Gema Vertical axis ZA16 Guide

Rev. 00 1017 581 EN
Operating instructions and Spare parts list
Vertical axis
ZA16
Translation of the original operating instructions

Rev. 00 04/21
Documentation ZA16
© 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,
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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.
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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
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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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ZA16 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
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
Packaging .............................................................................................................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
Expansion with additional axes of motion................................................18
CDB position regulator with CAN BUS (Power unit).............................................19
Technical Data......................................................................................................20
Versions...................................................................................................20
Electrical data ..........................................................................................20
Drive unit data..........................................................................................20
Dimensions ..............................................................................................21
Sound pressure level...............................................................................21
Rating plate..............................................................................................22
Assembly / Connection 23
Grounding of the axis............................................................................................24
Electrical connections / cable connections...........................................................25
Start-up 27
Preparation for start-up.........................................................................................27
General information .................................................................................27

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Table of contents ZA16
Reference point.......................................................................................28
Reference point and mechanical stops................................................................28
Setting the reference point ......................................................................28
Setting the lower mechanical stop...........................................................29
Setting the upper mechanical stop..........................................................30
Operation 31
Decommissioning / Storage 33
Introduction...........................................................................................................33
Safety rules..............................................................................................33
Requirements on personnel carrying out the work..................................33
Storage conditions................................................................................................33
Hazard notes...........................................................................................33
Type of storage........................................................................................34
Storage duration......................................................................................34
Space requirements ................................................................................34
Physical requirements.............................................................................34
Decommissioning.................................................................................................34
Putting out of service...............................................................................34
Cleaning...................................................................................................34
Preservation ............................................................................................34
Maintenance during storage.................................................................................35
Maintenance schedule.............................................................................35
Maintenance works..................................................................................35
Maintenance / Repairs 37
General information..............................................................................................37
Maintenance schedule..........................................................................................38
Drive unit...............................................................................................................38
Replacing the drive unit...........................................................................39
Toothed belt..........................................................................................................40
Replacing the toothed belt.......................................................................41
Tensioning the drive belt.........................................................................41
Adjusting the toothed belt tension with the belt tension measuring device
.................................................................................................................42
Toothed wheel......................................................................................................43
Replacing the upper toothed drive wheel................................................43
Rollers –Z carriage..............................................................................................45
Maintenance of the position regulator..................................................................46
Replacing the position regulator...........................................................................46
Fault clearance 47
Disposal 49
Introduction...........................................................................................................49
Safety regulations....................................................................................49
Requirements on personnel carrying out the work..................................49
Disposal regulations................................................................................49
Materials..................................................................................................50
Disposal of operating material..............................................................................50
Disassembly of component groups......................................................................50
Preparation..............................................................................................50
Spare parts list 51
Ordering spare parts.............................................................................................51
ZA16 –complete ..................................................................................................52

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ZA16 Table of contents
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ZA16 –complete...................................................................................................53
Toothed wheel.......................................................................................................54
Toothed wheel.......................................................................................................55
Z carriage..............................................................................................................56
Drive unit (complete).............................................................................................57
Proximity switch ....................................................................................................58
Electrical module...................................................................................................59

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ZA16 About these instructions
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7
About these instructions
General information
This operating manual contains all the important information which you
require for the working with the ZA16. 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 ZA16
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.
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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ZA16 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 ZA16
Special safety regulations
–The vertical axis may only be switched on and operated after careful
reading of this manual. Incorrect operation of the axes control unit
can lead to accidents, malfunctions or damage to the plant.
WARNING
The power of the vertical axis is much stronger than that of a
human being!
►All axes must be secured against access during operation (see
local 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 vertical axis should only be unplugged when the power supply is
disconnected
–The connecting cables between the control unit and the reciprocator
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 upper
mechanical stop")!
–When repairing the reciprocator, both the reciprocator control unit
and the reciprocator 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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ZA16 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 ZA16

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ZA16 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.
Packaging
Selection of packing material
Suitably stable wood packing material must be used.
Procedure when packing
Transport the unit only in a horizontal position.
Reciprocators with a stroke length of more than 1800 mm must be
supported in the center of the column.
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 one fork lift must be available.

