ZA06 Reciprocator
Contents
1. Motor gearbox unit without pulse generator complete incl pos 1 6 1004 019 1 Motor gearbox 0 75 kW incl pos 2 1004 020 2 Plug insert 10 P 211 540 3 Locknut M6 1003 822 4 Cable bush ID5 mm 1003 821 5 Washer 6 4 16x1 6 mm 215 805 6 Torque support 6 M6 1003 819 7 Pulse generator 268 925 8 Hexagon screw M10x25 mm 214 116 9 Toothed belt wheel 368 610 10 Tensioning set 25 50x22 mm 264 199 11 Hexagon ribbed nut M10 234 656 12 Flange bearing 25 mm 264 210 13 Motor brake cable ZA 1004 018 14 Socket insert 10 P 211532 15 Switch lever 386 456 16 Switch plate 386 464 17 Countersunk head screw M5x10 mm 214 671 18 Heat sink 386 740 19 Brake resistor 100 Ohm 400 W 264 172 20 Heat sink holder 1003 978 21 Cap screw 50x16 mm 1002 965 22 Ribbed washer M4 264 822 23 Countersunk cylinder screw M4x8 mm 216 259 42 e Spare parts list ZA06 Reciprocator i iTw Gema ZA06 Reciprocator drive unit ie ZA06 Reciprocator drive unit complete ZA06 Reciprocator Spare parts list e 43 iTrv Gema ices ZA06 Reciprocator electrical module 1 Frequency converter ATV31 ZA06 1003 985 2 Signals frequency converter connection 1000 314 3 Spacer 4 0 4 8 9 4 mm 266 833 4 Relay 24 VDC for motor brake 250 961 5 Axis adaptor complete 1000 247 6 Frequency converter mains connection 1000 312 7 Hexagon sh2. 7 View A 7 2 3 2 k A 2 NI x H SIR AR EC X CI tH KO tO tOj GB 45 11 L 4 ZA06 Reciprocator Automatic guns Spare parts list 45 iTrv Gema i Gun holder for 5 8 guns 1 Clamp element half order in pairs 363 987 2 Cross clamping element 40 40 mm 363 910 3 Cross clamping element 40 30 mm 363 936 Cross clamping element 30 30 mm 363 952 4 see gun attachment etc 5 Allen cylinder screw M8x50 mm 235 113 6 Tube O 30x600 mm 337 528 Tube 30x800 mm 337 536 Tube 30x1000 mm 337 544 Tube 30 mm 103 306 6 1 Tube plug 30 mm for pos 6 236 373 7 Tube 40x600 mm 337 552 Tube 40x1000 mm 337 560 Tube 40x1500 mm 337 579 Tube 40x2000 mm 337 587 Tube 9 40 mm 103 314 7 1 Tube plug 40 mm for pos 7 236 381 Please indicate length View A Automatic guns 46 e Spare parts list ZA06 Reciprocator m iTw Gema Gun holder for 2x1 4 guns 1 Clamp element half order in pairs 363 987 2 Cross clamping element 40 40 mm 363 910 Cross clamping element 40 30 mm 363 936 Cross clamping element 30 30 mm 363 952 see gun attachment etc Allen cylinder screw M8x50 mm 235 113 Tube 30x600 mm 337 528 Tube O 30x800 mm
3. x4 0 O X8 X3 A X2 A sw os b bn QO Oo O o Oo 00000000 35238 i B 28522585 Shaina p gt BR Typ ATV 31 0000 Nr 1 003 985 GND 24 SIG 4 5 E E A Halala pafof elo S 11d gd dd gd X1 X2 X3 X4 Power supply FU power supply Motor brake connection Proximity switch connection FU Frequency converter X5 X6 X7 X8 Drive I O connection Drive I O connection FU signal connection Incremental pulse generator connection Schematic diagrams e 29 EN iri Gema Frequency converter Overview Frequency converter General information The frequency converter in the ZA06 Reciprocator is installed for power regulation The parameters of this device are already adjusted to the Gema specific values and therefore may not be changed no more All adjustments of stroke speed of etc can be made at the OptiMove control for details see the corresponding reciprocator control unit man ual ZA06 Reciprocator Frequency converter e 31 srw Gema Jadi Function operation Access to menus Switch on xx Displays the frequency converter status Gi e 69 Kee Motor frequency presett
4. FU does not require a preventive mainte nance However it is recommended to carry out the following inspections by the user in regular intervals Check condition and tightness of the cable connections Check the efficacy of the ventilation average life span of the fan approx 3 5 years Remove the dust from frequency converter FU Replace the frequency converter If a frequency converter exchange has taken place it is to be noted that all shielded cables are properly attached again on the EMV plate AN 34 e Frequency converter Attention The cover plate of the frequency converter is to be kept always closed Before interventions take place in the device the power supply must be switched off After switching off the power supply wait at least 10 min before working on the equipment because the internal condensers need this time for discharging ZA06 Reciprocator iTw Gema Spare parts list Ordering spare parts When ordering spare parts for powder coating equipment please indicate the following specifications Type and serial number of your powder coating equipment Order number quantity and description of each spare part Example Type ZA06 Reciprocator Serial number 1234 5678 Order no 203 386 1 piece Clamp 18 15 mm When ordering cable or hose material the required length must also be given The spare part numbers of this yard meter ware is always marked with an T
5. The powder spray equipment can be turned off by using the main switch or failing that the emergency shut down Individual components can be turned off during operation by using the appropriate switches Individual safety regulations for the operating firm and or operating personnel 1 Any operating method which will negatively influence the techni cal safety of the moving axis is to be avoided 2 The operator should care about no non authorized personnel works on the moving axis e g this also includes using the equipment for non conform work General safety regulations e 5 iTw Gema 6 e General safety regulations V 06 08 3 For dangerous materials the employer has to provide an operat ing instructions manual for specifying the dangers arising for hu mans and environment by handling dangerous materials as well as the necessary preventive measures and behavior rules The operating instructions manual has to be written in an under standable form and in the language of the persons employed and has to be announced in a suitable place in the working area 4 The operator is under obligation to check the moving axis at least once every shift for signs of external damage defects or changes including the operating characteristics which could influence safety and to report them immediately 5 The operator is obliged to check that the moving axis only oper ates when in satisfactory condition 6 Asfaras itis necessary th
6. and collision protection 1 Gun fixture 30 mm 350 150 2 Gun fixture 39 mm for plastic tube only 354 317 2 Gun fixture 40 mm 1000 507 3 Gun fixture 40 mm transverse 356 670 4 Collision protection 30 mm for ZA axis 364 215 5 Dummy piece complete 30 mm for ZA axis 364 231 6 Collision protection 30 mm for YT axis 364 223 7 Dummy piece complete 30 mm for YT axis 364 240 Gun fixtures 30 a a 1 Z 4 Fu 39 0 40 T i 2 Ed n n 40 SUOR LL 3 Ed Collision protection Eed 30 e e re pe 8 4 119 5 g A 30 ees 5 119 5 a 0 0 30 a te 6 119 5 30 NC eg PES 7 1195 ZA06 Reciprocator Spare parts list 49
7. and remove the toothed belt when it is completely outside of the reciprocator Screw on the new toothed belt at the upper clamp plate Pass the loose end of the toothed belt over the upper toothed wheel from inside the reciprocator column 10 Screw on the toothed belt at the lower clamp plate 11 Tension the toothed belt but do not overstretch see chapter Tensioning the toothed belt 26 e Maintenance ZA06 Reciprocator Toothed wheel AN ZA06 Reciprocator iTw Gema Replacing the upper toothed wheel Attention The following workings should only be carried out by trained per sonnel Procedure 1 Release the motor brake 12 manually let the Z carriage 10 move down onto the lower stop 2 Switch off the electric power Remove the boarding side panels 4 Remove the locking plates 21 and loosen the tensioning Screws so that the toothed belt 3 is slack 5 Completely remove the front tensioning screw Attention danger of accident The Z carriage must definitely rest on the rubber buffer before this tensioning screw is removed 6 Hold the toothed wheel 9 tight in one hand whilst the eye bolt is being removed from the spindle Remove the toothed 3 belt from the toothed wheel Remove the toothed wheel 9 and replace it The installation takes place exactly in the reverse order If necessary remove the service cover on the base 1 to check if the toothed belt 3 is sitting correctly on th
8. cR 15 Sue IR E ret tte ce eene ti eden sena oo aati 15 Drive unit data 24e eie ee ede g ere Aman Zeie 16 IBI DP T 16 Start up 17 Preparation for start up ennemis 17 General information nnns 17 Reference polnt lia Ia ee a TOR da d eerie uad ias 18 Electrical connections cable connections maa aaana aa aanaanaa nanana nanan 18 Checkpoints before switching on 19 Grounding protection type eem eem ennemis 19 Hoses arid cables e ni eerte aio date Pen re HER dl 19 Reference point and mechanical etops nanan nananana naaa anannaanas ann nnna anuna 19 Setting the reference point eee 20 Setting the lower mechanical stop anas 21 Setting the upper mechanical stop aa aananananananaanannanann 21 Maintenance 23 General information ipte due db erue geal 23 ZA06 Reciprocator Table of contents e 1 iTw Gema V 06 08 Drveunit imet pee trt n t nad 23 Replacing the drive unt 24 Toothed belt aaa ai He P I a Oe P ea po ceases 25 Tensioning the toothed bet 26 Replace the toothed belt nna aa nana nnanaa nasaan ananasasasannana 26 Toothed wheel NANANA 27 Replacing the upper toothed wheel nananana aasawa anaanasaaaaaasna 27 el E e Lissone elenina EE pacata paa 28 Schematic diagrams 29 ZA06 Reciprocator wiring dagram ii 29 Frequency converter
9. 31 OVeIVIGW zc eric RI eo ied em it et tens 31 Generalinformiation e deng tme aee p red tee utr ga 31 Fungtion 0peratloN maan kA ban AN Maga NB ana apa 32 Access to menus onc ier tod cene eet beg reda hem tna 32 Access to menu Daramelers enne 33 Adjusted parameters eb Uber ote tees 33 Replace the frequency converter eee 34 Spare parts list 35 Ordering Spare Darts oie ee ett ee ated tend ene Ft aede eR ae 35 ZA06 Reciprocator spare parts list aasa aaanasasssassnna anan 36 ZA06 Reciprocator spare parts list nasaan anasnsssas anna aa anas 37 ZA06 Reciprocator toothed wheel en 38 ZA06 Reciprocator Z carriage complete sss 40 ZA06 Reciprocator drive unit COMplete 42 ZA06 Reciprocator electrical module sse 44 ZA06 Reciprocator gun holders sss eene 45 Gun holder for 1 4 oun 45 Gun holder for 5 8 GUNS sss enne 46 Gun holder for 2x1 4 ouns i 47 Vertical gun holder en here Ptr eii 48 Gun fixtures and collision protection sss 49 2 e Table of contents ZA06 Reciprocator vole iTw Gema General safety regulations This chapter specifies out the fundamental safety regulations that must be followed by the user and third parties using the ZA06 Reciprocator These safety regulations must be read and understood before the ZA0
10. 337 536 Tube O 30x1000 mm 337 544 Tube 9 30 mm 103 306 6 1 Tube plug 30 mm for pos 6 236 373 7 Tube 40x600 mm 337 552 Tube 40x1000 mm 337 560 Tube 40x1500 mm 337 579 Tube 40x2000 mm 337 587 Tube 9 40 mm 103 314 7 1 Tube plug 40 mm for pos 7 236 381 Please indicate length View A 7 3 2 NM vs Sg ECI EVL N C6 LU 4 L5 1f NN Automatic guns gt Ge Ge ZA06 Reciprocator Spare parts list e 47 iTrv Gema i Vertical gun holder 1 Clamp element half order in pairs 363 987 2 Cross clamping element 40 40 mm 363 910 3 Cross clamping element 40 30 mm 363 936 Cross clamping element 30 30 mm 363 952 4 see gun attachment etc 5 Allen cylinder screw M8x50 mm 235 113 6 Tube O 30x600 mm 337 528 Tube 30x800 mm 337 536 Tube 30x1000 mm 337 544 Tube 30 mm 103 306 6 1 Tube plug 30 mm for pos 6 236 373 7 Tube 40x600 mm 337 552 Tube 40x1000 mm 337 560 Tube 40x1500 mm 337 579 Tube 40x2000 mm 337 587 Tube 40 mm 103 314 7 1 Tube plug 40 mm for pos 7 236 381 Please indicate length View A gt tO toj tO tc is D SN gt Automatic guns TON HERA 48 e Spare parts list ZA06 Reciprocator iTw Gema Gun fixtures
11. 6 Reciprocator is used Safety symbols pictograms The following warnings with their meanings can be found in the ITW Gema operating instructions The general safety precautions must also be followed as well as the regulations in the operating instructions DANGER Danger due to live electricity or moving parts Possible consequences Death or serious injury WARNING Improper use of the equipment could damage the machine or cause it to malfunction Possible consequences minor injuries or damage to equip ment INFORMATION Useful tips and other information Conformity of use ZA06 Reciprocator 1 The ZA06 Reciprocator is built to the latest specification and con forms to the recognized technical safety regulations It is de signed for the normal application of powder coating 2 Any other use is considered as non conform The manufacturer is not responsible for damage resulting from improper use of this equipment the end user alone is responsible If the ZA06 Recip rocator is to be used for other purposes or other substances out side of our guidelines then ITW Gema GmbH should be con sulted 3 Observance of the operating service and maintenance instruc tions specified by the manufacturer is also part of conformity of use The ZA06 Reciprocator should only be used maintained General safety regulations e 3 iTw Gema V 06 08 and started up by trained personnel who are informed about and are familiar with the
12. 6 28 Reciprocator height 2 385 m 2 885 m 3 385 m 3 885 m Stroke length upto 1 3m upto1 8m upto2 3m upto2 8m 0 08 up to 0 6 m s Acceleration 0 1 2 0 m s Position detection with incremental pulse generator Max lifting weight max 50 kg on the Z carriage Electrical data ZA06 Reciprocator Power supply 230 VAC from control unit Tolerance 10 Power consumption 1 1 kw Frequency 50 60 Hz Protection type IP54 Isolation Class F Control unit OptiMove CR04 CR05 CR06 Temperature range oc x 10 6 32 F 104 F ZA06 Reciprocator Technical data e 15 iTrv Gema 16 e Technical data V 06 08 Drive unit data ZA06 Reciprocator Drive unit Asynchronous three phase AC motor Performance 0 75 kW Motor voltage frequency 3x230 VAC 87 Hz Electrical wiring Triangle three phase Motor RPM 2450 1 min Drive torque 80 Nm Brake torque 10 Nm Lubricant type Shell Omala 220 Lubricant quantity 0 25 liters Dimensions D x gig tit i D 350 750 30 5 30 5 460 394 LL E NER 210 250 684 La ZA06 Reciprocator dimensions ZA06 Reciprocator Start up m iTw Gema Preparation for start up Attention these operating instructions f Before connecting or switching on the reciprocator read carefu
13. 7 981 21 Hexagon screw M10x180 mm 201 855 Please indicate length Wearing part 38 e Spare parts list ZA06 Reciprocator vale iTw Gema ZA06 Reciprocator toothed wheel HT SE 10 QUELLI C 11 p ee 12 13 14 15 16 17 wad 18 a TI d 20 19 ZA06 Reciprocator toothed wheel ZA06 Reciprocator Spare parts list e 39 iTrv Gema ices ZA06 Reciprocator Z carriage complete 1 Carriage fixed side without pos 9 10 386 677 2 Carriage adjustable side without pos 9 10 386 685 3 Roller complete 307 1652 4 Spacer sleeve 308 013 5 Hexagon screw M10x110 mm 214 221 6 Hexagon screw M10x100 mm 214 213 7 Hexagon ribbed nut M10 black 234 656 9 Hexagon grub screw M5x16 mm 237 744 10 Hexagon nut M5 205 150 Wearing part NN ZA06 Reciprocator Z carriage complete 40 e Spare parts list ZA06 Reciprocator vee iTw Gema ZA06 Reciprocator proximity switch 1 Hexagon screw M10x180 mm 201 855 2 Ribbed washer M10 237 981 3 Stop plate 386 782 4 Rubber buffer 35x40 mm M8 A 211 664 5 Counter profile 40 20x115 mm 386 774 6 Limit switch holder 1003 980 7 Hexagon ribbed nut M10 234 656 8 Proximity switch 229 180 1 2 3 5 o N Co ZA06 Reciprocator proximity switch ZA06 Reciprocator Spare parts list 41 iTw Gema vds ZA06 Reciprocator drive unit complete
14. 78 16 Gun holder plate complete 386 693 Gun holder plate special not shown 1004 453 Spacer not shown 1004 456 17 Hexagon shakeproof screw M8x20 mm 244 422 18 Hexagon shakeproof nut M8 244 449 20 Milled nut M6 brass 200 433 21 Shake proof washer A type M6 200 450 22 Washer 6 4 12 5x1 6 mm brass 200 476 23 Hexagon nut M6 brass 200 417 24 Hexagon screw M6x35 mm 389 838 Please indicate length 36 e Spare parts list ZA06 Reciprocator EN iri Gema ZA06 Reciprocator spare parts ZA06 Reciprocator spare parts ZA06 Reciprocator Spare parts list e 37 iTw Gema al ZA06 Reciprocator toothed wheel 1 Eyebolt M16 264 415 2 Guide plate 386 588 3 Hexagon shakeproof nut M8 244 449 4 Hexagon ribbed nut M10 234 656 5 Counter profile 40 20x115 mm 386 774 6 Toothed wheel 386 600 7 Toothed belt 103 730 ZA06 13 L 4215 mm ZA06 18 L 5215 mm ZA06 23 L 6215 mm ZA06 28 L 7215 mm 8 _Tensioning screw 386 596 9 Hexagon shakeproof screw M6x12 mm 244 406 10 Locking plate 386 634 11 Hexagon shakeproof screw M8x20 mm 244 422 12 Toothed wheel spindle 386 766 13 Spacer ring 31 9 28x11 mm 386 618 14 Bearing 15 32x9 mm 241 709 15 Snap ring A 15 233 617 16 Snap ring I 32 245 780 17 Eyebolt M10x60 mm 264 202 18 Rubber buffer 35x40 mm M8 A 211 664 19 Stop plate 386 782 20 Ribbed washer M10 23
15. A06 reciprocator reference point and mechanical stops Attention In order to avoid damages to the booth or the gun holders the ref erence point must be checked before the first start up and if neces sary reset It must be noted that the axes in reference travel moves up to 25 mm below the control s zero point therefore the mechanical stop must be set in accordance to the gun slots The position of the upper and the lower stop plate is set by an ITW Gema service engineer when the reciprocator is assembled Attention The reference point must be referenced before each start up at each switching on after an interruption of the power supply etc ZA06 Reciprocator iTw Gema Setting the lower mechanical stop Attention The setting of the lower mechanical stop must take place without load and the reciprocator must be disconnected from mains Procedure 1 Release the brake switch manually 2 Letthe Z carriage sink down until the powder gun holder is ap proximately 50 mm above edge of the gun slot Remove the boarding side panels 4 Loosen the screws and move the lower stop plate up to the Z carriage 5 Tighten the screws 6 Refit the boarding side panels Setting the upper mechanical stop Attention The setting of the upper mechanical stop must take place without load and the reciprocator must be disconnected from mains In order to set the upper mechanical stop the stop position hast to be measure
16. Operating instructions and spare parts list ZA06 Reciprocator iTw Gema aun Documentation ZA06 Reciprocator Copyright 2006 ITW Gema GmbH All rights reserved This publication is protected by copyright Unauthorized copying is pro hibited by law No part of this publication may be reproduced photocop ied 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 ITW Gema GmbH OptiFlex OptiTronic OptiGun EasyTronic OptiSelect OptiFlow and Su perCorona are registered trademarks of ITW Gema GmbH OptiStar OptiSpray OptiMatic OptiMove OptiMaster OptiPlus Multi Tronic and Gematic are trademarks of ITW Gema 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 con cerned approve of or are bound in any form by this manual We have en deavored to retain the preferred spelling of the trademarks and regis tered 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 issue ITW Gema GmbH makes no representations or warranties with respect to the contents or use of this publication and reserves the right to revise this public
17. age 1 ZA06 Reciprocator vertical cross section ZA06 Reciprocator Function description e 13 iTw Gema V 06 08 Schematic presentation Reciprocator Reciprocator Frequency control unit converter H e LU 15 0 Schematic presentation Special characteristics The ZA06 Reciprocator is conspicuous because of its rugged construc tion a new drive system and an improved Z axis carriage design Further characteristics 50 kg load capacity for automatic gun and gun holders 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 Mobile version available IP54 protection type 4 standard stroke heights available 1 3 m 1 8 m 2 3 m 2 8 m Intermediate and larger sizes available in steps of 250 mm Upgrading with XT11 Horizontal axis The ZA06 Reciprocator can be equipped with the XT11 Horizontal axis if required The XT11 Horizontal axis extends the travel distance und the functionality of the reciprocator 14 e Function description ZA06 Reciprocator V 06 08 Technical data ZA06 Reciprocator Versions iTw Gema The ZA06 Reciprocator is available depending on operational area in four versions with different standard stroke heights Stroke speed Reciprocator ZA06 13 ZA06 18 ZA06 23 ZA0
18. akeproof nut M6 244 430 8 Handhold 244 864 9 Hexagon screw M6x12 mm 213 810 10 Drive I O connection complete 1004 105 11 Power supply 1003 990 12 Cylinder screw M3x8 mm 268 801 13 Shake proof washer A type M3 205 885 14 Hexagon nut M3 202 142 15 Adhesive seal strip 9x2 mm 100 250 ZAO6 power supply cable OptiMove L 20 m not shown 1000 280 ZA06 signal cable OptiMove L 20 m not shown 1000 281 ZA06 Reciprocator electrical module 44 e Spare parts list ZA06 Reciprocator ZA06 Reciprocator gun holders Note V 06 08 iTw Gema ers Please contact the ITW Gema Service department in the case of The following examples show a possible configuration of gun hold special configurations Gun holder for 1 4 guns 1 Clamp element half order in pairs 363 987 Cross clamping element 40 40 mm 363 910 Cross clamping element 40 30 mm 363 936 Cross clamping element 30 30 mm 363 952 see gun attachment etc Allen cylinder screw M8x50 mm 235 113 Tube 30x600 mm 337 528 Tube 30x800 mm 337 536 Tube 30x800 mm 337 544 Tube 30 mm 103 306 6 1 Tube plug 30 mm for pos 6 236 373 7 Tube 40x600 mm 337 552 Tube 40x1000 mm 337 560 Tube 40x1500 mm 337 579 Tube 40x2000 mm 337 587 Tube 40 mm 103 314 7 1 Tube plug 40 mm for pos 7 236 381 Please indicate length
19. ation and make changes to its content without prior notice Printed in Switzerland ITW Gema GmbH Movenstrasse 17 9015 St Gallen Switzerland Phone 41 71 313 83 00 Fax 41 71 313 83 83 E Mail info itwgema ch Homepage www itwgema ch vole iTw Gema Table of contents General safety regulations 3 Safety symbols pictogramS sse enne 3 Contormity Of USC s dicts ierra t rr RD UE eer a de e ete 3 Technical safety regulations for moving axves Laman anannn wa nnnnawanannansawananann 4 General information sess 4 Safety conscious working emen 5 Individual safety regulations for the operating firm and or operating per Clo HE 5 Notes on special types of hasard anna an annnanas anna aaanaanasananann 6 Safety requirements for electrostatic powder coating 7 A summary of the rules and regulations 8 Product specific security measures eem 10 Special safety regulations for ZA06 Reciprocator nananana annnawwaannnaann 10 About this manual 11 General information cerro aes reote rhe tfr na gino 11 Function description 13 ZAQG ReclDIOCatoOF x giten etm redu 13 Schematic presentation aa aana naanakan 14 Special characteristics nasasa aa aannanaa naaa aa annsnasansnnnnna anuna 14 Upgrading with XT11 Horizontal axis 14 Technical data 15 ZAQG ele TE 15 M Ion
20. d for this reason consider the maximum height of the booth gun slots Attention An incorrect too high set stroke limit can lead to damage to the re ciprocator and or the booth Procedure 1 Remove the boarding side panels 2 Loosen the screws and move the upper stop plate up to the measured position Tighten the screws 4 Refit the boarding side panels Attention After the adjustment of the mechanical stops the system parameter for the upper stop must be checked on the reciprocator control unit The value must not be larger than the maximum stroke possible be tween the stops ZA06 Reciprocator Start up e 21 m iTw Gema Maintenance General information AN Drive unit AN AN ZA06 Reciprocator Attention Before doing maintenance works to the reciprocator always be sure that nobody can switch on the reciprocator The reciprocator has to be free of load and disconnected from mains The ZA06 Reciprocator was designed to operate with a minimum of maintenance The gear box of the three phase AC motor is self lubricating and maintenance free Regular maintenance and inspection of the reciprocator increases the working reliability and avoids damages repair downtimes etc Blow off the outside of the reciprocator with compressed air or clean it with a soft cloth from top to bottom at least once a week If necessary blow off the slots Attention Before doing maintenance works to the drive u
21. e operating firm must ensure that the operating personnel wear protective clothing e g facemasks 7 The operating firm must guarantee cleanliness and an overview of the workplace with suitable instructions and checks in and around the moving axis 8 No safety devices should be dismantled or put out of operation If the dismantling of a safety device for set up repair or servicing is necessary reassembly of the safety devices must take place immediately after the maintenance or repair work is finished The moving axis must be turned off while servicing is carried out The operator must train and commit the responsible personnel to this 9 Activities such as checking powder fluidization or checking the high voltage spray gun etc must be carried out with the powder spraying equipment switched on Notes on special types of hazard Power It is necessary to refer once more to the danger of life from high voltage current if the shut down procedures are not observed High voltage equipment must not be opened the plug must first be taken out other wise there is danger of electric shock Powder Powder air mixtures can be ignited by sparks There must be sufficient ventilation in the powder coating booth Powder lying on the floor around the powder spraying device is a potentially dangerous source of slipping Static charges Static charges can have the following consequences Charges to people electric shocks sparking Chargin
22. e toothed drive wheel Letthe Z carriage slowly run up and down the column a few times to see if the toothed belt must be tensioned more Maintenance e 27 iTw Gema hicks Z carriage rollers If the Z carriage 10 starts to vibrate excessively during operation espe cially at the reversing points in most cases the cause lies in too much play in the carriage rollers or even loose rollers 34 32 33 31 30 Z carriage rollers In this case proceed as follows 1 Release the motor brake 12 manually let the Z carriage 10 move down onto the lower stop 2 Switch off the electric power 3 Remove the boarding front and side panels 4 Loosen the lock nut 32 on the grub screw 33 5 Loosen the nut 34 on the roller axle bolt 30 Attention Never loosen more than one roller at the same time Adjust only one roller after another 6 Adjust the roller pressure with the grub screw in such a way that the roller 31 can just be turned by hand Tighten the roller axle bolt 30 and the nut 34 Tighten the grub screw 33 and secure it Fit the panels again and fasten them firmly The Z carriage should run evenly and quietly again 28 Maintenance ZA06 Reciprocator V 06 08 Schematic diagrams ZA06 Reciprocator wiring diagram iTw Gema X1 Hi ZA04 AXIS ADAPTER NR 1 000 247 ZA06 Reciprocator wiring diagram ZA06 Reciprocator PE le
23. en yellow must be connected to the earthing screw of the electrostatic powder spraying hand ap pliance The earthing cable must have a good metallic connec General safety regulations e 7 iTw Gema 8 e General safety regulations 10 11 12 13 14 15 16 V 06 08 tion with the coating booth the recovery unit and the conveyor chain and with the suspension arrangement of the objects The electricity and powder supply to the hand guns must be set up so that they are fully protected against heat and chemical damage The powder coating device may only be switched on once the booth has been started up If the booth cuts out then the powder coating device must be switched off The earthing of all electricity conducting devices e g hooks conveyor chains must be checked on a weekly basis The earthing resistance must amount to maximally 1 MOhm The control device must be switched off if the hand gun is cleaned or the nozzle is changed When working with cleaning agents there may be a risk of haz ardous fumes The manufacturers instructions must be observed when using such cleaning agents The manufacturers instructions and the applicable environmental requirements must be observed when disposing of powder lac quer and cleaning agents If any part of the spray gun is damaged broken parts tears or missing then it should not be used For your own safety only use accessories and attachments listed in
24. flammable Smoking is forbidden in the entire plant area 12 As a general rule for all powder spraying installations and moving axes persons with pacemakers should never enter high voltage areas or areas with electromagnetic fields Persons with pace makers should not enter areas with powder spraying installa tions WARNING We emphasize that the customer himself is responsible for the safe operation of equipment ITW Gema is in no way responsible for any resulting damages Safety conscious working Each person responsible for the assembly start up operation service and repair of powder spraying equipment must have read and under stood the operating instructions and the Safety regulations chapter The operator must ensure that the user has had the appropriate training for powder spraying equipment and is aware of the possible sources of dan ger The control units for the spray guns must only be set up and used in zone 22 The spray guns are permitted in the zone 21 created by them The powder spraying equipment should only be used by trained and au thorized personnel This applies to modifications to the electrical equip ment which should only be carried out by a specialist The operating instructions and the necessary closing down procedures must be followed before any work is carried out concerning the set up start up operation modification operating conditions mode of operation servicing inspection or repairs
25. g of objects must be avoided see chapter Earthing Grounding Earthing All electricity conducting parts and machinery found in the workplace ac cording to DIN VDE 0745 part 102 must be earthed 1 5 meters either side and 2 5 meters around each booth opening The earthing resistance must amount to maximally 1 MOhm The resistance must be tested on a regular basis The condition of the machinery surroundings as well as the suspension gear must ensure that the machinery remains earthed If the ZA06 Reciprocator ZA06 Reciprocator vole iTw Gema earthing of the machinery includes the suspension arrangements then these must constantly be kept clean in order to guarantee the necessary conductivity The appropriate measuring devices must be kept ready in the workplace in order to check the earthing Compressed air When there are longer pauses or stand still times between working the powder spraying equipment should be drained of compressed air There is a danger of injury when pneumatic hoses are damaged and from the uncontrolled release and improper use of compressed air Crushing and cutting During operation moving parts may automatically start to move in the operating area It must be ensured that only instructed and trained per sonnel go near these parts The operator should ensure that barriers comply with the local security regulations Access under exceptional cirrumstances The operating firm must ensure that local co
26. he wear parts are always marked with a All dimensions of plastic hoses are specified with the external and inter nal diameter Example 8 6 mm 8 mm outside diameter o d 6 mm inside diameter i d WARNING Only original ITW Gema spare parts should be used because the hazardous location approval will be preserved that way The use of spare parts from other manufacturers will invalidate the ITW Gema guarantee conditions ZA06 Reciprocator Spare parts list e 35 iTw Gema al ZA06 Reciprocator spare parts list 1 Drive unit complete see ZA06 Reciprocator drive unit complete 2 Service cover MA 1004 016 3 Hexagon screw M6x10 mm 1001 081 4 Service cover MS 1004 015 5 Cable lead through 50 mm 5 4 1004 006 6 Electrical module see ZA06 Reciprocator electrical module 7 Zcarriage complete see ZA06 Reciprocator Z carriage complete 8 Toothed wheel see ZA06 Reciprocator toothed wheel 9 Proximity switch see ZA06 Reciprocator proximity switch 10 Service cover SS 1004 017 11 Cable lead through 50 mm double 1004 007 12 Cable grommet QT6 1004 531 13 Panel lateral ZA06 13 386 502 ZA06 18 386 510 ZA06 23 386 529 ZA06 28 386 537 ZA06 33 38 1004 454 14 Panel front ZA06 13 1004 011 ZA06 18 1004 012 ZA06 23 1004 013 ZA06 28 1004 014 ZA06 33 38 1004 455 15 Membrane grommet 1003 5
27. heels 9 weekly for contamination and wear and remove powder deposits with a vacuum cleaner Switch on the reciprocator and check the Z carriage 10 for quiet running Check the toothed belt 3 for elongation or wear noisy running strong vibration of the belt when revers ing the direction of travel ZA06 Reciprocator Maintenance e 25 iTrv Gema ver Attention bg For safety reasons two people should always carry out the follow ing maintenance work Tensioning the toothed belt Remove the locking plates 21 Tighten the toothed belt evenly with the tensioning screws 22 The guide plate 20 must not be unscrewed for any reason factory setting 21 22 de Ze These screws may not be loosen for any reason factory setting 20 ZA06 Reciprocator top view Replace the toothed belt Procedure 1 Release the motor brake 12 manually let the Z carriage 10 move down onto the lower stop Switch off the electric power Remove the boarding side panels 4 Remove the locking plates 21 and loosen the tensioning screws so that the toothed belt 3 is slack 5 Loosen the lower clamp plate with the toothed belt on the Z car riage 10 and set it down Note the position of the clamp plate on the toothed belt holder because it must be fitted in approximately the same position on assembly Remove the damaged toothed belt from the reciprocator column Loosen the screws on the upper clamp plate
28. ing equipment 4 DIN VDE 0165 Setting up electrical equipment in locations in areas with danger of explosion Sources Carl Heymanns Verlag KG Luxemburger Strasse 449 5000 K ln 41 or from the appropriate employers association Beuth Verlag GmbH Burgrafenstrasse 4 1000 Berlin 30 General secretariat Rue Br derode 2 B 1000 Bruxelles or the appro priate national committee VDE Verlag GmbH Bismarckstrasse 33 1000 Berlin 12 ZA06 Reciprocator General safety regulations e 9 iTw Gema V 06 08 Product specific security measures The installation work to be done by the customer must be carried out according to local regulations Before starting up the plant a check must be made that no foreign objects are in the booth or in the ducting input and exhaust air It must be observed that all components are grounded ac cording to the local regulations before start up Special safety regulations for ZA06 Reciprocator 10 e General safety regulations 1 The ZA06 Reciprocator should only be started up after carefully reading of these operating instructions Incorrect operation of the reciprocator control unit can lead to accidents malfunctions or damage to the plant Attention the power of the reciprocators axes is very 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 whe
29. ing is visible Krees only at first switch on Settings JI AE SC nt Dive uni o o e T EE nputsoutputs a cer Gesong H eae Menus e L Functions NG o e conf Communication DIS sur Monitoring L SO Frequency converter access to menus 32 e Frequency converter ZA06 Reciprocator iTw Gema Access to menu parameters The storage recording of the indicated selection takes place with ev The display flashes during storage Example Menu Parameter Value or allocation gt O See 1 flashing e storage dEC 26 0 Frequency converter access to menus storage Adjusted parameters Menu SET Code Value ACC 0 1 sec DEC 0 1 sec HSP 110 Hz ITH 3 7A TDC1 1 0 sec SDC1 3 7A CL2 3 0A SFR 16 kHz Menu DRC Code Value UNS 210V FRS 87 Hz NCR 3 3A NSP 2540 rpm COS 0 8 RSC active TUN Pon NRD no SFR 16 kHz TFR 110 Hz SRF yes Menu I O Code Value CRL3 4 7 MA ZA06 Reciprocator Frequency converter e 33 iTrv Gema V 06 08 Menu CTL Code Value LAC L2 FR1 Al3 Menu FUN Code Value RPC BRA no LC2 LC2 LI6 CL2 CL2 3 0A Note The resetting of the frequency converter to the ITW Gema factory setting takes place by the FSC parameter in the DRC menu Maintenance The frequency converter
30. lead to accidents malfunction or damage to the control itself Before every start up check the equipment for operational safety regular servicing is essential Safety regulations BGI 764 and VDE regulations DIN VDE 0147 part 1 must be observed for safe operation Safety precautions specified by local legislation must be ob served The plug must be disconnected before the machine is opened for repair The plug and socket connection between the powder spraying equipment and the mains network should only be taken out when the power is switched off The connecting cable between the controlling device and the spray gun must be set up so that it cannot be damaged during operation Safety precautions specified by local legislation must be observed ZA06 Reciprocator ZA06 Reciprocator vole iTw Gema 8 Only original ITW Gema spare parts should be used because the explosion protection will also be preserved that way Damage caused by other parts is not covered by guarantee 9 Ifthe ITW Gema moving axis is used in conjunction with machin ery from other manufacturers then their safety regulations must also be taken into account 10 Before starting work familiarize yourself with all installations and operating elements as well as with their functions Familiariza tion during operation is too late 11 Caution must be exercised when working with a powder air mix ture A powder air mixture in the right concentration is
31. lly Before the reciprocator is put into operation the upper stroke limit must be set on the reciprocator control unit see therefore the user manual of the reciprocator control unit General information Attention Before start up works are done make certain that nobody can switch on the reciprocator Switch off and lock the mains switch Before starting up the following checks should be done ZA06 Reciprocator Check the gun holder and hose holder if they are firmly fitted Mount the gun holder in such a way that they do not hit the bottom of the booth slots on start up and cause damage Lay out the cables and hoses in such a way that even at the highest stroke no strain can arise Make sure that no guns can collide with the work pieces Check the grounding of the guns and hose carriers Check if the upper and the lower reversing point of the Z car riage are set correctly The stroke length of the reciprocator must be in the range of the booth opening collision danger Make sure that the automatic guns cannot collide with the work pieces incorrectly adjusted stroke parameters on the reciprocator control unit Start up e 17 iTrv Gema AN V 06 08 Reference point At every start up after the mains have been interrupted the reference point of the reciprocator must be referred again see Reference point and mechanical stops After the reference point is reached the recipro cator begins to carry out the move
32. ments set on the reciprocator control unit Before the reciprocator is put into operation the upper stroke limit must be set on the reciprocator control unit see therefore the corresponding reciprocator control unit operating manual Attention Incorrect setting of the upper and lower stroke limits can cause damages to the reciprocator to the booth and or to the applicators Electrical connections cable connections 18 Start up OptiMove Control unit connections The ZA06 power supply line is connected to the 2 2 Drive supply connection on the reciprocator control unit by the ZA06 power supply cable The ZAO06 Drive I O connection is connected to the 2 3 Drive UO connection on the reciprocator control unit by the ZA06 signal cable ZA06 Reciprocator iTw Gema Checkpoints before switching on Before switching on the following checks should be done Check if the cables and hoses are laid out correctly Check if the guns have a clear run and do not touch the booth slots Check the distance between the work pieces and the guns Attention Before connecting or switching on the reciprocator read carefully these operating instructions Grounding protection type All metal parts of the reciprocator must be grounded according to the lo cal safety regulations The gun holders must be connected to the ground ing screw on the reciprocator base by the grounding strip All electrical in
33. n the clamp ring in front of the flange bearing 2 Use an appropriate iron rod from the side in the hole of the clamp ring and release the clamp ring from the motor spindle counter clockwise with a hammer Remove the clamp ring but do not remove the flange bearing 2 EL ZA06 Reciprocator flange bearing If the grub screw or the hole is not accessible release the brake manually and turn the drive wheel by hand on an appropriate po sition Open the clip and pull out the plug Disconnect the incremental pulse generator cable from connec tion X8 see electrical diagram and pull the plug through the ca ble lead through into the motor compartment Support the back of the motor in such a way it remains balanced and does not tilt backwards when the motor flange screws are loosen Remove the screws and carefully remove the motor from the rear of the reciprocator base The installation takes place exactly in the reverse order 24 e Maintenance ZA06 Reciprocator iTw Gema NA p 6 5 4 11 ZA06 Reciprocator Toothed belt The toothed belt 3 should be checked regularly because it is exposed to large loads when in operation The toothed belt 3 should be checked weekly for contami nation Powder deposits should be removed with a vacuum cleaner because this can influence the quiet running and shorten the service life of the toothed belt Check the toothed w
34. n the reciprocator is not operating The plugs and sockets of the reciprocator control unit and the power unit of the ZA06 Reciprocator should only be unplugged when the power supply is disconnected The connecting cables between the control unit and the recipro cator must be laid in such a way that they cannot be damaged during axes operation Please observe the local safety regula tions The maximum upper stroke limit of the reciprocator must al ways 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 dam aged 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 ac cording to the local safety regulations Repairs may be done only by authorized ITW Gema service cen ters Unauthorized conversions and modifications can lead to in juries and damage to the equipment The ITW Gema GmbH guarantee would no longer be valid Only original ITW Gema spare parts may be used The use of spare parts from other manufacturers will invalidate the ITW Gema guarantee conditions We point out that the customer himself is
35. nditions are met when re pairs are made to the electronic parts or when the equipment is restarted so that there are additional measures such as barriers to prevent unau thorized access Prohibition of unauthorized conversions and modifica tions to machines All unauthorized conversions and modifications to electrostatic spraying equipment are forbidden for safety reasons The powder spraying equipment should not be used if damaged the faulty part must be immediately replaced or repaired Only original ITW Gema replacement parts should be used Damage caused by other parts is not covered by guarantee Repairs must only be carried out by specialists or in ITW Gema work shops Unauthorized conversions and modifications may lead to injury or damage to machinery The ITW Gema GmbH guarantee would no longer be valid Safety requirements for electrostatic powder coating 1 This equipment is dangerous if the instructions in this operating manual are not followed 2 Allelectrostatic conductive parts in particular the machinery within 5 meters of the coating equipment must be earthed 3 The floor of the coating area must conduct electricity normal concrete is generally conductive 4 The operating personnel must wear electricity conducting foot wear e g leather soles 5 The operating personnel should hold the gun with bare hands If gloves are worn these must also conduct electricity 6 The supplied earthing cable gre
36. nit always be sure that the reciprocator has to be free of load and disconnected from mains The gearbox of the three phase AC motor is self lubricating and mainte nance free Observe the contamination of the enclosure strong contamination on the outside can increase the operating temperature of the drive unit Therefore clean the drive unit from time to time with a vacuum cleaner etc Check the drive unit gearbox monthly for oil loss If the drive unit gearbox has to be changed for any reason the complete unit has to be replaced Attention For safety reasons two people should always carry out the follow ing maintenance work Maintenance e 23 iTrv Gema V 06 08 Replacing the drive unit If itis necessary to replace a drive unit gearbox the complete motor unit must be dismantled from the reciprocator base Therefore the reciproca tor has to be free of load and disconnected from mains Procedure 1 11 12 Release the motor brake 12 manually let the Z carriage 10 move down onto the lower stop Remove all cover plates from the reciprocator Remove the locking plates 7 and loosen the tensioning screws so that the toothed belt 3 is slack Loosen the lower clamp plate with the toothed belt on the Z car riage 10 and set it down Note the position of the clamp plate on the toothed belt holder because it must be fitted in approximately the same position on assembly Loosen the grub screw o
37. possible hazards involved Start up i e the execution of a particular operation is forbidden until it has been established that the ZA06 Reciprocator has been set up and wired according to the guidelines for machinery 98 37 EG EN 60204 1 machine safety must also be ob served Unauthorized modifications to the ZA06 Reciprocator exempts 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 must be ob served Explosion protection Protection type Temperature class C Ex 13D IP54 T6 zone 21 Technical safety regulations for moving axes General information The ITW Gema moving axis is designed with safety in mind and is built according to the latest technological specifications This equipment can be dangerous if it is not used for its specified purpose Consequently it should be noted that there exists a danger to life and limb of the user or third party a danger of damage to the equipment and other machinery belonging to the user and a hazard to the efficient operation of the equipment 1 4 e General safety regulations The moving axis should only be started up and used once the operating instructions have been carefully studied Improper use of the controlling device can
38. r in tended use in potentially explosive atmospheres EN 12100 1 EN 12100 2 Machine safety a EN IEC 60079 0 Electrical equipment for locations where there is danger of explosion 3 EN 50 050 EN 50 053 part 2 Electrical apparatus for potentially explosive atmos pheres electrostatic hand held spraying equipment a Requirements for the selection installation and use of electrostatic spraying equipment for flammable materi als hand held electrostatic powder spray guns 3 EN 50 177 Stationary electrostatic spraying equipment for flamma ble coating powder EN 12981 Coating plants spray booths for application of organic powder coating material safety requirements EN 60 529 identi cal DIN 40050 IP Type protection contact foreign bodies and water protection for electrical equipment 2 EN 60 204 identi cal DIN VDE 0113 VDE regulations for the setting up of high voltage elec trical machine tools and processing machines with mains voltages up to 1000 V VDE Association of German Engineers Regulations DIN VDE 0100 Regulations for setting up high voltage equipment with mains voltages up to 1000 V s DIN VDE 0105 part 1 part 4 VDE regulations for the operation of high voltage equipment 4 General regulations Supplementary definitions for stationary electrical spray ing equipment DIN VDE 0147 part 1 Setting up stationary electrostatic spray
39. responsible for the safe operation of the equipment ITW Gema GmbH will not be re sponsible for any resulting damage ZA06 Reciprocator vole iTw Gema About this manual General information ZA06 Reciprocator This operating manual contains all the important information which you require for the working with the ZA06 Reciprocator It will safely guide you through the start up process and give you references and tips for the optimal use of your new powder coating system Information about the function mode of the individual system components reciprocators booths powder gun control units powder guns etc should be referenced to their corresponding documents About this manual e 11 iTw Gema Function description ZA06 Reciprocator The ZA06 Reciprocator moving axis was designed for automatic coating with powder guns The reciprocator carriage oscillates vertically on the column The movement sequences stroke and stroke speed are con trolled by the reciprocator control unit The gun holders are fitted on the shield 4 of the Z carriage 5 The Z car riage 5 is moved up and down on the central column by a toothed belt 3 inside the reciprocator This vertical column serves also as a runway for the rollers The drive unit 2 and the electrical connection are installed in the reciprocator base 1 An incremental pulse generator which is in stalled in the motor case enables the exact positioning of the Z carri
40. stallations are implemented in accordance to VDE IP54 protection type regulations Hoses and cables All movable hoses and cables must be laid out in such a way that they are neither subjected to any loads nor can hang on other parts The elec tric cables of the reciprocators must be protected from mechanical dam age Reference point and mechanical stops The reference point serves as starting point for the reciprocator control unit for calculating the upper and lower reversing point and the maximum stroke By switching on the reciprocator control unit the reciprocator travels automatically to the reference point proximity switch The reciprocator control units are programmed in such a way that the reference point is always located 50 mm above the reversing point For transport reasons the ZAO6 Reciprocator is delivered with the rubber buffer and the carriage in lowest position Attention In order to avoid damages to the booth or the gun holder etc the reference point must be set before the first start up ZA06 Reciprocator Start up e 19 iTrv Gema Proximity switch Stop plate with rubber buffer 20 e Start up Ad V 06 08 Setting the reference point 1 Move the stop plate with rubber buffer and proximity switch to the desired position and fasten it 2 Set the response gap of the proximity switch to approx 2 mm Consider the lower edge of the gun slot Gun slot lower edge Z
41. the operating instructions The use of other parts can lead to risk of injury Only original ITW Gema replacement parts should be used Repairs must only be carried out by specialists and under no cir cumstances should they be carried out in the operating area The former protection must not be reduced Conditions leading to dangerous levels of dust concentration in the powder spraying booths or in the powder spraying areas must be avoided There must be sufficient technical ventilation available to prevent a dust concentration of more than 50 of the lower explosion limit VEG UEG max permissible pow der air concentration If the UEG is not known then a value of 10 g m should be used A summary of the rules and regulations The following is a list of relevant rules and regulations which are to be observed Guidelines and regulations German professional asso ciation BGV A1 Prevention principles BGV A3 Electrical equipment and material BGI 764 Electrostatic coating BGR 132 Guidelines for the avoidance of the dangers of ignition due to electrostatic charging guideline Static Electric ity VDMA 24371 Guidelines for electrostatic coating with synthetic pow der Part 1 General requirements Part 2 Examples of use ZA06 Reciprocator V 06 08 iTw Gema EN European standards RL94 9 EC The approximation of the laws of the Member States relating to apparatus and safety systems for thei
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