Gema UA05-X Guide

Rev. 00 1024 603 EN
Operating instructions and Spare parts list
Gun axis
UA05-X
Translation of the original operating instructions

Rev. 00 05/22
Documentation UA05-X
© Copyright 2017 Gema Switzerland GmbH
All rights reserved.
This publication is protected by copyright. Unauthorized copying is
prohibited 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.
Gema, EquiFlow, MagicCompact, MagicCylinder, OptiCenter, OptiFlex,
OptiGun, OptiSelect and OptiStar are registered trademarks of Gema
Switzerland GmbH.
ClassicLine, ClassicStandard, ClassicOpen, DVC (Digital Valve Control),
GemaConnect, MagicControl, MagicPlus, MonoCyclone, MRS,
MultiColor, MultiStar, OptiAir, OptiControl, OptiColor, OptiFeed, OptiFlow,
OptiHopper, OptiMove, OptiSieve, OptiSpeeder, OptiSpray, PCC (Precise
Charge Control), RobotGun, SIT (Smart Inline Technology) and
SuperCorona are registered 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
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 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
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.
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: [phone]
Email: [email protected]

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UA05-X Table of contents
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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.......................................................................................21
Electrical data ..........................................................................................22
Dimensions ..............................................................................................23
Sound pressure level...............................................................................24
Rating plate..............................................................................................24
Controller cabinet.....................................................................................24
Assembly / Connection 27
Place of installation and operation........................................................................28
Grounding of the axis............................................................................................29
Electrical/pneumatic connections and cable connections ....................................29

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Table of contents UA05-X
Start-up 31
Preparation for start-up.........................................................................................31
General information.................................................................................31
Reference point.......................................................................................32
Setting values/parameters.......................................................................32
Reference point and mechanical stop..................................................................32
Setting of the mechanical stop................................................................33
Operation 35
Decommissioning / Storage 37
Introduction...........................................................................................................37
Safety rules..............................................................................................37
Requirements on personnel carrying out the work..................................37
Storage conditions................................................................................................37
Hazard notes...........................................................................................37
Type of storage........................................................................................37
Storage duration......................................................................................37
Space requirements ................................................................................37
Physical requirements.............................................................................38
Shut-down.............................................................................................................38
Putting out of service...............................................................................38
Cleaning...................................................................................................38
Preservation ............................................................................................38
Maintenance during storage.................................................................................38
Maintenance schedule.............................................................................38
Maintenance works..................................................................................38
Maintenance / Repairs 39
General information..............................................................................................39
Maintenance schedule..........................................................................................40
Drive unit...............................................................................................................40
Replacing the drive unit...........................................................................41
Toothed belt..........................................................................................................42
Replacing the toothed belt.......................................................................42
Replacing the gliding elements.............................................................................43
Setting the support roller ......................................................................................47
Maintenance of the position regulator..................................................................48
Replacing the position regulator...........................................................................48
Fault clearance 49
Disposal 51
Introduction...........................................................................................................51
Safety rules..............................................................................................51
Requirements on personnel carrying out the work..................................51
Disposal regulations................................................................................51
Materials..................................................................................................52
Disposal of operating material..............................................................................52
Disassembly of component groups......................................................................52
Preparation..............................................................................................52
Spare parts list 53
Ordering spare parts.............................................................................................53
UA05-X –complete ..............................................................................................54
Support roller –complete .....................................................................................55

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UA05-X Table of contents
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Position regulator..................................................................................................56

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UA05-X About these instructions
•
7
About these instructions
General information
This operating manual contains all the important information which you
require for the working with the UA05-X. It will safely guide you through
the start-up process and give you references and tips for the optimal use
when working with your powder coating system.
Information about the functional mode of the individual system
components should be referenced in the respective enclosed documents.
Keeping the Manual
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.
DANGER
Indicates a hazardous situation which, if not avoided, will result in death
or serious injury.
WARNING
Indicates a hazardous situation which, if not avoided, could result in
death or serious injury.
CAUTION
Indicates a hazardous situation which, if not avoided, could result in
minor or moderate injury.
ATTENTION
Indicates a potentially harmful situation. If not avoided, the equipment or
something in its surrounding may be damaged.

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About these instructions UA05-X
ENVIRONMENT
Indicates a potentially harmful situation which, if not avoided, may have
harmful consequences for the environment.
MANDATORY NOTE
Information which must be observed.
NOTICE
Useful information, tips, etc.
Structure of Safety 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 voltage (H) created in the gun cascade is guided through the
center electrode."

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UA05-X Safety
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9
Safety
Basic safety instructions
–This product is built to the latest specification and conforms to the
recognized technical safety regulations and is designed for the
normal application of powder coating.
–Any other use is considered non-compliant. The manufacturer shall
not be liable for damage resulting from such use; the user bears sole
responsibility for such actions. 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. The
standard "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 specific security regulations
–This product 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.
–The installation work to be done by the customer must be carried out
according to local regulations.
–It must be ensured, that all components are earthed according to the
local regulations before start-up.
For further security information, see the more detailed Gema
safety regulations!

