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Gema MagicCylinder EquiFlow QCS04 Operating Instructions And Spare Parts List

Powder coating booth
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Rev. 00
1024 612
Operating instructions and Spare parts list
Powder coating booth
MagicCylinder EquiFlow
(QCS04)
Translation of the original operating instructions

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Summary of Contents for Gema MagicCylinder EquiFlow QCS04

  • Page 1 Rev. 00 1024 612 Operating instructions and Spare parts list Powder coating booth MagicCylinder EquiFlow (QCS04) 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

    Rev. 00 05/23 Table of contents About these instructions General information ....................7 Keeping the Manual ....................7 Safety symbols (pictograms) ................... 7 Structure of Safety Notes ................8 Presentation of the contents ................... 8 Figure references in the text ..............8 Safety Basic safety instructions ..................
  • Page 4 Rev. 00 05/23 Cleaning operation mode ..................26 Automatic booth cleaning ................ 27 Powder recovery system ..................27 Automatic powder guns ..................27 Guns exterior cleaning ..................28 Function description ..................... 28 Operational procedure ................29 Powder flow ..................... 29 Assembly / Connection Set-up and assembly ....................
  • Page 5 Rev. 00 05/23 Return to service ....................47 Commissioning following storage ............47 Disposal Introduction ......................49 Requirements on personnel carrying out the work ........49 Disposal regulations ................. 49 Materials ....................49 Spare parts list Ordering spare parts ..................... 51 MagicCylinder QCS04 –...

  • Page 7: About These Instructions

    Please keep this Manual ready for later use or if there should be any queries. Safety symbols (pictograms) The following warnings with their meanings can be found in the Gema instructions. The general safety precautions must also be followed as well as the regulations in the relevant instructions.

  • Page 8: Structure Of Safety Notes

    Rev. 00 05/23 ENVIRONMENT Indicates a potentially harmful situation, which, if not avoided, may have harmful consequences for the environment. MANDATORY NOTE Information that must be observed. NOTICE Useful information, tips, etc. Structure of Safety Notes Every note consists of 4 elements: –...
  • Page 9 Rev. 00 05/23 About these instructions • 9 MagicCylinder EquiFlow (QCS04)
  • Page 10 Rev. 00 05/23 10 • About these instructions MagicCylinder EquiFlow (QCS04)

  • Page 11: 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. – Start-up (i.e. the execution of intended operational tasks) is forbidden until it has been established that this product has been set up and wired according to the guidelines for machinery.

  • Page 12: Product Specific Security Regulations

    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. 12 • Safety...

  • Page 13: Inspection

    Rev. 00 05/23 Inspection Before switching on the booth, check the following points (where applicable): – No foreign material in the central suction unit in the booth and in the powder suction – Pneumatic conduction and powder hose are connected to the powder recirculating –...

  • Page 14: Emergency Action

    Switch off the installation. unusual noises, unusual – Disconnect the mains plug. generation of heat – Contact the Technical Service Department of Gema. – Fire in the electrical Disconnect the mains plug. system – Extinguish the fire with an appropriate fire extinguisher.

  • Page 15: Residual Risks

    Rev. 00 05/23 Residual risks Unavoidable design features of a device as well as the intended application area can also pose a risk to the user if operated correctly. Depending on the design and equipment of the booth, certain residual risks cannot be completely excluded, despite the design of the device according to the current state of technology.
  • Page 16 Rev. 00 05/23 16 • Safety MagicCylinder EquiFlow (QCS04)

  • Page 17: Transport • 17

    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 Switzerland GmbH. Packing material Not necessary for the internal transport. For external transport: see chapter "Decommissioning / Storage"...

  • Page 18: Transport

    Rev. 00 05/23 Transport Data concerning goods to be transported – The space requirements correspond to the size of the components plus the packaging – Weight see "Technical Data" Loading, transferring the load, unloading Suitable lifting equipment is to be used for all procedures. Exercise caution at temperatures below +5 °C to -15 °C.

  • Page 19: Product Description

    Rev. 00 05/23 Product description Intended use Coating booth systems are used for the electrostatic powder coating of all types of workpieces in large batches with color changes. As part of the process controlled coating plant, they are laid out for fully automatic operation.

