Gema MagicCompact BA04 Guide

En
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
© Copyright 2016 Gema Switzerland GmbH
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ited by law. No part of this publication may be reproduced, photocopied,
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express written consent of Gema Switzerland GmbH.
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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
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Reference is made in this manual to different trademarks or registered
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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
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publication and make changes to its content without prior notice.
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www.gemapowdercoating.com.
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Printed in Switzerland
Gema Switzerland GmbH
Mövenstrasse 17
9015 St.Gallen
Switzerland
Phone: [phone]
Fax: [phone]
Email: [email protected]

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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

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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

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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

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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

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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

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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!

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MagicCompact BA04 About this manual • 9
About this manual
General information
This operating manual contains all the important information which you
require for the working with the MagicCompact BA04 powder coating
booth. It will safely guide you through the start-up process and give you
references and tips for the optimal use of your new powder coating sys-
tem.
Information about the function mode of the individual system components
– booth, OptiCenter, gun control unit, gun or powder injector – should be
referenced to their corresponding documents.
DANGER:
Working without operating instructions
Working without operating instructions or with individual pages
from the operating instructions may 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 on "Safety regulations".
► Work should only be carried out in accordance with the instructions in
the relevant documents.
► Always work with the complete original document.

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MagicCompact BA04 Design and function • 11
Design and function
Field of application
MagicCompact BA04 coating booths are used for the electrostatic powder
coating of all types of workpieces in large batches with frequent color
changes. As part of the process controlled coating plant, they are laid out
for fully automatic operation.
The most important characteristics of the coating booths are:
– Superstructure and booth basement in plastic material
– Low booth basement height (simple conversion and fitting)
– Permanent powder suction from the entire booth floor (suction open-
ings integrated into the booth floor)
– Automatic floor cleaning (no powder accumulation)
– Integrated exhaust air main collector
– Fast color change by one person
– The guns are arranged vertically
Function description
The principle of function is determined by the requirements placed on the
booth, which are:
– The protection of the coating process from external influences, com-
bined with keeping the area around the booth clean
– The powder recovery
– The avoidance of an explosive powder/air mixture inside the booth
An efficient exhaust air system is used to keep the area around the booth
clean and to prevent explosive powder/air mixtures.
The fan in the After Filter extracts the air from the inside of the booth
through the cyclone and afterwards through the filter elements. The air
stream created thereby, flowing from the outside to the inside of the
booth, prevents powder escaping to the outside of the booth, so that
keeping clean the area around the booth is ensured. The maintenance of
the air flow prevents as well the creation of dangerous powder/air mix-
tures.
The powder recovery takes place by the powder separation in the cyclone
separator during operation.

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12 • Design and function MagicCompact BA04
The booth control takes place by the corresponding control unit with op-
erating interface.
The gun control units are fitted into one or two control cabinets. The
switching on and off of the guns takes place by the gap detection unit in
the automatic mode.
NOTE:
More detailed information about the control units/components and
the operating interfaces are found in the corresponding user manu-
als!
Operational procedure
NOTE:
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 re-
leased.
The operational condition is reached, as soon as all external plant units
such as chain conveyor, OptiCenter, reciprocators (optionally), fire protec-
tion (optionally) etc. are switched on.
The operating functions in the OptiCenter can be released now and the
coating process can begin. This process is interrupted only if a ventilator
motor malfunction is present. Other malfunctions are indicated by an
alarm or a message, displayed on the control cabinet.
The suction effect of the filters is monitored during operation. Therefore,
the differential pressure and thus the suction performance of the exhaust
air system is measured. A blockage of the filter elements is indicated by a
decrease of the suction performance (the differential pressure arises). By
reaching a fixed preset value, a signal lamp on the control cabinet illumi-
nates and at the same time an alarm sounds.
(Detailed information about the After Filter is found in the corresponding
operating manual).

