Powder coating booth MagicCylinder
Contents
1. tnt armen mel 27 Maintenance and repair of the cyclone separator ennen en 28 Maintenance and repair of the sieve machine ennenene neren 28 Maintenance of the After Filter pressure gauges filter and fan 28 Replacing spare parts m ener 28 Functional check o obe ERROR ER ER NER RA 29 General information sss 29 Procedure of the function Check ii 29 Decommissioning storage 31 Introduction nef e e e hte nns 31 Safety TUS iia et in P Ur e ere tes 31 Requirements on personnel carrying out the work nn 31 Storage condHONS rene artnr drsn bete t HD REN et EE 31 Storage durationz sia ED HE annata 31 Space requirements nennen 31 Physical requirements rigo ee ele ni Bun 31 Hazard notes 5 Anson neben idee teet 31 De el p EET 32 Decommissi ning 3 22 22 2 22 6 een keinen 32 Cleatilig 1 iier een EROR ER RE ERAS 32 Disassembly attachment of transport safety devices 32 PaCckillg En 32 Identification stile sazia iaia lai 32 Maintenance during storage nennen 32 Maintenance schedule 4 nennen ns 32 Maintenance Works 32 Return tO Service inversteren ene o dee cue derden a e Vase ead aaa apie eld 32 Commissioning following storage i 32 Packing transport 33 Introduction ua ciali nali eden2. 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 requirements Storage must be inside a dry building at a temperature between 5 and 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 06 14 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 booth parts against additional forces Identification Apply the label Protect from dampness and moisture on the product
3. 6 1 8 6 mm 245 950 11 Elbow joint 1 8 2 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 5 0 kPa differential pressure 243 779 16 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 1002 205 22 5 0 8 0 1002 174 30 5 0 8 0 1002 175 37 5 0 8 0 1002 176 45 5 0 8 0 1002 177 55 5 0 8 0 46 Spare parts list MagicCylinder ven Gema MagicCylinder Fan control unit 10 MagicCylinder Fan control unit MagicCylinder Spare parts list e 47
4. 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 mounting the booth 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 V 06 14 Gema Packing transport Introduction 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 a crane If there are any uncertainties please contact Gema Packing material Not necessary for the internal transport For external transport see Storage Transport MagicCylinder Data concerning goods to be transported The spac
5. data e 19 V 06 14 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 Grounding 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 Commissioning e 21 Operation V 06 14 Gema Before switching on the booth Strictly observe the safety regulations see also chapteer General safety regulations Check the grounding of the booth and the other plant units and ensure it if necessary If necessary carry out a function check before starting work After long stops standstills 1 2 3 Fill in or refill powder Check the tight seating of the filter cartridges Place the refuse container under the After Filter Switch on the booth 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
6. maintenance of the air flow prevents as well the creation of dangerous powder air mixtures The powder recovery takes place by the powder separation in the cyclone separator during operation Design and function e 11 Gema 12 e Design and function V 06 14 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 ofthe 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 external plant units such as chain conveyor OptiCenter reciprocators optionally fire protection optionally etc are switched on The operating functions in the OptiCenter 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 Therefor
7. on the operating unit the fan in the OptiCenter runs up Activate the OptiCenter see therefore the corresponding user manual Switching off the booth O1 door wed MagicCylinder Quit the automatic operation mode Switch off all additional plant units Switch off the system in the main menu Switch off the OptiCenter Switch off the main switch Operation e 23 Gema V 06 14 Alarm messages If malfunctions take place the signal horn sounds and an alarm message is shown see the chapter Troubleshooting and the control unit user manual Filter cleaning 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 alarm 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 p
8. opening if necessary wipe off the booth walls Clean the OptiCenter if necessary change the powder hoses bright dark Initiate the filter cartridges cleaning manually Clean the OptiCenter 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 Prepare the equipment for coating Make the recovery system ready for operation Put the OptiCenter into coating operation Put the booth into coating operation switch on the plant move the XT axis into coating position start the correct reciprocators program Check the guns for functioning high voltage and powder output This short instructions should facilitate above all the handling of by any means the enclosed manuals of the components and the plant for the daily always recurring works They do not replace presuppose that you read and understand the corresponding chapters in the operating manual as well as the safety regulations MagicCylinder Operation e 25 Maintenance V 06 14 Gema Maintenance and repair MagicCylinder Daily or after each shift Weekly 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 c
