Gema MagicCompact BA04 Mode d’emploi

Translation of the original operating instructions

Operating instructions and spare parts list

Powder coating booth

MagicCompact BA04

V 10/17

Documentation – powder coating booth MagicCompact BA04

This publication is protected by copyright. Unauthorized copying is prohib-

ited by law. No part of this publication may be reproduced, photocopied,

translated, stored on a retrieval system or transmitted in any form or by

any means for any purpose, neither as a whole nor partially, without the

express written consent of Gema Switzerland GmbH.

MagicCompact, MagicCylinder, MagicPlus, MagicControl, OptiFlex, Opti-

Control, OptiGun, OptiSelect, OptiStar and SuperCorona are registered

trademarks of Gema Switzerland GmbH.

OptiFlow, OptiCenter, OptiMove, OptiSpeeder, OptiFeed, OptiSpray, Op-

tiSieve, OptiAir, OptiPlus, OptiMaster, MultiTronic, EquiFlow, Precise

Charge Control (PCC), Smart Inline Technology (SIT) and Digital Valve

Control (DVC) are trademarks of Gema Switzerland GmbH.

All other product names are trademarks or registered trademarks of their

respective holders.

Reference is made in this manual to different trademarks or registered

trademarks. Such references do not mean that the manufacturers con-

cerned approve of or are bound in any form by this manual. We have en-

deavored to retain the preferred spelling of the trademarks, and registered

trademarks of the copyright holders.

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.

For the latest information about Gema products, visit

www.gemapowdercoating.com.

For information regarding patents, see

www.gemapowdercoating.com/patents or

www.gemapowdercoating.us/patents.

Printed in Switzerland

Gema Switzerland GmbH

Mövenstrasse 17

9015 St.Gallen

Switzerland

Phone: +41-71-313 83 00

Fax: +41-71-313 83 83

Email: [email protected]

V 10/17

MagicCompact BA04 Table of contents • 1

Table of contents

General safety regulations 5

Safety symbols (pictograms) ................................................................................... 5

Intended use ........................................................................................................... 5

Product-specific safety measures ........................................................................... 6

General information ................................................................................... 6

Installation .................................................................................................. 6

Operating the equipment ........................................................................... 7

Inspection ................................................................................................... 7

Entering the booth ...................................................................................... 7

Repairs ....................................................................................................... 7

About this manual 9

General information ................................................................................................ 9

Design and function 11

Field of application ................................................................................................ 11

Function description .............................................................................................. 11

Operational procedure ............................................................................. 12

Powder flow.............................................................................................. 13

Booth – superstructure .......................................................................................... 13

Booth – basement ................................................................................................. 14

Floor blow-off system ............................................................................... 14

Powder suction ........................................................................................ 15

Exhaust air system with After Filter ....................................................................... 16

Fire protection ....................................................................................................... 16

Cleaning operation mode ...................................................................................... 16

Automatic booth cleaning ......................................................................... 16

Powder recovery ................................................................................................... 16

Automatic powder guns ........................................................................................ 17

Cleaning the guns ................................................................................................. 18

Technical Data 19

MagicCompact BA04 powder coating booth ......................................................... 19

Electrical data .......................................................................................... 19

Pneumatic data ........................................................................................ 19

Dimensions .............................................................................................. 19

Sound pressure level ............................................................................... 20

Start-up 21

Set-up and assembly ............................................................................................ 21

Installation ................................................................................................ 21

Cable connections / junctions ............................................................................... 21

Grounding ................................................................................................ 21

V 10/17

2 • Table of contents MagicCompact BA04

Operation 23

Before switching on the booth .............................................................................. 23

Switch on the booth .............................................................................................. 23

Switching off the booth ......................................................................................... 23

Alarm messages ................................................................................................... 24

Filter cleaning ....................................................................................................... 24

Color change and cleaning ................................................................................... 24

Maintenance 27

Maintenance and repair ........................................................................................ 27

Daily or after each shift ............................................................................ 27

Weekly ..................................................................................................... 27

Biannually ................................................................................................ 27

Maintenance and repair of the cyclone separator ................................................ 28

Maintenance and repair of the sieve machine ...................................................... 28

Maintenance of the After Filter pressure gauges (filter and fan) .......................... 28

Replacing spare parts ........................................................................................... 28

Functional check ................................................................................................... 29

General information ................................................................................. 29

Procedure of the function check .............................................................. 29

Decommissioning, storage 31

Introduction ........................................................................................................... 31

Safety rules .............................................................................................. 31

Requirements on personnel carrying out the work .................................. 31

Storage conditions ................................................................................................ 31

Storage duration ...................................................................................... 31

Space requirements ................................................................................ 31

Physical requirements ............................................................................. 31

Hazard notes ........................................................................................... 31

Shut-down ............................................................................................................. 32

Decommissioning .................................................................................... 32

Cleaning................................................................................................... 32

Disassembly/attachment of transport safety devices .............................. 32

Packing .................................................................................................... 32

Identification ............................................................................................ 32

Maintenance during storage ................................................................................. 32

Maintenance schedule ............................................................................. 32

Maintenance works .................................................................................. 32

Return to service .................................................................................................. 33

Commissioning following storage ............................................................ 33

Packing, transport 35

Introduction ........................................................................................................... 35

Safety rules .............................................................................................. 35

Requirements on personnel carrying out the work .................................. 35

Packing material ................................................................................................... 35

Transport .............................................................................................................. 35

Data concerning goods to be transported ............................................... 35

Mode of transportation ............................................................................. 36