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MagicCompact BA04 Design and function • 13
Powder flow
fig. 1: MagicCompact – powder flow in the plant
1 Booth
2 Cyclone separator
3 Screen
4 Dense phase conveyor
5 After filter
6 Waste container
7 OptiCenter
8 Automatic powder guns
The powder is fluidized in the OptiCenter (7). The injectors transport the
powder through the hoses to the guns (8). The guns spray the powder/air
mixture onto the workpieces to be coated.
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 OptiCenter by a dense phase conveyor (4), where it is
available again for the coating process.
The rest of the non-separated powder (most of it is fine particles) goes in-
to the after filter (5). The after filter separates the powder into a waste
container (6), which is positioned directly under the filter elements and is
very easy to empty. The cleaned air then exits the filter and is fed directly
back into the workshop environment.
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 posi-
tioned at the necessary required distance outside of the booth. This en-
sures the powder repelling effect of the booth, also for a longer coating
period.
The interior of the booth is illuminated by lightings, which are fitted into
the booth ceilings.
The basic version of the MagicCompact BA04 booth has no hand coating
openings. The booth can be equipped either on one or both sides with
manual coating equipment, as precoating or touch-up station alternatively.
1
3
4
2
5
6
7
8

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14 • Design and function MagicCompact BA04
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. 2: Basement
Floor blow-off system
fig. 3: floor blow-off system (arrows = blow-off direction)
A blow-off rail with blow nozzles is integrated lengthwise into the booth
floor. The blow-off rail consists of various segments, which can be pneu-
matically controlled one by one.
Floor blow-off
Suction duct

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MagicCompact BA04 Design and function • 15
The required blow-off pressure depends on the booth size and the pow-
der type. In preset intervals, the nozzles blow the powder, located on the
floor, in the direction of the suction slots. The powder is aspirated via the
slots, cleaning the booth floor in this way.
The valves for the control of the floor blow-off segments are located in the
booth basement.
NOTE:
The compressed air input pressure for the floor blow-off system
must amount to 5.0 bar!
– The pressure regulator for the floor blow-off system can be set to
max. 3 bar!
Powder suction
fig. 4: powder suction (cutaway view)
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.
The suction duct is gathered in a cross duct at the booth end, which can
be visually controlled through a service lid. The ducts are autocleaning
and can be blown out with compressed air.
The collected powder is delivered to the cyclone separator.
Any deposited overspray powder on the walls must sometimes be moved
manually.

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16 • Design and function MagicCompact BA04
Exhaust air system with After Filter
An efficient exhaust air system is used to keep the area around the booth
clean and to prevent explosive powder/air mixtures. The exhaust air is
created by the fan in the After Filter.
Detailed information about the After Filter is found in the corresponding
operating manual.
Fire protection
For safety reasons, it is recommended to equip the plant with a CO2 fire
extinguishing system. An existing fire protection is merged in the security
concept of the plant and assumes the plant interlocking release.
Cleaning operation mode
During the automatic gun cleaning, the work piece entrance or exit door is
closed, thereby an increased air inlet speed results at the remaining
openings at the booth.
This ensures a dust-free environment around the booth during the color
change procedure.
Automatic booth cleaning
The cleaning of the booth floor takes place automatically with the combi-
nation of the floor blow-off system and the powder suction (see the chap-
ter on "Booth – Basement")
Powder recovery
A safe and clean powder recovery is ensured by following components:
– Cyclone separator
– Sieve machine
– Dense phase conveyor
– OptiCenter
The powder which does not adhere on the workpiece (overspray) is fed
from the suction opening, through a conduction, to the cyclone intake.
The powder is separated in the cyclone and then sieved in the sieve ma-
chine. The recovered powder is fed back to the OptiCenter.
NOTE:
Further information about the powder recovery components you will
find in the corresponding user manuals!

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MagicCompact BA04 Design and function • 17
Automatic powder guns
OptiGun-AX automatic powder gun types are used in the MagicCompact
BA04 powder coating booth. These guns were particularly developed for
an automatic, simple cleaning.
fig. 5: Automatic powder guns
The connections for the powder hose, the high voltage and the electrode
rinsing air are outside of the coating booth. These supply attachments are
integrated into the gun, enabling the guns to can be cleaned automatically
by blow-off nozzles.
The powder hose connection makes possible a perfect fixing of the pow-
der hose by the clamping device. This is a prerequisite for the automatic
rinsing of the powder transport equipment (further information about au-
tomatic guns, see in the corresponding user manual).
On the booth, a distinction between light and dark colors is principally
made.

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18 • Design and function MagicCompact BA04
Cleaning the guns
fig. 6: Cleaning the guns
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.
By activating the cleaning function on the control unit, the reciprocators
and the guns move out of the booth. At the same time, each gun is blown
off cleanly from the outside, by four flat jet blow-off nozzles.
These flat jet blow-off nozzles are found on the gun slots, on the outside
of the booth. If necessary, this cleaning sequence can be repeated.