  • Page 20: Reasonably Foreseeable Misuse

    Rev. 00 05/23 For a better understanding of the interrelationships in powder coating, it is recommended that the operating instructions for all other components be read as well, so as to be familiar with their functions too. Reasonably foreseeable misuse –...

  • Page 21: Dimensions

    Rev. 00 05/23 Dimensions MagicCylinder EquiFlow (QCS04) Booth diameter 2.5 m (in the interior) Booth basement height min. 0.71 m - max. 1 m Weight – with superstructure height approx. 2600 kg 3000 mm – more or less weight per approx.

  • Page 22: Design And Function

    Rev. 00 05/23 Design and function Overall view Fig. 2 Superstructure Gun blow off equipment Basement Lighting Manual coater platform Exhaust air ducting Booth door Booth – superstructure The booth superstructure is a double walled plastic panel construction, ensuring an optimum powder repelling effect. All grounded parts, including the booth superstructure supports, are positioned at the necessary required distance outside of the booth.

  • Page 23: Booth - Basement

    Rev. 00 05/23 Booth – basement The booth basement consists of reinforced plastic material. The booth basement contains the floor blow-off unit and the powder suction (suction duct). Fig. 3: Basement Floor blow-off system Suction duct Product description • 23 MagicCylinder EquiFlow (QCS04)

  • Page 24: Floor Blow-Off System

    Rev. 00 05/23 Floor blow-off system Blow-off rails with blow nozzles are integrated lengthwise into the booth floor. Each blow-off rail consists of various segments, which can be pneumatically controlled one by one. Fig. 4: floor blow-off system (arrows = blow-off direction) The required blow-off pressure is 2 bar.

  • Page 25: Powder Suction

    Rev. 00 05/23 Powder suction 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 26: Exhaust Air System With After Filter

    Rev. 00 05/23 Optionally, the manual coater platform can also be equipped with a powder suction system. The extracted powder is fed directly into the after filter. The platform must be cleaned manually, but the exhaust air ducting to the after filter is self-cleaning. Fig.

  • Page 27: Automatic Booth Cleaning

    Rev. 00 05/23 Automatic booth cleaning The cleaning of the booth floor takes place automatically with the combination of the floor blow-off system and the powder suction (see the chapter on "Booth – basement") Powder recovery system A safe and clean powder recovery is ensured by following components: –...

  • Page 28: Guns Exterior Cleaning

    Rev. 00 05/23 Guns exterior cleaning 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 coating booth. Fig. 8: Guns exterior cleaning By activating the cleaning function on the control unit, the axes and the guns move out of the booth.

  • Page 29: Operational Procedure

    Rev. 00 05/23 More detailed information about the control units/components and the operating interfaces are found in the corresponding user manuals! Operational procedure Only the multiple color version is described in this user manual! By switching on the booth, the fan in the After Filter starts up and after the start-up phase, the plant units which are interlocked with the booth are released.
  • Page 30 Rev. 00 05/23 The powder which does not adhere on the workpieces falls on the booth floor and is sucked off through the slots in the booth floor, and delivered to the cyclone separator (2) as powder/air mixture. Centrifugal force separates the powder from the air in the cyclone. The separated powder is cleaned in the integrated sieve (3) and transported back to the powder container in the OptiCenter by a powder recirculating conveyor (4), where it is available again for the coating process.

  • Page 31: Assembly / Connection

    Rev. 00 05/23 Assembly / Connection Set-up and assembly WARNING Danger of toppling over due to insufficient floor bearing capacity ► Ensure that the floor bearing capacity is at least 500 kg/m² CAUTION Danger of injury The assembly and installation process must be carried out using the customer's existing equipment, due to heavy and bulky parts.

  • Page 32: Grounding The Booth

    Rev. 00 05/23 Grounding the booth DANGER Missing or incorrect grounding A poor or missing ground connection can be dangerous to the machine operator. ► Ground all metal parts in accordance with general local regulations. ► Check grounding regularly. Appropriate connection points are provided on the booth superstructure and the booth basement, on the cyclone separator, on the duct and on the filter housing for equipotential bonding.

