ZA06 Reciprocator
Contents
1. 2 Service cover MA 1004 016 3 Hexagon screw M6x10 mm 1001 081 4 Service cover MS 1004 015 5 lead through 50 mm 5 4 1004 006 6 Electrical module see ZA06 Reciprocator electrical module 7 7 complete see ZA06 Reciprocator Z carriage complete 8 Toothed wheel see ZA06 Reciprocator toothed wheel 9 Proximity switch see ZA06 Reciprocator proximity switch 10 Service cover SS 1004 017 11 Cable lead through 50 mm double 1004 007 12 Cable grommet QT6 1004 531 13 Panel lateral ZA06 13 386 502 ZA06 18 386 510 ZA06 23 386 529 ZA06 28 386 537 ZA06 33 38 1004 454 14 Panel front ZA06 13 1004 011 ZA06 18 1004 012 ZA06 23 1004 013 ZA06 28 1004 014 ZA06 33 38 1004 455 15 Membrane grommet 1003 578 16 Gun holder plate complete 386 693 Gun holder plate special not shown 1004 453 Spacer not shown 1004 456 17 Hexagon shakeproof screw M8x20 mm 244 422 18 Hexagon shakeproof nut M8 244 449 20 Milled nut M6 brass 200 433 21 Shake proof washer A type 6 200 450 22 Washer 6 4 12 5x1 6 mm brass 200 476 23 Hexagon nut M6 brass 200 417 24 Hexagon screw M6x35 mm 389 838 Please indicate length 36 e Spare parts list ZA06 ni 2 06 Reciprocator spare parts ZA06 Reciprocator spare parts ZA06 Spare parts list 37 iu 7 06 Reciprocator toothed wheel2. Maintenance General information Drive unit ZA06 AN Attention Before doing maintenance works to the reciprocator always be sure that nobody can switch on the reciprocator The reciprocator has to be free of load and disconnected from mains The ZA06 Reciprocator was designed to operate with a minimum of maintenance The gear box of the three phase AC motor is self lubricating and maintenance free Regular maintenance and inspection of the reciprocator increases the working reliability and avoids damages repair downtimes etc Blow off the outside of the reciprocator with compressed air or clean it with a soft cloth from top to bottom at least once a week If necessary blow off the slots Attention Before doing maintenance works to the drive unit always be sure that the reciprocator has to be free of load and disconnected from mains The gearbox of the three phase AC motor is self lubricating and mainte nance free Observe the contamination of the enclosure strong contamination on the outside can increase the operating temperature of the drive unit Therefore clean the drive unit from time to time with a vacuum cleaner etc Check the drive unit gearbox monthly for oil loss If the drive unit gearbox has to be changed for any reason the complete unit has to be replaced Attention For safety reasons two people should always carry out the follow ing maintenance work Maintenance e
3. 15 0 e 1 flashing DIO SS picca dEL 26 0 Frequency converter access to menus storage Adjusted parameters Menu SET Code Value ACC 0 1 sec DEC 0 1 sec HSP 110 Hz ITH 3 7 A TDCI 1 0 sec SDC1 3 7A CL2 3 0A SFR 16 kHz Menu DRC Code Value UNS 210 V FRS 87 Hz NCR 3 3A NSP 2540 rpm COS 0 8 RSC active TUN Pon NRD no SFR 16 kHz TFR 110 Hz SRF yes Menu I O Code Value CRL3 4 7 MA ZA06 Frequency converter e 33 V 02 13 Menu CTL Code Value LAC L2 FR1 Al3 Menu FUN Code Value RPC BRA no LC2 LC2 LI6 CL2 CL2 3 0A Note The resetting of the frequency converter to the Gema factory setting takes place by the FSC parameter in the DRC menu Maintenance The frequency converter FU does not require a preventive mainte nance However it is recommended to carry out the following inspections by the user in regular intervals Check condition and tightness of the cable connections Check the efficacy of the ventilation average life span of the fan approx 3 5 years Remove the dust from frequency converter FU Replace the frequency converter AN 34 e Frequency converter If a frequency converter exchange has taken place it is to be noted that all shielded cables are properly attached again on the EMV plate Attention The cover plate of the frequency converter is to be kept always closed Before interventions ta
4. 42 2 06 Reciprocator electrical 44 2 06 Reciprocator gun holders esee 45 Gun holder for 1 4 goung 45 Gun holder for 5 8 goung 46 Gun holder for 2x1 4 goung 47 Vertical gun holder 48 Gun fixtures and collision Droiechon 49 2 e Table of contents ZA06 Gema General safety regulations This chapter specifies out the fundamental safety regulations that must be followed by the user and third parties using the ZA06 Reciprocator These safety regulations must be read and understood before the ZA06 Reciprocator is used Safety symbols pictograms The following warnings with their meanings can be found in the Gema operating instructions The general safety precautions must also be fol lowed as well as the regulations in the operating instructions DANGER Danger due to live electricity 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 equip ment INFORMATION Useful tips and other information Conformity of use ZA06 1 The ZAO6 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 li
