Gema MagicControl 4.0 Operating Instructions Manual Download Page 12

Page: 12 / 82

Rev. 00 08/17

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Product description

MagicControl 4.0 (CM40)

For further information, also refer to the enclosed Declaration of
Conformity.

European directives RL

EG-RL
2006/42/EU

Machinery

EG-RL
2014/34/EU

Equipment and Protective Systems in Potentially
Explosive Atmospheres (ATEX)

EG-RL
2014/30/EU

Electromagnetic compatibility

EN European standards

EN 50177

Stationary electrostatic application equipment for
ignitable liquid coating material - Safety
requirements

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

Enclosures for electrical equipment (1000 Volts
maximum)

DIN EN 60898-
1:2006-03

Electrical accessories - Circuit-breakers for
overcurrent protection for household and similar
installations

EN 50178

Electronic equipment for use in power
installations

IEC/EN 61131-2

Programmable controllers, Equipment
requirements and tests

EN 12981

Coating plants

– spray booths for application of

organic powder coating material - Safety
requirements

Recognized safety-related regulations

764 / DGUV
Information
209-052

Electrostatic coating
Trade Union information concerning health and
safety during work (BGI)

Summary of Contents for MagicControl 4.0

Page 1: ...Rev 00 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: ...suse 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 Manual operating mod...

Page 4: ...ta 40 Edit gun values select or deselect 40 Edit axis values select or deselect axes 41 Coating programs 43 Load coating programs 44 Creating coating programs 44 Copy and insert coating programs 44 Naming coating programs 46 Search coating programs 46 User administration 47 Status display 47 Login 47 Log out 50 Change user 50 User profile 50 Maintenance Repairs 61 General information 61 Periodic c...

Page 5: ... duration 75 Space requirements 75 Physical requirements 75 Maintenance during storage 76 Maintenance schedule 76 Maintenance works 76 Disposal 77 Introduction 77 Requirements on personnel carrying out the work 77 Disposal regulations 77 Materials 77 Disassembly of component groups 78 Spare parts list 79 Ordering spare parts 79 MagicControl CM40 complete 80 ...

Page 6: ......

Page 7: ...nual 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 WA...

Page 8: ...d source of the danger Possible consequences of the danger Prevention of the danger SIGNAL WORD Nature and source of the hazard Possible consequences of the danger Prevention of the danger Software version This document describes the operation of the control unit MagicControl 4 0 CM40 with software version starting from CM40_1_01a Presentation of the contents Figure references in the text Figure r...

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: ...rained personnel who are informed about and are familiar with the possible hazards involved Any other use is considered non compliant The manufacturer is not responsible for any incorrect use and the risks associated with such actions are assumed by the user alone For a better understanding of the interrelationships in powder coating it is recommended that the operating instructions for all other ...

Page 12: ...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 Enclosures for electrical equipment 1000 Volts maximum DIN EN 60898 1 2006 03 Electrical accessories Circuit breakers for overcurrent protection for household and simil...

Page 13: ...ooth 2 Cyclone separator 3 Sieve 4 Dense phase conveyor 5 After Filter 6 Refuse container 7 OptiCenter 8 Automatic guns Typical characteristics Powder coating in 2 operating modes Cleaning in cleaning mode User administration and language management Recipe management application data management Configuration and parameter data management Alarm handling Diagnostic functions Operating data acquisiti...

Page 14: ...FT color screen with touch screen function CAN bus technology Multilingual version Installation in control cabinet or on stands MagicControl CM40 Monitor 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 Numbe...

Page 16: ...ically 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 MagicControl CM40 Climate 0 50 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...

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: ...buted 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 Cancel ...

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: ...ges 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 gu...

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: ...t With the system diagnostics the user has an overview of the remaining service duration of components and can better plan for maintenance intervals and spare parts Individual operating times can be read in the corresponding screens Daily correction The control offers the possibility to correct the powder output for all guns per station in percent The output values can be corrected without modifyi...

Page 24: ...Rev 00 08 17 24 Product description MagicControl 4 0 CM40 ...

Page 25: ... Connection 25 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 8 Possibilities of installation ...

Page 26: ...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 27: ...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 28: ...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 special parameters such as software version daily correction powder output correction etc ...

Page 29: ...the device the functional check is to be performed without powder Starting the plant 1 Turn the main switch to the ON position The plant control starts the operating system the PLC control and the operating software to the start page Fig 9 Start page 2 Touch the screen The screen switches to the main page ...

Page 30: ...age not logged in 3 Press the Select key to log in with your user name and password Fig 11 User selection 4 Select the desired user profile and confirm by pressing the key 5 Press the Password key Fig 12 Password input 6 Enter password and confirm by pressing RET ...

Page 31: ...rograms and application data Operating data management LM Configuration Diagnostics Settings with the exception of some functions that are only available after switching on the control voltage In some cases the frequency converter must also be started up and the control units supplied with power 8 Turn the key switch to turn on the control voltage The indicator lamp lights up ...

Page 32: ...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 15 Automatic operation mode 2 Press the symbol to load coating objects for more information see below ...

Page 33: ... 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 middle m...

Page 34: ...y 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 parts pass through the object re...

Page 35: ...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 the effective position which is entered in the control This can lead to collision or faulty coatin...

Page 36: ...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 19 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 Press the key The following page is displayed ...

Page 37: ...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 38: ...ning is still in progress Fig 21 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 39: ...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 36 2 To exit Cleaning mode press and hold the key for 2 seconds Fig 22 3 The display changes to this screen Fig 23 4 Turn the key switch to 0 to turn off the control voltage The indicator lamp goes out ...

Page 40: ...gicControl 4 0 CM40 5 Press and hold the key for a further 2 seconds Fig 24 Start page 6 Turn the main switch to the OFF position Application data Edit gun values select or deselect 1 Press the key The following page is displayed ...

Page 41: ... not spray powder 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 ...

Page 42: ...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 43: ...he position of the respective axis Coating programs 1 Press the symbol to load coating programs Fig 27 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 44: ...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 45: ...a is copied to the clipboard 3 Select the coating program to which the data shall be copied from the clipboard Fig 30 4 Press the key 5 The following security prompt is displayed Fig 31 6 Confirm Data is copied to the current coating program Fig 32 7 Naming a coating program ...

Page 46: ... be changed clicking on another line only moves the selection 2 Touch the highlighted line again A keyboard opens to name the coating program Fig 33 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 34 ...

Page 47: ...put The number searched for is displayed at the top of the list User administration 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 29 By clicking on the symbol in the log in status bar if another user has previously logged off Fig 35 Login Log ...

Page 48: ...ogged out Log in procedure 1 Press the Select key Fig 36 Log in Main page not logged in 2 The screen switches to the next page Fig 37 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 49: ...peration 49 Fig 38 Log in User input 4 Enter user name and confirm by pressing RET 5 Press the Password key Fig 39 Log in Password input 6 Enter password and confirm by pressing RET Fig 40 7 Press the key The following screen is displayed ...

Page 50: ... page 39 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 51: ...Rev 00 08 17 MagicControl 4 0 CM40 Operation 51 Fig 42 2 Press the key The following page is displayed Fig 43 Settings 3 Press the key The following page is displayed Fig 44 4 Press the User key ...

Page 52: ...7 Press the Groups key A corresponding dialog opens Fig 46 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 53: ...rm password key A keyboard opens and the password for the new user must be entered again Fig 48 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 54: ...gicControl 4 0 CM40 Fig 49 2 Press the User key A keyboard opens to enter the user name to be deleted Fig 50 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 51 ...

Page 55: ...d using the arrow keys 7 Press the RET key to confirm 8 Press the key The following page is displayed Fig 52 Change user password 1 In the Settings menu press the key The following page is displayed Fig 53 2 Press the Password key A keyboard opens to enter the last password used ...

Page 56: ...y A keyboard 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 55 ...

Page 57: ...ed Fig 56 3 Press the key The following page is displayed Fig 57 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 58: ... 0 CM40 Fig 58 2 Press the key The following page is displayed Fig 59 3 Press the LANGUAGE key The following page is displayed Fig 60 4 Select desired language The change takes effect immediately and the control switches to the previous page ...

