Gema MagicCompact BA04 Operating Instructions And Spare Parts List
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Gema MagicCompact BA04 Operating Instructions And Spare Parts List

Powder coating booth
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Operating instructions and spare parts list
MagicCompact BA04
Powder coating booth
Translation of the original operating instructions

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Summary of Contents for Gema MagicCompact BA04

  • Page 1 Operating instructions and spare parts list MagicCompact BA04 Powder coating booth 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 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.

  • Page 3: Table Of Contents

    V 06/13 Table of contents General safety regulations About this manual Design and function Technical data Commissioning Operation Maintenance Decommissioning, storage Packing, transport Troubleshooting Spare parts list Table of contents • 1 MagicCompact BA04...

  • Page 5: General Safety Regulations

    V 06/13 General safety regulations This chapter sets out the fundamental safety regulations that must be followed by the user and third parties using the MagicCompact BA04 powder coating booth. These safety regulations must be read and understood before the MagicCompact BA04 powder coating booth is put into operation.
  • Page 6 4. Start-up (i.e. the execution of a particular operation) is forbidden until it has been established that the MagicCompact BA04 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.
  • Page 7 Please observe the local safety regulations! 8. Only original Gema spare parts should be used, because the explosion protection will also be preserved that way. Any warranty claim for damage caused by the use of foreign parts is void.
  • Page 8 Static charges Static charges can have the following consequences: Charges to people, electric shocks, sparking. Charging of objects must be avoided - see chapter "Grounding". 6 • General safety regulations MagicCompact BA04...
  • Page 9 Any warranty claim for damage caused by the use of foreign parts is void. Repairs must only be carried out by specialists or by authorized Gema service centers. Unauthorized conversions and modifications can lead to injuries and damage to the equipment.
  • Page 10 14. For your own safety, only use accessories and attachments listed in the operating instructions. The use of other parts can lead to risk of injury. Only original Gema spare parts should be used! 15. Repairs must only be carried out by specialists and under no circumstances should they be carried out in the operating area.
  • Page 11 Electrical Apparatus for Use in the Presence of EN 61241-10: Combustible Dust. Part 10: Classification of Areas 2004 Where Combustible Dusts Are or May Be Present Explosive Atmospheres. Basic Concepts and EN 1127-1:2008 Methodology General safety regulations • 9 MagicCompact BA04...
  • Page 12 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...
  • Page 13 Checks or cleaning can take place from the booth openings without problems Warning: Danger of slipping and/or injury! Repairs Warning: Carrying out of repairs is only permitted when the booth is switched off, and must be done only by trained personnel! General safety regulations • 11 MagicCompact BA04...

  • Page 15: 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 system.

  • Page 17: Design And Function

    As part of the process controlled coating plant, they are laid out for fully automatic operation. The most important characteristics of the MagicCompact BA04 coating booths are: Superstructure and booth basement in plastic material...
  • Page 18 (Detailed information about the After Filter is found in the corresponding operating manual). 16 • Design and function MagicCompact BA04...
  • Page 19 After Filter (5). The After Filter separates the powder into a refuse container (6), which is positioned directly under the filter elements and is very easy to empty. Then, the cleaned air leaves the filter and is fed directly back into the workshop environment. Design and function • 17 MagicCompact BA04...
  • Page 20 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 21 V 06/13 Floor blow-off system MagicCompact BA04 - floor blow-off system (arrows = blow-off direction) A blow-off rail with blow nozzles is integrated lengthwise into the MagicCompact BA04 booth floor. The blow-off rail consists of various segments, which can be pneumatically controlled one by one.
  • Page 22 V 06/13 Powder suction MagicCompact BA04 - powder suction (cutaway view) The powder suction takes place via a lengthwise suction duct in the booth floor. The powder, which has been blown by the floor blow-off system in the direction of the suction slot, is then sucked in along the entire booth length.
  • Page 23 The powder is separated in the cyclone and then sieved in the sieve machine. The recovered powder is fed to the powder center and back into the powder container. Note: Further information about the powder recovery components you will find in the corresponding user manuals! Design and function • 21 MagicCompact BA04...
  • Page 24 V 06/13 Automatic guns OptiGun-AX or PG 2-AX automatic powder gun types are used in the MagicCompact BA04 powder coating booth. These guns were particularly developed for an automatic, simple cleaning. MagicCompact BA04 - automatic guns The connections for the powder hose, the high voltage and the electrode rinsing air are outside of the coating booth.
  • Page 25 V 06/13 Cleaning the guns MagicCompact BA04 - 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 BA04 MagicCompact coating booth.

  • Page 27: Technical Data

    V 06/13 Technical data MagicCompact BA04 powder coating booth Electrical data MagicCompact BA04 3x400 V / 50 Hz Input voltage (other voltages and frequencies on request) Pneumatic data MagicCompact BA04 Input pressure min. 6 bar / max. 10 bar Air entry speed 0.7 m/sec...
  • Page 28 V 06/13 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 29: Commissioning

    Observe the safety regulations! Earthing The booth grounding is to be checked at every start-up. The grounding connection is customer specific and fitted on the booth basement, the cyclone separator and the filter housing. Commissioning • 27 MagicCompact BA04...