5. Please indicate length View A 3 2 Y de 1 V Sm 6 L 2 4 Automatic guns 46 e Spare parts list ZA06 Gun holder for 2x1 4 guns 1 Clamp element half order in pairs 363 987 Cross clamping element 2 40 40 mm 363 910 Cross clamping element 2 40 30 mm 363 936 Cross clamping element 30 30 mm 363 952 see gun attachment etc Allen cylinder screw M8x50 mm 235 113 Tube 30x600 mm 337 528 Tube 0 30x800 mm 337 536 Tube 30x1000 mm 337 544 Tube 30 mm 103 306 6 1 Tube plug 30 mm for pos 6 236 373 7 Tube 40x600 mm 337 552 Tube 40 1000 mm 337 560 Tube 40x1500 mm 337 579 Tube 40x2000 mm 337 587 Tube 40 mm 103 314 7 1 Tube plug 40 mm for pos 7 236 381 Please indicate length View A 7 3 2 MEN AL c Be VI d 6 ges Automatic guns ZA06 Spare parts list 47 Vertical gun holder 1 Clamp element half order in pairs 363 987 Cross clamping element 40 40 mm 363 910 Cross clamping element 40 30 mm 363 936 Cross clamping element 30 30 mm 363 952 4 see gun attachment etc 5 Allen cylinder screw M8x50 mm 235 113 6 Tube 30 600 mm 337 528 Tube
6. 30x800 mm 337 536 Tube 30x1000 mm 337 544 Tube 30 mm 103 306 6 1 Tube plug 30 mm for pos 6 236 373 7 Tube 40x600 mm 337 552 Tube 40x1000 mm 337 560 Tube 40 1500 mm 337 579 Tube 40x2000 mm 337 587 Tube 40 mm 103 314 7 1 Tube plug 40 mm for pos 7 236 381 Please indicate length View A D Automatic guns 48 e Spare parts list ZA06 Gun fixtures and collision protection 1 Gunfixture 930mm 350 150 2 Gun fixture 39 mm for plastic tube only 354 317 2 Gunfixture 40 mm 1000 507 3 Gun fixture 2 40 mm transverse 356 670 4 Collision protection 30 mm for ZA axis 364 215 5 Dummy piece complete 30 mm for ZA axis 364 231 6 Collision protection 30 mm for YT axis 364 223 7 Dummy piece complete 30 mm for YT axis 364 240 h Gun fixtures 30 5 sai 1 L 39 0 40 na ae 2 SE 1 dies 040 3 27 Collision protection Sn cu 30 i pi 4 119 5 alfa 30 E 5 119 5 2 L ST 030 NELLE 225 6 119 5 1 A Al 030 7 119 5 ZA06 Spare parts list
7. 1 Eyebolt M16 264 415 2 Guide plate 386 588 3 Hexagon shakeproof nut M8 244 449 4 Hexagon ribbed nut M10 234 656 5 Counter profile 40 20x115 mm 386 774 6 Toothed wheel 386 600 7 Toothed belt 103 730 ZA06 13 L 4215 mm ZA06 18 L 5215 mm 2 06 23 L 6215 mm ZA06 28 L 7215 mm 8 Tensioning screw 386 596 9 Hexagon shakeproof screw M6x12 mm 244 406 10 Locking plate 386 634 11 Hexagon shakeproof screw M8x20 mm 244 422 12 Toothed wheel spindle 386 766 13 Spacer ring 31 9 28x11 mm 386 618 14 Bearing 15 32x9 mm 241 709 15 Snap ring A 15 233 617 16 Snap ring l 32 245 780 17 Eyebolt M10x60 mm 264 202 18 Rubber buffer 35 40 mm M8 A 211 664 19 Stop plate 386 782 20 Ribbed washer M10 237 981 21 Hexagon screw M10x180 mm 201 855 Please indicate length Wearing part 38 e Spare parts list ZA06 us 2 06 Reciprocator toothed wheel A H 9 S 10 2 El Cem 12 17 hall Ne del ZA06 Reciprocator toothed wheel ZA06 Spare parts list e 39 2 06 Reciprocator Z carriage complete 1 Carriage fixed side without pos 9 10 386 677 2 Carriage adjustable side without pos 9 10 386 685 3 Roller complete 307 165 4 Spacer sleeve 308 013 5 Hexagon screw M10x110 mm 214 221 6 Hexagon screw M10x100 mm 214 213 7 Hexagon ribbed nut M10 black 234 656 9 Hexagon grub screw M5x16 mm 237 744 10 Hexag
8. Tensioning the toothed belt 21 2 25 Remove the locking plates 21 Tighten the toothed belt evenly with the tensioning screws 22 The guide plate 20 must not be unscrewed for any reason factory setting These screws may not be loosen for any reason factory setting 20 ZA06 Reciprocator top view Replace the toothed belt Procedure 1 10 11 Release the motor brake 12 manually let the Z carriage 10 move down onto the lower stop Switch off the electric power Remove the boarding side panels Remove the locking plates 21 and loosen the tensioning screws so that the toothed belt 3 is slack Loosen the lower clamp plate with the toothed belt on the Z car riage 10 and set it down Note the position of the clamp plate on the toothed belt holder because it must be fitted in approximately the same position on assembly Remove the damaged toothed belt from the reciprocator column Loosen the screws on the upper clamp plate and remove the toothed belt when it is completely outside of the reciprocator Screw on the new toothed belt at the upper clamp plate Pass the loose end of the toothed belt over the upper toothed wheel from inside the reciprocator column Screw on the toothed belt at the lower clamp plate Tension the toothed belt but do not overstretch see chapter Tensioning the toothed belt ZA06 Toothed wheel n Gema Replacing the upper toothed wheel Attention T
9. e 49
10. this can lead to damage to the reciprocator and or the booth Warning During a test run it must be guaranteed that the unit is not dam ZA06 General safety regulations e 5 dos aged by the test In particular the limitations of the stroke range have to be observed for further information see chapter Setting the upper mechanical stop 6 When repairing the reciprocator both the reciprocator control unit and the reciprocator must be disconnected from the mains ac cording to the local safety regulations 7 Repairs may be done only by authorized Gema service centers Unauthorized conversions and modifications can lead to injuries and damage to the equipment The Gema Switzerland GmbH guarantee would no longer be valid 8 Only original Gema spare parts should be used The use of spare parts from other manufacturers will invalidate the Gema guarantee conditions 9 We point out that the customer himself is responsible for the safe operation of the equipment Gema Switzerland GmbH is in no way responsible for any resulting damage 6 e General safety regulations ZA06 About this manual General information ZA06 This operating manual contains all the important information which you require for the working with the ZA06 Reciprocator 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
