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Gema MultiStar CG10, Operating Instructions And Spare Parts List

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Gema MultiStar CG10 Operating Instructions And Spare Parts List Download Page 49

 

Rev. 00  08/17 

 

MultiStar CG10 

Maintenance / Repairs  

  49 

 

Maintenance / Repairs 

 

 

General information 

The product was designed for a maintenance-free operation. 

 

Periodic checks 

 

The periodic checks include examining all connecting cables and hoses. 

The corresponding parts should be replaced immediately if any damage 
to cables or hoses is discovered. 

All plugs must be properly tightened. 

 

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 by an authorized specialist. 

Improper tampering can result in serious danger for user and equipment. 

 

 

 

Summary of Contents for MultiStar CG10

Page 1: ...Rev 00 1011 508 EN Operating instructions and Spare parts list Gun control unit MultiStar CG10 Translation of the original operating instructions ...

Page 2: ...f 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 trade...

Page 3: ...l data 12 Pneumatic data 13 Dimensions 13 Sound pressure level 13 Rating plate 13 Powder output reference values 14 Air flow rates 14 Design and function 15 Overall view 15 Operating elements 16 Connections 19 Scope of delivery 20 Typical properties Characteristics of the functions 21 Operating modes 21 Adjustable programs 21 Preset coating programs Easy Mode only 22 Gun activation 22 Gun conditio...

Page 4: ...g the correction values 41 Powder output powder hose correction 42 Correction factor diagram 44 Daily correction value C2 45 External powder output correction C3 Easy Mode only 45 Setting the background illumination 45 Activate deactivate the keyboard lock 45 Checking the software version 46 RAM Reset 46 Decommissioning Storage 47 Decommissioning 47 If in disuse for several days 47 Storage conditi...

Page 5: ... Requirements on personnel carrying out the work 55 Disposal regulations 55 Materials 55 Disassembly of component groups 55 Spare parts list 57 Ordering spare parts 57 MultiStar CG10 Gun control unit 58 Front plate and power pack 59 Inside back plate 60 Connecting material 61 ...

Page 6: ......

Page 7: ...ease keep this Manual ready for later use or if there should be any queries Safety symbols pictograms The following warnings with their meanings can be found in the Gema instructions The general safety precautions must also be followed as well as the regulations in the relevant instructions DANGER Indicates a hazardous situation which if not avoided will result in death or serious injury WARNING I...

Page 8: ...E Useful information tips etc Software version This document describes the operation of the control unit MultiStar CG10 with software version starting from 1 00 See chapter Checking the software version on page 46 Presentation of the contents Figure references in the text Figure references are used as cross references in the descriptive text Example The high voltage H created in the gun cascade is...

Page 9: ... 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 Prod...

Page 10: ...ons 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: ...his 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 user alone For a better understanding of the interrelationships in powder coating it...

Page 12: ... guns MultiStar CG10 X connectable OptiGun GA03 yes OptiGun GA02 yes ATTENTION The gun control unit may only be used with the specified gun types Electrical data MultiStar CG10 X Nominal input voltage 100 240 VAC Frequency 50 60 Hz Connected load 300 VA Nominal output voltage to the gun 12 V Nominal output current to the gun 1 2 A Alarm output potential free relay max 2 A 250 VAC Temperature range...

Page 13: ...imensions MultiStar CG10 CG10 X Width 425 mm 425 mm Depth 320 mm 320 mm Height 178 mm 178 mm Weight approx 13 2 kg approx 12 8 kg Sound pressure level MultiStar CG10 X Normal operation 60 dB A The sound pressure level was measured while the unit was in operation measurements were taken at the most frequent operator positions and at a height of 1 7 m from the ground The specified value is applicabl...

Page 14: ...wear and different powder types can affect the table values Total air 3 Nm h 4 Nm h 5 Nm h Powder output g min Powder output 20 60 70 80 40 115 140 160 60 175 210 220 80 220 260 270 100 250 300 310 Air flow rates MultiStar CG10 X per gun Total air flow rate 0 6 5 Nm h Electrode rinsing air flow rate 0 3 0 Nm h The total air consumption for the device is determined based on the 2 configured air val...

