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Gema CM40, Operating Instructions And Spare Parts List

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Gema CM40 Operating Instructions And Spare Parts List Download Page 112

 

Rev. 01  12/21

 

112  

•

  Fault clearance 

MagicControl 4.0 (CM40) 

Faults 

 

 

Fault 

Cause 

Corrective action 

Control voltage 
indicator lamp does 
not light up 

Safety circuit not OK 

Check and correct 
any errors, see 
enclosed wiring 
diagram 

 

Lamp defective 

Replace 

Axes cannot be 
referenced 

The reference key is 
not displayed: 

–  Axes are already 

referenced 

–  Not all axes are 

detected on the 
CAN bus 

–  Control is in an 

undefined state 

Check control 
voltage. 
On the diagnostics 
page, check which 
axes are not 
accessible via CAN 
bus (see also 
Operating Manual or 
the respective axis). 
Switch off the control 
voltage and switch it 
on again after 10 
seconds, otherwise 
restart the plant. 

 

 

 

 

Summary of Contents for CM40

Page 1: ...Rev 01 1011 534 EN Operating instructions and Spare parts list System control MagicControl 4 0 CM40 Translation of the original operating instructions ...

Page 2: ...s 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 tr...

Page 3: ...nably foreseeable misuse 13 Powder circuit 13 Typical characteristics 13 Scope of delivery 14 Technical Data 15 System 15 Electrical data 15 Dimensions 15 Display 15 Connections 16 Environmental conditions 16 Rating plate 16 Design and function 17 Operating and display elements 17 Connections and interfaces 18 Symbols 19 Meaning of the colors 20 Operating modes 21 Automatic operating mode AUTO 21 ...

Page 4: ...n 42 Working interruptions or coating breaks 43 Switching off the plant 43 Coating Data 44 Edit gun values select or deselect 44 Edit axis values select or deselect axes 45 Coating programs 47 Load coating programs 48 Creating coating programs 48 Copy and insert coating programs 48 Naming coating programs 49 Search coating programs 50 User administration 51 Status display 51 Login 51 Log out 54 Ch...

Page 5: ... After filter pressure monitoring 93 Introduction 93 Typical characteristics 94 Description of the pressure switches 94 Pressure switch overview 95 Display of the pressure values in MagicControl CM40 96 Configuration 97 1503 After filter type 97 1504 Volume flow 97 1561 Meter above sea level 97 1562 Temperature 98 OptiControl ISC08 Adjustment instructions 99 ATEX Stop powder 99 Alarm 100 Operating...

Page 6: ...ioning Storage 113 Shutdown 113 Storage conditions 113 Hazard notes 113 Type of storage 113 Storage duration 113 Space requirements 113 Physical requirements 113 Maintenance during storage 114 Maintenance schedule 114 Maintenance works 114 Disposal 115 Introduction 115 Requirements on personnel carrying out the work 115 Disposal regulations 115 Materials 115 Disassembly of component groups 116 Spa...

Page 7: ...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 ...

Page 8: ...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 Software version This document describes the operation of the product MagicControl 4 0 CM40 with software version starting from CM40_1 4 See chapter Checking the software version on page 63 Presentation of the contents Figure referenc...

Page 9: ... 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 ...

Page 10: ...uctions 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 ...

Page 11: ...ance instructions specified by the manufacturer is also part of conformity of use This product should only be used maintained and started up by trained personnel who are informed about and are familiar with the possible hazards involved Any other use is considered non compliant The manufacturer is not responsible for any incorrect use and the risks associated with such actions are assumed by the u...

Page 12: ...irements EN 50050 2 Electrostatic equipment for areas where there is danger of explosion electrostatic hand held equipment Part 2 Electrostatic hand held spraying equipment IEC EN 60950 Safety of information technology equipment UL 61010 2 201 Industrial controls section Requirements for the place of installation DIN EN 60529 Degrees of protection provided by enclosures IP Code NEMA 250 2003 Enclo...

Page 13: ...1 Booth 2 Cyclone separator 3 Screen 4 Powder recirculating 5 After filter 6 Waste container 7 OptiCenter 8 Automatic powder guns Typical characteristics Powder coating in 2 operating modes Cleaning in cleaning mode User administration and language management Coating Program Data Management Configuration and parameter data management Alarm handling Diagnostic functions Operating data acquisition C...

Page 14: ...with symbols Touch Panel CAN bus technology Multilingual version Installation in control cabinet or on stands MagicControl CM40 Color Screen 15 6 SD card 1 Number of guns 55 Number of stations 10 Number of axes 24 Axis type from ZA04 from XT09 Scope of delivery SD card Operating manual ...

