MagicCylinder EquiFlow-en
Contents
1. nnn nennen nennen eneen enne neen enen nnnn ann 16 Powd r TeCOVEry EE 16 Automatic GUNS EEE 17 Cleaning the goung 18 Technical data 19 MagicCylinder QCS04 Powder coating booth nnee eneen eenen 19 Electrical data cia a rer ee k 19 Pneumatie dada ici ici dd 19 Compressed air Consumption nen 19 DIMENSIONS ere intere EEE ee Darin DI Nn cents 19 Sound pressure level sssssssssesinsssrnsrnesr nesr netrnesnnstnnntnn nesune tn nen nsennsenn enn 20 Commissioning 21 Set up and assembly A 21 peter gedeien 21 Cable connections junctions ococcnccinnninnnnccnnnnannnccnnncccnnrn cnn aran narrar nan 21 Edi WEE 21 MagicCylinder EquiFlow Table of contents e 1 Gema on Operation 23 Before switching on the booth neen enneer enne enenenennneerenennenenenneenenvenn 23 Switehio n the bo0th airera ee ireen ren 23 Switching off the bo6thi 2 12 23 Alarm MOSSOS EE 24 Filtericle ning serna E 24 Color change and cleaning nnen ennnenenneereneerenenennnenenenvenennenenennneenenn 24 Maintenance 27 Maintenance and repr ttr arte 27 Daily or after each shift 24 een nee 27 UE EE aia 27 Biannual yesek e e ee SEE Heksri Au eend 27 Maintenance and repair of the cyclone separator sesssseesisssiresrresrnssrresrrsens 28 Maintenance and repair of the sieve machine 28 Maintenance of the After Filter pressure gauges filter and fan 28 Replacing spare parts estic date 28 Functional CHECK ss2. door drive unit MagicCylinder EquiFlow Spare parts list e 47 Gema a MagicCylinder QCS04 fan control unit Fan control unit complete see table 4 Plastic tube 6 4 mm 103 144 6 Locknut M20x1 5 mm 266 035 7 Locknut M40x1 5 mm 265 357 8 Cable connection M20 1 8 15 mm 266 019 9 Cable connection M40 1 28 5 33 mm 265 349 10 Elbow joint 6 1 8 6 mm 245 950 11 Elbow joint 1 8 a 6 mm 254 061 12 Adjusting elbow 6 8 mm 237 990 13 Lead through connection 8 8 mm 253 880 14 Switch 0 75 5 6 kPa 243 744 Switch 1 25 11 0 kPa 243 752 15 Pressure gauge 0 2 5 kPa differential pressure 243 760 Pressure gauge 0 5 0 kPa differential pressure 243 779 16 Pressure gauge 0 5 0 kPa differential pressure 243 779 Pressure gauge 0 8 0 kPa differential pressure 251 844 20 Main switch see corresponding wiring diagram 21 Connecting socket plug see corresponding wiring diagram Wearing part Pressure gauge kPa Order Motor number performance kW Filter Fan pos 15 pos 16 1004 358 5 5 5 0 8 0 1004 359 7 5 5 0 8 0 1004 937 11 25 5 0 1004 360 11 5 0 8 0 1004 938 15 2 5 5 0 1004 361 15 5 0 8 0 1002 178 22 25 5 0 1002 205 22 5 0 8 0 1002 179 30 25 5 0 1002 174 30 5 0 8 0 1002 180 37 2 5 5 0 1002 175 37 5 0 8 0 1002 176 45 5 0 8 0 1002 177 55 5 0 8 0 48 e Spare parts list MagicCyli
3. 3 Plug screw M12 1006 905 4 Sensor Actor cable 30 m 1008 243 MagicCylinder QCS04 Sensor Actor Box MagicCylinder EquiFlow Spare parts list e 43 Gema a MagicCylinder QCS04 gun blow off equipment 44 e Spare parts list Please indicate length Wearing part Gun blow off unit complete pos 1 4 1010015 1 Nozzle holder complete 1010 013 2 Nozzle 1010 014 3 T piece 3 8i 3 8a 3 8i 223 034 4 Allen grub screw M6x16 mm 214 850 5 Hose connector 17 mm 3 8 a 233 077 6 Hose clamp Y 17 25 mm 223 085 7 Compressed air hose 16 4 26 6 mm black 105 155 8 Solenoid valve 1005 592 9 Valve coil 24 VDC for pos 10 1005 119 10 Valve cable 3 pins M12 for pos 11 1008 244 11 Grounding cable complete 1006 077 MagicCylinder EquiFlow V 12 13 Gema MagicCylinder QCS04 gun blow off equipment MagicCylinder QC S04 gun blow off equipment MagicCylinder EquiFlow Spare parts list e 45 Gema eg MagicCylinder QCS04 door drive unit 1 Holder large 389 714 2 _ Holder small 389 706 3 Drive shaft MKCO2 A026 4 4 Coupling 389 730 5 Hinge 373 770 6 Rotary actuator 389 790 7 Lever 389 749 8 Support 389 722 13 Connection case complete 373 885 15 Cable 7x0 75 mm 100 536 16 Cable 4x1 mm 100 579 17 Valve cable L 0 7 m 373 605 18 Proximity switch
4. diciones la 29 General Information isis de eee 29 Procedure of the function check 29 Decommissioning storage 31 Introduction tated BEE 31 Safety rules en e ida 31 Requirements on personnel carrying out the work 31 Storage cOndItIONS 3 1 4 HH ta ee ebenda 31 Storage duration annen enne eeennenrennenennvenennereeneernnnenenneenenenenn 31 Space requirements nnn enne eeennenrenenennnenenneeeenerenaneeenneenenenenn 31 Physical requirements A 31 Hazard Not iia india diles 31 A ee ee a ea brennen rer energie late 32 Decommissioning WEE 32 GIS Une en 32 Disassembly attachment of transport safety devices nen 32 PACKING En 32 Ke inr Leon 32 Maintenance during storage nennen eeerenneneerenneeenvennenervennenennennenn 32 Maintenance schedule nnn eneen er enenenneeerennerreneernnneneneevenn 32 Maintenance workS annae enen EAn erR EEANN Ern 32 Return LO Service socios ESA dens EEEE elie denon nied Gade ee 32 Commissioning following storage nnen enneerenneer eenen nneneneenenn 32 Packing transport 33 INTOQUCION PE 33 Safety TIOS iii aia 33 Requirements on personnel carrying out the work 33 Packing material 25 2 2er a 33 ee EE 33 Data concerning goods to be transported nennen eneen eneen 33 Mode of transportatton rca nn cc cnnn canario 34 Loading transferring the load unloading nnen eeen 34 Troubleshooting 35 General Information 35 Problem MND tooo ctrl 35 Setting AT 37 2
