Related Manuals for Gema ZA13
Summary of Contents for Gema ZA13
- Page 1 Rev. 02 1011 516 Operating instructions and Spare parts list Vertical axis ZA13 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
Dimensions ....................21 Sound pressure level ................21 Rating plate ....................22 Assembly / Connection Grounding of the axis .................... 24 Electrical connections / cable connections ............25 Start-up Preparation for start-up ..................27 Table of contents 3 ZA13... - Page 4 Materials ....................48 Disposal of operating material ................48 Disassembly of component groups ..............48 Preparation ....................48 Spare parts list Ordering spare parts ..................... 49 ZA13 – complete ....................50 ZA13 – complete ....................51 4 Table of contents ZA13...
- Page 5 Drive wheel – for 50 mm drive belt ............... 56 Drive unit (complete) – for 30 mm drive belt ............57 Drive unit (complete) – for 50 mm drive belt ............58 Proximity switch ....................59 Electrical module ....................60 Table of contents 5 ZA13...
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Page 7: About These Instructions
General information This operating manual contains all the important information which you require for the working with the ZA13. It will safely guide you through the start-up process and give you references and tips for the optimal use when working with your powder coating system. -
Page 8: Structure Of Safety Notes
Presentation of the contents Figure references in the text Figure references are used as cross references in the descriptive text. Example: "The high voltage (H) created in the gun cascade is guided through the center electrode." 8 About these instructions ZA13... -
Page 9: Safety
If this product is to be used for other purposes or other substances outside of our guidelines then Gema Switzerland GmbH should be consulted. -
Page 10: Special Safety Regulations
Unauthorized conversions and modifications can lead to injuries and damage to the equipment. The Gema Switzerland GmbH guarantee would no longer be valid. – Only original Gema spare parts should be used! The use of spare parts from other manufacturers will invalidate the Gema guarantee conditions! –... - Page 11 ► Before working with the device, organize the required documents and read the section "Safety regulations". ► Work should only be carried out in accordance with the instructions of the relevant documents. ► Always work with the complete original document. Safety 11 ZA13...
- Page 12 Rev. 02 06/21 12 Safety ZA13...
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Page 13: Transport
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. Transport 13 ZA13... - Page 14 Rev. 02 06/21 14 Transport ZA13...
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Page 15: Product Description
Rev. 02 06/21 Product description Intended use The ZA13 axis serves exclusively to move vertically powder applicators in automatic coating equipment. fig. 1 Observance of the operating, service and maintenance instructions specified by the manufacturer is also part of conformity of use. This... -
Page 16: Utilization
Rev. 02 06/21 Utilization The ZA13 type axis is used as the basis for all stages of automation, from a simple vertical stroke to complex, multi-dimensional processes. Depending on the design of the applicators, this unit may be used with all types of powder coating. -
Page 17: Schematic Presentation
Rev. 02 06/21 fig. 2: Structure Basement Z carriage Drive unit Power unit Drive belt Holding brake Gun holder plate Schematic presentation fig. 3: Schematic presentation Axis control Motor cables Position regulator Drive motor Pulse generator wiring Product description 17 ZA13... -
Page 18: Special Characteristics
4 standard stroke heights available: 1.3 m / 1.8 m / 2.3 m / 2.8 m Expansion with additional axes of motion The vertical axis can be equipped with UA04 gun axes to expand its functionality. A maximum of 6 gun axes can be mounted. fig. 4: ZA13 with UA04 18 Product description ZA13... -
Page 19: Cdb Position Regulator With Can Bus (Power Unit)
5: CDB position regulator with CAN BUS X1 Load connections (Mains X4 RS 232 Interface voltage, Motor) X5 not occupied X2 Control connection X7 Pulse generator connection X3 Motor winding temperature S3 CAN address monitoring (optional) Product description 19 ZA13... -
Page 20: Technical Data
Rev. 02 06/21 Technical Data Versions The vertical axis is available, depending on operational area, in four versions with different standard stroke heights. ZA13-13 ZA13-18 ZA13-23 ZA13-28 Reciprocator height 2.385 m 2.885 m 3.385 m 3.885 m – H up to 1.3 up to 1.8... -
Page 21: Dimensions
Rev. 02 06/21 Dimensions fig. 6: Dimensions Sound pressure level ZA13 Normal operation < 60 dB(A) 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 22: Rating Plate
Rev. 02 06/21 Rating plate fig. 7: Rating plate Fields with a gray background contain contract-specific data! 22 Product description ZA13... -
Page 23: Assembly / Connection
► In order to enter the inner area, the door interlocks must be released by the control unit. This release signal may only be activated by technical personnel. ► Except for normal operation, all other operating modes must be set up by an authorized technical representative. Assembly / Connection 23 ZA13... -
Page 24: Grounding Of The Axis
► Ground all metal parts of the axis according to the general, local safety regulations. ► Check regularly the grounding of the axis. At least one corresponding connection point at the axis is reserved for the potential equalization. fig. 8: Potential equalization – connection point 24 Assembly / Connection ZA13... -
Page 25: Electrical Connections / Cable Connections
24 VDC source so that in event of an interruption of power to the reciprocator the reference point remains in memory, i.e. after rewiring the power feed it is not necessary to reference the axes again. Assembly / Connection 25 ZA13... - Page 26 Rev. 02 06/21 26 Assembly / Connection ZA13...
