Subscribe to Our Youtube Channel
Related Manuals for Gema Classic Standard 2
Summary of Contents for Gema Classic Standard 2
- Page 1 Operating instructions and spare parts list Powder coating booth ClassicStandard ClassicOpen 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.
-
Page 3: Table Of Contents
V 02/25 Table of contents About this instructions General ........................3 Keeping the manual ....................3 Safety symbols (pictograms) ................... 3 Presentation of the contents ................... 4 Figure references in the text ..............4 Safety General ........................5 Intended use ......................5 Product specific safety information ................. - Page 4 V 02/25 Procedure ....................23 Position the powder trolley ..............24 Start-up ......................... 24 Procedure ....................24 Operation Functional check ....................25 Start-up ......................... 25 Safety recommendations ..................25 Switch on the booth ....................26 Procedure ....................26 Switching off the booth ..................26 Procedure ....................
-
Page 5: About This Instructions
Safety symbols (pictograms) The following contains a list of warnings with their meanings found in the Gema operating instructions. Apart from the regulations in the relevant operating instructions, the general safety precautions must also be fol- lowed . DANGER Indicates a hazardous situation which, if not avoided, will result in death or serious injury. -
Page 6: Presentation Of The Contents
V 02/25 NOTICE Indicates a potentially harmful situation which, if not avoided, the equipment or something in its surrounding may be damaged. ENVIRONMENT Indicates a potentially harmful situation which, if not avoided, may have harmful consequences for the environment. MANDATORY NOTE Information which must be observed. -
Page 7: 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. – Observance of the operating, service and maintenance instructions specified by the manufacturer is also part of the intended use. -
Page 8: Product Specific Safety Information
– Before starting up the plant a check must be made that no foreign objects are in the booth or in the ducting (input and exhaust air) For further information, see the more detailed Gema safety regu- lations. Inspection Before the booth is switched on, the following points are to be checked: –... -
Page 9: Repairs
V 02/25 Repairs WARNING Danger during repair work Carrying out repairs with the cab switched on can result in death or serious injury! ► Switch off the booth with the main switch and disconnect from the mains ► Repairs should only be carried out by qualified personnel Safety •... -
Page 11: Function Description
V 02/25 Function description Field of application The Classic powder coating booth is intended exclusively for the electro- static coating with organic or metallic powders. Any other use is not con- sidered as intended use. The manufacturer is not responsible for any in- correct use and the risks associated with such actions are assumed by the user alone. -
Page 12: Classic Booths With Jet Cleaning
V 02/25 Classic booths with Jet cleaning ClassicStandard 2 Fig. 1: ClassicStandard 2 ClassicStandard 4 Fig. 2: ClassicStandard 4 10 • Function description Powder coating booth Classic... - Page 13 V 02/25 ClassicOpen Fig. 3: ClassicOpen Exhaust air unit/fan hous- 10 Work area 11 Rail for workpiece sus- Pressure tank for filter pension cleaning 12 Powder trolley / -powder Filter cartridges collector Function description • 11 Powder coating booth Classic...
-
Page 14: Operating Elements
V 02/25 Operating elements Fig. 4: Operating elements Main switch (-871Q1) Control voltage ON (-873H1) Plant OFF (-874S1) Plant ON (-874S2) Motor fault (-874H1) Fan overpressure (-875H1) Filter cartridges cleaning ON/OFF (-875S1) also indicator light when active S = Switch/push button H = Indicator lamp Equipment The control unit is equipped with the corresponding operating el-... -
Page 15: Exhaust Air System (Recirculation Air)
V 02/25 Exhaust air system (recirculation air) The exhaust fan (4) of the exhaust system is located in the fan housing (1) above the filter cartridges (2). It sucks air from the booth interior through the filter cartridges, and returns the clean air through the filter pads (3) to the environment. -
Page 16: Filter Cleaning
V 02/25 Filter cleaning Each filter cartridge (2) is equipped with a cleaning device and can be cleaned while the booth is in operation. The cleaning procedure is acti- vated manually by the relevant switch on the control cabinet. The filter cartridges not be cleaned more than 1-2 times per shift! The cartridges are cleaned by compressed air impulses, injected by pres- sure pipes inside the cartridges. -
Page 17: Fire Protection
Poorly functioning or non-functioning fire protection elements ► Local regulations must be observed when positioning the ele- ments! The positioning shown here is only a suggestion on the part of Gema. Position of the detector for ClassicStandard 2 and 4 Installation with angled... -
Page 19: Technical Data
V 02/25 Technical Data Classic powder coating booths General data Classic Standard 2 Standard 4 Open Cleaning system Number of filter elements Filter surface (m²) Powder trolley yes, 80 liters Filter elements Classic Standard 2 Standard 4 Open Filter material COL270-W (one ply) Filter surface area load 200 m³/m²·h... -