Loading, transferring the load, unloading ................................................ 36

Troubleshooting 37

General ................................................................................................................. 37

Problem fixing ....................................................................................................... 37

Setting values ....................................................................................................... 39

V 10/17

MagicCompact BA04 Table of contents • 3

Spare parts list 41

Ordering spare parts ............................................................................................. 41

MagicCompact BA04 – spare parts list ................................................................. 42

Floor blow-off system – Pneumatics ..................................................................... 43

Pressure regulator ................................................................................................ 44

Sensor/Actor Box .................................................................................................. 45

Gun blow off equipment ........................................................................................ 46

Door drive unit ....................................................................................................... 48

Fan control unit ..................................................................................................... 50

V 10/17

MagicCompact BA04 General safety regulations • 5

General safety regulations

This chapter sets out the fundamental safety regulations that must be fol-

lowed by the user and third parties using the MagicCompact BA04 pow-

der coating booth.

These safety regulations must be read and understood before the powder

coating booth is put into operation.

Safety symbols (pictograms)

The following warnings with their meanings can be found in the Gema

Switzerland operating instructions. The general safety precautions must

also be followed as well as the regulations in the operating instructions.

DANGER!

danger due to live electricity or moving parts Possible consequences:

Death or serious injury

ATTENTION!

Improper use of the equipment could damage the machine or cause it to

malfunction. Possible consequences: minor injuries or damage to equip-

ment

NOTE:

Useful tips and other information

Intended use

– The powder coating booth is built to the latest specification and con-

forms to the recognized technical safety regulations and is designed

for the normal application of powder coating.

– Any other use is not considered as intended use. The manufacturer

is not responsible for any incorrect use and the risks associated with

such actions are assumed by the user alone. Gema Switzerland

GmbH must be consulted prior to any use of the powder Powder

coating booth for any purposes or substances other than those indi-

cated in our guidelines.

– Observance of the operating, service and maintenance instructions

specified by the manufacturer is also part of the intended use. The

V 10/17

6 • General safety regulations MagicCompact BA04

powder coating booth should only be used, maintained and started

up by trained personnel, who are informed about and are familiar

with the possible hazards involved.

– Start-up (i.e. the execution of a particular operation) is forbidden until

it has been established that the 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.

– Unauthorized modifications to the powder coating booth exempts the

manufacturer from any liability from resulting damage.

– The relevant accident prevention regulations, as well as other gen-

erally recognized safety regulations, occupational health and struc-

tural regulations are to be observed.

– Furthermore, the country-specific safety regulations also must be

observed.

Explosion protection Protection type

II 3D IP54

Product-specific safety measures

General information

The MagicCompact BA04 powder coating booth is a constituent part of

the equipment and is therefore integrated in the system's safety concept.

If it is to be used in a manner outside the scope of the safety concept,

then corresponding measures must be taken.

NOTE:

For further information, see the more detailed Gema safety regula-

tions!

Installation

– Installation work performed by the customer must be carried out ac-

cording to local regulations.

– 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)

– All components must be grounded according to the local regulations

before start-up.

– The ground connection of the booth should be checked each time

the equipment is put into operation. The ground must be connected

by the customer to the base of the booth, Multi- cyclone, and filter

housing(s). Also make sure that the workpieces, and all other sys-

tems are properly grounded

V 10/17

MagicCompact BA04 General safety regulations • 7

Operating the equipment

In order to be able to operate the equipment safely, it is necessary to be

familiar with the safety regulations, the operational characteristics and

functioning of the various plant components.

For this purpose, read the safety notes, this operating manual and the

operating instructions of the control unit with touch panel, before starting

up the plant.

In addition, all further equipment-specific operating instructions, e.g. the

OptiFlex and all additional components should also be read.

To obtain practice in operating the plant, it is absolutely essential to start

the operation according to the operating instructions. Later on, they also

serve as a useful aid in the event of possible malfunctions or uncertainty

and make many inquiries unnecessary. 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.

Inspection

Before switching on the booth, check the following points (where applica-

ble):

– 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 dense

phase conveyor

– Pneumatic conduction to the After Filter is connected, the filter ele-

ment door is closed, the waste container is placed and fitted

Entering the booth

ATTENTION:

Danger of slipping and/or injury!

Repairs

ATTENTION:

Carrying out of repairs is only permitted when the booth is switched

off, and must be done only by trained personnel!

Table des matières

Manuels Équipement industriel populaires d'autres marques

ABB

ABB Unifix AD Manuel

Mark 7

Mark 7 Evolution Manuel utilisateur

Husky

Husky HyPET Manuel utilisateur

bora

bora PM-1800 Manuel utilisateur

Grizzly

Grizzly T32428 Manuel utilisateur

Siemens

Siemens 8MF1 Series Manuel utilisateur

ABB

ABB HT610965 Manuel utilisateur

ABB

ABB SafeLink Manuel utilisateur

Phoenix

Phoenix PHX-150 Manuel utilisateur

ABB

ABB A165-L32 Manuel utilisateur

ABB

ABB HT842936 Manuel utilisateur

Rioned

Rioned UrbanJet Manuel utilisateur

Hermetica

Hermetica 10 Series Manuel utilisateur

HORNER

HORNER OEE Solution Manuel utilisateur

Hammerhead

Hammerhead HG375 Manuel utilisateur

SCHUNK

SCHUNK VERO-S NSE-A3 138 Instructions d'utilisation

ABB

ABB HT566657 Manuel utilisateur

Webasto

Webasto GSE CAN Manuel utilisateur