Page 15: ...6 guns and an optional additional control unit MultiStar Extend for the control of up to 6 additional guns The application parameters high voltage electricity and powder output can be programmed easily and quickly using a central entry and display field The additional control unit is managed by the main control unit Overall view fig 3 1 Front plate with control and display elements 2 Additional pa...

Page 16: ...l 1 Designation Function A1 A4 Display of actual values desired values and system parameters Flashes if the possible range is exceeded A5 Display of program numbers error diagnosis codes and status information S1 Powder output display in S4 Total air volume display in Nm h S7 High voltage display in kV S9 Spraying current display in µA S12 remote Remote operation mode no local operation possible S...

Page 17: ...isplays and LEDs Level 2 Designation Function S3 Electrode rinsing air display in Nm h S19 Display illumination 0 8 fig 6 LEDs Additional panel Designation Function L21 L32 Gun LED green red or orange the color depends on the condition of the corresponding gun ...

Page 18: ... values and system parameters T9 Select Switch between display levels T10 T11 Program change T12 Gun release Switchover to system parameter mode press for at least 5 secs T13 Preset mode for flat parts T14 Preset mode for complex parts with depressions T15 Preset mode for overcoating parts already coated T16 Power switch On Off T21 32 Gun selection keys ...

Page 19: ...ain air IN Compressed air connection 2 1 Power IN Mains cable connection Gun 1 12 Gun cable connection 2 3 Aux CAN bus connection IN 2 4 Aux CAN bus connection OUT 2 5 Ext Communication cable connection X Cable lead through Alarm output Digital Input for individual gun triggering Electrode rinsing air connection Supplementary air connection Conveying air connection Grounding connection ...

Page 20: ...input ON OFF 100 240 VAC PE PE grounding Gun connection 1 Ground 2 empty 3 empty 4 empty 5 empty 6 Oscillator 7 PE grounding CAN IN plug with 4 pins 2 3 Aux 1 Ground 2 24 VDC 3 CAN high 4 CAN low Enclosure shield CAN OUT socket with 4 pins 2 4 Aux 1 Ground 2 24 VDC 3 CAN high 4 CAN low Enclosure shield Scope of delivery Mains cable Operating manual ...

Page 21: ...lable over Display Pilot X 3 preset programs for Flat parts Complex parts Re coating X 12 digital I O s for individual gun triggering X X Individual powder hose length correction X X Help Codes for easy device diagnostic X X Remote control via CAN bus X X Adjustable programs In this operating mode 250 20 im Advanced Mode individually definable programs P001 P250 P01 P20 are available These program...

Page 22: ...hile powder and air volumes can be set and stored for each coating program Gun activation The guns can be individually activated or deactivated on the additional panel Gun condition display On the additional panel the LEDs on the buttons 1 12 display the condition of the respective gun Easy Mode Advanced Mode gun selected Gun deactivated LED off flashing orange Gun active no defects green flashing...

Page 23: ...nt brightness settings are available for the display The setting remains in place when the machine is switched on off fig 10 Auto Power Save mode If no powder is being applied then the background lighting turns off automatically 5 minutes after a button has been pressed last time Correction factor for the powder output The gun control unit enables a zeroing out of the powder output This allows for...

Page 24: ...Rev 00 08 17 24 Product description MultiStar CG10 ...

Page 25: ...tar CG10 Assembly Connection 25 Assembly Connection Assembly guide The gun control unit is installed in an AS control cabinet as standard Please contact Gema for other installation possibilities fig 11 AS control cabinet ...

Page 26: ...hose 4 Powder hose 5 Supplementary air hose 6 Conveying air hose 7 Signal cable 8 Injector 9 Maintenance unit 10 Compressed air hose Connect grounding cable to the booth or the suspension arrangement Check ground connections with Ohm meter and ensure 1 MOhm or less The compressed air must be free of oil and water Close the unused connections with the provided dust protection caps ...

