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Summary of Contents for Gema XT10 Horizontal axis
- Page 1 Operating instructions and spare parts list XT10 Horizontal axis 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.
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Page 3: Table Of Contents
Function description ....................18 Safety and monitoring devices ................18 Start-up Assembly of the XT10 Horizontal axis ..............19 Connecting the XT10 Horizontal axis to the ZA reciprocator ........19 Preparation for start-up ..................21 General information ..................21 Reference point ..................21 Electrical connections / cable connections ............22 Checkpoints before switching on ................22... - Page 4 Fault clearance Troubleshooting ....................37 Spare parts list Ordering spare parts ..................... 39 XT10 Horizontal axis - spare parts list ..............40 Drive unit ....................... 42 Running wheel bearing ..................44 Guide wheel bearing ..................... 46 Electrical module ....................48...
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Page 5: General Safety Regulations
These safety regulations must be read and understood before the XT10 is put into operation. Safety symbols (pictograms) The following warnings with their meanings can be found in the Gema operating instructions. The general safety precautions must also be followed as well as the regulations in the operating instructions. -
Page 6: A Summary Of The Directives And Standards
4. Start-up (i.e. the execution of a particular operation) is forbidden until it has been established that the XT10 horizontal axis 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: Product-Specific Safety Measures
Product-specific safety measures XT10 Horizontal axis The XT10 Horizontal axis is a constituent part of the system and is thus integrated 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. - Page 8 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.
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Page 9: About This Manual
General information This operating manual contains all the important information you require for the working with the XT10 horizontal axis. 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 11: Function Description
Function description Field of application The XT10 Horizontal axis is used for the coating of parts with different widths. By coating in this way, the powder guns must be driven into each corresponding position for every given width. The XT10 Horizontal axis can be used in connection with a ZA reciprocator. -
Page 12: Special Characteristics
02/13 Special characteristics The XT10 Horizontal axis is a feeding axis and has the following characteristics: Same control as for the ZA reciprocator Freely adjustable speed setting on the axes control unit Built-in leveling pads Minimum space requirement No additional space required for dismantling and service... -
Page 13: Technical Data
02/13 Technical data XT10 Horizontal axis Electrical data XT10 Power supply 230 VAC (from control unit) Tolerance ± 10% Power consumption 0.3 kW Frequency 50/60 Protection type IP54 Isolation C lass F Control unit CM-30 10 °C - 40 °C Temperature range (50 °F - 104 °F) -
Page 14: Dimensions
Dimensions Total length = travel distance + 750 50 Free space 50 Free space Horizontalachse XT10 - Abmessungen Versions The XT10 Horizontal axis is available in two versions with different travel distances. XT10-10 XT10-14 Travel distance length 1000 mm 1400 mm... -
Page 15: Set-Up, Assembly And Commissioning
02/13 Set-up, assembly and commissioning Warning: If a free-standing horizontal axis is not anchored firmly to the floor, uncontrolled movement of the machine or insufficient stability can cause injuries. - Firmly anchor the horizontal axis to the floor if it is not mounted to another axis of motion Warning: The movement of the reciprocator can cause injuries. -
Page 17: Design And Function
02/13 Design and function Mechanical structure The XT10 Horizontal axis consists of the following components: XT10 Horizontal axis - mechanical structure Drive unit - complete Frame Leveling bolt Rubber buffer 3 Baseb oard Carriage Design and function • 17 XT10... -
Page 18: Function Description
02/13 Function description The XT10 Horizontal axis is a feeding axis for adjusting the gun position to the parts to be coated The XT10 Horizontal axis position detection takes place by a pulse generator installed onto the drive unit The drive takes place by the drive unit, installed onto the axis... -
Page 19: Start-Up
Assembly of the XT10 Horizontal axis The axis must be leveled, in order to ensure a safe and perfect operation. After positioning, the XT10 Horizontal axis must be firmly fixed on the floor. Connecting the XT10 Horizontal axis to the ZA reciprocator 1. - Page 20 02/13 Electrical modules in the ZA reciprocator 4. Break out the required opening in the feed-through rubber and pull through the cables. Cable feed-through in the ZA reciprocator 5. Connect the cable (according to the enclosed wiring diagram) 6. Push back the electrical modules and fasten them 20 •...