5. 246 760 21 Throttle check valve 266 825 23 Solenoid valve 5 1 8 220 VAC 259 705 24 _ Inline regulator 6 bar 263 320 27 Silencer 1 8 a 251 305 30 Double nipple 1 8 a 1 4 a 242 209 32 Y connection fitting 1 8 a 8mm 253 936 33 Adjusting elbow 8 8 mm 238 287 35 Elbow joint 1 4 a 8 mm 254 029 39 Plastic tube 8 6 mm black antistatic 103 756 40 Rubber buffer 40x28 mm M8a 248 592 41 Hexagon screw M5x10 mm 205 699 43 Hexagon shakeproof screw M6x12 mm 244 406 45 Hexagon shakeproof screw M8x20 mm 244 422 46 Cylinder Allen screw M4x20 mm 216 291 47 Cylinder Allen screw M4x16 mm 216 283 48 Cap screw M5x35 mm 201 715 50 Hexagon nut M4 205 192 51 Hexagon nut M5 205 150 55 Lock washer M4 205 680 56 Lock washer M5 205 168 57 Washer 5 3 10x1 mm 205 320 58 Allen grub screw M4x8 mm 214 736 59 Coiled spring pin 4x20 mm 259 683 46 e Spare parts list MagicCylinder EquiFlow V 12 13 Gema MagicCylinder QCS04 door drive unit A 18 ke 8 W EE D TE o E21 33 39 a 41 56 57 40 At E 58 4 47 15 13 46 50 55 i Ce 16 EE HS 17 er 23 48 51 56 5 is 2 PA AR MagicCylinder QCS04
6. QC S04 cleaning the guns The automatic guns are cleaned very simply and quickly The cleaning of the automatic guns takes place by the gun blow off equipment on the MagicCylinder QCS04 coating booth By activating the cleaning function on the control unit the reciprocators and the guns move out of the booth At the same time each gun is blown off cleanly from the outside by four flat jet blow off nozzles These flat jet blow off nozzles are found on the gun slots on the outside of the booth If necessary this cleaning sequence can be repeated 18 e Design and function MagicCylinder EquiFlow V 12 13 Technical data Gema MagicCylinder QCS04 Powder coating booth MagicCylinder EquiFlow Electrical data MagicCylinder QCS04 Input voltage 3x400 V 50 Hz other voltages and frequencies on request Pneumatic data MagicCylinder QCS04 Input pressure Air entry speed min 6 bar max 10 bar 0 7 m sec Rinsing air in filter housing max 18 Nm h Water vapor content of compressed air max 1 3 g m Oil content of compressed air max 0 1 mg m Compressed air consumption MagicCylinder QCS04 Rinsing air in filter housing max 18 Nm h Dimensions MagicCylinder QCS04 Booth diameter max 2 5 m in the interior Booth length Booth basement height 5 8 m 0 6 m Weight depending on the size Technical d
7. e Table of contents MagicCylinder EquiFlow V 12 13 Gema Spare parts list 39 len ee eth cde ett elle HA ee 39 MagicCylinder QCS04 spare parts let 40 Floor blow off system PneumatiCS anna enneenennenrenneennnenenneern enne nensenennenen 41 Pressure e e E E 42 Sensor Actor BO HH dan da 43 MagicCylinder QCS04 gun blow off equipment nnn annen ereen enen 44 MagicCylinder QCS04 door drive unt 46 MagicCylinder QCS04 fan control unit anneer enneerennenenenenenneeeenenn 48 MagicCylinder EquiFlow Table of contents e 3 V 12 13 Gema General safety regulations This chapter sets out the fundamental safety regulations that must be followed by the user and third parties using the MagicCylinder EquiFlow powder coating booth These safety regulations must be read and understood before the MagicCylinder EquiFlow powder coating booth is put into operation Safety symbols pictograms Proper use MagicCylinder EquiFlow 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 electrically live or moving parts Possible consequences death or serious injury WARNING Improper use of the equipment could damage the machine or cause it to malfunction Possible consequences minor injuries or damage to equipment INFORMATION Useful t
8. external plant units such as chain conveyor powder center reciprocators optionally fire protection optionally etc are switched on The operating functions in the powder center can be released now and the coating process can begin This process is interrupted only if a ventilator motor malfunction is present Other malfunctions are indicated by an alarm or a message displayed on the control cabinet The suction effect of the filters is monitored during operation Therefore the differential pressure and thus the suction performance of the exhaust air system is measured A blockage of the filter elements is indicated by a decrease of the suction performance the differential pressure arises By reaching a fixed preset value a signal lamp on the control cabinet illuminates and at the same time an alarm sounds Detailed information about the After Filter is found in the corresponding operating manual MagicCylinder EquiFlow V 12 13 Gema Powder flow MagicCylinder powder flow in the plant 1 Booth 5 After Filter 2 Cyclone separator 6 Refuse container 3 Sieve 7 Powder center 4 Dense phase conveyor 8 Automatic guns The powder container is located in the powder center 7 Here the powder is vibrated and fluidized The injectors transport the powder through the hoses to the guns 8 The guns spray the powder air mixture onto the workpieces to be coated The powder which does not adhere on the workpieces f
9. mounting the cabin make sure that all plastic components such as panels have been acclimatized at a room temperature of at least 15 C for at least 24 hours WARNING Avoid stress cracks MagicCylinder EquiFlow V 12 13 Gema Packing transport Introduction Packing material Transport MagicCylinder EquiFlow This chapter describes special precautions that must be taken during internal transport of the product if the customer himself must pack transport and ship the product such as to have renovations or service work carried out by the manufacturer or the product must be shipped for disposal recycling Safety rules Suitable equipment e g a crane must be used when moving parts that are sometimes bulky and heavy Components being disassembled must be adequately secured before they are detached Requirements on personnel carrying out the work Use only technical personnel who are trained in operating the respective equipment e g acrane If there are any uncertainties please contact Gema Not necessary for the internal transport For external transport see Storage Data concerning goods to be transported The space requirements correspond to the size of the components plus the packaging Weight see Technical Data Points of attachment see Mode of transportation Packing transport e 33 Gema er Mode of transportation For short distances shifts of position within the same room