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Transport ZA16

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ZA16 Product description
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15
Product description
Intended use The ZA16 axis serves exclusively to move vertically powder applicators in
automatic coating equipment.
fig.
1
Observance of the operating, service and maintenance instructions
specified by the manufacturer is also part of conformity of 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 considered non-compliant. 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 ZA16
Utilization
The ZA16 type axis is used as the basis for all stages of automation, from
a simple vertical stroke to complex, multi-dimensional processes.
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 stroke limiters
–Incorrect programming of the upper and lower turning points
–Use in connection with not permissible control units
–Loading the Z carriage with more weight than allowed (see
"Technical Data")
–Operation without the proper training
–Operating the reciprocator without the protective fence
Function The reciprocator carries out a linear, oscillating up-and-down motion in
the vertical direction (called Z motion). The movement sequences (stroke
and stroke speed) are controlled by the reciprocator control unit.
The U-axis brackets are screwed onto the Z-carriage. The Z carriage is
moved up and down on the central column by a drive belt inside the
reciprocator. This vertical column serves also as a runway for the rollers.
The drive unit and the electrical connection are installed in the vertical
axis base. A pulse generator, which is installed in the motor case, enables
the exact positioning of the Z carriage.
The power unit as well as the corresponding wiring are housed in an
electronics module, which is plugged into the axis.
If the power is interrupted, the motion of the Z carriage is stopped
momentarily with the holding brake built into the drive unit. The holding
brake can be activated manually during maintenance or in an emergency.
To ensure that the reciprocator 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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ZA16 Product description
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17
fig.
2
: Structure
1 Basement
2 Drive unit
3 Toothed belt
4 U-axis bracket
5 Z carriage
6 Power unit
7 Holding brake
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 ZA16
Special characteristics
This axis is conspicuous because of its rugged construction, a new drive
system and an improved Z axis carriage design.
Further characteristics:
–130 kg load capacity for max. 8 gun axes type UA05
–Built-in holding brake
–Quiet running
–High speed, maximum acceleration and braking action
–Safe operation and simple maintenance
–High efficiency due to low energy consumption
–Designed for continuous operation
–IP54 protection type
–5 standard stroke heights available: 1.3 m / 1.8 m / 2.3 m / 2.8 m /
3.3 m
Expansion with additional axes of motion
The vertical axis can be equipped with UA05 gun axes to expand its
functionality. A maximum of 8 gun axes can be mounted.
fig.
4
: ZA16 with eight UA05

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ZA16 Product description
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19
CDB position regulator with CAN BUS (Power unit)
fig.
5
: CDB position regulator with CAN BUS
X1 Load connections (Mains
voltage, Motor)
X2 Control connection
X3 Motor winding temperature
monitoring (optional)
X4 RS 232 Interface
X5 CAN addresses
X6 not occupied
X7 Pulse generator connection

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Product description ZA16
Technical Data
Versions
The vertical axis is available, depending on operational area, in five
versions with different standard stroke heights.
ZA16-
13
18
23
28
33
Reciprocator
height –H
2.385 m
2.885 m
3.385 m
3.885 m
4.385 m
Max. object
height –L
1.795 m
2.295 m
2.795 m
3.295 m
3.795 m
Weight
195 kg
220 kg
240 kg
261 kg
281 kg
Stroke speed
0.08 up to 0.4 m/s
Acceleration
0.1-1.5 m/s²
Position
detection
by pulse generator
Max. lifting
weight
max. 130 kg on the Z carriage
(max. 8 UA05 axes)
Electrical data
ZA16
Power supply
3 x 400 VAC
Tolerance
10%
Frequency
50/60 Hz
Power consumption
1.5 kW
Protection type
IP54
Isolation
Class F
Control unit
CM40
Temperature range
+10°C - +40°C (50°F - 104°F)
Drive unit data
ZA16
Drive unit
Motor/gearbox unit
Performance
1.5 kW
Motor voltage/frequency
3 x 400 VAC, 50 Hz
Gear ratio
24.58
Motor RPM
1420 rpm
Drive torque
430 Nm
Brake torque
10 Nm
Approval
II 3D ExtD T<160°C