9. 8 592 41 Hexagon screw M5x10 mm 205 699 43 Hexagon shakeproof screw M6x12 mm 244 406 45 Hexagon shakeproof screw M8x20 mm 244 422 46 Allen cylinder screw M4x20 mm 216 291 47 Allen cylinder screw M4x16 mm 216 283 48 Cap screw M5x35 mm 201715 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 Please indicate length 44 e Spare parts list MagicCylinder ven Gema MagicCylinder door drive unit 18 Ve p 7 43 41 56 21 g 32 oma 6 E 41 56 57 33 39 i i SIS 4 47 12 15 H 45 16 3 13 46 50 55 Pur 23 48 51 56 Fe Ae lt lt JAN I E59 10 42 53 11 45 40 54 Vestibule round Manual coating 9 49 40 54 MagicCylinder door drive unit MagicCylinder Spare parts list e 45 Gema V 06 14 MagicCylinder 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
10. Operating instructions and spare parts list Powder coating booth MagicCylinder Translation of the original operating instructions Gema Gema ui Documentation MagicCylinder powder coating booth Copyright 2007 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 MagicCompact MagicCylinder MagicPlus MagicControl OptiFlex OptiControl OptiGun OptiSelect OptiStar and SuperCorona are registered trademarks of Gema Switzerland GmbH OptiFlow OptiCenter OptiMove OptiSpeeder OptiFeed OptiSpray OptiSieve 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 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 holder
11. als MagicCylinder Design and function e 15 Gema Automatic guns 16 e Design and function V 06 14 OptiGun AX or PG 2 AX automatic powder gun types are used in the MagicCylinder powder coating booth These guns were particularly developed for an automatic simple cleaning BERE MagicCylinder 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 booth a distinction between light and dark colors is principally made As a result of this the powder hoses are double placed from the OptiCenter MagicCylinder vin Gema Cleaning the guns MagicCylinder 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 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 fl
12. at 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 MagicCylinder Design and function e 17 V 06 14 Technical data MagicCylinder powder coating booth MagicCylinder Electrical data Gema MagicCylinder Input voltage 3x400 V 50 Hz other voltages and frequencies on request Pneumatic data MagicCylinder Input pressure min 6 bar max 10 bar Air entry speed 0 7 m sec Water vapor content of compressed air max 1 3 g m Oil content of compressed air max 0 1 mg m Dimensions MagicCylinder Booth diameter Booth basement height 2 5 m in the interior 12m Weight with superstructure height 3000 mm approx 2600 kg more or less weight per 500 mm height approx 300 kg Sound pressure level MagicCylinder Sound pressure level max 80 dB A 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 Technical
13. e 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 V 06 14 Gema Powder flow MagicCylinder Powder flow in the plant 1 Booth 5 After Filter 2 Cyclone separator 6 Refuse container 3 Sieve 7 OptiCenter 4 Dense phase conveyor 8 Automatic guns The powder container is located in the OptiCenter 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 falls to the booth floor and is sucked 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 in the OptiCenter 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 Afte
14. e 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 V 06 14 Mode of transportation For short distances shifts of position within the same room 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 V 06 14 Troubleshooting General information A Problem fixing MagicCylinder WARNING Gema 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 eme
15. eanings 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 tips and other information 1 The MagicCylinder 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 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 06 14 3 Observance of the operating service and maintenance instructions specified by the manufacturer is also part of conformity of use The MagicCylinder 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 4 Start up i e the execution of a particular operation i
16. he booth grounding is to be checked at every start up The grounding connections are customer specific and are made MagicCylinder V 06 14 Gema on the base of the booth The grounding of the workpieces and other plant units must also be checked 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 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 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 Pne
17. lant control unit Color change and cleaning 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 Close the booth doors Switching over the booth control to cleaning operation Move the guns to the cleaning position 2 Prepare the OptiCenter for cleaning Remove the powder container from the OptiCenter the recovery hose remains on the powder container Set the OptiCenter to the cleaning mode Coarse cleaning of the OptiCenter 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 OptiCenter 24 e Operation MagicCylinder 5 10 NOTE V 06 14 Gema 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 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
18. leaner 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 NOTE Disconnect the measuring lines of the pressure gauges on the manometer and blow it off from the manometer to the measuring point beginning of the line Definition of the lines 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 V 06 14 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 regular