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Page 27: Start-Up
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). Start-up 27 ZA13... -
Page 28: Reference Point
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! 28 Start-up ZA13... - Page 29 ► Fit the mechanical stop to the gun slots because the axis moves up to 25 mm below the control’s zero point, when referencing! The position of the upper and the lower stop plate is set by a Gema service engineer when the reciprocator is assembled.
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Page 30: Setting The Lower Mechanical Stop
Refit the boarding/side panels After the adjustment of the mechanical stops, check the system parameter for the upper stop on the axis control unit! The value must not be larger than the maximum stroke possible between the stops! 30 Start-up ZA13... -
Page 31: Operation
255 programs – change the program number – directly modify the running program – acknowledge the error message – input the system parameters – etc. For further information, see the corresponding operating manual! Operation 31 ZA13... - Page 32 Rev. 02 06/21 32 Operation ZA13...
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Page 33: Decommissioning / Storage
Requirements on personnel carrying out the work All work should be carried out only by authorized technical personnel. Storage conditions Hazard notes There is no danger to personnel or the environment if the unit is stored properly. Decommissioning / Storage 33 ZA13... -
Page 34: Type Of Storage
– Unplug 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). 34 Decommissioning / Storage ZA13... -
Page 35: Maintenance During Storage
Rev. 02 06/21 Maintenance during storage Maintenance schedule No maintenance schedule is necessary. Maintenance works During long-term storage, periodically perform a visual check for corrosion. Decommissioning / Storage 35 ZA13... - Page 36 Rev. 02 06/21 36 Decommissioning / Storage ZA13...
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Page 37: Maintenance / Repairs
The vertical 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 reciprocator increases the working reliability and avoids damages, repair downtimes etc.! Maintenance / Repairs 37 ZA13... -
Page 38: Maintenance Schedule
Therefore, clean the drive unit from time to time (with a vacuum cleaner etc.). If the drive unit gearbox has to be changed for any reason, the complete unit has to be replaced! 38 Maintenance / Repairs ZA13... -
Page 39: Replacing The Drive Unit
Note the position of the clamp plate on the drive 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 Maintenance / Repairs 39 ZA13... -
Page 40: Toothed Belt
– Switch on the reciprocator and check the Z carriage for quiet running. Check the toothed belt for elongation or wear (noisy running, strong vibration of the belt when reversing the direction of travel) 40 Maintenance / Repairs ZA13... -
Page 41: Replacing The Drive Belt
(factory setting)! fig. 16: Top plate Let the Z carriage slowly run up and down the column a few times, to see if the drive belt does not ride up on the toothed wheel Maintenance / Repairs 41 ZA13... -
Page 42: Drive Wheel
– Let the Z carriage slowly run up and down the column a few times, to see if the drive belt must be tensioned more (see chapter "Tensioning the drive belt") 42 Maintenance / Repairs ZA13... -
Page 43: Rollers - Z Carriage
Tighten the roller axle bolt (30) and the nut (34) Tightening torque: 50 Nm 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! Maintenance / Repairs 43 ZA13... -
Page 44: Maintenance Of The Position Regulator
► Before interventions take 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! 44 Maintenance / Repairs ZA13... -
Page 45: Fault Clearance
Cracking noise rollers tightened too adjust the counter during operation strong rollers without clearance, ensure the correct tightening torque Fault clearance 45 ZA13... - Page 46 The Z carriage runs control unit defective repair or replace into the upper stop maximum upper set correctly stroke limit incorrectly set 46 Fault clearance ZA13...