11. 19 V 02 13 Replacing the drive unit If itis necessary to replace a drive unit gearbox the complete motor unit must be dismantled from the reciprocator base Therefore the reciproca tor has to be free of load and disconnected from mains Procedure 1 11 12 Release the motor brake 12 manually let the Z carriage 10 move down onto the lower stop Remove all cover plates from the reciprocator Remove the locking plates 7 and loosen the tensioning screws so that the toothed belt 3 is slack Loosen the lower clamp plate with the toothed belt on the Z car riage 10 and set it down Note the position of the clamp plate on the toothed belt holder because it must be fitted in approximately the same position on assembly Loosen the grub screw on the clamp ring in front of the flange bearing 2 Use an appropriate iron rod from the side in the hole of the clamp ring and release the clamp ring from the motor spindle counter clockwise with a hammer Remove the clamp ring but do not remove the flange bearing 2 EL ZA06 Reciprocator flange bearing If the grub screw or the hole is not accessible release the brake manually and turn the drive wheel by hand on an appropriate po sition Open the clip and pull out the plug Disconnect the incremental pulse generator cable from connec tion X8 see electrical diagram and pull the plug through the ca ble lead through into the motor compa
12. CR04 CR05 CR06 Temperature range 2 32 F 104 F ZA06 Technical data e 11 12 e Technical data V 02 13 Drive unit data 7 06 Reciprocator Drive unit Asynchronous three phase AC motor Performance 0 75 KW Motor voltage frequency 3x230 VAC 87 Hz Electrical wiring Triangle three phase Motor RPM 2450 1 min Drive torque 80 Nm Brake torque 10 Nm Lubricant type Shell Omala 220 Lubricant quantity 0 25 liters Dimensions d 1 350 750 LL 684 ZA06 Reciprocator dimensions ZA06 us Gema Start up Preparation for start up Attention Before connecting or switching on the reciprocator read carefully N these operating instructions Before the reciprocator is put into operation the upper stroke limit must be set on the reciprocator control unit see therefore the user manual of the reciprocator control unit General information Attention Before start up works are done make certain that nobody can switch on the reciprocator Switch off and lock the mains switch Before starting up the following checks should be done Check the gun holder and hose holder if they are firmly fitted Mount the gun holder in such a way that they do not hit the bottom of the booth slots on start up and cause damage
13. En Operating instructions and spare parts list ZA06 Reciprocator Translation of the original operating instructions Gema Documentation ZA06 V 02 13 Copyright 2006 Gema Switzerland GmbH All rights reserved This publication is protected by copyright Unauthorized copying is pro hibited by law No part of this publication may be reproduced photocop ied 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 OptiFlex OptiTronic OptiGun EasyTronic OptiSelect OptiFlow and SuperCorona are registered trademarks of Gema Switzerland GmbH OptiStar OptiSpray OptiMatic OptiMove OptiMaster OptiPlus Multi Tronic 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 con cerned approve of or are bound in any form by this manual We have en deavored to retain the preferred spelling of the trademarks and regis tered 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 issue Gema Switzerland GmbH makes no representations or warranti
14. Lay out the cables and hoses in such a way that even at the highest stroke no strain can arise Make sure that no guns can collide with the work pieces Check the grounding of the guns and hose carriers Check if the upper and the lower reversing point of the Z car riage are set correctly The stroke length of the reciprocator must be in the range of the booth opening collision danger Make sure that the automatic guns cannot collide with the work pieces incorrectly adjusted stroke parameters on the reciprocator control unit ZA06 Start up e 13 V 02 13 Reference point At every start up after the mains have been interrupted the reference point of the reciprocator must be referred again see Reference point and mechanical stops After the reference point is reached the recipro cator begins to carry out the movements set on the reciprocator control unit Before the reciprocator is put into operation the upper stroke limit must be set on the reciprocator control unit see therefore the corresponding reciprocator control unit operating manual Attention Incorrect setting of the upper and lower stroke limits can cause damages to the reciprocator to the booth and or to the applicators Electrical connections cable connections 14 Start up OptiMove Control unit connections The ZA06 power supply line is connected to the 2 2 Drive supply connection on the reciprocator control unit by t
