Gema XT12 Quick guide

Rev. 00 1024 607 EN
Operating instructions and Spare parts list
Horizontal axis
XT12
Translation of the original operating instructions

Rev. 00 12/22
Documentation XT12
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Reference is made in this manual to different trademarks or registered
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To the best of our knowledge and belief, the information contained in this
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www.gemapowdercoating.com/patents or
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Printed in Switzerland
Gema Switzerland GmbH
Mövenstrasse 17
9015 St.Gallen
Switzerland
Phone: [phone]
Email: [email protected]

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XT12 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 ...........................................................................18
Special characteristics.............................................................................18
Expansion with additional axes of motion................................................19
CDB position regulator with CAN BUS (Power unit).............................................20
Technical Data......................................................................................................21
Versions...................................................................................................21
Electrical data ..........................................................................................21
Drive unit data..........................................................................................21
Dimensions ..............................................................................................22
Sound pressure level...............................................................................22
Rating plate..............................................................................................23
Assembly / Connection 25
Grounding of the axis............................................................................................26
Electrical connections / cable connections...........................................................27
Start-up 29
Preparation for start-up.........................................................................................29

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Table of contents XT12
General information.................................................................................29
Reference point.......................................................................................30
Reference point and mechanical stops................................................................30
Setting the reference point ......................................................................31
Operation 33
Decommissioning / Storage 35
Introduction...........................................................................................................35
Safety rules..............................................................................................35
Requirements on personnel carrying out the work..................................35
Storage conditions................................................................................................35
Hazard notes...........................................................................................35
Type of storage........................................................................................36
Storage duration......................................................................................36
Space requirements ................................................................................36
Physical requirements.............................................................................36
Shut-down.............................................................................................................36
Putting out of service...............................................................................36
Cleaning...................................................................................................36
Preservation ............................................................................................36
Maintenance during storage.................................................................................37
Maintenance schedule.............................................................................37
Maintenance works..................................................................................37
Maintenance / Repairs 39
General information..............................................................................................39
Maintenance plan.................................................................................................40
Drive unit...............................................................................................................40
Replacing the drive unit...........................................................................41
Toothed belt..........................................................................................................44
Replacing the toothed belt.......................................................................44
Tensioning the drive belt.........................................................................46
Adjusting the toothed belt tension with the belt tension measuring device
.................................................................................................................47
Toothed wheel......................................................................................................48
Replacing the toothed wheel...................................................................48
Guide rollers / counter rollers ...............................................................................51
Replacing the guide roller / counter roller................................................51
Elastomer coupling...............................................................................................53
Preventive maintenance and replacement of the flexible element..........53
Replacement of the flexible element.......................................................54
Installing the element cover.....................................................................55
Maintenance of the position regulator..................................................................56
Replacing the position regulator...........................................................................56
Fault clearance 57
Disposal 59
Introduction...........................................................................................................59
Safety regulations....................................................................................59
Requirements on personnel carrying out the work..................................59
Disposal regulations................................................................................59
Materials..................................................................................................60
Disposal of operating material..............................................................................60
Disassembly of component groups......................................................................60
Preparation..............................................................................................60

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XT12 Table of contents
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Spare parts list 61
Ordering spare parts.............................................................................................61
XT12 –complete...................................................................................................62
Toothed wheel.......................................................................................................63
Guide roller / counter roller ...................................................................................64
Drive unit (complete).............................................................................................65
Electrical module...................................................................................................66

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XT12 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 XT12. 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 XT12
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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XT12 Safety
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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 XT12
Special safety regulations
–The horizontal 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 horizontal 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 reciprocator is not
operating!
–It must be noted, that the horizontal axis has to be grounded before
start-up!
–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 horizontal
axis must be laid in such a way, that they cannot be damaged during
axes operation. The movement sequence of the Z axis must be
observed too. Please observe the local safety regulations!
–The travel distance limits of the horizontal axis must always be set
with reference to the side openings of the booth. If an incorrect travel
distance limit is set, this can lead to damage to the vertical axis
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 must be observed
(for further information, see chapter “Setting the mechanical travel
distance limits”)
–When repairing the horizontal axis, the axis control unit and the
power pack must be disconnected from the mains according to the
local safety regulations!
–Repairs may only be made by authorized Gema repair centers or by
personnel correspondingly trained by Gema. 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 information, see the more detailed Gema safety
regulations.

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XT12 Safety
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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 XT12

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XT12 Transport
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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.
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 XT12

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XT12 Product description
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15
Product description
Intended use The XT12 axis serves exclusively to move horizontally powder applicators
in automatic coating equipment.
Fig.
1
: Horizontal axis with ZA vertical axis
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 XT12
Utilization
The XT12 axis is used for the coating of parts with different widths. With
this type of coating, the powder applicators must be moved to the position
specified for each width. Typically, the horizontal axis is used in
conjunction with a vertical ZA-axis.
Reasonably foreseeable misuse
–Operation in rooms with gases
–Horizontal axis is not anchored firmly to the floor
–The axis mounted on the horizontal axis is not fixed properly
–Incorrect setting of the mechanical travel distance limiters
–Incorrect programming of reversing 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 horizontal axis without the protective fence
Function The horizontal axis is a feeding axis, and carries out a linear, oscillating
backwards and forwards motion in the horizontal direction (called X
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 horizontal axis position detection takes place by
a pulse generator installed at the drive unit.
A Z-axis is screwed onto the carriage. The carriage is moved backwards
and forwards, driven by a drive belt inside the axis frame. The frame also
acts as a runway for the rollers. The drive unit and the electrical
connection are installed in the horizontal axis base. A pulse generator,
which is installed at the motor case, enables the exact positioning of the
carriage.
The power unit as well as the corresponding wiring are housed in an
electronics module, which is plugged into the Z-axis.
To ensure that the 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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XT12 Product description
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17
Fig.
2
: Structure
1 Drive unit
2 Trolley
3 Power unit
4 Basement
5 Baseboard
6 Leveling bolt
7 Rubber buffer
8 Z-axis
9 Levelling pad

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Product description XT12
Schematic presentation
Fig.
3
: Schematic presentation
1 Axis control
2 Position regulator
3 Pulse generator wiring
4 Motor cables
5 Drive motor
Special characteristics
This axis is conspicuous because of its rugged construction, a new drive
system and an improved axis carriage design.
Further characteristics:
–Smooth running is designed for continuous operation
–Freely adjustable speed setting on the axes control unit
–Total stability at maximum load of the axis up to 400 kg
–Robust, dirt-resistant and easily accessible components
–Same control as for the ZA vertical axes
–Manually movable when the control unit is switched off
–No additional space required for dismantling and service works
–Low overall height with integrated leveling strips
(For more information about the controlling of the axis, see the axes
control unit operating manual)

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XT12 Product description
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Expansion with additional axes of motion
The horizontal axis can be equipped with a vertical axis to expand its
functionality. Only one Z-axis can be mounted.
Fig.
4
: Horizontal axis with ZA vertical axis

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Product description XT12
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