19. ly Check the gaskets and if necessary replace 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 please 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 2 NOTE 1 Only original Gema spare parts should be used 28 e Maintenance MagicCylinder Functional check V 06 14 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 Switch o
20. ma 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 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 Powder recovery A safe and clean powder recovery is ensured by following components Cyclone separator Sieve machine Dense phase conveyor OptiCenter The powder which does not adhere on the workpiece overspray is fed from the central suction opening in the funnel through a pipe to the cyclone intake The powder is separated in the cyclone and then sieved in the sieve machine The recovered powder is fed by the dense phase conveyor to the OptiCenter and back into the powder container NOTE e 1 Further information about the powder recovery components you will find in the corresponding user manu
21. meter i d WARNING Only original 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 Gema guarantee conditions MagicCylinder Spare parts list e 39 Gema V 06 14 MagicCylinder Spare parts list Fluorescent tube 200 240 V 50 Hz 18 W 1004 542 Fluorescent tube 200 240 V 50 Hz 36 W 1004 543 Door drive unit see separate spare parts list Gun blow off equipment see separate spare parts list O A WIN gt Fan control unit see separate spare parts list 40 e Spare parts list MagicCylinder ven Gema MagicCylinder Spare parts MagicCylinder Spare parts MagicCylinder Spare parts list e 41 Gema V 06 14 MagicCylinder gun blow off equipment 1 Intermediate piece complete 381 110 2 End piece complete 381 160 3 Tube Y 18 16 mm distance between nozzles 381 144 4 Tube Y 18 16 mm L 1950 mm 381 152 13 Hose clamp 17 25 mm 223 085 14 Plug cap 1 243 612 15 Plug cap 1 2 259 306 16 Hose connector 17 mm 1 2 223 069 17 Y piece 1 2 1 2 1 2 267 171 18 Double nipple 1 1 1003 544 19 Adapter nipple 1 1 2 252 875 20 Ball valve 1 1 1 1003 546 21 Solenoid valve 1003 547 23 Compressed air hose Y 16 4 26 6 mm black 105 155 24 Cable socket 3 pins with female c
22. n 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 operation of the OptiCenter is described in the corresponding user manual Switch on the gun control units if necessary 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 06 14 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 Storage duration If the physical conditions are maintained the unit can be stored
23. 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 Check the powder for dampness Check if too much powder was fed through the cyclone e g during the booth cleaning Automatic floor blow off system not OK 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 OptiCenter and other plant units you will find in the corresponding operating instructions Troubleshooting e 37 V 06 14 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 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 dia
24. onnectors 227 919 25 Allen grub screw M6x10 mm 214 841 26 O ring Y 18x2 mm 244 287 27 Flat jet nozzle 250 716 28 Nozzle nut 250 724 Please indicate length Wearing part 42 Spare parts list MagicCylinder ven Gema MagicCylinder gun blow off equipment Version with control valve q eg 15 Ld SY 14 n 16 i ear PTE Manual control version 16 E 15 Vo 14 Y 2 16 SSR 16 23 19 i3 jk o 20 18 MagicCylinder gun blow off equipment MagicCylinder Spare parts list e 43 Gema V 06 14 MagicCylinder door drive unit 1 Holder large 389 714 2 Holder small 389 706 3 Drive shaft 1000 128 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 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 8 251 305 30 Double nipple 1 8 1 4 242 209 32 Y connection fitting 1 8 8 mm 253 936 33 Adjusting elbow 8 8 mm 238 287 35 Elbow joint 1 4 8 mm 254 029 39 Plastic tube 8 6 mm black antistatic 103 756 40 Rubber buffer 40x28 mm M8a 24
25. out this manual e 9 V 06 14 Gema Design and function Field of application MagicCylinder 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 coating booths are Superstructure and booth basement in plastic material Automatic floor cleaning no powder accumulation Central suction unit under the center of the booth Fast color change by one person The guns are arranged vertically Function description MagicCylinder 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 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
26. r 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 MagicCylinder Design and function e 13 Gema Booth superstructure The MagicCylinder booth superstructure is a double walled plastic panel construction forming a side section and a half roof on each side Horizontal spacing ribs guarantee high stability of the booth walls and the necessary distance between the inner and outer liners for 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 manual touch up stations The booth can be equipped either on one or both sides with manual coating equipment as precoating or touch up station alternatively Booth basement The booth basement is funnel shaped with a central suction opening made of reinforced plastic material Oversprayed powder depositing in the funnel is blown down into the central suction unit MagicCylinder Basement 14 e Design and function MagicCylinder V 06 14 Ge