15. able for damage resulting from such use the user bears sole responsibility for such actions Gema Switzerland GmbH must be consulted prior to any use of the ZA06 Recipro cator for any purposes or substances other than those indicated in our guidelines 3 Observance of the operating service and maintenance instruc tions specified by the manufacturer is also part of conformity of use The 7 06 reciprocator should only be used maintained and General safety regulations e 3 V 02 13 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 ZA06 Reciprocator has been set up and wired according to the guidelines for machinery 2006 42 EG EN 60204 1 machine safety must also be ob served Unauthorized modifications to the ZA06 Reciprocator exempt the manufacturer from any liability from resulting damage The relevant accident prevention regulations as well as other generally recognized safety regulations occupational health and structural regulations are to be observed Furthermore the country specific safety regulations also must be observed Explosion protection Protection type 1 3D 1757 A summary of the directives and standards 4 e General safety regulations European directives RL 94 9 EWG Equipment and Protect
16. an interruption of the power supply etc ZA06 m Setting the lower mechanical stop Attention The setting of the lower mechanical stop must take place without load and the reciprocator must be disconnected from mains Procedure 1 Releasethe brake switch manually 2 Letthe Z carriage sink down until the powder gun holder is ap proximately 50 mm above edge of the gun slot Remove the boarding side panels 4 Loosen the screws and move the lower stop plate up to the Z carriage 5 Tighten the screws 6 Refit the boarding side panels Setting the upper mechanical stop Attention The setting of the upper mechanical stop must take place without load and the reciprocator must be disconnected from mains In order to set the upper mechanical stop the stop position hast to be measured for this reason consider the maximum height of the booth gun slots Attention An incorrect too high set stroke limit can lead to damage to the re ciprocator and or the booth Procedure 1 Remove the boarding side panels 2 Loosen the screws and move the upper stop plate up to the measured position Tighten the screws 4 Refit the boarding side panels Attention After the adjustment of the mechanical stops the system parameter N for the upper stop must be checked on the reciprocator control unit The value must not be larger than the maximum stroke possible be tween the stops ZA06 Start up e 17 us
17. en usteet AE See ei teeta 26 Maintenance during storage 26 Maintenance schedule 26 Maintenance works nennen nennen nnne nnne 26 Packing transport 27 s iei ndi coo rrt are im Es 27 Requirements on personnel carrying out the 27 Packing materlal 5 2 5 roihi d ota ia e dies 27 Selection of packing matertal 27 Procedure when packing 27 TRANS ele GE 27 Data concerning goods to be transported 27 Loading transferring the load unloading 27 Schematic diagrams 29 2 06 Reciprocator wiring diagram 29 Frequency converter 31 RE 31 General Riet le TT 31 Function operation 32 eet Bu UE 32 Access to menu parameters 33 Adjusted poarameterg 2 33 Replace the frequency converter 34 Spare parts list 35 Ordering spare parts 35 2 06 Reciprocator spare parts list 36 2 06 Reciprocator spare Darts 37 2 06 Reciprocator toothed wheel 38 2 06 Reciprocator Z carriage 40 2 06 Reciprocator drive unit
18. er 1003 978 21 Capscrew 50x16 mm 1002 965 22 Ribbed washer M4 264 822 23 Countersunk cylinder screw M4x8 mm 216 259 42 Spare parts list ZA06 n Gema 2 06 Reciprocator drive unit ZA06 Reciprocator drive unit complete ZA06 Spare parts list e 43 2 06 Reciprocator electrical module 1 Frequency converter 1 1 kW for ZA06 1003 985 2 Signals frequency converter connection 1000 314 3 Spacer 4 4 8 9 4 mm 266 833 4 Relay 24 VDC for motor brake 250 961 5 Axis adaptor complete 1000 247 6 Frequency converter mains connection 1000 312 7 Hexagon shakeproof nut M6 244 430 8 Handhold 244 864 9 Hexagon screw M6x12 mm 213 810 10 Drive I O connection complete 1004 105 11 Power supply 1003 990 12 Cylinder screw M3x8 mm 268 801 13 Shake proof washer A type 205 885 14 Hexagon nut 202 142 15 Adhesive seal strip 9x2 mm 100 250 ZA06 power supply cable OptiMove L 20 m not shown 1000 280 2 06 signal cable OptiMove L 20 m not shown 1000 281 5 4 3 2 ZA06 Reciprocator electrical module 44 e Spare parts list ZA06 2 06 Reciprocator gun holders Note The following examples show a possible configuration of gun hold 1 ers Please contact the Gema Service department in the case of special configurations Gun holder for 1 4 guns 1 Clam