  • Page 33: Start-Up

    Rev. 00 05/23 Start-up Preparation for start-up Important notes NOTICE Damage to the booth or to the ducting Foreign objects in the booth or in the ducting can cause damages to the plant or facility! ► Only trained personnel shall be permitted to proceed with the start-up! Before the start-up the following points are to be checked: −...
  • Page 34 Rev. 00 05/23 34 • Start-up MagicCylinder EquiFlow (QCS04)

  • Page 35: Operation

    Rev. 00 05/23 Operation WARNING Inhalation and penetration of powders During manual cleaning tasks, powder can be inhaled inadvertently. ► Wearing appropriate protective equipment is mandatory. ► Switch on the after-filter so that any dust produced is directed away from the machine operator. Before switching on the booth –...

  • Page 36: Switching Off The Booth

    Rev. 00 05/23 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 Alarm messages If malfunctions take place, the signal horn sounds and an alarm message is shown (see the chapter "Troubleshooting"...
  • Page 37 Rev. 00 05/23 – Set the OptiCenter to the cleaning mode – Coarse cleaning of the OptiCenter 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 –...
  • Page 38 Rev. 00 05/23 38 • Operation MagicCylinder EquiFlow (QCS04)

  • Page 39: Maintenance / Repairs

    Rev. 00 05/23 Maintenance / Repairs WARNING Risk of collapse/falling through! Walking on the booth roof can result in serious falls with serious injury or death. ► Never step on the booth roof! Daily or after each shift – Blow off the powder hoses –...
  • Page 40 Rev. 00 05/23 40 • Maintenance / Repairs MagicCylinder EquiFlow (QCS04)

  • Page 41: Troubleshooting

    Rev. 00 05/23 Troubleshooting Safety Securing against unexpected start-up The machine starting unexpectedly may cause serious injuries to persons working on the machine. Set the safety switch to <0> and lock it. Remove the key and keep it with you. Explosion protection Lack of maintenance and a lack of ignition protection can lead to explosions.

  • Page 42: General

    (see wiring diagram), see also the "Troubleshooting" section in the After Filter operating manual. – In the case of repeated alarm, contact your Gema service center – Pressure increase is Pressure increase on the filter Switch off the gun control units,...
  • Page 43 Rev. 00 05/23 Fault Cause Corrective action Minimum pressure in the filter Alarm has been housing not reached released: – Message Fan Too little pressure, too overpressure much exhaust air, because too little or no air resistance – Filter housing door is Close the filter housing door open –...
  • Page 44 Rev. 00 05/23 Fault Cause Corrective action Automatic floor blow-off Pressure reducing valve Check the compressed air supply system not OK defective or adjusted incorrectly Solenoid valve defective (coil, Replace or check cable) or missing signal 44 • Troubleshooting MagicCylinder EquiFlow (QCS04)

  • Page 45: 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 Switzerland GmbH. Storage conditions Storage duration If the physical conditions are maintained, the unit can be stored indefinitely.

  • Page 46: Physical Requirements

    Rev. 00 05/23 Physical requirements Storage must be inside a dry building at a temperature between +5 – +60 °C. Hazard notes The safety data sheets of the corrosion protection agent used must be observed. There is no danger to personnel or the environment if the unit is stored properly.

  • Page 47: Maintenance During Storage

    Rev. 00 05/23 Maintenance during storage Maintenance schedule For longer storage periods (> 1 year) check the anti-corrosion measures periodically. Maintenance works If any deficiencies in the anti-corrosion protection measures are found, these must be eliminated. Return to service Commissioning following storage It is essential to pay attention to the ambient temperature before starting installation of the booth.
  • Page 48 Rev. 00 05/23 48 • Decommissioning / Storage MagicCylinder EquiFlow (QCS04)

  • Page 49: 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 manufacturer’s documentation must be observed.
  • Page 50 Rev. 00 05/23 50 • Disposal MagicCylinder EquiFlow (QCS04)

  • Page 51: Spare Parts List

    Ø 8/6 mm, 8 mm outside diameter (o/d) / 6 mm inside diameter (i/d) WARNING Use of non-original Gema spare parts Use of Non-Gema replacement spare parts may invalidate some or all approval certificates and accreditations; and the user assumes all explosion risks associated with use of these parts. Use of these replacement spare parts may void any and all warranty claims.