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Safety UA05-X
Special safety regulations
–The axis may only be switched on and operated after careful reading
of this manual. Incorrect operation of the axis control unit can lead to
accidents, malfunctions or damage to the plant.
WARNING
The power of the axes is much stronger than that of a human
being!
►All axes must be protected from access during operation (see
local safety regulations).
►Never stand under the Z carriage when the vertical axis is not
operating!
–The plugs and sockets of the axis control unit and the power unit of
the axis should only be unplugged when the power supply is
disconnected
–The connecting cables between the control unit and the axis must be
laid in such a way, that they cannot be damaged during axes
operation. Please observe the local safety regulations!
–The maximum upper stroke limit of the vertical axis must always be
set with reference to the maximum height 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 control unit and the axis must
be disconnected from the mains according to the local safety
regulations!
–Repairs may be done only by authorized Gema service centers.
Unauthorized conversions and modifications can lead to injuries and
damage to the equipment. The Gema Switzerland GmbH guarantee
would no longer be valid.
–Only original Gema spare parts should be used! The use of spare
parts from other manufacturers will invalidate the Gema guarantee
conditions!
–We point out that the customer himself is responsible for the safe
operation of the equipment. Gema Switzerland GmbH is in no way
responsible for any resulting damage.
For further security information, see the more detailed Gema
safety regulations!

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UA05-X Safety
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11
WARNING
Working without instructions
Working without instructions or with individual pages from the
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 "Safety regulations".
►Work should only be carried out in accordance with the
instructions of the relevant documents.
►Always work with the complete original document.

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Safety UA05-X

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UA05-X Transport
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13
Transport
Introduction This chapter describes special precautions that must be taken during
internal transport of the product if:
–the customer himself must pack, transport and ship the product,
such as to have renovations or service work carried out by the
manufacturer
or
–the product must be shipped for disposal (recycling).
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 requirements correspond to the size of the axes of motion plus
the packaging.
Loading, transferring the load, unloading
At least two people must be available.

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Transport UA05-X

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UA05-X Product description
•
15
Product description
Intended use The UA05-X axis is used exclusively for horizontal adjustment or
horizontal oscillation movements of up to 3 automatic guns
simultaneously.
Fig.
1
Observance of the operating, service and maintenance instructions
specified by the manufacturer is also part of the intended use. 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 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.

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Product description UA05-X
Utilization
The axis was designed for automatic coating with powder applicators.
With the corresponding axis control unit, the automatic powder guns can
be positioned with the multi-gun axis according to the coating
requirements for the object. The axis is installed in a horizontal position,
other positions after consultation with Gema Switzerland GmbH only.
Depending on the design of the applicators, this unit may be used with all
types of powder coating.
Reasonably foreseeable misuse
–Operation in rooms with gases
–Incorrect setting of the mechanical travel distance limiters
–Incorrect programming of the front and rear turning points
–Use in connection with not permissible control units
–Loading the carriage with more weight than allowed (see "Technical
Data")
–Operation without the proper training
–Operating the axis without the protective fence
Function The gun axis is a feeding axis. The axis 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.
The gun holders are fitted on the carriage (2). The carriage (2) is moved
backwards and forwards on the linear guide unit by a drive belt (4) inside
the axis. The drive unit (1) and the electrical connection are installed in
the axis rear part. A pulse generator, which is installed in the motor case,
enables the exact positioning of the carriage.
The power supply is located in a separate control cabinet. One power unit
is needed for each axis.
If the power is interrupted, the motion of the carriage is stopped
momentarily.
To ensure that the gun axes cannot become a hazard during normal
operation, the axes are shielded by a protective fence that is 2.3 m high.
The fence has doors that are released by the control unit to allow
authorized technical personnel access to the axes.

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UA05-X Product description
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17
Fig.
2
: Structure
1 Drive unit
2 Trolley
3 Roller bracket
4 Linear guide unit
5 Spacer
6 Mounting bracket
Schematic presentation
Fig.
3
: Schematic presentation
1 Axis control
2 Position regulator
3 Pulse generator wiring
4 Motor cables
5 Drive motor

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Product description UA05-X
Special characteristics
This axis is conspicuous because of its rugged, compact construction, a
new drive system and an improved carriage design.
Further characteristics:
–Up to 3 automatic guns arranged along the UA axis (gun
arrangement in a single row)
–Extremely smooth operation with toothed belt transmission
–High speed, maximum acceleration
–Precision point accuracy of the feed motion
–Safe operation and simple maintenance
–Simple assembly and disassembly
–Grid formation with separation of 87 mm between automatic guns
–Robust, dirt-resistant and easily accessible components
–Maximum stroke-length 1800 mm
–Free axis programming via MagicControl CM40
–Bus-/CAN bus technology integrated into the control unit
–Can be combined with Gema Laser scanner technologie
–IP54 protection type
Combination with additional axes of motion
The UA05-X multi-gun axis can be mounted on the ZA16, ZA15, ZA07 or
ZS04 vertical axes.
Fig.
4
: ZA16 with UA05-3
Use an additional suitable bracket for mounting on ZA15 / ZA07 /
ZS04.
–Please contact Gema.

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UA05-X Product description
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19
Position regulator 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

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Product description UA05-X
Technical Data
Versions
The gun axis is available in several versions.
Automatic guns ARE NOT included in the following order
numbers.
–The guns and the corresponding nozzles are determined
according to the order.
When equipped with two automatic guns
UA05-2 for underside coating
Type of mounting
Travel distance
(mm)
Order number
right
600
1024 951
right
1000
1024 952
right
1400
1024 953
right
1800
1024 954
left
600
1024 956
left
1000
1024 957
left
1400
1024 958
left
1800
1024 959
UA05-2 for top coating
Type of mounting
Travel distance
(mm)
Order number
right
600
1024 961
right
1000
1024 962
right
1400
1024 963
right
1800
1024 964
left
600
1024 966
left
1000
1024 967
left
1400
1024 968
left
1800
1024 969