10. station alternatively Design and function e 13 Gema V 12 13 Booth basement 14 e Design and function The booth basement consists of reinforced plastic material The booth basement contains the floor blow off unit and the powder suction suction duct Floor blow off system MagicCylinder QC S04 floor blow off system arrows blow off direction Blow off rails with blow nozzles are integrated into the booth floor The blow off rails consist of various segments which can be pneumatically controlled one by one The required blow off pressure depends on the booth size and the powder type In preset intervals the nozzles blow the powder located on the floor in the direction of the suction slots The powder is aspirated via the slots cleaning the booth floor in this way The valves for the control of the floor blow off segments are located in the booth basement NOTE The compressed air input pressure for the floor blow off system must be set at 5 0 bar MagicCylinder EquiFlow wee Gema Powder suction MagicCylinder QCS04 powder suction cutaway view The powder suction takes place via a lengthwise suction duct in the booth floor The powder which has been blown by the floor blow off system in the direction of the suction slot is then sucked in along the entire booth length The suction duct is gathered in a cross duct at the booth end which can be visually controlled through a service lid The
11. En MagicCylinder EquiFlow Powder coating booth Type QCS04 Translation of the original operating instructions Gema Gema me Documentation MagicCylinder EquiFlow powder coating booth O Copyright 2009 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 OptiTronic OptiGun EasyTronic EasySelect EasyFlow and SuperCorona are registered trademarks of Gema Switzerland GmbH OptiMatic OptiMove OptiMaster OptiPlus MultiTronic and Gematic 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 t
12. actice 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 check The following points are to be checked at every booth start up No foreign material in the central suction unit in the booth and in the powder suction Pneumatic conduction and powder hose are connected to the dense phase conveyor Pneumatic conduction to the After Filter is connected the filter element door is closed the waste container is placed and fitted Entering the booth Because of its design the booth needs nearly never to be entered Checks or cleaning can take place from the booth openings without problems WARNING Danger of slipping and or injury gt Repairs WARNING Carrying out of repairs is only permitted when the booth is switched off and must be done only by trained personnel gt MagicCylinder EquiFlow General safety regulations e 7 V 12 13 Gema About this manual General information MagicCylinder EquiFlow This operating manual contains all the important information which you require for the working with the MagicCylinder EquiFlow powder coating boot
13. alls on the booth floor and is sucked off through the slots in the booth floor and delivered to the cyclone separator 2 as powder air mixture In the cyclone separator the powder is separated by the influence of centrifugal force The separated powder is cleaned in the integrated sieve 3 and transported back to the powder container by a dense phase conveyor 4 where it is available again for the coating process The rest of the non separated powder most of it is fine particles goes into the After Filter 5 The After Filter separates the powder into a refuse container 6 which is positioned directly under the filter elements and is very easy to empty Then the cleaned air leaves the filter and is fed directly back into the workshop environment Booth superstructure MagicCylinder EquiFlow The MagicCylinder QCS04 booth superstructure is a double walled plastic panel construction ensuring an optimum powder repelling effect All grounded parts including the booth superstructure supports are positioned at the necessary required distance outside of the booth This ensures the powder repelling effect of the booth also for a longer coating period The interior of the booth is illuminated by lightings which are fitted into the booth ceilings The basic version of the MagicCylinder booth has no hand coating openings The booth can be equipped either on one or both sides with manual coating equipment as precoating or touch up
14. arm The differential pressure is displayed on the pressure gauge Pressure monitoring on the filter is only displayed optically on the pressure gauge Pressure monitoring on the fan is displayed optically and the alarm is initiated by 2 manostats optically and acoustically The upper limiting value by which the alarm is initiated is plant specific and is set by our trained service personnel when assembling the booth The setting of the cycle times must be done only by trained service personnel The input is entered directly on the operating unit of the plant control see also the operating manual of the plant control unit Color change and cleaning 24 e Operation The color change can begin when the last workpieces have left the booth In automatic operation mode the coating is stopped automatically Following a step by step description of the color change procedure from bright to dark or vice versa is given A prerequisite for a quick and efficient color change is that it is done by 2 people so that some of these steps can be carried out simultaneously 1 Prepare the booth for cleaning The booth must be empty of hangers Stop the conveying system Close the booth doors Switching over the booth control to cleaning operation Move the guns to the cleaning position 2 Prepare the powder center for cleaning Remove the powder container from the powder center the recovery hose remains on the powder contai