Page 15: ... effective Reverse voltage protection yes Protection yes internal inaccessible melting fuse Electrical insulation no Current consumption max 21 6 W 24 VDC Switch on current max 1 A2 s Dimensions MagicControl CM40 Mechanical dimensions 404 x 255 x 76 mm Window 388 x 239 mm Display MagicControl CM40 Technology Projected Capacitive Touch PCT Screen diagonal 15 6 Resolution 1366 x 768 pixels WXGA Numb...

Page 16: ...vanically isolated SUB D connector 9 pin CAN CAN1 not galvanically isolated SUB D connector 9 pin SD card slot SDSC or SDHC according to SDA specification 2 0 Environmental conditions Touch Panel Climate 10 40 C 10 95 relative humidity not condensing Vibration shock drop test Vibration IEC 60068 2 6 Shock IEC 60068 2 27 Drop test IEC 60068 2 31 Rating plate A rating place is attached to the back o...

Page 17: ...lay elements Fig 4 Front and back Designation Description 1 Display touch sensor Operating and display elements Acquisition of the actuation of the operating elements shown on the display Operated by touch using fingers 2 SD card slot Slot for SD card 3 CTRL button Exits the visualization program ...

Page 18: ... LAN1 10 100 Mbps 3 USB host USB 2 0 not galvanically isolated plug type A full power 500 mA 4 USB device USB 2 0 not galvanically isolated plug type B 5 COM1 RS 232 not galvanically isolated SUB D connector 9 pin 6 COM2 RS 485 not galvanically isolated SUB D connector 9 pin 7 CAN CAN1 not galvanically isolated SUB D connector 9 pin 8 Power supply MSTB plug connector 3 pin 9 SD card slot SDSC or S...

Page 19: ...istributed on the user interface Automatic operation mode Cleaning operation mode Manual operation mode Main menu Plant OFF Press and hold 2 seconds Cyclone Powder management Filter ON OFF or High Low frequency Guns ON OFF powder Squeegee ON OFF Floor blow off ON OFF Guns External cleaning ON OFF Axes move to reference position Axes ON OFF Safety grid access release ON OFF Reference axes Start Can...

Page 20: ...or ON OFF Meaning of the colors System components Background color Grey present but not active Border color Orange active state e g fan running powder management system is ready Border color Red Error Guns and axes black grey present but not active orange active state e g gun sprays powder axis running red Error ...

Page 21: ...es are carried out manually or automatically Daily correction of the powder output can be modified Status display of object recognition Manual operating mode MAN MAN is the manual operating mode for operating simple plants without gap control or object recognition and for testing and running in the application Guns and axes are individually controlled manually by the user Manual positioning of gun...

Page 22: ...ftware has 5 user levels as standard predefined by Gema User level 0 admin User level 1 Gema service User level 2 user 1 User level 3 user 2 User level 4 user 3 These user levels are pre programmed and cannot be changed The functions available depending on the user level are explained below Functions available at user level User Admin Gema Service user 1 user 2 user 3 User level 0 1 2 3 4 User gro...

Page 23: ...ive With its integrated statistics trend tools and monitoring of wear parts the plant control offers the user the possibility to analyze important production information to support system optimizations System diagnosis The system diagnosis provides the user with an overview of the remaining service life of the components which enables the user to better plan for maintenance intervals and spare par...

Page 24: ...n operation and how long this control has been used Fig 8 For further information see chapter Machine data Batch management Batch management is used to record the consumed powder divided into production batches The recorded consumption data is continuously updated and then displayed on the screen in tabular form If a height light grid is present in addition to the powder consumption the coated sid...

Page 25: ...ing an optional barcode reader Fig 9 Fig 10 Chronological listing of batches produced Line management Enables the analysis and efficiency optimization of the powder coating equipment The most important production parameters are recorded and displayed in daily weekly monthly graphs ...

Page 26: ...11 Power control Real time measurement and visualization of the power and or compressed air consumption as well as the temperature and humidity curve To use this functionality appropriate measuring devices must be installed at the supply points of the plant Fig 12 ...

Page 27: ...ect on all guns and can be changed in the range of 50 150 This means that 50 150 of the programmed powder quantity is conveyed without influencing the total air volume Fig 13 The day correction is used In injector plants as compensation for wearing parts In plants with always equal parts as correction factor of the powder mixture For different colors as a correction of the application without adju...