Page 20: Pneumatic Data
V 02/25 Pneumatic data Classic Standard 2 Standard 4 Open Inlet pressure (bar) min. 6 / max. 10 Recommended inlet pres- 7 bar sure Water vapor content of max. 1.3 g/m³ compressed air Oil content of compressed max. 0.1 mg/kg 15 m³/h Compressed air consump- tion at filter cleaning max. -
Page 21: Rating Plate
V 02/25 Rating plate Fields with a gray background contain contract-specific data. Technical Data • 19 Powder coating booth Classic... -
Page 23: Set-Up, Assembly And Commissioning
V 02/25 Set-up, assembly and commissioning Earthing the powder coating booth DANGER Missing or incorrect grounding A poor or missing ground connection can be dangerous to the ma- chine operator. ► Ground all Powder coating booth metal parts in accordance with general local regulations. -
Page 24: Set-Up And Assembly
V 02/25 Set-up and assembly See enclosed installation and assembly instructions! 22 • Set-up, assembly and commissioning Powder coating booth Classic... -
Page 25: Start-Up
V 02/25 Start-up General Before starting up, it may be necessary to run a function check. – A start-up should be carried out before the start of every shift, and after the booth has been standing idle for long period! CAUTION If the brake rollers are not locked after moving the coating booth, the booth could start to roll and crush body parts... -
Page 26: Position The Powder Trolley
V 02/25 Position the powder trolley CAUTION Careless handling can result in slight bruising to hands and fin- gers ► Handle the collection container with care! Push the powder trolley laterally under the booth floor all the way to the stop position and press it on with the clamping lever NOTICE The powder trolley can be damaged when it is extended ►... -
Page 27: Operation
V 02/25 Operation CAUTION Risk of injury on the crane rail People with a body length > 1.77 m can injure their head on the crane rail ► When the cabin is not in use, the eyelet must be retracted inside the booth! Functional check Check the grounding of the booth and the other connected equipment and... -
Page 28: Switch On The Booth
V 02/25 Switch on the booth The shield (if present) must be in the working position during op- eration! CAUTION Risk of injury with the shield If handled carelessly, the shield could be lifted out of its holder and crush feet or toes when it hits the booth floor. ►... -
Page 29: Switching On/Off The Lighting (Classicstandard Only)
V 02/25 Switching on/off the lighting (ClassicStandard only) ClassicStandard manual powder coating booths are fitted with two strip lightings in the roof of the booth as standard equipment. The lighting is switched on and off with the main switch. Filter cleaning CAUTION Too loud noises Sound peaks occur during cleaning, which can lead to hearing... -
Page 30: Color Change
V 02/25 Color Change Procedure Clean the booth (see therefore chapter "Booth cleaning") Clean the powder trolley thoroughly (see therefore in chapter "Clean- ing the powder trolley") Clean the injector separately, blow off the powder hose and clean the gun according to the corresponding operating manual Replace the filter cartridges (see therefore in chapter "Replacing the filter cartridges") Parameterization... -
Page 31: Entering And Selecting A Menu Option
V 02/25 Entering and selecting a menu option Select the Set Param menu with the ↓ key. Important: No other menu may be select- ed, otherwise the program becomes unusable for the con- trol unit! Press OK. The first block B1 appears. Press the ↑... - Page 32 V 02/25 Parameterization Block-No. Designation Default value Remarks (Parameter) Cleaning im- This value puls: should be ad- B001 TH = 0.2 secs. Filter clean- justed only by ing times experienced Break time: ImpParam plant special- TL = 10.0 ists! secs. Do not adjust the other parameters! 30 •...
-
Page 33: Maintenance
V 02/25 Maintenance General DANGER Serious injuries or death During assembly, cleaning, maintenance and commissioning when close to live components, an electric shock can cause serious inju- ry or death. ► All work must be carried out only by trained personnel and when no power is applied! CAUTION Risk of burns... -
Page 34: Coarse Booth Cleaning
V 02/25 Clean the filter cartridges and check for visible weekly damages, if necessary, replace (see chapter "Replacing the filter cartridges“) Check the filter pads on the exhaust air exits of the fan housing, a large powder deposit indi- cates a defective filter cartridge, replace the defective filter cartridge or the complete filter set (see chapter "Replacing the filter cartridg- es“) -
Page 35: Booth Cleaning
V 02/25 Booth cleaning NOTICE Damage to the filter cartridges Too strong a jet of compressed air can damage the structure of the filter cartridges. ► Never blow off the filter cartridges with compressed air gun! Procedure Switch on the booth Press the switch (filter cleaning) and wait until all filter cartridges have been blown off, then press the... -
Page 36: Replacing Spare Parts
V 02/25 Replacing spare parts General WARNING Contact with live components can lead to death by electric shock. ► The replacement of spare parts may only be carried out by trained personnel! ► The plant must be switched off before replacing spare parts! Spare parts can be ordered according to the spare parts list. - Page 37 V 02/25 Procedure for replacing the push button switch Fig. 14: Procedure for replacing the push button switch Maintenance • 35 Powder coating booth Classic...
