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Gema UA05 Operating Instructions Manual Download Page 3

 

Rev. 00  09/22 

 

UA05 

Table of contents  

•

  3 

 

Table of contents 

About these instructions 

7

 

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 

9

 

Basic safety instructions ......................................................................................... 9

 

Product specific security regulations ...................................................................... 9

 

Special safety regulations ........................................................................ 10

 

Transport 

13

 

Introduction ........................................................................................................... 13

 

Requirements on personnel carrying out the work .................................. 13

 

Packing material.................................................................................................... 13

 

Selection of packing material ................................................................... 13

 

Procedure when packing ......................................................................... 13

 

Transport ............................................................................................................... 13

 

Data concerning goods to be transported ................................................ 13

 

Loading, transferring the load, unloading ................................................ 13

 

Product description 

15

 

Intended use ......................................................................................................... 15

 

Utilization .................................................................................................. 16

 

Reasonably foreseeable misuse ........................................................................... 16

 

Function ................................................................................................................ 16

 

Schematic presentation ........................................................................... 17

 

Special characteristics ............................................................................. 18

 

Combination with additional axes of motion ............................................ 18

 

Position regulator with CAN BUS (Power unit) ..................................................... 19

 

Technical Data ...................................................................................................... 20

 

Versions ................................................................................................... 20

 

Mechanical data ....................................................................................... 20

 

Electrical data .......................................................................................... 21

 

Pneumatic data ........................................................................................ 21

 

Dimensions .............................................................................................. 22

 

Sound pressure level ............................................................................... 22

 

Rating plate .............................................................................................. 22

 

Controller cabinet ..................................................................................... 23

 

Assembly / Connection 

25

 

Place of installation and operation ........................................................................ 26

 

Grounding of the axis ............................................................................................ 27

 

Electrical/pneumatic connections and cable connections .................................... 27

 

Summary of Contents for UA05

Page 1: ...Rev 00 1011 549 EN Operating instructions and Spare parts list Gun axis UA05 Translation of the original operating instructions ...

Page 2: ...rks 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 concerned approve of or are bound in any form by this manual We have endeavored to retain the preferred spelling of the trademarks and registered ...

Page 3: ...al 13 Procedure when packing 13 Transport 13 Data concerning goods to be transported 13 Loading transferring the load unloading 13 Product description 15 Intended use 15 Utilization 16 Reasonably foreseeable misuse 16 Function 16 Schematic presentation 17 Special characteristics 18 Combination with additional axes of motion 18 Position regulator with CAN BUS Power unit 19 Technical Data 20 Version...

Page 4: ...ing 36 Preservation 36 Maintenance during storage 36 Maintenance schedule 36 Maintenance works 36 Maintenance Repairs 37 General information 37 Maintenance schedule 38 Drive unit 38 Replacing the drive unit 39 Toothed belt 40 Replacing the toothed belt 40 Replacing the gliding elements 41 Setting the support roller 45 Maintenance of the position regulator 45 Replacing the position regulator 46 Fau...

Page 5: ...Rev 00 09 22 UA05 Table of contents 5 ...

Page 6: ......

Page 7: ...p 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 DANGER Indicates a hazardous situation which if not avoided will result in death or serious injury WARNING Indicates...

Page 8: ...y Notes Every note consists of 4 elements Signal word Nature and source of the danger Possible consequences of the danger Prevention of the danger SIGNAL WORD Nature and source of the hazard Possible consequences of the danger Prevention of the danger Presentation of the contents Figure references in the text Figure references are used as cross references in the descriptive text Example The high v...

Page 9: ...dard Machine safety must also be observed Unauthorized modifications to the product exempt the manufacturer from any liability from resulting damage The relevant accident prevention regulations as well as other generally recognized safety regulations occupational health and structural regulations are to be observed Furthermore the country specific safety regulations also must be observed Product s...