Page 28: ...Rev 01 12 21 28 Product description MagicControl 4 0 CM40 ...

Page 29: ... Connection 29 Assembly Connection Mounting instructions The plant control is installed either in a control cabinet or as a stand alone unit on a stand Please contact Gema for other installation possibilities Fig 14 Possibilities of installation ...

Page 30: ...loss or destruction of the SD card Only insert the SD card into the operating panel with the power switched off Avoid writing data on to the SD card when there is also a drop in voltage Only remove the SD card from the operating panel with the power switched off Before switching off make sure that no software is writing data on to the SD card Inserting SD card SD cards are protected against incorr...

Page 31: ...s allows faster commissioning since fewer parameters need to be set on site The application data in the laboratory report if available provides additional help and can be used as the basic setting for guns and axes The control can be subsequently adjusted and extended Changes of correction values may only be made by Gema trained personnel Some of the configurations or settings can be made during o...

Page 32: ... and topology of the CAN network is specified in the electrical diagram The following data can be accessed via the CAN network All desired values process data All actual values process data All control values All system parameters except Baud rate and CAN address All error messages All other parameters such as software version daily correction powder output correction etc ...

Page 33: ...he initial commissioning of the device the functional check must be performed without powder Starting the plant 1 Turn the main switch to the ON position The plant control is started up to the start page Fig 15 Start page 2 Touch the screen The screen switches to the main page ...

Page 34: ...age not logged in 3 Press the Select key to log in with your user name and password Fig 17 User selection 4 Select the desired user profile and confirm by pressing the key 5 Press the Password key Fig 18 Password input 6 Enter password and confirm by pressing RET ...

Page 35: ...e Modify and manage coating programs and application data Operating data management LM Configuration and parameters Diagnostics Settings with the exception of some functions that are only available when the after filter is running and the control units are switched on 8 Turn the key switch to turn on the control voltage The indicator lamp lights up ...

Page 36: ...mponents e g powder management system into the correct operating mode for more information see the relevant operating manual If some plant components are not yet ready for operation a message will be displayed Automatic operation mode 1 Press the key to select automatic operation mode fig 21 Automatic operation mode 2 Press the symbol to load coating programs for more information see below ...

Page 37: ...ost entry is set to the number searched for Currently selected line Currently loaded object that is available for editing 3 Select coating program and confirm selection The plant control is now ready for production Plants with program change per station internal or external For plants with internal or external program change proceed as follows 1 For external program changes the number in the middl...

Page 38: ...ic mode objects are detected by the existing object recognition and the control switches the guns and the axes on and off according to their configured functions If no parts pass through the object recognition the motor power is throttled in automatic mode on plants with a controlled after filter with frequency converter FC In ECO mode the guns are also switched off ECO mode is not exited until pa...

Page 39: ...recognition If the conveyor stops the coating procedure is interrupted The active conveyor can be simulated In systems without pulse generator For testing purposes If the pulse generator is defective If the conveyor is not yet ready for operation ATTENTION Collision or faulty coating By simulating an active conveyor the control is given a physically active conveyor This can result in an offset of ...

Page 40: ...plied by the correction value The correction value is not saved and must be reset after each restart Example Powder output value PA 50 Daily correction value 60 New powder output value 50 x 0 6 30 Fig 25 1 Press the corresponding station key If several stations are present press to enlarge the window 2 Enter desired value max 150 min 50 3 Press the RET key to confirm Cleaning operation mode 1 Pres...

Page 41: ...and the guns are cleaned from the outside 3 Put the powder management system into cleaning mode 4 Press the key The outside cleaning of the guns is started and the key turns orange External cleaning of the gun can be repeated as often as required by pressing this key 5 Follow the cleaning steps of the respective powder management system MagicCenter OptiCenter or Powder Center 6 After cleaning the ...

Page 42: ...ning is still in progress Fig 27 12 Select the operating mode and coat or 13 End production and switch off the plant Safety grid function 1 Press the key The safety grid door is released If the door is opened the axes are disconnected from the power supply 2 After the cleaning maintenance work has been completed press the key The safety grid is locked again 3 Press the key Axes are ready for opera...

Page 43: ...f time the system should be brought into an economical state Switching off the plant 1 Clean the plant See chapter Cleaning operation mode on page 40 2 To exit Cleaning mode press and hold the key for 2 seconds Fig 28 3 The display changes to this screen Fig 29 4 Turn the key switch to 0 to turn off the control voltage The indicator lamp goes out ...

