Gema OptiCenter OC03 - User Manual

Your global partner for high quality powder coating
CM30 with OptiCenter OC03
Operator
Quick Guide

Summary

Switch on the plant

Login Procedure

Steps to log in to the CM30 system using username and password.

Axis Referencing

Calibrating the machine's axes for correct operation.

Select Coating Mode

Choosing the active operating mode for powder coating.

Select Waste Powder Mode

Choosing the mode for handling waste powder.

Switch off the installation

Exit Cleaning Mode and Standby

Process of exiting cleaning and entering standby mode.

Power Down Procedure

Steps for safely shutting down the system using the key switch.

Color Change and Cleaning Operations

CM30 Panel Operations for Cleaning

Procedures on the CM30 panel to initiate and manage cleaning.

OptiCenter Cleaning Sequence

Detailed steps for cleaning the OptiCenter system.

Return to Coating Mode

Steps to finalize cleaning and resume normal coating operations.

Main Menu Navigation

Main Menu Overview

Explanation of the primary user interface and its functions.

Status and Legend Interpretation

Understanding system status indicators and operational legends.

Gun Settings and Control

Pistol Parameter Adjustment

Configuring specific parameters for spray guns.

Gun Activation and Status Monitoring

Managing gun ON/OFF states and spray activity.

Axis Settings and Control

Axis Parameter Adjustment

Configuring movement and speed parameters for machine axes.

Axis Activation and Status Monitoring

Managing axis movement, referencing, and operational status.

Schematic Powder Circuit Diagram

Overview

1. Usage Features
2. Maintenance Features (Color Change / Cleaning Mode)

This document provides an operator's quick guide for the Gema CM30 with OptiCenter OC03, a system designed for high-quality powder coating applications. The guide outlines the essential steps for operating, maintaining, and performing color changes on the equipment.

The CM30 with OptiCenter OC03 is a comprehensive powder coating system that integrates several key components to ensure efficient and consistent application of powder. Its primary function is to apply powder coatings to objects, which are typically transported through a booth on a conveyor system. The OptiCenter OC03 acts as the central powder management unit, handling powder supply, recovery, and cleaning processes. The system is designed to provide a controlled environment for powder application, ensuring uniform coating thickness and minimizing powder waste.

Usage Features:

The system's operation begins with a straightforward switch-on procedure. Users log in via a touchscreen interface, which offers various user levels, including AdminConfig, config, gema, para, startup, and different user accounts. After logging in, the system requires referencing its axes, a critical step to ensure precise gun movement and coating accuracy. Once the axes are referenced, the operator selects the "Coating mode" to prepare for powder application.

For powder supply, the OptiCenter OC03 is used. The operator places a powder bag into the FP cone, covers it, and inserts the FP lance. The system then prompts the selection of a powder mode, with "Waste powder mode" being an option. A crucial caution is highlighted regarding the "Waste powder mode": it uses only fresh powder, and no powder is recovered in this mode. Operators are advised to switch to "Recovery mode" after a certain period to avoid unnecessary powder consumption. The system also includes steps to confirm the RP hose position, which is essential for proper powder flow and recovery.

The CM30 panel provides a main menu with several key functions. Operators can close or open automatic doors, manage powder, access all programs, and adjust conveying speed. The panel displays the current operating mode, object recognition status, and any active errors. It also allows for increasing or reducing powder output per station, acknowledging alarms, and calling up programs for local changes.

The "Guns settings" interface allows for detailed control over individual powder guns. Operators can view and adjust parameters such as powder output, total air, high voltage, spray current, and electrode rinsing air. The interface also indicates whether a gun is activated or deactivated and if it is spraying powder. Error numbers are displayed to help diagnose issues. Changes can be applied per station or to all stations, and there are options to acknowledge errors, view error descriptions, save changes, and exit the screen.

The "Axes settings" interface provides control over the movement of the powder guns. Operators can set upper and lower reversing points, and view the current position and speed of each axis. The interface also displays the approximate spraying distance and allows for starting or stopping axes before and after the object. Critical warnings like "Fix position !! Caution !!" and "!! Collision danger !!" are displayed to alert operators to potential issues.

Maintenance Features (Color Change / Cleaning Mode):

The system is designed with a comprehensive color change and cleaning procedure to ensure efficient transitions between different powder colors and to maintain optimal performance. This process is initiated by exiting the "Coating mode" and selecting the "Cleaning mode" on the CM30 panel.

The cleaning process involves several steps:

1. Closing the doors: This isolates the booth for cleaning.
2. Coarse cleaning of the booth: This involves manually cleaning the interior of the powder coating booth.
3. Cleaning the outside of the guns: This step is particularly important if using a foreign booth or if no doors are present.
4. Exiting the Coating mode on the OptiCenter: This prepares the powder management unit for cleaning.
5. Selecting the Cleaning mode on the OptiCenter: This activates the cleaning functions of the OptiCenter.
6. Putting the fresh powder lance in the park position: This secures the lance during cleaning.
7. Selecting the cleaning possibility (Schnell/Qualität): Operators can choose between a quick or quality cleaning option.
8. Moving the FP cone under the OptiSpeeder: This positions the cone for emptying.
9. Emptying the OptiSpeeder: This is done by pressing the "Emptying OptiSpeeder" key twice.
10. Moving back the FP cone: After emptying, the cone is returned to its original position.
11. Changing the recovery hose position: This reconfigures the system for recovery hose cleaning.
12. Confirming the sequence: The system automatically continues the cleaning sequence.
13. Waiting for a specific mask to be displayed: This indicates the next step in the process.
14. Cleaning the OptiSpeeder and placing the cover: This ensures thorough cleaning of the unit.
15. Connecting the RP hose to the "Cleaning" connection: This prepares for cleaning the recovery hose.
16. Confirming the connection: This initiates the recovery hose cleaning.
17. Removing the powder bag and thoroughly cleaning the OC: This is a critical step for preventing contamination.
18. Fine booth cleaning: A more detailed cleaning of the booth interior.
19. Cleaning the ducting: Ensuring all powder pathways are clear.
20. Cleaning and removing the sieve: This prevents blockages and ensures proper powder flow.
21. Starting recovery hose cleaning: This cleans the recovery hose system.
22. Cleaning the cone: Thoroughly cleaning the powder cone.
23. Cleaning the cyclone: Using only one nozzle at a time for effective cleaning.
24. Inserting the sieve and closing the cyclone: Reassembling the cyclone components.
25. Placing the bag with new color and connecting the RP hose to the "Waste" connection: This prepares the system for the next color.
26. Exiting the Cleaning mode: This completes the cleaning process.
27. Selecting the "Spray to waste" mode on the OptiCenter: This purges any remaining old powder from the system.
28. Confirming the RP hose position: Ensures proper setup for spraying to waste.
29. Opening the doors on the CM30 panel: Prepares the booth for operation.
30. Exiting the Cleaning mode on the CM30 panel: Completes the cleaning sequence on the main panel.
31. Returning to the Coating mode: The system is now ready for operation with the new color.

The system also includes a switch-off procedure, which involves exiting the "Cleaning mode," pressing the "Standby" key, exiting "Standby," pressing the "Exit" key, and finally turning the key switch to 0. This ensures a safe and proper shutdown of the equipment.

Gema OptiCenter OC03 Specifications