  • Page 52: Magiccylinder Qcs04 - Spare Parts List

    Rev. 00 05/23 MagicCylinder QCS04 – spare parts list Floor blow-off system – Pneumatics (see separate spare parts list) Gun blow off equipment (see separate spare parts list) Sensor/Actor-Box (see separate spare parts list) Pressure regulator (see separate spare parts list) Door drive unit (see separate spare parts list) Lamp –...

  • Page 53: Floor Blow-Off System - Pneumatics

    Rev. 00 05/23 Floor blow-off system – Pneumatics Solenoid valve – 1/2", NW 13.5 - 24 VDC, without pos. 2 1005 120 Valve coil for pos. 1 – 24 VDC 1005 119 Valve cable – 3 pins, L= 3 m 1008 244 T-piece –...

  • Page 54: Pressure Regulator

    Rev. 00 05/23 Pressure regulator Pressure regulator – 0-8 bar, 1” (gun blow-off cleaning) 1008 185 Pressure gauge – 0-10 bar, 1/8" 243 620 Adapter nipple – 1/8"-1/4" 265 454 Double nipple – 1"-1", divisible 1005 563 1017 084 Pressure regulator – 0-4 bar, 1” (floor blow-off system) Fig.

  • Page 55: Sensor/Actor Box

    Rev. 00 05/23 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. 13: Sensor/Actor Box Spare parts list • 55 MagicCylinder EquiFlow (QCS04)

  • Page 56: Gun Blow Off Equipment

    Rev. 00 05/23 Gun blow off equipment Nozzle type 1 – complete (pos. 1-4) 1013 088 Nozzle type 2 – complete (pos. 2-5) 1013 089 Nozzle holder type 1 – complete 1013 090 O-ring – Ø 20x3 mm 224 863 Nozzle 1013 094 Allen grub screw –...
  • Page 57 Rev. 00 05/23 Gun blow off equipment Fig. 14: Gun blow off equipment Spare parts list • 57 MagicCylinder EquiFlow (QCS04)

  • Page 58: Door Drive Unit

    Rev. 00 05/23 Door drive unit Switch box 1014 076 Rotary drive 90° left 1017 401 Rotary drive 90° right 1013 836 Rotary drive 180° left 1017 402 Rotary drive 180° right 1014 075 Solenoid valve – 24 VDC, without pos. 4 1014 077 Valve cable –...
  • Page 59 Rev. 00 05/23 Door drive unit Fig. 15: Door drive unit Fig. 16: Door monitoring and door locking Spare parts list • 59 MagicCylinder EquiFlow (QCS04)

  • Page 60: Lamp

    Rev. 00 05/23 Lamp LED module Type 1500, 230 V, 60 W, length 1512 mm 1027 219 Type 1200, 230 V, 45 W, length 1227 mm 1027 218 Type 600, 230 V, 22 W, length 582 mm 1027 217 Adhesive seal strip – 19x4 mm 1014 137* Screw –...

  • Page 61: Switching Unit (Exhaust Air)

    Rev. 00 05/23 Switching unit (exhaust air) Proximity switch 1024 053 Connection cable 1023 123 Seal (inflatable) – complete Ø 450 mm 1016 743 Ø 500 mm 1016 744 Ø 550 mm 1016 745 Ø 600 mm 1016 746 Ø 650 mm 1016 747 Ø...

  • Page 62: Booth Accessories

    Rev. 00 05/23 Booth accessories Cleaning wand for the booth basement – complete Type 8000 1018641 Type 10000 1018642 Type 12000 1018643 Type 14000 1018644 Type 16000 1018645 Type 20000 1018646 Type 24000 1018647 Cleaning wand for the booth superstructure (coarse cleaning) – complete 200G type 1016 554 300G type...
  • Page 63 Rev. 00 05/23 Booth accessories Fig. 19: Booth accessories Spare parts list • 63 MagicCylinder EquiFlow (QCS04)
  • Page 65 Rev. 00 05/23 Index About these instructions ........7 Maintenance ............ 39 Assembly ............31 Operation ............35 Basic safety instructions ........11 Pictograms ............7 Connection ............31 Pneumatic data ..........20 Presentation of the contents .......8 Product description .......... 19 Decommissioning ..........
  • Page 66 Rev. 00...

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