19. es with respect to the con tents or use of this publication and reserves the right to revise this publi cation 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 Table of contents ZA06 General safety regulations 3 Safety symbols pictograms i 3 C nformity e TEE 3 A summary of the directives and standards 4 Product specific safety measures i 5 PA le Keele E 5 Special safety regulations for ZA06 Reciprocator i 5 About this manual 7 General Te Ee EE H Function description 9 ZAU6 R eciprocatofis anita iaia ariano 9 Schematic presentation iii 10 Special characteristicS ansa e iret ali 10 Upgrading with XT11 Horizontal avis 10 Technical data 11 2 06 Reciprocatori iuri iii ioc illa 11 NEPSIONS E E 11 Electrical data EEN 11 Drive unit datas tee retten dte re tette i ibt nettes 12 Dimensions EE 12 Start up 13 Preparation for start up eei eed ea ee 13 Generar informatione n iecore eR ert ee tite ro betae 13 Reference polnt 2 e enger me incen Ete RED RE ctore pt 14 Electrical connections cable CONNECHIONS see 14 Checkpoints before switching on ui 15 Grounding protecti
20. he ZA06 power supply cable The ZAO06 Drive I O connection is connected to the 2 3 Drive UO connection on the reciprocator control unit by the ZA06 signal cable ZA06 n Checkpoints before switching on Before switching on the following checks should be done Check if the cables and hoses are laid out correctly Check if the guns have a clear run and do not touch the booth slots Check the distance between the work pieces and the guns Attention Before connecting or switching on the reciprocator read carefully these operating instructions Grounding protection type All metal parts of the reciprocator must be grounded according to the lo cal safety regulations The gun holders must be connected to the ground ing screw on the reciprocator base by the grounding strip All electrical installations are implemented in accordance to VDE IP54 protection type regulations Hoses and cables All movable hoses and cables must be laid out in such a way that they are neither subjected to any loads nor can hang on other parts The elec tric cables of the reciprocators must be protected from mechanical dam age Reference point and mechanical stops The reference point serves as starting point for the reciprocator control unit for calculating the upper and lower reversing point and the maximum stroke By switching on the reciprocator control unit the reciprocator travels au tomatically to the reference point proximi
21. he following workings should only be carried out by trained per sonnel Procedure 1 Release the motor brake 12 manually let the Z carriage 10 move down onto the lower stop 2 Switch off the electric power Remove the boarding side panels 4 Remove the locking plates 21 and loosen the tensioning Screws so that the toothed belt 3 is slack 5 Completely remove the front tensioning screw Attention danger of accident The Z carriage must definitely rest on the rubber buffer before this tensioning screw is removed 6 Hold the toothed wheel 9 tight in one hand whilst the eye bolt is being removed from the spindle 7 Remove the toothed 3 belt from the toothed wheel 8 Remove the toothed wheel 9 and replace it The installation takes place exactly in the reverse order ZA06 If necessary remove the service cover on the base 1 to check if the toothed belt 3 is sitting correctly on the toothed drive wheel Let the Z carriage slowly run up and down the column a few times to see if the toothed belt must be tensioned more Maintenance e 23 Voss Z carriage rollers If the Z carriage 10 starts to vibrate excessively during operation espe cially at the reversing points in most cases the cause lies in too much play in the carriage rollers or even loose rollers 34 32 33 31 30 Z carriage rollers In this case proceed as follows 1 Release the motor brake 12 manually let the Z car
22. ic safety measures EN 61241 10 2004 ZA06 Reciprocator The ZA06 Reciprocator is a constituent part of the system and is thus in tegrated into the safety system of the plant If it is to be used in a manner outside the scope of the safety concept then corresponding measures must be taken Note For further information see the more detailed Gema safety regula tions Special safety regulations for ZA06 Reciprocator 1 The 7 06 Reciprocator should only be started up after carefully reading of these operating instructions Incorrect operation of the reciprocator control unit can lead to accidents malfunctions or damage to the plant 2 Attention the power of the reciprocators axes is very much stronger than that of a human being All axes must be secured against access during operation see local regulations Never stand under the Z carriage when the reciprocator is not operating 3 The plugs and sockets of the reciprocator control unit and the power unit of the ZA06 Reciprocator should only be unplugged when the power supply is disconnected 4 The connecting cables between the control unit and the recipro cator must be laid in such a way that they cannot be damaged during axes operation Please observe the local safety regula tions 5 The maximum upper stroke limit of the reciprocator must always be set with reference to the maximum height of the booth gun slots If an incorrect too high stroke limit is set
