Rev. 00 1011 534 EN
Operating instructions and Spare parts list
System control
MagicControl 4.0 (CM40)
Translation of the original operating instructions
Rev. 00 08/17
Documentation MagicControl 4.0 (CM40)
© Copyright 2017 Gema Switzerland GmbH
All rights reserved.
This publication is protected by copyright. Unauthorized copying is
prohibited by law. No part of this publication may be reproduced,
photocopied, translated, stored on a retrieval system or transmitted in any
form or by any means for any purpose, neither as a whole nor partially,
without the express written consent of Gema Switzerland GmbH.
Gema, EquiFlow, MagicCompact, MagicCylinder, OptiCenter, OptiFlex,
OptiGun, OptiSelect and OptiStar are registered trademarks of Gema
Switzerland GmbH.
ClassicLine, ClassicStandard, ClassicOpen, DVC (Digital Valve Control),
GemaConnect, MagicControl, MagicPlus, MonoCyclone, MRS,
MultiColor, MultiStar, OptiAir, OptiControl, OptiColor, OptiFeed, OptiFlow,
OptiHopper, OptiMove, OptiSieve, OptiSpeeder, OptiSpray, PCC (Precise
Charge Control), RobotGun, SIT (Smart Inline Technology) und
SuperCorona are trademarks of Gema Switzerland GmbH.
All other product names are trademarks or registered trademarks of their
respective holders.
Reference is made in this manual to different trademarks or registered
trademarks. Such references do not mean that the manufacturers
concerned approve of or are bound in any form by this manual. We have
endeavored to retain the preferred spelling of the trademarks, and
registered trademarks of the copyright holders.
To the best of our knowledge and belief, the information contained in this
publication was correct and valid on the date of publication. Gema
Switzerland GmbH makes no representations or warranties with respect
to the contents or use of this publication, and reserves the right to revise
this publication and make changes to its content without prior notice.
For the latest information about Gema products, visit
www.gemapowdercoating.com.
For patent information, see www.gemapowdercoating.com/patents or
www.gemapowdercoating.us/patents.
Printed in Switzerland
Gema Switzerland GmbH
Mövenstrasse 17
9015 St.Gallen
Switzerland
Phone: +41-71-313 83 00
Fax.: +41-71-313 83 83
E-mail: info@gema.eu.com
Rev. 00 08/17
MagicControl 4.0 (CM40) Table of contents 3
Table of contents
About these instructions 7
General information ................................................................................................ 7
Keeping the Manual ................................................................................................ 7
Safety symbols (pictograms) ................................................................................... 7
Structure of Safety Notes ........................................................................... 8
Software version ..................................................................................................... 8
Presentation of the contents ................................................................................... 8
Figure references in the text ...................................................................... 8
Safety 9
Basic safety instructions ......................................................................................... 9
Product specific security regulations ...................................................................... 9
Product description 11
Intended use ......................................................................................................... 11
A summary of the directives and standards ............................................. 11
Reasonably 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
Manual operating mode (MAN) ................................................................ 21
Cleaning operating mode (CLN) .............................................................. 21
User levels and access ......................................................................................... 22
Functions available at user level .............................................................. 22
Operating data management (LM) ........................................................................ 23
Daily correction ..................................................................................................... 23
Assembly / Connection 25
Mounting instructions ............................................................................................ 25
Inserting the SD card ............................................................................................ 26
Inserting SD card ..................................................................................... 26
Removing SD card ................................................................................... 26
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4 Table of contents MagicControl 4.0 (CM40)
Start-up 27
Preparation for start-up ......................................................................................... 27
Basic conditions ....................................................................................... 27
General information .............................................................................................. 27
CAN bus ............................................................................................................... 28
General .................................................................................................... 28
Operation 29
Operation .............................................................................................................. 29
Starting the plant .................................................................................................. 29
Automatic operation mode .................................................................................... 32
Plants with program change per station (internal or external) ................. 33
Gap control .............................................................................................. 34
Manual mode ........................................................................................................ 34
Guns start independently from the conveyor ........................................... 35
Setting the daily correction ................................................................................... 35
Cleaning operation mode ..................................................................................... 36
Safety grid function .................................................................................. 38
Working interruptions or coating breaks ............................................................... 39
Switching off the plant .......................................................................................... 39
Application data .................................................................................................... 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 checks .................................................................................................... 61
Cleaning and maintenance ...................................................................... 61
Repairs .................................................................................................... 62
Storage and transport .............................................................................. 62
Operating data management (LM) ....................................................................... 63
Machine utilization ................................................................................... 63
System diagnosis .................................................................................... 64
Customer profile ...................................................................................... 66
SD card – data backup ............................................................................ 67
Powder output/powder hose correction ................................................... 67
Correction factor – diagram ..................................................................... 70
Repair work ........................................................................................................... 70
Fault clearance 71
Main page error display ........................................................................................ 71
Faults .................................................................................................................... 72
Diagnostic ............................................................................................................. 72
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MagicControl 4.0 (CM40) Table of contents 5
Decommissioning / Storage 75
Shutdown .............................................................................................................. 75
Storage conditions ................................................................................................ 75
Hazard notes ............................................................................................ 75
Type of storage ........................................................................................ 75
Storage 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
Rev. 00 08/17
MagicControl 4.0 (CM40) About these instructions 7
About these instructions
General information
This operating manual contains all important information which you
require for the working with the MagicControl 4.0 (CM40). It will safely
guide you through the start-up process and give you references and tips
for the optimal use when working with your powder coating system.