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Page 21: Preparation For Start-Up
02/13 Preparation for start-up Warning: Before connecting or switching on the horizontal axis, read carefully these operating instructions! Before the horizontal axis is put into operation, the upper stroke limit must be set on the reciprocator control unit! (see the user manual of the axis control unit) General information Warning: Before start-up works are done, make certain that nobody can... -
Page 22: Electrical Connections / Cable Connections
02/13 Electrical connections / cable connections Electrical module Electrical module CM-30 control - XT10 - connections Note: All internal connections between the XT10 axis and the electrical module are to be made according to the enclosed wiring diagram. 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... -
Page 23: Hoses And Cables
In order to avoid damages to the booth, to the gun holders etc. the reference point must be set before the first start-up! Rubber buffer XT10 horizontal axis - reference point and mechanical stops Warning: In order to avoid damages to the booth or the gun holders, the... -
Page 24: Initial Start-Up
02/13 Initial start-up Danger! Never stand on the horizontal axis or under the carriage of the vertical axis when it is in operation! Danger of accident! Warning: The power of the horizontal axis is much stronger than that of a human being! All axes must be secured against admittance during operation (see local regulations). -
Page 25: Maintenance
The horizontal axis has to be free of load and disconnected from mains! The XT10 horizontal axis was designed to operate with a minimum of maintenance. The motor gear box is self-lubricating and maintenance- free. Regular maintenance and inspection of the horizontal axis increases the working reliability and avoids damages, repair downtimes etc.! -
Page 26: Maintenance Schedule
02/13 Maintenance schedule Note: The following maintenance schedule is based on operation of 8 hours per day. Time interval Maintenance works weekly Blow off the outside of the horizontal axis with compressed air or clean it with a soft cloth at least once a week. -
Page 27: Replacing The Drive Unit
If it is necessary to replace a drive unit gearbox, the complete motor unit must be dismantled from the horizontal axis. Therefore, the horizontal axis has to be free of load and disconnected from mains. XT10 Horizontal axis - drive unit Procedure: 1. Remove the Z axis from the carriage plate 2. -
Page 28: Drive Belt
For safety reasons, two people should always carry out the following maintenance work! Tensioning the drive belt XT10 Horizontal axis - Tensioning the drive belt Clamp the drive belt (23) with the clamp block (8) and tighten the screws (6) -
Page 29: Counter Rollers
02/13 Counter rollers If the X carriage starts to vibrate excessively during operation, especially at the reversing points, in most cases the cause lies in too much play in the carriage rollers, or even loose rollers! XT carriage - rollers In this case, proceed as follows: 1. -
Page 31: Decommissioning, Storage
02/13 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. ZA.. -
Page 32: Storage Conditions
02/13 Storage conditions Type of storage Horizontal axes can be stacked. Storage duration If the physical conditions are maintained, the unit can be stored indefinitely. Space requirements The space requirements correspond to the sizes of the axes of motion. The load-bearing capacity of the floor should be at least 200 kg/m². There are no special requirements concerning distance to neighboring equipment. -
Page 33: Shut-Down
02/13 Shut-down Decommissioning Before starting any kind of work, the axes of motion must be disconnected from the power supply: Unplug the power cable Unplug the ground cable Cleaning The running surfaces of horizontal axis must be thoroughly cleaned. Maintenance during storage Maintenance schedule No maintenance schedule is necessary. -
Page 35: Packing, Transport
02/13 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 the product must be shipped for disposal (recycling). -
Page 37: Fault Clearance
Remove the powder accumulation on the running surfaces Check for a foreign body - if present, remove it Check the XT10 Horizontal axis for proper running (move manually) Consider the indications in the axes control unit operating manual! Fault clearance • 37... -
Page 39: 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 40: Xt10 Horizontal Axis - Spare Parts List
02/13 XT10 Horizontal axis - spare parts list Attention! When ordering toothed belts, indicate the toothed belt length (according to travel distance + 855 mm). By replacing the toothed belt, screw in the grub screw, so that the steel cables in the toothed belt are touched and the grounding is ensured! ZA.. - Page 41 02/13 XT10 Horizontal axis - spare parts XT10 Horizontal axis - spare parts list Spare parts list • 41 XT10...
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Page 42: Drive Unit
02/13 Drive unit Motor/gearbox unit - 0.18 kW, complete (pos. 1-5) - for XT Axes with serial numbers 18301.xxxx (see Rating plate) 1003 823 - for XT Axes with serial numbers 18302.xxxx (see Rating plate) 1008 445 Torque support - Ø 6 mm 1003 819 Locknut - M6 1003 822... - Page 43 02/13 Drive unit XT10 Horizontal axis - drive unit Spare parts list • 43 XT10...
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Page 44: Running Wheel Bearing
Ribbed washer - M8 242 870 Hexagon nut - M6 205 095 Hexagon screw - M6x25 mm 213 845 Hexagon screw - M8x10 mm 213 900 # Wearing part XT10 Horizontal axis - running wheel bearing 44 • Spare parts list XT10... - Page 45 02/13 Running wheel bearing Running wheel bearing - FS Spare parts list • 45 XT10...
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Page 46: Guide Wheel Bearing
221 317 Countersunk screw K-SI - M8x70 mm 258 440 Hexagon screw - M6x25 mm 213 845 Hexagon screw - M8x10 mm 213 900 # Wearing part XT10 Horizontal axis - guide wheel bearing 46 • Spare parts list XT10... - Page 47 02/13 Guide wheel bearing Guide wheel bearing - LS Spare parts list • 47 XT10...
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Page 48: Electrical Module
CAN bus cable 1.0 m 391 620 CAN T-distribution box 265 772 Adhesive seal strip - 9x2 mm 100 250* * Please indicate length XT10 Horizontal axis - electrical module in the ZA05 Reciprocator 48 • Spare parts list XT10... - Page 49 02/13 Spare parts list • 49 XT10...
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