Page 59: ...Rev 00 08 17 MagicControl 4 0 CM40 Operation 59 ...

Page 60: ...Rev 00 08 17 60 Operation MagicControl 4 0 CM40 ...

Page 61: ...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 62: ...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 63: ...panel must be protected from mechanical loads outside its intended use The operating panel may only be transported in the appropriate packaging and in the correct manner Before recommissioning During storage and transport in cold weather and in the event of extreme temperature differences ensure that no moisture is deposited on or inside the unit condensation If condensation is present the unit ma...

Page 64: ...gaps waiting states maintenance times Overall equipment effectiveness The overall equipment effectiveness is defined by the duty cycle and coating time expressed as a percentage Overall equipment effectiveness coating time x 100 duty cycle Coating area Calculated area m based on the area output and triggering times of the guns Powder consumption Trend towards powder consumption kg based on output ...

Page 65: ...l parts Max highest value 10 Warning status red Maintenance Time remaining until the next maintenance date expressed in see profile for maintenance interval Min value Max value Leave current page or return to main menu 2 Press the key The following page is displayed Fig 64 Injector safety nozzle Powder hoses Electrode holder ...

Page 66: ...group is selected orange Countdown shows the remaining hours to change wearing parts Reset reset to 100 after change of wearing parts Key for individual or per group reset Back to the main menu Leave current page or return to main menu Value can be edited in User Level 2 Customer profile 1 Press the key The following page is displayed Fig 65 Input of specific basic data Average max powder output o...

Page 67: ...tment Inserting the SD card See chapter Inserting the SD card on page 26 Powder output powder hose correction The settings in the following example are carried out for each gun individually Powder output corrections are made at the first start up after a service work after the solution of application problems or by using different hose diameters It is recommended to create a table with input field...

Page 68: ...on Gun activated deactivated Powder output Total air Minimum powder output Powder hose correction Changes per gun or all guns at the same time Exit current page 4 Set the total air to 4 0 Nm h on the 4 display Set the powder output to 0 on the 3 display 5 Check the correction value for minimum powder output C0 on the 5 display and set it to 1 8 Nm h if necessary ...

Page 69: ...until the powder output amounts to 10 15 g Annotate the adjusted minimum powder output value C0 in the table Powder hose correction procedure 1 Set the powder output value to 80 on the 6 display 2 Put the measuring bag over the gun nozzle and fasten it Switch on the gun for 60 seconds 3 Switch off the gun after 60 seconds remove the measuring bag and weigh it 4 Annotate the powder output in g min ...

Page 70: ...ram The hose length correction factor is chosen in such a way that 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 by an authorized Gema service workshop The repairs must only be performed ...

Page 71: ...n page error display 1 Touch information bar The following screen is displayed Fig 70 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 72: ...ce 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 Diagnostic 1 Press the key The f...

Page 73: ...00 08 17 MagicControl 4 0 CM40 Fault clearance 73 Fig 72 General information Light grids axes guns objects Gun settings Digital inputs and outputs CAN bus addresses Interfaces Application pumps Exit screen ...

Page 74: ...Rev 00 08 17 74 Fault clearance MagicControl 4 0 CM40 ...

Page 75: ...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 76: ... 76 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 77: ...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 78: ...ING 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 79: ... 18 15 mm When ordering cable or hose material the required length must also be given The spare part numbers of this bulk stock is always marked with an Wearing parts are always marked with a 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 ATTENTION Use of non original Gema spare parts When us...

Page 80: ...Rev 00 08 17 80 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 73 MagicControl CM40 ...

Page 81: ...the text 8 G Guidelines European 12 I Intended use 11 M Maintenance 61 Maintenance during storage 76 O Operating and display elements 17 Operation 29 P Periodic checks 61 Pictograms 7 Presentation of the contents 8 Product description 11 Product specific security regulations 9 R Rating plate 16 Repair work 70 Repairs 61 S Safety 9 Safety grid 38 Safety symbols 7 Scope of delivery 14 Shutdown 75 Sp...

Page 82: ...Rev 00 ...

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