Gema MagicCompact BA04 Operating Instructions And Spare Parts List
Powder coating booth
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Summary of Contents for Gema MagicCompact BA04
- Page 1 Operating instructions and spare parts list Powder coating booth MagicCompact BA04 Translation of the original operating instructions...
- Page 2 To the best of our knowledge and belief, the information contained in this publication was correct and valid on the date of publication. Gema Swit- zerland 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.
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Page 3: Table Of Contents
Automatic booth cleaning ................. 16 Powder recovery ....................16 Automatic powder guns ..................17 Cleaning the guns ....................18 Technical Data MagicCompact BA04 powder coating booth ............19 Electrical data ..................19 Pneumatic data ..................19 Dimensions ....................19 Sound pressure level ................20 Start-up Set-up and assembly .................... - Page 4 Transport ......................35 Data concerning goods to be transported ..........35 Mode of transportation ................36 Loading, transferring the load, unloading ..........36 Troubleshooting General ......................... 37 Problem fixing ....................... 37 Setting values ....................... 39 2 • Table of contents MagicCompact BA04...
- Page 5 V 10/17 Spare parts list Ordering spare parts ..................... 41 MagicCompact BA04 – spare parts list ..............42 Floor blow-off system – Pneumatics ..............43 Pressure regulator ....................44 Sensor/Actor Box ....................45 Gun blow off equipment ..................46 Door drive unit ....................... 48 Fan control unit .....................
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Page 7: General Safety Regulations
General safety regulations This chapter sets out the fundamental safety regulations that must be fol- lowed by the user and third parties using the MagicCompact BA04 pow- der coating booth. These safety regulations must be read and understood before the powder coating booth is put into operation. -
Page 8: Product-Specific Safety Measures
Product-specific safety measures General information The MagicCompact BA04 powder coating booth is a constituent part of the equipment and is therefore integrated in the system's safety concept. If it is to be used in a manner outside the scope of the safety concept, then corresponding measures must be taken. -
Page 9: Operating The Equipment
For this reason, the operating manual must always be available at the plant. Should difficulties arise, however, your Gema service center is always ready to assist. Inspection... -
Page 11: About This Manual
General information This operating manual contains all the important information which you require for the working with the MagicCompact BA04 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 sys- tem. -
Page 13: Design And Function
Design and function Field of application MagicCompact BA04 coating booths are used for the electrostatic powder coating of all types of workpieces in large batches with frequent color changes. As part of the process controlled coating plant, they are laid out for fully automatic operation. -
Page 14: Operational Procedure
(Detailed information about the After Filter is found in the corresponding operating manual). 12 • Design and function MagicCompact BA04... -
Page 15: Powder Flow
The interior of the booth is illuminated by lightings, which are fitted into the booth ceilings. The basic version of the MagicCompact BA04 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 station alternatively. -
Page 16: Booth - Basement
3: floor blow-off system (arrows = blow-off direction) A blow-off rail with blow nozzles is integrated lengthwise into the booth floor. The blow-off rail consists of various segments, which can be pneu- matically controlled one by one. 14 • Design and function MagicCompact BA04... -
Page 17: Powder Suction
The 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. MagicCompact BA04 Design and function • 15... -
Page 18: Exhaust Air System With After Filter
The powder is separated in the cyclone and then sieved in the sieve ma- chine. The recovered powder is fed back to the OptiCenter. NOTE: Further information about the powder recovery components you will find in the corresponding user manuals! 16 • Design and function MagicCompact BA04... -
Page 19: Automatic Powder Guns
This is a prerequisite for the automatic rinsing of the powder transport equipment (further information about au- tomatic guns, see in the corresponding user manual). On the booth, a distinction between light and dark colors is principally made. MagicCompact BA04 Design and function • 17... -
Page 20: Cleaning The Guns
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 • Design and function MagicCompact BA04... -
Page 21: Technical Data
V 10/17 Technical Data MagicCompact BA04 powder coating booth Electrical data MagicCompact BA04 3x400 V / 50 Hz Input voltage (other voltages and fre- quencies on request) Pneumatic data MagicCompact BA04 Inlet pressure min. 6 bar / max. 10 bar Air entry speed 0.7 m/sec... -
Page 22: Sound Pressure Level
V 10/17 Sound pressure level MagicCompact BA04 max. 80 dB(A) Sound pressure level 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. -
Page 23: Start-Up
The ground connection of the booth should be checked each time the equipment is put into operation. The grounding connection is customer specific and fitted on the booth basement, the cyclone separator and the filter housing. MagicCompact BA04 Start-up • 21... -
Page 25: Operation
Activate the OptiCenter (see therefore the corresponding user man- ual) Switching off the booth 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 MagicCompact BA04 Operation • 23... -
Page 26: Alarm Messages
Clean the guns externally and move them to the blow off position Blow off (internal cleaning) the powder hoses in direction from the OptiCenter Coarse cleaning of the booth – Coarse cleaning of the booth with the air lance 24 • Operation MagicCompact BA04... - Page 27 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. MagicCompact BA04 Operation • 25...