Page 10: ...eight of the booth gun slots If an incorrect too high stroke limit is set this can lead to damage to the reciprocator and or the booth ATTENTION During a test run it must be guaranteed that the unit is not damaged by the test In particular the limitations of the stroke range have to be observed for further information see chapter Setting the mechanical stop When repairing the axis both the axis co...

Page 11: ...ay result in damage to property and personal injury if relevant safety information is not observed 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 ...

Page 12: ...Rev 00 09 22 12 Safety UA05 ...

Page 13: ...ycling Requirements on personnel carrying out the work All work must be carried out by personnel trained in packing machines Packing material Selection of packing material Suitably stable wood packing material must be used Procedure when packing Transport the unit only in a horizontal position Axes must be supported in the center Transport Data concerning goods to be transported The space requirem...

Page 14: ...Rev 00 09 22 14 Transport UA05 ...

Page 15: ...se This product should only be used maintained and started up by trained personnel who are informed about and are familiar with the possible hazards involved 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 For a better understanding of the interrelationships in powder ...

Page 16: ...xis carries out a linear oscillating backwards and forwards motion in the horizontal direction called U motion in order to adjust the gun position to the parts to be coated The movement sequences travel distance and travel speed are controlled by the axis control unit During reverse motion the gun is blown off using the integrated blow off device 5 The gun holders are pressed onto the carriage 2 w...

Page 17: ... Fig 2 Structure 1 Drive unit 2 Trolley 3 Gun holder fastener 4 Linear guide unit 5 Blow off device Schematic presentation Fig 3 Schematic presentation 1 Axis control 2 Position regulator 3 Pulse generator wiring 4 Motor cables 5 Drive motor ...

Page 18: ...simple maintenance Simple assembly and disassembly A grid formation with separation of 110 mm between the automatic guns with the distance mechanically adjustable Robust dirt resistant and easily accessible components Integrated cleaning function blow off Maximum stroke length 1850 mm Free axis programming via MagicControl CM40 Bus CAN bus technology integrated into the control unit Can be combine...

Page 19: ...r with CAN BUS Power unit fig 5 Position regulator with CAN BUS X1 Load connections motor brake resistor X2 Control voltage 230 VAC X3 Power supply AC X4 Pulse generator connection incl motor winding temperature monitoring X5 CANopen connector X6 USB connector ...

Page 20: ...r right 650 1024 761 right 850 1024 762 right 1050 1024 763 right 1250 1024 764 right 1450 1024 765 right 1650 1024 766 right 1850 1024 767 left 650 1024 769 left 850 1024 770 left 1050 1024 771 left 1250 1024 772 left 1450 1024 773 left 1650 1024 774 left 1850 1024 775 Mechanical data UA05 Height 0 1 m Grid formation mechanically adjustable 0 11 m Travel distance up to 1 85 m Weight axis with sup...

Page 21: ...quency 50 60 Hz Protection type IP54 Isolation motor Class F Control unit CM40 CM30 Temperature range 0 C 40 C 32 F 104 F Pneumatic data UA05 Max input pressure 8 bar Min input pressure 6 bar Max water vapor content of the compressed air 1 3 g m Max oil vapor content of the compressed air 0 1 mg m Max compressed air consumption 10 Nm h with 2 bar ...

Page 22: ...aken at the most frequent operator positions and at a height of 1 7 m from the ground The specified value is applicable only for this product itself and does not take into account external noise sources or cleaning impulses The sound pressure level may vary depending on the product configuration and space constraints Rating plate Fig 7 Rating plate Fields with a gray background contain contract sp...

Page 23: ...oltage 230 VAC 50 60 Hz Control signal CANopen Protection type IP54 Pneumatic data Max input pressure 8 bar Min input pressure 4 bar Max water vapor content of the compressed air 1 3 g m Max oil vapor content of the compressed air 0 1 mg m Dimensions Width according to order Height according to order Depth according to order Weight according to order ...

Page 24: ...Rev 00 09 22 24 Product description UA05 ...