Page 44: ... 0 CM40 5 Press and hold the key for a further 2 seconds Fig 30 Start page 6 Turn the main switch to the OFF position Coating Data Edit gun values select or deselect 1 Press the key The following page is displayed Fig 31 Application data Guns ...

Page 45: ...der Program that is being edited Access to gun parameters Access to axes parameters Access to all coating programs Save changes Exit current page without saving any changes are discarded Changes per station or all stations Error description 2 Press the corresponding gun key 2 The key turns orange and the gun is selected or activated Only guns which are activated can be switched on 3 Touch the corr...

Page 46: ...alues values are set in the configuration menu Reference axis Manual operation mode The symbol changes to ON OFF after referencing Automatic operation mode The symbol is no longer visible after referencing Current position or error number Current program Access to gun parameters Access to axes parameters Access to all coating programs object data administration Save changes Exit current page witho...

Page 47: ...he position of the respective axis Coating programs 1 Press the symbol to load coating programs Fig 33 Coating programs Confirm program selection Copy data Insert data Exit screen Scroll bar Delete entry in search field Datasearch by alphanumeric entry Data search by program number entry The topmost entry is set to the number searched for Currently selected line Currently loaded object that is ava...

Page 48: ...f the error message Program not available is displayed when copying or loading coating programs this means that no coating programs have been created and that the program must be created again 1 Copy any existing program preferably a related similar one so that you do not have to make many changes 2 Insert 3 Load 4 Edit coating programs Copy and insert coating programs 1 Select coating program ...

Page 49: ...opied from the clipboard Fig 36 4 Press the key 5 The following security prompt is displayed Would you like to overwrite the program 6 Confirm Data is copied to the current coating program Fig 37 7 Naming a coating program Naming coating programs 1 Touch the desired table entry The line is highlighted Only lines which are highlighted can be changed clicking on ...

Page 50: ...coating program Fig 38 Naming coating programs 3 Enter object name 4 Press the RET key to confirm Search coating programs Search by name 1 Press the search field 7 A keyboard opens to search for coating programs by alphanumeric entry fig 39 Only coating programs that match the search are listed Pay attention to upper and lower case as well as spaces ...

Page 51: ...on Status display The log in status is displayed in the corresponding bar User logged in User logged out Login The user can log in in two ways When starting the plant See chapter Starting the plant on page 33 By clicking on the symbol in the log in status bar if another user has previously logged off Fig 40 Login Log in by user selection Log in by entering user name Enter user password Confirm Can...

Page 52: ...dure 1 Press the Select key Fig 41 Log in Main page not logged in 2 The screen switches to the next page Fig 42 Log in User selection 3 Select the desired user profile and confirm by pressing the key Alternatively the user can enter their name directly by pressing the User key ...

Page 53: ...peration 53 Fig 43 Log in User input 4 Enter user name and confirm by pressing RET 5 Press the Password key Fig 44 Log in Password input 6 Enter password and confirm by pressing RET Fig 45 7 Press the key The following screen is displayed ...

Page 54: ... page 43 By pressing the symbol in the log in status bar User is logged off Change user The user change takes place by logging out and in User profile Depending on user rights individual functions and settings may not be accessible and are locked See chapter Functions available at user level on page 22 Create user 1 Press the key The following page is displayed ...

Page 55: ...rol 4 0 CM40 Operation 55 Fig 47 2 Press the key The following page is displayed Fig 48 Settings 3 Press the key The following page is displayed Fig 49 4 Press the User key A keyboard opens to enter the name of the new user ...

Page 56: ...corresponding dialog opens Fig 51 8 Assign the desired user group to the new user from the list of available user groups Select the desired group using the arrow keys Press the MARK key the selected group is marked with Press the RET key to confirm 9 Press the New password key A keyboard opens to enter a password for the new user ...

Page 57: ...rm password key A keyboard opens and the password for the new user must be entered again Fig 53 13 Press the RET key to confirm 14 Press the key The new user now appears in the list of available users and can be deleted or changed at any time Delete users 1 In the Settings menu press the key The following page is displayed ...

Page 58: ...2 Press the User key A keyboard opens to enter the user name to be deleted Fig 55 3 Enter the user name to be deleted 4 Press the RET key to confirm OR 5 Press the key A corresponding dialog opens Fig 56 6 Select the user to be deleted using the arrow keys ...

Page 59: ...ress the RET key to confirm 8 Press the key The following page is displayed Fig 57 Change user password 1 In the Settings menu press the key The following page is displayed Fig 58 2 Press the Password key A keyboard opens to enter the last password used ...