Information about the functional mode of the individual system
components should be referenced in the respective enclosed documents.
Keeping the Manual
Please keep this Manual ready for later use or if there should be any
queries.
Safety symbols (pictograms)
The following warnings with their meanings can be found in the Gema
instructions. The general safety precautions must also be followed as well
as the regulations in the relevant instructions.
DANGER
Indicates a hazardous situation which, if not avoided, will result in death
or serious injury.
WARNING
Indicates a hazardous situation which, if not avoided, could result in
death or serious injury.
CAUTION
Indicates a hazardous situation which, if not avoided, could result in
minor or moderate injury.
ATTENTION
Indicates a potentially harmful situation. If not avoided, the equipment or
something in its surrounding may be damaged.
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8 About these instructions MagicControl 4.0 (CM40)
ENVIRONMENT
Indicates a potentially harmful situation which, if not avoided, may have
harmful consequences for the environment.
MANDATORY NOTE
Information which must be observed.
NOTICE
Useful information, tips, etc.
Structure of Safety Notes
Every note consists of 4 elements:
– Signal word
– Nature and 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 references are used as cross references in the descriptive text.
Example:
"The high voltage (H) created in the gun cascade is guided through the
center electrode."
Rev. 00 08/17
MagicControl 4.0 (CM40) Safety 9
Safety
Basic safety instructions
– This product is built to the latest specification and conforms to the
recognized technical safety regulations and is designed for the
normal application of powder coating.
– Any other use is considered non-compliant. The manufacturer shall
not be liable for damage resulting from such use; the user bears sole
responsibility for such actions. If this product is to be used for other
purposes or other substances outside of our guidelines then Gema
Switzerland GmbH should be consulted.
– Start-up (i.e. the execution of intended operational tasks) is
forbidden until it has been established that this product has been set
up and wired according to the guidelines for machinery. The
standard "Machine safety" must also be observed.
– Unauthorized modifications to the product exempt the manufacturer
from any liability from resulting damage.
– The relevant accident prevention regulations, as well as other
generally recognized safety regulations, occupational health and
structural regulations are to be observed.
– Furthermore, the country-specific safety regulations also must be
observed.
Product specific security regulations
– This product is a constituent part of the equipment and is therefore
integrated in the system's safety concept.
– If it is to be used in a manner outside the scope of the safety
concept, then corresponding measures must be taken.
– The installation work to be done by the customer must be carried out
according to local regulations.
– It must be ensured, that all components are earthed according to the
local regulations before start-up.
For further security information, see the more detailed Gema
safety regulations!
Rev. 00 08/17
10 Safety MagicControl 4.0 (CM40)
WARNING
Working without instructions
Working without instructions or with individual pages from the
instructions 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.
Rev. 00 08/17
MagicControl 4.0 (CM40) Product description 11
Product description
Intended use
This plant control unit is designed exclusively for monitoring, operating
and controlling powder coating systems and associated components (see
also the chapter entitled "Technical Data").
The plant control is particularly suitable for the fully automatic coating of
any parts.
Fig. 1
Observance of the operating, service and maintenance 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 user alone!
For a better understanding of the interrelationships in powder coating, it is
recommended that the operating instructions for all other components be
read as well, so as to be familiar with their functions too.
A summary of the directives and standards
This product was built according to the current state of the art. The
product is subject to the European directives and complies with the
following standards.
The product is suitable for the intended purpose and can be used in the
appropriate areas.
Rev. 00 08/17
12 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 608981:2006-03
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)
Rev. 00 08/17
MagicControl 4.0 (CM40) Product description 13
Reasonably foreseeable misuse
– Operation without the proper training
– Use in connection with unauthorized coating devices or components
Powder circuit
The control monitors and controls the powder circuit in coating plants. The
powder circuit depends on the plant layout and configuration.
An overview of the effective powder circuit is shown in the enclosed wiring
diagram.
Fig. 2: Example of a powder coating plant
1 Booth
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 acquisition
– Control and regulation of height, length and depth detection
– Storage of operating data (e.g.: running time of guns, axes, fans) on
the SD cards
– Data exchange with higher-level plant controls (option)
– PC-based central control module for booths, gun controls, axes and
powder supply
Rev. 00 08/17
14 Product description MagicControl 4.0 (CM40)
– Large-screen 15.6” display with symbols
– TFT 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
Rev. 00 08/17
MagicControl 4.0 (CM40) