Gema ZA08 Guide

Rev. 01 1011 456 EN
Operating instructions and Spare parts list
Vertical axis
ZA08
Translation of the original operating instructions

Rev. 01 11/22
Documentation ZA08
© 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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ZA08 Table of contents
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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 ...........................................................................18
Special characteristics.............................................................................18
Expansion with additional axes of motion................................................19
Frequency converter (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
General information .................................................................................29

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Table of contents ZA08
Reference point.......................................................................................30
Reference point and mechanical stops................................................................30
Setting the reference point ......................................................................31
Setting the lower mechanical stop...........................................................32
Setting the upper mechanical stop..........................................................32
Operation 33
Decommissioning / Storage 35
Introduction...........................................................................................................35
Safety regulations....................................................................................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
Decommissioning.................................................................................................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 schedule..........................................................................................40
Drive unit...............................................................................................................40
Replacing the drive unit...........................................................................41
Toothed belt..........................................................................................................42
Replacing the toothed belt.......................................................................43
Tensioning the drive belt.........................................................................43
Toothed wheel......................................................................................................45
Replacing the upper toothed drive wheel................................................45
Rollers –Z carriage..............................................................................................46
Frequency converter maintenance.......................................................................47
Replacing the frequency converter.......................................................................47
Fault clearance 49
Disposal 51
Introduction...........................................................................................................51
Safety regulations....................................................................................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
ZA08 –complete ..................................................................................................54
ZA08 –complete ..................................................................................................55
Toothed wheel......................................................................................................56

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ZA08 Table of contents
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Toothed wheel.......................................................................................................57
Z carriage..............................................................................................................58
Drive unit (complete).............................................................................................59
Proximity switch ....................................................................................................60
Electrical module...................................................................................................61
Gun holders...........................................................................................................62
Gun holder for 1-4 guns...........................................................................62
Gun holder for 5-8 guns...........................................................................63
Gun holder for 2x1-4 guns.......................................................................64
Vertical gun holder...................................................................................65
Gun fixtures and collision protection.....................................................................66

Rev. 01 11/22
ZA08 About these instructions
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About these instructions
General information
This operating manual contains all the important information which you
require for the working with the ZA08. 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 ZA08
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."

Rev. 01 11/22
ZA08 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 ZA08
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!