Page 60: ...oard opens 6 Enter the new password 7 Press the RET key to confirm 8 Press the Confirm password key A keyboard opens and the new password must be entered again 9 Press the RET key to confirm 10 Press the key Search users This function is used to display all created and active users 1 Press the key The following page is displayed Fig 60 2 Press the key ...

Page 61: ...1 3 Press the key The following page is displayed Fig 62 User language The user language is part of the user profile and can be changed to one of the pre installed languages if required The selected language is loaded each time you log in 1 Press the key The following page is displayed ...

Page 62: ... 0 CM40 Fig 63 2 Press the key The following page is displayed Fig 64 3 Press the LANGUAGE key The following page is displayed Fig 65 4 Select desired language The change takes effect immediately and the control switches to the previous page ...

Page 63: ...Rev 01 12 21 MagicControl 4 0 CM40 Operation 63 Checking the software version 1 Push the button 2 Push the button 3 Push the button The following page with the actual software version is displayed ...

Page 64: ...Rev 01 12 21 64 Operation MagicControl 4 0 CM40 ...

Page 65: ... MagicControl CM40 Introduction Fig 66 Main menu with overview of the maintenance status of the plant Display Overview of wear parts service life Maintenance scheduling Displayed states Green Wear parts OK Orange 10 remaining service life overdue part change error message ...

Page 66: ... main page changes to orange When the set time has expired the color of the actual value and the symbol on the main page changes to red A message appears on the main screen at the same time The wear part should now be replaced Reset As soon as the wear part is replaced the actual value should be reset by pressing the reset key Last reset When the reset key is pressed the current date is entered un...

Page 67: ...ig 68 Service life of the gun nozzle per gun Basic setting 600 hours Powder hose By tapping the corresponding key or by changing pages you can access the status overview of the powder hoses Fig 69 Service life of the powder hose per gun Basic setting 1500 hours Injector By tapping the corresponding key or by changing pages you can access the status overview of the injectors ...

Page 68: ...g key or by changing pages you can access the status overview of the IN pinch valves Fig 71 Service life of the IN pinch valve of the application pumps Basic setting 1000 hours OUT pinch valve application pump By tapping the corresponding key or by changing pages you can access the status overview of the OUT pinch valves Fig 72 Service life of the OUT pinch valve of the application pumps ...

Page 69: ...pages you can access the status overview of the Pinch valve diagnostic Fig 74 Interval An interval between 2 pinch valve diagnoses of 16 00 hours is entered by Gema as a basic value The pinch valve diagnostic of the application pumps takes place automatically after the powder hose rinsing When the time has expired without a color change the following message appears Pinch valve diagnostic required...

Page 70: ...nging pages you can access the status overview of the System service Fig 75 Depending on the service carried out on the plant service can enter a future date here and confirm with the reset button User Level 1 GemaService has access rights In addition the message System service required appears on the main screen ...

Page 71: ...he individual operating modes conveyor movements coating surfaces as well as gun and axis hours Fig 76 Machine data main screen Pressing the arrow key will take you to the overview of the operating hours of the guns and axes Automatic Time during which the CM40 is in automatic mode Manual Time during which the CM40 is in manual mode Cleaning Time during which the CM40 is in cleaning mode Switch of...

Page 72: ...object Coating area Means the lateral object surface determined by the object recognition Only in conjunction with light grid Distance Traveled conveyor distance after release of the coating system Time On Conveyor running time FL Stop Conveyor standstill FS In stop state 100 x FS FL FS Number of stops Number of activated conveyor stops by operator conveyor system system error After filter After f...

Page 73: ... in addition to the powder consumption the coated side elevation area is also recorded In the basic version batch management is operated manually Operation The basic version of Batch Management allows you to log the most important information for each individual production batch in the simplest possible way All information about the respective batch the continuously added powder quantities as well...

Page 74: ...resh powder e g powder box The Powder consumption is updated accordingly in field 3 5 When the batch is finished weigh or estimate the remaining or recovered powder Enter the value in field 4 weight field and subtract it from the current batch recording using the key The Powder consumption is updated accordingly in field 3 6 Press the Stop key to stop the recording The corresponding data is update...

Page 75: ...tly Cleaning and maintenance The operating panel is maintenance free However the following work may be necessary Cleaning the screen if it becomes dirty Recalibrating the capacitive screen if it no longer responds correctly to touch Touch sensitive screen If dirty ATTENTION Pointed sharp objects or corrosive liquids can damage the screen Cleaning the screen Do not use any pointed or sharp objects ...

Page 76: ...s artificial aging reduces the service life of the operating panel Protect the operating panel from direct sunlight or other sources of UV radiation ATTENTION Risk of short circuit In the event of climatic fluctuations ambient temperature or humidity moisture may be deposited on or inside the operating panel If the control panel is subjected to condensation there is a risk of short circuit Never s...

Page 77: ...nit may only be switched on after it is fully dry SD card data backup The contents of the SD card can be saved on another medium in order to be able to copy them back in case of card damage or data loss Further information can be found in the SD card user manual Some operating systems do not display individual files This is often the case with autoexec bat files for example When copying the data m...

Page 78: ...nce Repairs MagicControl 4 0 CM40 Powder output correction procedure 1 Press the key The following page is displayed Fig 80 2 Press the key The following page is displayed Fig 81 3 Press the key The following page is displayed ...

Page 79: ... it to 100 if necessary For the next steps a measuring bag is necessary for weighing the powder output Do not forget to note the dead weight of the measuring bag 7 Put the measuring bag over the gun nozzle and fasten it 8 Press the gun key 2 to switch on the gun for 60 seconds 9 After this time has elapsed switch off the gun remove the measuring bag and weigh it The powder output should be between...

Page 80: ...o following formula C1 smallest powder output x 100 measured powder output 5 Annotate the calculated values C1 for each individual gun in the table and enter the values to the control unit therefore repeat the steps 2 and 3 Example table for powder output powder hose correction Gun Powder output correction C0 No Before correction After correction 1 C0 1 8 Nm h 20 g C0 1 7 Nm h 12 g 2 C0 1 8 Nm h 1...

Page 81: ...at no powder is visible if the powder portion is 0 by increasing the value the powder becomes visible then This behavior depends on the hose length and the hose diameter Repair work In the event of malfunctions or faults the product must be checked and repaired at an authorized Gema service location The repairs must only be performed by an authorized specialist Improper interventions can result in...

Page 82: ...Rev 01 12 21 82 Maintenance Repairs MagicControl 4 0 CM40 ...

Page 83: ...l units Axes Swivel axes Standard axes are displayed under General Inputs outputs Current state of inputs outputs simulation of inputs outputs CAN bus Display of the active CAN bus users Interface Display of the inputs outputs of the interface to a customer controller Application pump Display of the current pressure values of the application pumps Activation of the pinch valve diagnostic of the ap...

Page 84: ...gnostic MagicControl 4 0 CM40 General Fig 84 General diagnosis screen This screen displays Light grid segments Gun status Axis status and position Current object per station States of scanner zones Code plate information ...

Page 85: ...urrent pinch valve pressure D2 Opening time of control solenoid valve for pinch valve pressure leak tightness control D3 System backpressure 1 D4 System backpressure 2 D7 Pressure drop per each pinch valve closing Software version The current software version of the OptiStar gun control units is displayed The firmware update for CG22 and CG24 CP from firmware version 0 21 0 and higher is done auto...

Page 86: ...n This diagnosis page is used exclusively for swivel axes Swivel axes are a Gema product that is very rarely used Swivel axes are used when a customer has coating objects that are tilted at a precisely defined angle In this case one axis with a positive angle and one axis with a negative angle can be used This means that the coating distance remains unchanged over the entire height of the object F...

Page 87: ...PLC cards Inputs and outputs can be set in the GemaService user level Example If the wiring to an input is missing during start up and therefore an error is displayed it can be temporarily suppressed The same functionality is provided for all digital outputs When exiting the Inputs outputs screen the outputs are no longer overwritten The inputs remain set as temporarily programmed This functionali...

Page 88: ... Diagnostic MagicControl 4 0 CM40 CAN bus Fig 89 CAB bus diagnosis screen This screen displays the current CAN bus users in orange color By clicking on the question mark symbol you can display the CAN address overview ...

Page 89: ...Rev 01 12 21 MagicControl 4 0 CM40 Diagnostic 89 Standard interface Fig 90 Interface diagnosis screen This page is used to monitor the current information on the interface ...

Page 90: ...sis screen Pressing the Start key in the top line initiates the pinch valve diagnostic of all application pumps For all other Start keys a pinch valve diagnostic of the corresponding application pump is triggered The diagnostic function is only enabled if the OC07 OC03 has been cleaned beforehand ...

Page 91: ...ontrol 4 0 CM40 Diagnostic 91 Exhaust air Fig 92 Exhaust air diagnosis screen This page is used to observe the after filter differential pressures A detailed description can be found in the document LF pressure monitoring ...