Page 25: ...t of the gun axis can cause injuries Erect a protective fence around the reciprocator so that there is no danger of injury during normal operation CAUTION Injuries can occur inside the protective fence due to the movement of the gun axis 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 ...

Page 26: ...maximum load of the vertical axis is approx 130 kg Mount a maximum of 8 gun axes type UA05 either on one side or on both sides Fig 8 UA05 mounted on ZA16 left right Fig 9 UA05 mounted on ZA16 on both sides The power supply is located in a separate control cabinet The control cabinet should be mounted as close to the axis as possible ...

Page 27: ...g 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 10 Potential equalization connection point Electrical pneumatic connections and cable connections The electrical and pneumatic installations are to be done as indicated in the attached diagrams Caution damage to t...

Page 28: ...Rev 00 09 22 28 Assembly Connection UA05 ...

Page 29: ... off and lock the mains switch Before starting up check the following Check the gun holder and hose holder if they are firmly fitted Mount the gun holder in such a way that they do not hit the bottom of the booth slots on start up and cause damage Lay out the cables and hoses in such a way that even at the highest stroke no strain can Check the grounding of the guns and hose carriers Check if the ...

Page 30: ...corresponding operating manual The pressure for the blow off device should be approximately 2 bar Reference point and mechanical stop The reference point serves as starting point for the reciprocator control unit for calculating the front and rear reversing point and the maximum stroke Each time the reciprocator is switched on the control unit requests that the linear guide unit travels to the ref...

Page 31: ...ition hast to be measured for this reason consider the maximum distance to the booth gun slots ATTENTION An incorrect set stroke limit will lead to damage to the gun axis and or the booth Before connecting or switching on the axis read carefully these operating instructions See the user manual of the axis control unit Procedure 1 Switch off the power supply 2 Loosen the screws 2 and move the mecha...

Page 32: ...Rev 00 09 22 32 Start up UA05 ...

Page 33: ... axis control unit permits the selection and the start stop of the travel programs by the operator on the panel In addition the operator has the possibility to create up to 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 ...

Page 34: ...Rev 00 09 22 34 Operation UA05 ...

Page 35: ...rized technical personnel Storage conditions Hazard notes There is no danger to personnel or the environment if the unit is stored properly Type of storage For safety reasons gun axes should only be stored in a horizontal position 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 a...

Page 36: ...the axes of motion must be disconnected from the power supply Unplug the power cable Unplug the ground cable Cleaning The linear guide unit running surface of the gun axis must be thoroughly cleaned Preservation No preservation is necessary Maintenance during storage Maintenance schedule No maintenance schedule is necessary Maintenance works During long term storage periodically perform a visual c...

Page 37: ...n 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 The axis was designed to operate with a minimum of maintenance The motor is self lubricating and maintenance free Regular maintenance a...

Page 38: ...monthly 5 Toothed belt of the linear guide Check for wear and tension and replace if necessary 1 x monthly 6 Toothed drive belt Check for wear and tension and replace if necessary 1 x monthly 7 Drive unit Visually check 1 x monthly 8 Support roller Check for free movement and wear see chapter Setting the support roller 1 x monthly 9 Cable and hose connections Check if they are firmly fitted and fo...

Page 39: ...be carried out only by trained personnel and when no power is applied Procedure ATTENTION Incorrectly assembled parts may cause malfunctions or defects Reassembly is in reverse order Observe the tightening torques when assembling Fig 13 Drive unit 1 Switch off the power supply 2 Disconnect the motor power supply cable 3 Remove the protective cover 4 Loosen the tensioning screw 1 so that the drive ...

Page 40: ... only by trained personnel The toothed belt is exposed to high loads during operation and must therefore be checked regularly Check the toothed belt every six months for wear and tension according to the maintenance schedule Powder deposits should be preferably removed with a vacuum cleaner because this can influence the quiet running and shorten the service life of the toothed belt Switch on the ...