-
Page 38: Replacing The Filter Cartridges
V 02/25 Replacing the filter cartridges A filter cleaning operation must take place before every filter cartridge re- placement: Start up the booth Press the switch (filter cleaning) and wait until all filter cartridges have been blown off, then press the switch again to switch off the cleaning (see therefore chapter "Filter cleaning") Switch off the booth... -
Page 39: Replacing The Filter Pads On The Fan Housing
V 02/25 Replacing the filter pads on the fan housing Procedure Open the retaining grid on the exhaust air housing Check the clean air chamber (for powder deposits), and clean the chamber, if necessary Insert a new filter pad and close the retaining grid Replacing the solenoid valve on the pressure tank The solenoid valves are installed on the pressure tank in the exhaust air... -
Page 40: Replacing The Pressure Monitoring Manostat
V 02/25 Fig. 15: Replacing the solenoid valve on the pressure tank Replacing the pressure monitoring manostat (Filter cartridges differential pressure) -871S1 Fig. 16: Pressure monitoring manostat Procedure Loosen the screws and open the control panel Mark the manostat connections (electrical and pneumatic) and loos- en them Dismantle the manostat Blow off the air hoses... -
Page 41: Functional Check
V 02/25 Functional check A function check is to be carried out: – after a replacement of spare parts on the electrical/pneumatical part of the booth – after manipulations on the control unit, respectively on the electrical part of the plant Procedure Turn on the main switch –... -
Page 43: Troubleshooting
(see wiring diagram) and switch on the booth If the malfunction oc- curs repeatedly, please contact an Gema service center The plant has minimum exhaust air switched off, the volume not reached lamp lights up - too much powder on... - Page 44 V 02/25 Filter cartridge is Solenoid valve (coil) Replace the defective is defective or cable is not cleaned solenoid valve (coil) broken Check the cable for cable break Control relay defec- Replace the control tive module (see en- closed wiring dia- gram) 42 •...
-
Page 45: Spare Parts List
When using the spare parts from other manufacturers the explo- sion 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 • 43 Powder coating booth Classic... -
Page 46: Classicstandard / Classicopen - Spare Parts List
V 02/25 ClassicStandard / ClassicOpen – spare parts list The spare parts mentioned and illustrated in this spare parts list are identical for all booth types! – Only the number of individual elements may vary! Pressure tank – complete, see corresponding spare parts list Pneumatic parts –... -
Page 47: Classicstandard / Classicopen - Spare Parts List
V 02/25 ClassicStandard / ClassicOpen – spare parts list 10, 11, 12 Fig. 17: ClassicStandard 2 10, 11, 12 Fig. 18: ClassicStandard 4 10, 11, 12 Fig. 19: ClassicOpen Spare parts list • 45 Powder coating booth Classic... -
Page 48: Powder Trolley - Spare Parts List
V 02/25 Powder trolley – spare parts list Powder trolley – complete 1005 803 Roller – 50 mm 258 571 Hexagon shakeproof screw – M6x16 mm 244 503 Hexagon shakeproof nut – M6 244 430 Toggle clamp 247 073 Edge protection profile 100 552* Foam rubber profile –... -
Page 49: Fluidizing Powder Trolley - Spare Parts List
V 02/25 Fluidizing powder trolley – spare parts list Powder trolley – complete 1007 710 Rubber damper – Ø 20x20 mm 223 808 Turbine vibrator – complete, incl. pos. 2.1 1007 761 Filter Hose connector – Ø 12 mm, 1/4" 222 348 Toggle clamp 247 073... -
Page 50: Pressure Tank - Spare Parts List
V 02/25 Pressure tank – spare parts list Membrane valve – 24 VDC, complete (without pos. 2 and 2.1) 1005 858# Valve cable – complete 1006 075 Cable for pos. 2 103 578* Hose connector – Ø 25 mm, 1" 1005 856 Hose –... -
Page 51: Pneumatic Parts - Spare Parts List
V 02/25 Pneumatic parts – spare parts list Regulator/filter unit 1005 841 Pressure gauge – 0-10 bar 203 289 T-piece – 1/2"-1/2"-1/2" 223 301 Sealing plug – 1/4" 263 834 Differential pressure switch – 0.5-2.5 kPa 243 736 Plastic tube – Ø 4/6 mm (for pos. 5) 100 706* Elbow joint complete –... - Page 52 V 02/25 50 • Spare parts list Powder coating booth Classic...
Need help?
Do you have a question about the Classic Standard 2 and is the answer not in the manual?
Questions and answers