Page 92: ...Rev 01 12 21 92 Diagnostic MagicControl 4 0 CM40 ...

Page 93: ...ard the filter cabinet and the monitoring of the after filters have been revised The EN 16985 standard requires redundant back pressure and differential pressure monitoring See EN16985 2018 D Fig 93 Locking of the technical ventilation with the interface to the application system 1 Booth 2 PLC 3 Dynamic pressure indicator 4 Differential pressure monitor 5 Compressed air valve 3 3 4 4 2 5 1 ...

Page 94: ... the cleaning sequence begins with all filter cartridges being cleaned at least every hour Two different control cabinet types Star delta control version OptiControl ICS08 FC operation version OptiControl ICS09 Description of the pressure switches 315 B1 differential pressure monitor Fan Δp The differential pressure monitor measures the current differential pressure of the fan The pressure is disp...

Page 95: ... off point 315 B4 dynamic pressure monitor redundant The dynamic pressure monitor is an electrical pressure switch It is set to the ATEX Stop powder switch off point Pressure switch overview Differential pressure monitor System pressure Δp measurement against atmosphere Differential pressure monitor Filter cartridge Δp filter resistance Dynamic pressure monitor redundant Electrical pressure switch...

Page 96: ...ilter pressure monitoring MagicControl 4 0 CM40 Fig 95 Pressure monitoring pneumatic diagram Display of the pressure values in MagicControl CM40 After logging in to User level 1 the Exhaust Air page can be opened Fig 96 Note ...

Page 97: ...er type ID no Setting values range Default UL 1503 TAMA MAHLE HERDING TAMA g0 1504 Volume flow This parameter defines the nominal exhaust air volume The value is used as a reference value in exhaust air monitoring ID no Setting values range Default UL 1504 12 32 000 Nm h 0 g0 1561 Meter above sea level This parameter must be adjusted to the actual sea level of the installation location The exhaust...

Page 98: ... Temperature This parameter must be adjusted according to the ambient temperature in which the filter is installed The exhaust air is automatically adjusted depending on the temperature A higher temperature means thinner air and therefore a higher exhaust air level is required ID no Setting values range Default UL 1562 5 40 ºC 20 ºC g0 ...

Page 99: ... set value in this example 9 600 m h 3 Enter the actual value of the Δp ATEX Stop powder manually under 6 4 The electrical switching output in the two differential pressure switches 315B1 and 315B3 must now be calibrated to the exhaust air value ATEX Stop powder 315B1 315 B3 Setting the switching output This function is used to set the switching output to switched through for a defined pressure Se...

Page 100: ...flap position on the after filter must be changed until the volume flow measured with the anemometer corresponds to the set value in this example 10 800 m h 3 Enter actual value of system pressure Δp Alarm manually under 5 Operating point 1 Adjust the throttle valve on the after filter so that the fan Δp shows the pressure value 1 for operating point 2 Measure air volume in the ducting with an ane...

Page 101: ...nt is adjusted When replacing the filter cartridges the Fan Δp decreases In this case the frequency is corrected and the operating point is shifted downwards Calibration when operating with frequency converter 1 Set the speed frequency to 50 Hz 2 Adjust the throttle valve on the after filter so that the Fan Δp displays the pressure value 3 ATEX Stop powder 3 Measure the actual air volume in the du...

Page 102: ...ched or exceeded Important The M Mode key must not be pressed The M key is used to adjust the zero point deviation 315B2 315 B4 6 The electrical switching points of the dynamic pressure monitors 315B2 and 315B4 must also be set to the value Δp ATEX Stop powder at the corresponding exhaust air volume Alarm 1 Adjust the throttle valve on the after filter so that the fan Δp shows the pressure value 2...

Page 103: ...es not correspond to the set value the flap position on the after filter must be changed until the volume flow measured with the anemometer corresponds to the set value in this example 12 000 m h 3 Enter actual value Δp operating point under 4 manually 4 Fully open the throttle valve 5 Reduce the speed of the frequency converter until the operating point Fan Δp is reached 6 Press the Teach key to ...

Page 104: ...in a dynamic state Operating point alarm ATEX Stop powder The fan Δp values change by 10 steps for each speed increase of 1 Hertz The entire display area Fan Δp adapts to the new operating point value Exhaust air measurement For exhaust air measurement we recommend the Testo 405i hot wire anemometer which is both economical and practical 25 steps ...