27. rational procedure nennen 12 Powder 10W 2 terea inten iin en ao iaia 13 Booth superstructure ii 14 Booth basement nette er inde acts eat 14 Exhaust air system with After Filter 15 Fire protection tar cic antenne 15 Cleaning operation mode nonnen aa i aa eaea i a aeri 15 Powder TecoVOTy oaa ra raten OTT E AAT 15 Automatic GUNS eratara TERT asia 16 Cleaning the JUAS caaan A ed etui RR ERA e 17 Technical data 19 MagicCylinder powder coating booth 19 Electrical data oeren ansieae Reener 19 Pne miatic dat RICERCA a 19 DIMENSIONS Arnd SALARI nu dd eis 19 Sound pressure level nenn 19 Commissioning 21 Set up and assembly ssc igiene tia 21 Installation rise 22222 sacl EE Pp na ATEM IAE dept aes 21 Cable connections junctions nnn ennen enne eeenennvenenenneeeeenenneeeen eneen 21 Grounding REENER 21 Operation 23 Before switching on the booth nnen ene 23 owitch on the booth ant oerte rage cet rene tle b ee x cune tarn 23 Switching off the booth iocis ii 23 MagicCylinder Table of contents e 1 Gema vm Alarm messages med n eet rese e Ha e dond 24 Filter clearingzs ttr daten durend re fe order et federa 24 Color change and cleaning i 24 Maintenance 27 Maintenance and repai eene 27 Daily or after each Shift nee 27 Weekly u een 27 Biarin ally
28. rgency stop Problem error malfunction Procedures remedy Alarm has been released Message too little powder bright dark Display flashes in the OptiCenter Powder shortage in the powder container Acknowledge error fill in fresh powder Switch off the alarm fill in fresh powder Alarm has been released Message EMERGENCY STOP 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 In the case of repeated alarm contact your Gema service center Troubleshooting e 35 Gema 36 e Troubleshooting V 06 14 Problem error malfunction Procedures remedy The pressure increase is indicated on the filler 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 o
29. s 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 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 patent information see www gemapowdercoating com patents or www gemapowdercoating us patents 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 V 06 14 Gema Table of contents General safety regulations 5 Safety symbols pictograms nn 5 PROPER USC sais i er ns ii ART 5 Product specific safety MeaSUres nennen 6 General information nennen 6 Installation ertet tente eer nee et daan eee 6 Operating the equipment enen ennennee enen enenennennenenenn 7 Inspection chieck nine cete ere eer HERE et itta dens 7 Enteringithe DOO 1525 a eic et pt a el n ea ep D RR ERRARE MR ANTE 7 IpX zlerif s 7 About this manual 9 General information x4 tetti owen ete ended 9 Design and function 11 Field of application 52 teneo eet eee dus 11 F nctionidescriptior 2 rer re etae RR en aee ts 11 Ope
30. s forbidden until it has been established that the MagicCylinder 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 5 Unauthorized modifications to the MagicCylinder powder coating booth exempts the manufacturer from any liability from resulting damage 6 The relevant accident prevention regulations as well as other generally recognized safety regulations occupational health and structural regulations are to be observed 7 Furthermore the country specific safety regulations also must be observed Explosion protection Protection type CE qo PS inen Product specific safety measures 6 General safety regulations General information The MagicCylinder powder coating booth is a constituent part of the equipment and is therefore integrated in the system s safety concept If itis 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 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 T
31. te bie edet uda Pete dr Ie 33 Safety rules iaia t ale Hader 33 Requirements on personnel carrying out the Work 33 Packing material e Leve tete eco edu tee dus ete duis 33 Transport ieden kee eee IS 33 Data concerning goods to be transported nnn eneen 33 Mode of transportation nanne enene neer enenenneneeeenenenenenneneenenenn 34 Loading transferring the load uNIoading ennen eneen 34 Troubleshooting 35 General information een eee 35 Problem ANG varen retentie A ger lH 35 setting values ri ne ae ee 37 Spare parts list 39 Ordering spare partSs nennen sen nnenene rennen nente enne eterne nens 39 MagicCylinder Spare parts list eene 40 2 e Table of contents MagicCylinder V 06 14 Gema MagicCylinder gun blow off equipment nnee eeen enneeenen eneen enn 42 MagicCylinder door drive unit nnee ennen anneer een enneerenenneenenenn 44 MagicCylinder Fan control unit i 46 MagicCylinder Table of contents e 3 V 06 14 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 powder coating booth These safety regulations must be read and understood before the MagicCylinder powder coating booth is put into operation Safety symbols pictograms Proper use MagicCylinder The following warnings with their m
32. umatic conduction to the After Filter is connected the filter element door is closed the waste container is placed and fitted Entering the booth 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 General safety regulations e 7 V 06 14 Gema About this manual General information This operating manual contains all the important information which you require for the working with the MagicCylinder powder coating booth 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 and gun or powder injector should be referenced to their corresponding documents DANGER A 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 Safety regulations gt Work should only be carried out in accordance with the instructions of the relevant documents gt Always work with the complete original document MagicCylinder Ab
33. verpressure 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 too 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 Setting values MagicCylinder V 06 14 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
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