  • Page 31: Operation

    1. Quit the automatic operation mode 2. Switch off the gun control units and all additional plant units 3. Switch off the system in the main menu 4. Switch off the powder center 5. Switch off the main switch Operation • 29 MagicCompact BA04...
  • Page 32 Set the powder center to the cleaning mode Coarse cleaning of the powder center 3. Clean the guns externally and move them to the blow off position 4. Blow off (internal cleaning) the powder hoses in direction from the powder center 30 • Operation MagicCompact BA04...
  • Page 33 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. Operation • 31 MagicCompact BA04...

  • Page 35: Maintenance

    (beginning of the line). 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 the spare parts list! Maintenance • 33 MagicCompact BA04...
  • Page 36 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. Note: Only original Gema spare parts should be used! 34 • Maintenance MagicCompact BA04...
  • Page 37 (ES control unit etc.) 8. The control units and all interlocked plant units are ready for operation 9. The message "too little powder" appears on the operating unit after a delay, and the alarm horn sounds Maintenance • 35 MagicCompact BA04...

  • Page 39: Decommissioning, Storage

    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 Storage duration If the physical conditions are maintained, the unit can be stored indefinitely.
  • Page 40 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. 38 • Decommissioning, storage MagicCompact BA04...
  • Page 41 Commissioning following storage Before mounting the cabin, make sure that all plastic components such as panels have been acclimatized at a room temperature of at least 15°C for at least 24 hours. Warning: Avoid stress cracks! Decommissioning, storage • 39 MagicCompact BA04...

  • Page 43: 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 "Storage".
  • Page 44 -15 °C. In summer, the air temperature during transport should not exceed +60 °C. Warning: Avoid heat accumulations and storage in sunlight. Suitable lifting equipment is to be used for all procedures. 42 • Packing, transport MagicCompact BA04...

  • Page 45: Troubleshooting

    (see wiring diagram), switch has reacted see also the "Troubleshooting" section in the After Filter operating manual. In the case of repeated alarm, contact your Gema service center Troubleshooting • 43 MagicCompact BA04...
  • Page 46 "Troubleshooting" in the After Filter operating manual) Warning: If the pressure gauge shows a pressure rise higher than 3 kPa, contact your Gema agent immediately! Alarm has been released: Message Fan overpressure Minimum pressure in filter housing Too little pressure, too much exhaust...
  • Page 47 Pressure reducing valve defective or adjusted incorrectly Solenoid valve defective (coil, cable) or missing signal Setting values Note: The setting values for the powder center and other plant units you will find in the corresponding operating instructions! Troubleshooting • 45 MagicCompact BA04...

  • Page 49: Spare Parts List

    Ø 8/6 mm, 8 mm outside diameter (o/d) / 6 mm inside diameter (i/d) WARNING! Only original Gema spare parts should be used, because the explosion protection will also be preserved that way. The use of spare parts from other manufacturers will invalidate the Gema guarantee conditions! Spare parts list •...
  • Page 50 V 06/13 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 51 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 MagicCompact BA04 - Floor blow-off system - Pneumatics Spare parts list • 49 MagicCompact BA04...
  • Page 52 V 06/13 Pressure regulator Pressure regulator - 0-8 bar, 1"i 1008 185 Manometer - 0-10 bar, 1/8a 243 620 Adapter nipple - 1/8i-1/4a 231 932 MagicCompact BA04 - Pressure regulator 50 • Spare parts list MagicCompact BA04...
  • Page 53 Sensor/Actor Box Sensor-/Actor Box - M12 8P 1008 242 Y-distributor - threefold, M12 1008 246 Plug screw - M12 1006 905 Sensor-/Actor cable - 30 m 1008 243 MagicCompact BA04 - Sensor/Actor Box Spare parts list • 51 MagicCompact BA04...
  • Page 54 V 06/13 MagicCompact BA04 - gun blow off equipment Gun blow off unit, complete (pos. 1-4) 1010 015 1010 013 Nozzle holder, complete Nozzle 1010 014 T-piece - 3/8i-3/8a-3/8i 223 034 Allen grub screw - M6x16 mm 214 850 Hose connector - Ø 17 mm, 3/8"a 233 077 Hose clamp - Ø...
  • Page 55 V 06/13 MagicCompact BA04 - gun blow off equipment 5; 6; 7 MagicCompact BA04 - gun blow off equipment Spare parts list • 53 MagicCompact BA04...
  • Page 56 V 06/13 MagicCompact BA04 - door drive unit Holder - large 389 714 Holder - small 389 706 Drive shaft MKC02-A026-4 Coupling 389 730 Hinge 373 770 Rotary actuator 389 790 Lever 389 749 Support 389 722 Connection case - complete 373 885 Cable - 7x0.75 mm²...
  • Page 57 V 06/13 MagicCompact BA04 - door drive unit 7; 43 41; 56 33; 39 41; 56; 57 4; 47 1; 2 13; 46; 50; 55 23; 48; 51; 56 MagicCompact BA04 - door drive unit Spare parts list • 55...
  • Page 58 V 06/13 MagicCompact BA04 - fan control unit Fan control unit - complete see table Plastic tube - Ø 6/4 mm 103 144# Locknut - M20x1.5 mm 266 035 Locknut - M40x1.5 mm 265 357 Cable connection - M20/1/8-15 mm 266 019 Cable connection - M40/1/28.5-33 mm...
  • Page 59 V 06/13 MagicCompact BA04 - fan control unit MagicCompact BA04 - fan control unit Spare parts list • 57 MagicCompact BA04...

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