23. ion X4 Proximity switch connection FU Frequency converter X5 X6 X7 X8 Drive I O connection Drive I O connection FU signal connection Incremental pulse generator connection Schematic diagrams e 29 RE Frequency converter Overview Frequency converter General information The frequency converter in the ZA06 Reciprocator is installed for power regulation The parameters of this device are already adjusted to the Gema specific values and therefore may not be changed no more All adjustments of stroke speed of etc can be made at the OptiMove control for details see the corresponding reciprocator control unit manu al ZA06 Frequency converter e 31 Function operation Menus 32 e Frequency converter V 02 13 Access to menus Switch on Displays the frequency converter Gel status des Motor frequency presetting is visible only at first switch on ei Settings I acc o E 0 Inputs outputs a Gei se TL Fcions P Da Sc Se o e coni Geesen OS Se Seck 4 v Frequency converter access to menus ZA06 n Access to menu parameters The storage recording of the indicated selection takes place with ev The display flashes during storage Example Menu Parameter Value or allocation sec
24. ive Systems Intended for Use in Potentially Explosive Atmospheres 2004 108 EG Electromagnetic Compatibility EMC EN ISO 12100 1 EN European standards Safety of Machinery Basic Concepts General Princi ples for Design Part 1 Basic Terminology Methodolo EN ISO 12100 2 Safety of Machinery Basic Concepts General Princi 2004 ples for Design Part 2 Technical Principles EN ISO 14121 1 Safety of Machinery Risk Assessment Part 1 Princi 2007 ples on Safety of Machinery Electrical Equipment of Machines SE Part 1 General requirements Mi 9001 Quality Management Systems Requirements EN 12981 A1 Coating plants spray booths for application of organic 2009 powder coating material safety requirements Stationary electrostatic spraying equipment for flamma SE ble coating powder 1953 1998 Atomising Spraying Equipment for Coating Materials Potentially Explosive Atmospheres Application of Qual EN 13980 2002 Systems ZA06 n Gema Electrical Apparatus for Use in the Presence of Combus EIN B tible Dust General requirements EN 61241 2 2 Electrical Apparatus for Use in the Presence of Combus 1995 tible Dust Part 2 Methods Electrical Apparatus for Use in the Presence of Combus tible Dust Part 10 Classification of Areas Where Com bustible Dusts Are or May Be Present EN 1127 1 2008 2 Atmospheres Basic Concepts and Methodol Product specif
25. ke place in the device the power supply must be switched off After switching off the power supply wait at least 10 min before working on the equipment because the internal condensers need this time for discharging ZA06 US 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 of each spare part Example Type ZA06 Reciprocator 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 yard meter ware is always marked with an The wear parts are always marked with a All dimensions of plastic hoses are specified with the external and inter nal diameter Example 8 6 mm 8 mm outside diameter 0 d 6 mm inside diameter i d WARNING Only original Gema spare parts should be used because the haz ardous location approval will be preserved that way The use of spare parts from other manufacturers will invalidate the Gema guar antee conditions ZA06 Spare parts list e 35 iu 2 06 Reciprocator spare parts list 1 Drive unit complete see ZA06 Reciprocator drive unit complete
26. must be carried out by personnel trained in packing machines Packing material Selection of packing material Suitably stable wood packing material must be used Procedure when packing Transport the unit only in a horizontal position Reciprocators with a stroke length of more than 1800 mm must be sup ported in the center of the column Transport Data concerning goods to be transported The space requirements correspond to the size of the axes of motion plus the packaging Loading transferring the load unloading At least one fork lift must be available ZA06 Packing transport e 27 V 02 13 Schematic diagrams 2 06 Reciprocator wiring diagram ZA04 AXIS ADAPTER NR 1 000 247 ER ER x1 Q PE xs 4 x3 02 03 x4 o Kei bl bn Bremswiderstand oO 60000000 2 2 8 i 58592455 2 REFERER gt 31 Nr 1 003 985 GND SIG bi DE ZA06 Reciprocator wiring diagram ZA06 1 Power supply X2 FU power supply X3 Motor brake connect
27. on nut M5 205 150 Wearing part ZA06 Reciprocator Z carriage complete 40 e Spare parts list ZA06 V 02 13 2 06 Reciprocator proximity switch 1 Hexagon screw M10x180 mm 201 855 2 Ribbed washer M10 237 981 3 Stop plate 386 782 4 Rubber buffer 35x40 mm M8 A 211 664 5 Counter profile 40 20x115 mm 386 774 6 Limit switch holder 1003 980 7 Hexagon ribbed nut M10 234 656 8 Proximity switch 229 180 4 RB Wi Ni e j 1 2 3 6 7 8 ZA06 Reciprocator proximity switch ZA06 Spare parts list e 41 ZA06 Reciprocator drive unit complete Motor gearbox unit without pulse generator complete incl pos 1 6 1004 019 1 Motor gearbox 0 75 KW incl pos 2 1004 020 2 Pluginsert 10 211 540 3 Locknut M6 1003 822 4 Cable bush ID5 mm 1003 821 5 Washer 6 4 16x1 6 mm 215 805 6 Torque support 6 M6 1003 819 7 Pulse generator 268 925 8 Hexagon screw M10x25 mm 214 116 9 Toothed belt wheel 368 610 10 Tensioning set 25 50x22 mm 264 199 11 Hexagon ribbed nut M10 234 656 12 Flange bearing 25 mm 264 210 13 Motor brake cable ZA 1004 018 14 Socketinsert 10 P 211 532 15 Switch lever 386 456 16 Switch plate 386 464 17 Countersunk head screw M5x10 mm 214 671 18 Heat sink 386 740 19 Brake resistor 100 Ohm 400 W 264 172 20 Heat sink hold