15. ata e 19 Gema 2 Sound pressure level MagicCylinder QCS04 max 80 dB A Sound pressure level 4 A H in coating operation 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 coating booth itself and does not take into account external noise sources or cleaning impulses The sound pressure level may vary depending on the booth configuration and space constraints 20 e Technical data MagicCylinder EquiFlow V 12 13 Gema Commissioning Set up and assembly Installation Installation work to be done by the customer must be carried out according to local safety regulations Cable connections junctions The connecting cables between control unit and guns must be laid out in such a way that they cannot be damaged during operation Observe the safety regulations Earthing The booth grounding is to be checked at every start up The grounding connection is customer specific and fitted on the booth basement the cyclone separator and the filter housing MagicCylinder EquiFlow Commissioning e 21 Operation V 12 13 Gema Before switching on the booth Strictly observe the safety regulations see also General safety regulations Check the grounding of the booth and the other plant units and ensure it if necessary If nec
16. booth An efficient exhaust air system is used to keep the area around the booth clean and to prevent explosive powder air mixtures The fan in the After Filter extracts the air from the inside of the booth through the cyclone and afterwards through the filter elements The air stream created thereby flowing from the outside to the inside of the booth prevents powder escaping to the environment of the booth so that keeping the area around the booth clean is guaranteed The maintenance of the air flow prevents as well the creation of dangerous powder air mixtures Design and function e 11 Gema 12 e Design and function V 12 13 The powder recovery takes place by the powder separation in the cyclone separator during operation The booth control takes place by the corresponding control unit with operating interface The gun control units are fitted into one or two control cabinets The switching on and off of the guns takes place by the gap detection unit in the automatic mode NOTE More detailed information about the control units components and the operating interfaces are found in the corresponding user manuals Operational procedure NOTE Only the multiple color version is described in this user manual By switching on the booth the fan in the After Filter starts up and after the start up phase the plant units which are interlocked with the booth are released The operational condition is reached as soon as all
17. ducts are autocleaning and can be blown out with compressed air The collected powder is delivered to the cyclone separator Any deposited overspray powder on the walls must sometimes be moved manually Exhaust air system with After Filter An efficient exhaust air system is used to keep the area around the booth clean and to prevent explosive powder air mixtures The exhaust air is created by the fan in the After Filter Detailed information about the After Filter is found in the corresponding operating manual MagicCylinder EquiFlow Design and function e 15 Gema V 12 13 Fire protection For safety reasons it is recommended to equip the plant with a CO fire extinguishing system An existing fire protection is merged in the security concept of the plant and assumes the plant interlocking release Cleaning operation mode During the automatic gun cleaning the work piece entrance and exit door are closed thereby an increased air inlet speed results at the remaining openings at the booth This ensures a dust free environment around the booth during the color change procedure Automatic booth cleaning The cleaning of the booth floor takes place automatically with the combination of the floor blow off system and the powder suction see the chapter on Booth basement Powder recovery A safe and clean powder recovery is ensured by following components Cyclone separator Sieve machine Dense phase conveyor Powder c
18. eginning of the line H high L low The indicated blowing direction is absolutely to be observed The parts to be replaced during maintenance are available as spare parts see the spare parts list Maintenance e 27 Gema er Maintenance and repair of the cyclone separator The following activities on the cyclone should be carried out regularly Remove powder deposits and caked powder Check the gaskets sealing strips and locking mechanisms covers etc for functioning and sealing Replace the material abraded from the cyclone inside walls by abrasive powders by build up welding Further information see the corresponding operating manual Maintenance and repair of the sieve machine The following activities on the sieve machine should be carried out regularly Check the gaskets and if necessary replace them Check the clamping force of the clamping levers and if necessary reset them Clean the sieve mesh or if damaged replace it Further information see the corresponding operating manual Maintenance of the After Filter pressure gauges filter and fan The following check should be carried out regularly Notice the pressure on the pressure gauges and compare with the original pressure values which were set by the Gema service engineer at the first start up If errors arise see the troubleshooting guide and the After Filter operating instructions If it is not possible to adjust the original settings plea