Page 105: ...ed The tube diameter is shown in the assembly drawing of the ducting An incorrect diameter leads to an incorrect air volume result Measurement methods Single Selective Time We recommend the Temporal variant With this variant the exhaust air volume is measured over a defined time period A measuring time of 60 seconds produces a precise result Measurement direction Exhaust air ...

Page 106: ...nt in newly delivered plants This is located below the elbow Fig 97 Measuring point Measuring procedure 1 Run telescopic probe into the center of the tube 2 Take one or more measurements lasting 60 seconds Tests have shown that the measurement is most accurate if the measurement is only made in the center of the pipe 3 The results are displayed in the Smart Probes app ...

Page 107: ...Rev 01 12 21 MagicControl 4 0 CM40 After filter pressure monitoring 107 4 The results can be exported as a report in various formats ...

Page 108: ... complete pass as long as the pressure is lower than the value of parameter 1571 If the pressure rises above the value of parameter 1571 the filter cleaning is continued cyclically until the last stored differential pressure is reached again before the next cleaning cycle is triggered If the last stored pressure is not reached after max 4 complete cleaning cycles the last stored pressure is increa...

Page 109: ...ecolor en V2 Operation Once all settings have been made the after filter can be operated in the Fan p operating point position Error messages If the flow rate decreases during operation an alarm message appears 15070 Fan 1 too much exhaust air alarm appears if the differential pressure of fan p has fallen below the set value Fan p operating point by 0 2 kPa Alarm Cause Corrective action 15072 Fan ...

Page 110: ...monitor 315 B4 Behavior when ATEX differential pressure is reached After filter continues to run Gun control units switch off The System signal of the automatic and manual gun control units switches off Main solenoid valve switches off Cleaning mode not possible A pop up window appears when the cleaning button is pressed ...

Page 111: ...n page error display 1 Touch information bar The following screen is displayed Fig 98 Error display Selected error message Error description Error number Display error history Delete error history keep pressed for 2 seconds Acknowledge error Exit current page Help codes list ...

Page 112: ...p defective Replace Axes cannot be referenced The reference key is not displayed Axes are already referenced Not all axes are detected on the CAN bus Control is in an undefined state Check control voltage On the diagnostics page check which axes are not accessible via CAN bus see also Operating Manual or the respective axis Switch off the control voltage and switch it on again after 10 seconds oth...

Page 113: ... environment if the unit is stored properly Type of storage For safety reasons the product should only be stored in a horizontal position Storage duration If the physical conditions are maintained the unit can be stored indefinitely Space requirements The space requirements correspond to the size of the product There are no special requirements concerning distance to neighboring equipment Physical...

Page 114: ... 114 Decommissioning Storage MagicControl 4 0 CM40 Maintenance during storage Maintenance schedule No maintenance schedule is necessary Maintenance works During long term storage periodically perform a visual check ...

Page 115: ...e life When disposing of the product the applicable local and regional laws directives and environmental regulations must be complied with Materials The materials must be sorted according to material groups and taken to the appropriate collection points WARNING Risk of explosion Lithium battery If improperly handled there is a risk of explosion due to the lithium battery installed in the operating...

Page 116: ...NING Live components Risk of fatal injury from electric shock if touched Only trained authorized staff may open the electrical compartment Observe the safety symbols 1 Disconnect the mains supply and supply cables 2 Remove all product covers The product is now prepared for disassembly ...

Page 117: ...dering cable or hose material the required length must also be given The spare part numbers of this bulk stock is always marked with an The wearing parts are always marked with a marked All dimensions of plastic hoses are specified with the external and internal diameter Example Ø 8 6 mm 8 mm outside diameter o d 6 mm inside diameter i d WARNING Use of non original Gema spare parts When using the ...

Page 118: ...Rev 01 12 21 118 Spare parts list MagicControl 4 0 CM40 MagicControl CM40 complete 1 Micro Touch Panel MC 15 6 complete without pos 2 1015 320 2 SD card 4 GB on request Fig 99 MagicControl CM40 ...

Page 119: ...ces in the text 8 G Guidelines European 12 I Intended use 11 M Maintenance 75 Maintenance during storage 114 O Operating and display elements 17 Operation 33 P Periodic checks 75 Pictograms 7 Presentation of the contents 8 Product description 11 Product specific security regulations 9 R Rating plate 16 Repair work 81 Repairs 75 S Safety 9 Safety grid 42 Safety symbols 7 Scope of delivery 14 Shutdo...

Page 120: ...Rev 01 ...

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