28. on type ii 15 Hoses EE 15 Reference point and mechanical 15 Setting the reference point 16 Setting the lower mechanical Stop 17 Setting the upper mechanical stop 17 Maintenance 19 General informationi ries 19 BIN EE 19 Replacing the drive unit lessen 20 Teothedibels th ee e et edite tate et 21 Tensioning the toothed DEIt 22 Replace the toothed 24 4 22 Teothed whieel te eeiam ated letali 23 Replacing the upper toothed Wheel 23 Z cairlage rollers iet rep e eee Ve Ped PG en 24 Table of contents e 1 Goen Decommissioning storage 25 4 EE EUN 25 Safety rules rali 25 Requirements on personnel carrying out the 25 Storage conditions 2 ice E 25 Type orstorage recette athe ina 25 Storage duration eto RH peine iat 26 Space requirements epe nt ia 26 Physical requirements Ee 26 Hazardinotes ede ieri anali 26 Slo 26 DEecommISSsIONINg ii 26 Re 26 Zeenari
29. p element half order in pairs 363 987 Cross clamping element 2 40 40 mm 363 910 Cross clamping element 2 40 30 mm 363 936 Cross clamping element 30 30 mm 363 952 4 see gun attachment etc Allen cylinder screw M8x50 mm 235 113 6 30x600 mm 337 528 Tube 0 30x800 mm 337 536 Tube 0 30x800 mm 337 544 Tube 30 mm 103 306 6 1 Tube plug 30 mm for pos 6 236 373 7 Tube 40x600 mm 337 552 Tube 40 1000 mm 337 560 Tube 40x1500 mm 337 579 Tube 40 2000 mm 337 587 Tube 40 mm 103 314 7 1 Tube plug 40 mm for pos 7 236 381 Please indicate length View A 7 3 2 b DL V tol S_ 6 4 Automatic guns ZA06 Spare parts list e 45 Gun holder for 5 8 guns 1 Clamp element half order in pairs 363 987 Cross clamping element 40 40 mm 363 910 Cross clamping element 40 30 mm 363 936 Cross clamping element 30 30 mm 363 952 4 see gun attachment etc 5 Allen cylinder screw M8x50 mm 235 113 6 Tube 30 600 mm 337 528 Tube 30x800 mm 337 536 Tube 30x1000 mm 337 544 Tube 30 mm 103 306 6 1 Tube plug 30 mm for pos 6 236 373 7 Tube 40x600 mm 337 552 Tube 40x1000 mm 337 560 Tube 40 1500 mm 337 579 Tube 40x2000 mm 337 587 Tube 40 mm 103 314 7 1 Tube plug 40 mm for pos 7 236 381
30. riage 10 move down onto the lower stop Switch off the electric power Remove the boarding front and side panels Loosen the lock nut 32 on the grub screw 33 Loosen the nut 34 on the roller axle bolt 30 Attention Never loosen more than one roller at the same time Adjust only one roller after another S cog 6 Adjust the roller pressure with the grub screw in such a way that the roller 31 can just be turned by hand Tighten the roller axle bolt 30 and the nut 34 Tighten the grub screw 33 and secure it Fit the panels again and fasten them firmly The Z carriage should run evenly and quietly again 24 e Maintenance ZA06 m Gema Decommissioning storage Introduction Safety rules Before lifting a reciprocator off of its horizontal axes it must be secured from falling over with a lifting device such as a crane fork lift etc The point of attachment is the eye bolt A at the top of the reciprocator ZA06 Reciprocator top view Requirements on personnel carrying out the work All work should be carried out only by authorized technical personnel Storage conditions Type of storage For safety reasons reciprocators should only be stored in a horizontal position ZA06 Decommissioning storage e 25 Shut down V 02 13 Storage duration If the physical conditions are maintained the unit can be stored indefi nitely Space requirements The space requirement
31. rtment Support the back of the motor in such a way it remains balanced and does not tilt backwards when the motor flange screws are loosen Remove the screws and carefully remove the motor from the rear of the reciprocator base The installation takes place exactly in the reverse order 20 e Maintenance ZA06 ZA06 Reciprocator Toothed belt The toothed belt 3 should be checked regularly because it is exposed to large loads when in operation The toothed belt 3 should be checked weekly for contami nation Powder deposits should be removed with a vacuum cleaner because this can influence the quiet running and shorten the service life of the toothed belt Check the toothed wheels 9 weekly for contamination and wear and remove powder deposits with a vacuum cleaner Switch on the reciprocator and check the Z carriage 10 for quiet running Check the toothed belt 3 for elongation or wear noisy running strong vibration of the belt when revers ing the direction of travel ZA06 Maintenance e 21 22 e Maintenance V 02 13 Attention For safety reasons two people should always carry out the follow ing maintenance work