19. enter The powder which does not adhere on the workpiece overspray is fed from the suction opening through a conduction to the cyclone intake The powder is separated in the cyclone and then sieved in the sieve machine The recovered powder is fed to the powder center and back into the powder container NOTE Further information about the powder recovery components you will find in the corresponding user manuals 16 e Design and function MagicCylinder EquiFlow V 12 13 Gema Automatic guns OptiGun AX or PG 2 AX automatic powder gun types are used in the MagicCylinder QCS04 powder coating booth These guns were particularly developed for an automatic simple cleaning Kr MagicCylinder QCS04 automatic guns The connections for the powder hose the high voltage and the electrode rinsing air are outside of the coating booth These supply attachments are integrated into the gun enabling the guns to can be cleaned automatically by blow off nozzles The powder hose connection makes possible a perfect fixing of the powder hose by the clamping device This is a prerequisite for the automatic rinsing of the powder transport equipment further information about automatic guns see in the corresponding user manual On the MagicCylinder QCS04 booth a distinction between light and dark colors is principally made MagicCylinder EquiFlow Design and function e 17 Gema aa Cleaning the guns x MagicCylinder
20. enter the coating function can be initiated The injectors move downwards and the level control unit is activated The vibrator and the fluidization are switched on Switch on the gun control units Activate the automatic function on the operating unit the reciprocators move to the reference point All interlocked plant units are enabled ES control unit etc The control units and all interlocked plant units are ready for operation The message too little powder appears on the operating unit after a delay and the alarm horn sounds Maintenance e 29 V 12 13 Gema Decommissioning storage Introduction Safety rules Suitable equipment e g a crane must be used when moving parts that are sometimes bulky and heavy Components being disassembled must be adequately secured before they are detached Requirements on personnel carrying out the work Use only technical personnel who are trained in operating the respective equipment e g a crane If there are any uncertainties please contact Gema Storage conditions MagicCylinder EquiFlow Storage duration If the physical conditions are maintained the unit can be stored indefinitely Space requirements The space requirements correspond to the size of the booth parts plus the packaging The load bearing capacity of the floor should be at least 500 kg m There are no special requirements concerning distance to neighboring equipment Physical requiremen
21. essary carry out a function check before starting work After long stops standstills 1 2 3 Switch on the booth Fill in or refill powder Check the tight seating of the filter cartridges Place the refuse container under the After Filter Open the compressed air supply and set the input pressure for the After Filter Turn on the main switch the main switch is located on the control cabinet Turn the key switch the control unit is activated the operating unit is activated and the key switch returns to its starting position Start the system the main menu appears on the operating unit the fan in the powder center runs up Activate the powder center see therefore the corresponding user manual Switching off the booth Dr Je e MagicCylinder EquiFlow Quit the automatic operation mode Switch off the gun control units and all additional plant units Switch off the system in the main menu Switch off the powder center Switch off the main switch Operation e 23 Gema Alarm messages Filter cleaning V 12 13 If malfunctions take place the signal horn sounds and an alarm message is shown see the chapter Troubleshooting and the control unit user manual The filter cartridges in the After Filter are blown off cyclically from the inside during operation The predetermined cycle times are set at the factory but must be reset if the maximum differential pressure is repeatedly exceeded this initiates an al
22. h It will safely guide you through the start up process and give you references and tips for the optimal use of your new powder coating system Information about the function mode of the individual system components booth gun control unit manual gun or powder injector should be referenced to their corresponding documents About this manual e 9 V 12 13 Gema Design and function Field of application MagicCylinder QCS04 coating booths are used for the electrostatic powder coating of all types of workpieces in large batches with frequent color changes As part ofthe process controlled coating plant they are laid out for fully automatic operation The most important characteristics of the MagicCylinder QCS04 coating booths are Superstructure and booth basement in plastic material Low booth basement height Permanent powder suction from the entire booth floor suction openings integrated into the booth floor Automatic floor cleaning no powder accumulation Integrated exhaust air main collector Fast color change by one person The guns are arranged vertically Function description MagicCylinder EquiFlow The principle of function is determined by the requirements placed on the booth which are The protection of the coating process from external influences combined with keeping the area around the booth clean The powder recovery The avoidance of an explosive powder air mixture inside the
