30 8. If necessary, replace the powder bag, see also "Replacing the powder bag" 9. The exhaust system can be switched on and off manually. 10. The key closes the Coating menu and returns to the main menu 28  Coating operation OptiCenter OC02...

  • Page 31: Coating Without Powder Recovery (Spray Waste)

    V 10/10 Coating without powder recovery (spray waste) 3. The extraction system is switched off automatically Recovery hose Coating operation  29 OptiCenter OC02...
  • Page 32 The OptiSpeeder is now filled with powder. Coating can now commence 9. If necessary, replace the powder bag, see also "Replacing the powder bag" 10. The key closes the Coating menu and returns to the main menu 30  Coating operation OptiCenter OC02...

  • Page 33: Replacing The Powder Bag

    Switch this on if it is has not been switched on already 6. The powder pumps and the vibrator are stopped 7. Empty the used powder bag with the residual powder into another container or dispose of it Coating operation  31 OptiCenter OC02...
  • Page 34 V 10/10 32  Coating operation OptiCenter OC02...

  • Page 35: Switching Off The Opticenter Oc02 (After Each Work Day)

    V 10/10 Switching off the OptiCenter OC02 (after each work day) Note: Before the equipment can be turned off, the contents of the container (OptiSpeeder) must be emptied into the cone. If this is not done, the powder can escape from the container unhindered.

  • Page 37: Cleaning / Color Change

    4. Adjust the movement axes to the cleaning position, so that the guns can be cleaned from the inside. OptiCenter 5. End the coating procedure 6. Press the The following menu appears on the display: Cleaning / color change  35 OptiCenter OC02...
  • Page 38 V 10/10 36  Cleaning / color change OptiCenter OC02...
  • Page 39 V 10/10 Cleaning / color change  37 OptiCenter OC02...
  • Page 40 V 10/10 17. Press the 19. The pinch valve below the OptiSpeeder opens and the powder in the OptiSpeeder flows into the powder bag 38  Cleaning / color change OptiCenter OC02...
  • Page 41 20. The process is complete when the key starts flashing. The key can be pressed once again if necessary. If a key flashes, this is a sign that the next cleaning phase needs to be activated. Recovery hose Cleaning / color change  39 OptiCenter OC02...
  • Page 42 Magic Control CM-10 NOTE! If you do not want this powder to be recovered, connect the recovery hose to the waste connection. Recovery hose 31. Finish cleaning the booth 40  Cleaning / color change OptiCenter OC02...
  • Page 43 80 seconds (1-24 injectors) or 120 seconds (1-36 injectors). The key can be pressed once again if necessary. Otherwise, the next cleaning step can be activated. Recovery hose 37. Cleaning the OptiCenter Cleaning / color change  41 OptiCenter OC02...
  • Page 44 V 10/10 42  Cleaning / color change OptiCenter OC02...
  • Page 45 47. Press the button on the monocyclone. The cleaning process is started. 48. The hose is blown through in pulses Note: The procedure can be stopped or resumed manually by the user. Cleaning / color change  43 OptiCenter OC02...
  • Page 46 51. Close the sieve and funnel on the cyclone again 55. Press the The start mask appears on the display - The extraction system will continue running for approximately 1 minute Recovery hose 44  Cleaning / color change OptiCenter OC02...
  • Page 47 V 10/10 59. Do not start coating until the level probe indicator lights up. The OptiSpeeder is now filled with powder. 60. Keep the guns switched on until the first hangers have passed. Cleaning / color change  45 OptiCenter OC02...
  • Page 48 V 10/10 Recovery hose 46  Cleaning / color change OptiCenter OC02...

  • Page 49: Service/Parameterization

    Booth ready signal may be present 2. Switch on the control voltage in the powder management center with the key switch: the key switch returns to its starting position the interior lighting switches on the display shows the basic menu Service/parameterization  47 OptiCenter OC02...
  • Page 50 V 10/10 7. Press the key, the previous menu appears 48  Service/parameterization OptiCenter OC02...

  • Page 51: Messages

    - Pump defective - see corresponding operating manual OptiFeed PP06 - Hose clogged Check the recovery system - Check the level sensor (see also Error message no. 03) - Check the cyclone funnel for powder abrasion Messages  49 OptiCenter OC02...
  • Page 52 V 10/10 Display Description Activity - Contact an ITW Gema service center Powder recovery pump Powder pump is switched off overpressure - Hose clogged or connected Check the recovery system and/or incorrectly connect correctly - Pressure sensor at the OptiFeed...

  • Page 53: Maintenance

    Daily after longer working interruptions and at the end of shift WARNING Before switching off the plant, the OptiSpeeder must be emptied and cleaned Check weekly Check the injector nozzles and replace them, if necessary Maintenance  51 OptiCenter OC02...

  • Page 55: Spare Parts List

    Ø 8/6 mm, 8 mm outside diameter (o/d) / 6 mm inside diameter (i/d) WARNING! Only original ITW Gema spare parts should be used, because the explosion protection will also be preserved that way. The use of spare parts from other manufacturers will invalidate the ITW Gema guarantee conditions! Spare parts list ...

  • Page 56: Touch Panel Control Unit

    V 10/10 Touch panel control unit 1 Touch panel - 5.7" 269 450 Compact Flash card - 32 MB (not shown) 269 018 Touch panel control unit 54  Spare parts list OptiCenter OC02...
  • Page 57 V 10/10 Spare parts list  55 OptiCenter OC02...

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