32. s correspond to the sizes of the axes of motion The load bearing capacity of the floor should be at least 200 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 50 2 notes There is no danger to personnel or the environment if the unit is stored properly Decommissioning Before starting any kind of work the axes of motion must be disconnect ed from the power supply Unplug the power cable Unpiug the ground cable Cleaning The running surfaces of reciprocators must be thoroughly cleaned Preservation The cleaned running surfaces of the column on reciprocators must be preserved with a suitable corrosion inhibitor oiled Maintenance during storage 26 Decommissioning storage Maintenance schedule No maintenance schedule is necessary Maintenance works During long term storage periodically perform a visual check for corro sion ZA06 Packing transport Introduction This chapter describes special precautions that must be taken during in ternal transport of the product if the customer himself must pack transport and ship the prod uct such as to have renovations or service work carried out by the manufacturer or the product must be shipped for disposal recycling Requirements on personnel carrying out the work All work
33. the function mode of the individual system components reciprocators booths powder gun control units powder guns etc should be referenced to their corresponding documents About this manual e 7 Function description 2 06 Reciprocator The ZA06 Reciprocator moving axis was designed for automatic coating with powder guns The reciprocator carriage oscillates vertically on the column The movement sequences stroke and stroke speed are con trolled by the reciprocator control unit The gun holders are fitted on the shield 4 of the Z carriage 5 The Z car riage 5 is moved up and down on the central column by a toothed belt 3 inside the reciprocator This vertical column serves also as a runway for the rollers The drive unit 2 and the electrical connection are installed in the reciprocator base 1 An incremental pulse generator which is in stalled in the motor case enables the exact positioning of the Z carriage LT ZA06 Reciprocator vertical cross section ZA06 Function description e 9 Schematic presentation Reciprocator Reciprocator Frequency control unit converter Ee 5 0 Schematic presentation Special characteristics The ZA06 Reciprocator is conspicuous because of its rugged construc tion a new drive system and an improved Z axis carriage design Further characteristics 50 kg load capacity for automa
34. tic gun and gun holders Built in holding brake Quiet running High speed maximum acceleration and braking action Safe operation and simple maintenance High efficiency due to low energy consumption Designed for continuous operation Mobile version available IP54 protection type 4 standard stroke heights available 1 3 m 1 8 m 2 3 m 2 8 m Intermediate and larger sizes available in steps of 250 mm Upgrading with XT11 Horizontal axis The ZA06 Reciprocator can be equipped with the XT11 Horizontal axis if required The XT11 Horizontal axis extends the travel distance und the functionality of the reciprocator 10 e Function description ZA06 V 02 13 Technical data 2 06 Reciprocator Versions The ZA06 Reciprocator is available depending operational area in four versions with different standard stroke heights Reciprocator ZA06 13 ZA06 18 ZA06 23 ZA06 28 Reciprocator height 2 385 m 2 885 3 385 m 3 885 m Stroke length up to 1 3 upto 1 8 upto2 3m upto2 8m Stroke speed 0 08 up to 0 6 m s Acceleration 0 1 2 0 m s Position detection with incremental pulse generator Max lifting weight max 50 kg on the Z carriage Electrical data 2 06 Reciprocator Power supply 230 VAC from control unit Tolerance 10 Power consumption 1 1 kW Frequency 50 60 Hz Protection type IP54 Isolation Class F Control unit OptiMove
35. ty switch The reciprocator con trol units are programmed in such a way that the reference point is al ways located 50 mm above the reversing point For transport reasons the ZA06 Reciprocator is delivered with the rubber buffer and the carriage in lowest position Attention In order to avoid damages to the booth or the gun holder etc the reference point must be set before the first start up ZA06 Start up e 15 Proximity switch Stop plate with rubber buffer AN A 16 e Start up V 02 13 Setting the reference point 1 Move the stop plate with rubber buffer and proximity switch to the desired position and fasten it Set the response gap of the proximity switch to approx 2 mm Consider the lower edge of the gun slot 50 mm i Gun slot lower edge ZA06 reciprocator reference point and mechanical stops Attention In order to avoid damages to the booth or the gun holders the ref erence point must be checked before the first start up and if neces sary reset lt must be noted that the axes in reference travel moves up to 25 mm below the control s zero point therefore the mechanical stop must be set in accordance to the gun slots The position of the upper and the lower stop plate is set by an Gema ser vice engineer when the reciprocator is assembled Attention The reference point must be referenced before each start up at each switching on after
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