23. he contents or use of this publication and reserves the right to revise this publication and make changes to its content without prior notice Printed in Switzerland Gema Switzerland GmbH M venstrasse 17 9015 St Gallen Switzerland Phone 41 71 313 83 00 Fax 41 71 313 83 83 E Mail info gema eu com Homepage www gemapowdercoating com Gema V 12 13 Table of contents General safety regulations 5 Safety symbols pictograms annen eneen enneenenneer enne nnnneneneerenernenenenneeenn 5 ad ACE 5 Product specific safety measures nnen ennnerenneer enne nneneenennereenenennnenenneevenn 6 Installation ani tro 6 Operating the equipment nn 7 Inspectionicheck nen e een 7 Entering the DOOtH ooooocononoccconnncccccnonnccnnnnocccnnnnennnn cnn ENE TE 7 TEE 7 About this manual 9 Generaliinf rmation u erringen 9 Design and function 11 Field of application 11 Funetion dSSCHPUOM nido 11 Operational procedure nnn nennnenenneer eneen nora nnnn cn narran nn 12 Powder flow etc hilo fens 13 Booth superstructure nanne ennenrennernenenenneerenerreneernenenenneeneneneenennnnenennens 13 Booth basement Alu Lesen ernennt 14 Floor blow off system nanne nnen ennnenennereneneennnnenenneerenerneenennvenenenn 14 IS ee Eet EE 15 Exhaust air system with After Elter 15 FITO Protect iaa aia 16 Cleaning operation mode nnen erenneenenenenneerenereneneneneereneenenen nennen 16 Automatic booth cleaning
24. ion protection will also be preserved that way The use of spare parts from other manufacturers will invalidate the Gema guarantee conditions MagicCylinder EquiFlow Spare parts list e 39 Gema er MagicCylinder QCS04 spare parts list Floor blow off system Pneumatics see separate spare parts list Pressure regulator see separate spare parts list Sensor Actor Box see separate spare parts list Gun blow off equipment see separate spare parts list Door drive unit see separate spare parts list O O A O N ich Fan control unit see separate spare parts list MagicCylinder QCS04 spare parts 40 e Spare parts list MagicCylinder EquiFlow V 12 13 Floor blow off system Pneumatics Gema 3 Solenoid valve 1 2 NW 13 5 24 VDC 1005 120 4 Valve coil for pos 3 24 VDC 1005 119 7 Valve cable 3 pins M12 for pos 4 1008 244 15 Hose 12 10 mm 100 382 Please indicate length 15 MagicCylinder QC S04 Floor blow off system Pneumatics MagicCylinder EquiFlow Spare parts list e 41 Gema m Pressure regulator 1 Pressure regulator 0 8 bar 1 i 1008 185 2 Manometer 0 10 bar 1 8a 243 620 3 Adapter nipple 1 8i 1 4a 231 932 MagicCylinder QCS04 Pressure regulator 42 e Spare parts list MagicCylinder EquiFlow V 12 13 Sensor Actor Box Gema 1 Sensor Actor Box M12 8P 1008 242 2 Y distributor threefold M12 1008 246
25. ips and other information 1 The MagicCylinder EquiFlow powder coating booth is built to the latest specification and conforms to the recognized technical safety regulations and is designed for the normal application of powder coating 2 Any other use is considered non compliant The manufacturer shall not be liable for damage resulting from such use the user bears sole responsibility for such actions If the MagicCylinder EquiFlow powder coating booth is to be used for other purposes or other substances outside of our guidelines then Gema Switzerland GmbH should be consulted General safety regulations e 5 Gema V 12 13 Observance of the operating service and maintenance instructions specified by the manufacturer is also part of conformity of use The MagicCylinder EquiFlow powder coating booth should only be used maintained and 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 MagicCylinder EquiFlow powder coating booth has been set up and wired according to the guidelines for machinery 2006 42 EG EN 60204 1 machine safety must also be observed Unauthorized modifications to the MagicCylinder EquiFlow powder coating booth exempts the manufacturer from any liability from resulting damage The relevant accident prevention regulations as well as other genera
26. lly 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 CE oo le Product specific safety measures 6 e General safety regulations Installation Installation work performed by the customer must be carried out according to local regulations Before starting up the plant a check must be made that no foreign objects are in the booth or in the ducting input and exhaust air All components must be grounded according to the local regulations before start up The booth grounding is to be checked at every start up The grounding connections are customer specific and are made on the base of the booth The grounding of the workpieces and other plant units must also be checked MagicCylinder EquiFlow V 12 13 Gema 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 control unit with touch panel before starting up the plant In addition all further equipment specific operating instructions e g the OptiFlex OptiMatic or APS and all additional components should also be read To obtain pr