Page 27: ...t correctly connected Gun correctly connected Corresponding power and compressed air supply available Powder preparation and powder quality System parameters The Gun control unit is configured by using the system parameters This configuration will be saved in the equipment memory These values can be adjusted and requested manually or by remote interface CAN Entering the system parameters 1 Turn on...

Page 28: ... the last system parameter the first starts again and vice versa 6 Select parameter values according to the following table Abbreviations PA Powder output GL Total air FL Conveying air ZL Supplementary air No Description Values Display P00 Trigger mode 0 Global Trigger all guns parallel 1 Individual Trigger each gun separately PrLL SnGL P01 Operating mode 0 Easy 1 Advanced EASY AdV P02 Inlet press...

Page 29: ... Log level 0 1 2 3 4 5 LoG Default values are marked by bold print 7 Press key to quit the system parameter mode The display switches to the standard level System parameter P00 fig 13 System parameter P00 This parameter determines whether all connected guns are activated simultaneously or individually The system parameter P00 is set to 0 when device is starting If the parameter is set to 1 each in...

Page 30: ...cal setpoints for power and air volume settings In Advanced Mode powder and air volume are set individually for each gun System parameter P03 fig 15 This parameter is used to determine the measuring unit for all airs total air and electrode rinsing air If the parameter is set to 1 scfm then all air values are shown in this measuring unit These lines are displayed in blue ...

Page 31: ...r P07 fig 16 This parameter controls which air volume settings can be controlled by the user If P07 1 conveying air FL and supplementary air ZL can be controlled separately The display looks as follows fig 17 System parameter P10 fig 18 System parameter P10 ...

Page 32: ...ated Parameter value Level of detail of reports 0 no messages 1 few details 5 all messages Real time timings can be impaired from a level of detail of 4 CAN bus General The control unit is a simple CANopen slave It operates in a network with a central control unit Master Communication takes place exclusively between the Master and the Slaves Following data can be accessed by CANopen All desired va...

Page 33: ...with terminal resistor in order to terminate the network correctly A maximum of up to 127 MultiStar Control units can be operated in a network MultiStar no 1 MultiStar no 2 CAN Bus participant no 127 max fig 19 CAN bus connections 1 PLC control with CAN bus 2 Terminal resistor CAN bus cable plug assignment fig 20 CAN bus cable Pin Signal Color 1 GND white 2 24 VDC black 3 CAN H black 4 CAN L black...

Page 34: ...ode ID value can be set by editing the system parameter P06 Node ID system parameter P06 CAN Node ID 1 127 P06 value CAN Node ID 1 127 1 127 Baud rate system parameter P05 P05 value Baud rate 0 20 kbit s 1 50 kbit s 2 100 kbit s 3 125 kbit s 4 250 kbit s 5 500 kbit s 6 800 kbit s 7 1 Mbit s Default value of system parameter P05 3 The Baud rate is selected with 125 kbits as default This setting per...

Page 35: ...splay the corresponding condition Only guns which are connected can be activated For guns which are not connected GUN OFF will be displayed whilst the button is being pressed fig 21 Additional panel Limited number of usable guns Depending on device configuration the number of simultaneously usable guns is limited Pressing T12 and T10 simultaneously displays the number of usable guns fig 22 Number ...

Page 36: ...ms 1 Turn on the gun control unit with the ON key 2 Press the program key 3 Select desired program 001 250 01 20 Program 250 active 4 Change coating parameters as required Programs 001 250 01 20 are preset at the factory but can be modified at any time after which they are automatically stored Description Presetting Powder output 60 Total air 4 0 Nm h High voltage 80 kV Spray current 20 µA Electro...

Page 37: ... output depends on the selected powder output in and the powder cloud on the selected total air volume In Advanced Mode P01 1 separate setpoints can be used for the powder output volume total air and electrode rinsing air for each gun The values displayed correspond to the guns which were selected with the relevant button on the additional panel As a factory default value a powder rate of 60 and a...

Page 38: ...lume is thereby kept constant automatically by the control unit To achieve maximum efficiency we recommend avoided an overly high powder volume where possible 2 Check fluidization of the powder in the powder container 3 Point the gun into the booth switch the gun on and visually check the powder output Setting the electrode rinsing air 1 Press the key The second display level will be shown 2 Adjus...

Page 39: ...dently Gun release In order that the guns can spray powder some system relevant conditions must be complied and no error may be present MultiStar CG10 without bus connection 1 External release signal is present The corresponding symbol is displayed 2 Press the key The corresponding symbol is displayed 3 Guns start to spray 4 Press the key again The relevant symbol goes out and the coating stops ...

Page 40: ...emote operating and vice versa the powder output will cease so that the device is in a defined mode after transfer Remote operating mode is signaled by the symbol S12 remote System release in network operation The system release logic starts and stops the powder conveying and high voltage The release is determined due to the several internal and external signals Signal Designation Trigger Gun conn...

Page 41: ...n the plant Entering the correction values 1 Hold key down for 5 seconds The display switches to the following level 2 Press the key The display switches to the following level 3 The correction factor number is shown in the display A1 with a C placed in front 4 Set the corresponding correction value with the T3 or T4 key The value of the adjusted correction factor appears on corresponding display ...

Page 42: ... 150 100 C3 External powder output correction 50 50 0 8 On the additional panel select gun number 2 The relevant LED flashes orange 9 Carry out the relevant corrections see above 10 Press the key The display returns to the first standard display Powder output powder hose correction The settings in the following example are carried out for each gun individually Powder output corrections are made at...

Page 43: ... the gun return to the system parameter mode and increase the minimum powder output value C0 range 0 5 3 0 Nm h 9 If too much powder is expelled from the gun return to the system parameter mode and decrease the minimum powder output value C0 range 0 5 3 0 Nm h 10 Repeat steps 6 and 7 until the powder output amounts to 10 15 g Annotate the adjusted minimum powder output value C0 in the table Exit t...

Page 44: ...1 No Before correction After correction 1 C1 100 200 g C1 100 200 g 2 C1 100 250 g C1 80 200 g 3 C1 100 280 g C1 71 200 g etc Correction factor diagram Impact of the powder hose correction powder hose 11 mm x 12 m Powder output g min Powder setting fig 23 Correction factor diagram The hose length correction factor is chosen in such a way that no powder is visible if the powder portion is 0 by incr...

Page 45: ...ltered An active external control signal either increases or decreases the powder output by the value set in C3 Setting the background illumination 1 Press the key The display switches to the following level 2 Select the desired brightness Activate deactivate the keyboard lock 1 Hold key pressed 2 Press the corresponding key The keyboard lock will be activated The remote display blinks 3 The keybo...

Page 46: ...rection values as well as all user defined values in the Program mode and Preset mode will be overwritten with factory default values An active keyboard lock will be deactivated By resetting the RAM all user made settings will be set to factory default 1 Switch off the device 2 Press the key and hold it 3 Switch on the control unit the CLR display blinks 4 Wait for approximately 5 seconds until CL...

Page 47: ...ee therefore the corresponding user manuals 3 Turn off the compressed air main supply Storage conditions Hazard notes There is no danger to personnel or the 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 requi...

Page 48: ...nts Storage must be inside a dry building at a temperature between 5 and 50 C Do not expose to direct sunlight Maintenance during storage Maintenance schedule No maintenance schedule is necessary Maintenance works During long term storage periodically perform a visual check ...

Page 49: ...cables and hoses The corresponding parts should be replaced immediately if any damage to cables or hoses is discovered All plugs must be properly tightened 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 by an authorized specialist Improper tampering can result in serious danger fo...

Page 50: ...Rev 00 08 17 50 Maintenance Repairs MultiStar CG10 ...