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Page 47: Disposal
Requirements on personnel carrying out the work The disposal of the product is to be carried out by the owner or operator. When disposing of components that are not manufactured by Gema, the instructions in the respective third-party manufacturer’s documentation must be observed. -
Page 48: Materials
Disconnect the mains supply, supply cables and additional units. Remove all product covers. Drain all existing lubricant supplies and dispose of accordingly. The product is now prepared for disassembly. The instructions in the third-party manufacturer’s documentation must be followed! 48 Disposal ZA13... -
Page 49: Spare Parts List
When using the spare parts from other manufacturers the explosion protection is no longer guaranteed. If any damage is caused by this use all guarantee claims become invalid! ► Only original Gema spare parts should be used! Spare parts list 49 ZA13... -
Page 50: Za13 - Complete
Rev. 02 06/21 ZA13 – complete Drive unit – complete, see also "Drive unit (complete)" Hexagon screw – M6x12 mm 1005 774 Cable lead-through – Ø 50 mm, 5+4 1004 006 Electrical module, see "Electrical module" Electrical module for XT/ YT axis, see separate XT or YT axis spare parts list Z carriage –... -
Page 51: Za13 - Complete
Rev. 02 06/21 ZA13 – complete fig. 18: ZA13 – complete Spare parts list 51 ZA13... -
Page 52: Z Carriage
Rev. 02 06/21 Z carriage Carriage – fixed side (order specific) contact Gema Carriage – adjustable side (order specific) contact Gema Roller – complete 307 165# Spacer sleeve 308 013 Hexagon screw – M10x110 mm 214 221 Hexagon screw – M10x100 mm 214 213 Hexagon ribbed nut –... -
Page 53: Drive Wheel - For 30 Mm Drive Belt
Counter profile – 40/20x115 mm 386 774 Drive wheel 386 600 Drive belt 30 mm 1015 741#* ZA13-13 – L=4215 mm ZA13-18 – L=5215 mm ZA13-23 – L=6215 mm ZA13-28 – L=7215 mm Tensioning screw 386 596 Hexagon shakeproof screw – M6x12 mm... -
Page 54: Drive Wheel - For 30 Mm Drive Belt
Rev. 02 06/21 Drive wheel – for 30 mm drive belt fig. 20: Drive wheel – for 30 mm drive belt 54 Spare parts list ZA13... -
Page 55: Drive Wheel - For 50 Mm Drive Belt
Counter profile – 40/20x115 mm 386 774 Drive wheel 386 600 Drive belt 50 mm 1015 741#* ZA13-13 – L=4215 mm ZA13-18 – L=5215 mm ZA13-23 – L=6215 mm ZA13-28 – L=7215 mm Tensioning screw 386 596 Hexagon shakeproof screw – M6x12 mm... -
Page 56: Drive Wheel - For 50 Mm Drive Belt
Rev. 02 06/21 Drive wheel – for 50 mm drive belt fig. 21: Drive wheel – for 50 mm drive belt 56 Spare parts list ZA13... -
Page 57: Drive Unit (Complete) - For 30 Mm Drive Belt
1000 565 Brake resistor – 100 Ohm/600 W, complete, incl. heat sink 800 397 Heat sink holder 1003 978 Cap screw 1002 965 fig. 22: Drive unit (complete) – for 30 mm drive belt Spare parts list 57 ZA13... -
Page 58: Drive Unit (Complete) - For 50 Mm Drive Belt
1000 565 Brake resistor – 100 Ohm/600 W, complete, incl. heat sink 800 397 Heat sink holder 1003 978 Cap screw 1002 965 fig. 23: Drive unit (complete) – for 50 mm drive belt 58 Spare parts list ZA13... -
Page 59: Proximity Switch
Rubber buffer – Ø 35x40 mm, M8 211 664 Counter profile – 40/20x115 mm 386 774 Limit switch holder 1003 980 Hexagon ribbed nut – M10 234 656 Proximity switch 1017 650 fig. 24: Proximity switch Spare parts list 59 ZA13... -
Page 60: Electrical Module
Rev. 02 06/21 Electrical module For all electric components, see also the Spare parts list in the enclosed wiring diagram! Position regulator CDB-ZA13 (please indicate the axis serial number – see 1014 821 Rating plate) CAN bus cable 1011 646... - Page 61 Spare parts list ..........49 Start-up ............27 Storage ............33 Fault clearance ..........45 Figure references in the text ......8 Technical Data ..........20 Transport ............13 Maintenance ............. 37 Versions ............20 Spare parts list 61 ZA13...
- Page 62 Rev. 02...
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