27. nder EquiFlow ee Gema MagicCylinder QCS04 fan control unit MagicCylinder QCS04 fan control unit MagicCylinder EquiFlow Spare parts list e 49
28. ner Set the powder center to the cleaning mode Coarse cleaning of the powder center 3 Clean the guns externally and move them to the blow off position 4 Blow off internal cleaning the powder hoses in direction from the powder center MagicCylinder EquiFlow V 12 13 Gema 5 Coarse cleaning of the booth Coarse cleaning of the booth with the air lance Open the cyclone cone and remove the sieve leave the cyclone open Remove the recovery hose from the powder container 6 Clean the booth if necessary move the guns out of the booth if necessary clean the muzzles etc Blow off the booth with the air lance clean the suction opening if necessary wipe off the booth walls 7 Clean the powder center if necessary change the powder hoses bright dark Initiate the filter cartridges cleaning manually Clean the powder center floor vibrating table collecting container etc 8 Clean the recovery system Connect the recovery hose to the blow off connector Open the cyclone cone and clean the sieve Blow off the recovery system if necessary wipe off the cyclone cone Blow off the inside of the monocyclone with the air lance 9 Prepare the equipment for coating Make the recovery system ready for operation Put the powder center into coating operation insert the powder container with the new color move down the injectors Put the booth into coating operation switch on the pla
29. nt move the XT axis into coating position start the correct reciprocators program 10 Check the guns for functioning high voltage and powder output REMARK This short instructions should facilitate above all the handling of the plant for the daily always recurring works They do not replace by any means the enclosed manuals of the components and presuppose that you read and understand the corresponding chapters in the operating manual as well as the safety regulations MagicCylinder EquiFlow Operation e 25 Maintenance V 12 13 Gema Maintenance and repair MagicCylinder EquiFlow Daily or after each shift Blow off the powder hoses Clean the guns externally and the check wearing parts Check the vibrating sieve of the cyclone separator and clear away contamination with an industrial vacuum cleaner in single shift works or in each fifth shift in multi shift works Check the clean air chamber in the After Filter housing for powder deposits through the inspection window of the filter housing above the door If powder deposits are present this is an indication of defect filter elements replace the filter elements see After Filter operating instructions Check all oil separators and if necessary empty if oil is present the compressed air preparation must be checked Biannually Disconnect the measuring lines of the pressure gauges on the manometer and blow it off from the manometer to the measuring point b
30. ntainer Alarm has been released Message EMERGENCY STOP MagicCylinder EquiFlow protective switch Motor malfunction exhaust air fan corresponding motor protection switch has reacted Let the motor cool down switch on the corresponding motor protection switch again see wiring diagram see also the Troubleshooting section in the After Filter operating manual Inthe case of repeated alarm contact your Gema service center Troubleshooting e 35 Gema 36 e Troubleshooting V 12 13 Problem error malfunction Procedures remedy The pressure increase is indicated on the filter manometer Pressure increase on the filter cartridges Switch off the gun control units wait until the differential pressure returns to normal again Check the cleaning cycles by ear if necessary shorten the pause times in the cleaning cycle Check if the cleaning pressure is set on 5 bar on the pressure input valve see also the section Troubleshooting in the After Filter operating manual Warning If the pressure gauge shows a pressure rise higher than 3 kPa contact your Gema agent immediately Alarm has been released Message Fan overpressure Minimum pressure in filter housing not reached corresponding pressure gauge responding Alarm has been released Message Fan low pressure Maximum pressure in the filter housing exceeded corresponding pressure gauge responding Too little pressure to
31. o much exhaust air because too little or no air resistance Filter housing door is open Sieve machine not fitted tightly on the cyclone separator Waste container not fitted tightly see also the troubleshooting section in the After Filter manual Pressure too high insufficient exhaust air because the air resistance is too high Filter clogged valves defect or cleaning pressure too low at least 5 bar Poor compressed air quality contains oil or water Malfunctions on running in until the filter cake is built up on the filter cartridges see also the Troubleshooting section in the After Filter operating manual Alarm has been released Message Guns not OK Diagnostic adaptor of the guns indicates that no high voltage is being produced Turn on the gun control unit or correct the fault in the gun control unit or gun with the information in the corresponding operating instructions MagicCylinder EquiFlow Setting values MagicCylinder EquiFlow V 12 13 Gema Problem error malfunction Procedures remedy Bad separation efficiency of the cyclone Check all gaskets above all on the powder separation of the cyclone and if necessary repair them Check the exhaust air volume flow if necessary clear blocked tubes or repair the After Filter Check the cyclone casing for holes caused by wear Check the pretension force of the closings Sieve clogged up Automatic fl