Page 51: ... in the list must be individually acknowledged with the keys T10 or T11 The errors are displayed in the order of their appearance The T10 and T11 keys cannot be used for other functions as long as an error code is still shown For error codes which apply to a specific gun e g cable break or throttle defect LED L21 L32 will be illuminated red for the affected gun If for example the defect H11 is pre...

Page 52: ...or or gun defective The affected guns are signaled with a red LED Contact Gema Service H112 HV Overvoltage MU Measured HV 105 kV Contact a Gema service center H212 HV Overvoltage AU H113 Intermediate circuit voltage Overvoltage MU Intermediate circuit voltage too high Contact a Gema service center H213 Intermediate circuit voltage Overvoltage AU Power supply H21 Voltage supply error Mainboard MU M...

Page 53: ...is not between 1 and 127 Set Node ID to 127 H47 No CAN interface installed CAN interface is selected in the system parameters but no interface is installed Contact a Gema service center H48 No ACK to Boot Up Message received No CAN node is answering to the Boot Up Message Check cabling connections between the users otherwise contact Gema service Throttle motors H60 Conveying air reference position...

Page 54: ...ommunication error AU 194 Firmware Update necessary MU The Gun Controller firmware is not up to date Update contact Gema service 294 Firmware Update necessary AU 192 Gun Controller MU does not react No connection can be made with the Gun Controller Reason Additional device connected but not activated Contact a Gema service center 292 Gun Controller AU does not react Help codes list The last appear...

Page 55: ...erly at the end of its service 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 Disassembly of component groups WARNING Live components Risk of fatal injury from electric shock if touched Only trai...

Page 56: ...Rev 00 08 17 56 Disposal MultiStar CG10 ...

Page 57: ...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 using ...

Page 58: ...17 58 Spare parts list MultiStar CG10 MultiStar CG10 Gun control unit 1 Main control unit MultiStar CG10 complete 1011 601 2 Additional control unit MultiStar Extend CG10 X complete 1011 602 fig 24 MultiStar CG10 ...

Page 59: ...pacer sleeve Ø 3 1 6x15 mm 3 Washer Ø 3 2 7x0 5 mm 4 Locknut M3 5 Front frame complete incl pos 5 1 1011 592 6 Screw M4x18 mm 1000 192 8 Membrane keypad 7 Front plate gasket 1011 618 9 Spacer sleeve Ø 3 6 7x5 mm 10 Display 1007 044 11 PCB complete 1011 557 12 Illuminated push button complete 1012 840 13 Power pack 24 VDC 1011 565 14 PCB Controller Board complete 1011 554 fig 25 Front plate and pow...

Page 60: ...1009 068 3 Solenoid valve 1 2 NW 13 5 mm without pos 4 1005 120 4 Valve coil for pos 3 1005 119 5 Motor throttle complete 1000 064 6 Plastic tube Ø 10 8 mm 103 250 7 Silencer 1 2 1006 969 8 Plug Ø 10 mm 1011 615 9 Gun connection complete with cable 1011 570 10 Fuse 5 AT 200 166 Please indicate length Wearing part fig 26 Inside back plate ...

Page 61: ...03 756 3 Conveying air hose Ø 8 6 mm red 103 500 4 Hose Ø 26 6 16 4 mm 105 155 5 Mains cable see enclosed wiring diagram 6 CAN bus cable 0 5 m 1002 655 CAN bus cable 4 5 m 387 592 CAN bus cable 5 5 m 388 521 CAN bus cable 6 0 m 388 530 6 1 Bus terminal resistor not shown 387 606 7 Communication cable 0 6 m 1011 607 Please indicate length fig 27 ...

Page 62: ......

Page 63: ...veral days 47 F Fault clearance 51 Figure references in the text 8 M Maintenance 49 Maintenance during storage 48 O Operating elements 16 Operation 35 P Periodic checks 49 Pictograms 7 Presentation of the contents 8 Product description 11 Product specific security regulations 9 R Release code 36 Repair work 49 Repairs 49 S Safety 9 Safety symbols 7 Scope of delivery 20 Spare parts list 57 Start up...

Page 64: ...Rev 00 ...

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