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Page 29: Maintenance
(beginning of the line) - Definition of the lines: H = high, L = low) NOTE: The indicated blowing direction is absolutely to be observed! The parts to be replaced during maintenance are available as spare parts, see also the spare parts list! MagicCompact BA04 Maintenance • 27... -
Page 30: Maintenance And Repair Of The Cyclone Separator
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 engi- neer at the first start-up – If errors arise, see the troubleshooting guide and the After Filter op- erating instructions –... -
Page 31: Functional Check
(ES control unit etc.) The control units and all interlocked plant units are ready for opera- tion The message "too little powder" appears on the operating unit after a delay, and the alarm horn sounds MagicCompact BA04 Maintenance • 29... -
Page 33: Decommissioning, Storage
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 Storage duration If the physical conditions are maintained, the unit can be stored indefinite-... -
Page 34: Shut-Down
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. 32 • Decommissioning, storage MagicCompact BA04... -
Page 35: Return To Service
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. ATTENTION: Avoid stress cracks! MagicCompact BA04 Decommissioning, storage • 33... -
Page 37: Packing, Transport
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 "Stor- age". -
Page 38: Mode Of Transportation
-15 °C. In summer, the air temperature during transport should not exceed +60 °C. ATTENTION: Avoid heat accumulations and storage in sunlight. Suitable lifting equipment is to be used for all procedures. 36 • Packing, transport MagicCompact BA04... -
Page 39: Troubleshooting
(see wiring diagram), see also the "Trouble- shooting" section in the After Fil- ter operating manual. In the case of repeated alarm, contact your Gema service center MagicCompact BA04 Troubleshooting • 37... - Page 40 "Troubleshooting" in the After Fil- ter operating manual) ATTENTION: 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 hous- Too little pressure, too much ex- ing not reached –...
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Page 41: Setting Values
Pressure reducing valve defec- tive or adjusted incorrectly Solenoid valve defective (coil, cable) or missing signal Setting values NOTE: The setting values for the OptiCenter and other plant units you will find in the corresponding operating instructions! MagicCompact BA04 Troubleshooting • 39... -
Page 43: Spare Parts List
Ø 8/6 mm, 8 mm outside diameter (o/d) / 6 mm inside diameter (i/d) ATTENTION: Only original Gema spare parts should be used, because the explo- sion protection will also be preserved that way. The use of spare parts from other manufacturers will invalidate the Gema guarantee... -
Page 44: Magiccompact Ba04 - Spare Parts List
V 10/17 MagicCompact BA04 – 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) -
Page 45: Floor Blow-Off System - Pneumatics
Valve coil for pos. 3 – 24 VDC 1005 119 Valve cable – 3 pins, M12, for pos. 4 1008 244 Hose – Ø 12/10 mm 100 382* * Please indicate length fig. 8: Floor blow-off system – Pneumatics MagicCompact BA04 Spare parts list • 43... -
Page 46: Pressure Regulator
V 10/17 Pressure regulator Pressure regulator – 0-8 bar, 1" 1008 185 Pressure gage – 0-10 bar, 1/8" 243 620 Adapter nipple – 1/8"-1/4" 231 932 fig. 9: Pressure regulator 44 • Spare parts list MagicCompact BA04... -
Page 47: Sensor/Actor Box
V 10/17 Sensor/Actor Box Sensor-/Actor Box – M12 8P 1008 242 Y-distributor – threefold, M12 1008 246 Plug screw – M12 1006 905 Sensor/actuator cable – 30 m 1008 243 fig. 10: Sensor/Actor Box MagicCompact BA04 Spare parts list • 45... -
Page 48: Gun Blow Off Equipment
Valve coil – 24 VDC (for pos. 11) 1005 119 Valve cable – 3 pins, M12, for pos. 12 1008 244 Grounding cable – complete 1006 077 * Please indicate length # Wearing part 46 • Spare parts list MagicCompact BA04... - Page 49 V 10/17 Gun blow off equipment fig. 11: Gun blow off equipment MagicCompact BA04 Spare parts list • 47...
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Page 50: Door Drive Unit
Lock washer – M5 205 168 Washer – Ø 5.3/10x1 mm 205 320 Allen grub screw – M4x8 mm 214 736 Coiled spring pin – Ø 4x20 mm 259 683 * Please specify length 48 • Spare parts list MagicCompact BA04... - Page 51 V 10/17 Door drive unit 7; 43 41; 56 33; 39 41; 56; 57 4; 47 1; 2 13; 46; 50; 55 23; 48; 51; 56 fig. 12: Door drive unit MagicCompact BA04 Spare parts list • 49...
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Page 52: Fan Control Unit
Main switch – see corresponding wiring diagram # Wearing part Pressure gauge (kPa) Order Motor perfor- Filter number mance (kW) (pos. 15) (pos. 16) 1002 205 1002 174 1002 175 1002 176 1002 177 50 • Spare parts list MagicCompact BA04... - Page 53 V 10/17 Fan control unit fig. 13: Fan control unit MagicCompact BA04 Spare parts list • 51...
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