32. oor blow off system not OK Check the powder for dampness Check if too much powder was fed through the cyclone e g during the booth cleaning Check if the vibration motor is switched on Check if the vibration is strong enough If necessary adjust the oscillating weights on the vibration motor Check the compressed air supply Pressure reducing valve defective or adjusted incorrectly Solenoid valve defective coil cable or missing signal NOTE The setting values for the powder center and other plant units you will find in the corresponding operating instructions Troubleshooting e 37 V 12 13 Gema Spare parts list Ordering spare parts When ordering spare parts for powder coating equipment please indicate the following specifications Type and serial number of your powder coating equipment Order number quantity and description ofeach spare part Example Type MagicCylinder EquiFlow Serial number 1234 5678 Order no 203 386 1 piece Clamp 18 15 mm When ordering cable or hose material the required length must also be given The spare part numbers of this bulk stock is always marked with an Wearing parts are always marked with a All dimensions of plastic hoses are specified with the external and internal diameter Example 8 6 mm 8 mm outside diameter o d 6 mm inside diameter i d WARNING Only original Gema spare parts should be used because the explos
33. parts for the booth must be transported using a forklift truck Loading transferring the load unloading Exercise caution at temperatures below 5 to 15 C WARNING Avoid stress in the plastic material The plastic booth must not be transported at temperatures below 15 C gt In summer the air temperature during transport should not exceed 60 C WARNING Avoid heat accumulations and storage in sunlight gt Suitable lifting equipment is to be used for all procedures 34 e Packing transport MagicCylinder EquiFlow Gema V 12 13 Troubleshooting General information A WARNING Faults may be fixed by trained personnel only Malfunctions which arise during operation are registered together with emergency stops in a list with date and time indications An error message is displayed on the operating unit of the control unit If a fault arises the plant is not stopped However if an emergency stop arises the whole plant or units is switched off and the emergency stop mask is displayed on the operating unit The alarm horn sounds at the same time with every message malfunction or emergency stop Problem fixing Problem error malfunction Procedures remedy Alarm has been released Message too little powder bright dark Display flashes in the powder center Acknowledge error fill in fresh powder Switch off the alarm fill in fresh powder Powder shortage in the powder co
34. se contact an Gema service center Further information see the corresponding operating manual Replacing spare parts Spare parts are to be replaced by trained personnel only The plant must always be switched off when replacing spare parts Spare parts can be ordered from the spare parts list ed NOTE 1 Only original Gema spare parts should be used 28 e Maintenance MagicCylinder EquiFlow Functional check V 12 13 Gema General information A function check is to be carried out After a replacement of spare parts on the booth or on the electrical part of the booth or on plant units connected to the booth After manipulations on the electrical part or on external plant units connected to the booth control unit or on the booth control unit itself after long stops standstills Procedure of the function check 1 MagicCylinder EquiFlow Switch on the main switch control units and all interlocked equipment should not be able to be switched on Turn the key switch the control unit is activated the operating unit is activated and the key switch returns to its starting position Control units and all interlocked equipment should not be able to be switched on Start the system the main menu appears on the operating unit the fan in the powder center runs up The operation of the powder center is described in the corresponding user manual Ifthe powder container is positioned on the vibrating table in the powder c
35. ts Storage must be inside a dry building at a temperature between 5 40 C Do not expose to direct sunlight Hazard notes There is no danger to personnel or the environment if the unit is stored properly Decommissioning storage e 31 Gema Shut down V 12 13 Decommissioning Before starting any kind of work the whole plant must be disconnected from the supply current compressed air The fire suppression components connected to the booth are to be dismantled removed according to the instructions of the fire detection system supplier Cleaning Remove the contamination from the outside of all components Disassembly attachment of transport safety devices use supplied transport utilities again Packing A suitably stable pallet big enough must be used To prevent damage to the components collisions with other parts must be prevented It is definitely not recommended to stack the individual parts Should this nonetheless be planned the packaging must be made robust enough to protect the cabin parts against additional forces Identification Apply the label Protect from dampness and moisture on the product and the packaging Maintenance during storage Maintenance schedule No maintenance schedule is necessary Maintenance works During long term storage periodically perform a visual check Return to service A 32 e Decommissioning storage Commissioning following storage Before
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