Page 41: ...ten the tensioning screw 1 8 Let the carriage slowly run backwards and forwards a few times to see if the drive belt does not ride up on the toothed wheel Replacing the gliding elements If the carriage starts to vibrate excessively during operation especially at the reversing points in most cases the cause lies in too much play in the gliding elements fig 15 Material and tool required Procedure 1 ...

Page 42: ...Rev 00 09 22 42 Maintenance Repairs UA05 4 5 6 ...

Page 43: ...Rev 00 09 22 UA05 Maintenance Repairs 43 7 8 9 ...

Page 44: ...Rev 00 09 22 44 Maintenance Repairs UA05 10 11 12 The carriage should run evenly and quietly again ...

Page 45: ...ly with manual pressure Support roller is set too high Linear guide unit sluggish Wear on linear guide unit or tracking error during operation Support roller is set too low Gun extension tube is not supported Abrasion on the linear guide unit 5 Tighten the screw 3 Tightening torque 10 Nm 6 Tighten the lock nut 2 Check if the linear guide unit is blocked or runs rough Adjust if necessary The linear...

Page 46: ... hazard in contact with energized components Keep the cover plate of the position regulator closed at all times 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 Verify that the parts are deenergized by means of a...

Page 47: ...upport roller control unit defective repair or replace Connecting cables between the control unit and the axis not connected or defective connect repair Drive motor defective replace position regulator defective replace Toothed belt not tight or defective tighten or replace Safety grid not closed close Travel distance incorrectly set set correctly Travel distance too short or too long incorrect se...

Page 48: ...s see chapter Replacing the gliding elements Support roller incorrectly set check and set the support roller see chapter Setting the support roller The gun is vibrating badly during operation Support roller incorrectly set check and set the support roller see chapter Setting the support roller Gliding elements worn replace guiding elements see chapter Replacing the gliding elements Squeaking noise...

Page 49: ... operating material in an environmentally friendly manner 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 Disposal regulations The product must be disassembled and dispos...

Page 50: ...e adhered to when disposing of the operating material Disassembly of component groups Preparation WARNING Live components Risk of fatal injury from electric shock if touched Only trained authorized staff may open the electrical compartment Observe the safety symbols 1 Disconnect the mains supply supply cables and additional units 2 Remove all product covers 3 Drain all existing lubricant supplies ...

Page 51: ...material the required length must also be given The spare part numbers of this bulk stock is always marked with an The wearing parts are always marked with a marked All dimensions of plastic hoses are specified with the external and internal diameter Example Ø 8 6 mm 8 mm outside diameter o d 6 mm inside diameter i d WARNING Use of non original Gema spare parts When using the spare parts from othe...

Page 52: ...e chapter Technical Data on page 20 1 Toothed belt 1014 825 2 Servo motor 1022 222 3 Toothed belt wheel drive mount 1014 431 4 Toothed drive belt wheel 1014 433 5 Roll 1016 721 6 Blow off device complete 1020 712 7 Toothed belt 1020 074 8 Sliding bearing 1019 597 9 Bearing housing 1020 192 10 Housing cover 1020 191 Wearing part Please indicate length Fig 17 UA05 complete ...

Page 53: ...ponents see also the Spare parts list in the enclosed wiring diagram 1 Position regulator UA please indicate the axis serial number see Rating plate 1014 184 Motor cable not shown 1014 992 Pulse generator cable not shown 1014 993 Please indicate length fig 18 Position regulator ...

Page 54: ......

Page 55: ...ce 47 Figure references in the text 8 M Maintenance 37 Maintenance during storage 36 Mechanical data 20 O Operation 33 P Pictograms 7 Pneumatic data 21 Presentation of the contents 8 Product description 15 Product specific security regulations 9 R Rating plate 22 Repairs 37 S Safety 9 Safety symbols 7 Sound pressure level 22 Spare parts list 51 Start up 29 Storage 35 T Technical Data 20 Transport ...

Page 56: ...Rev 00 ...

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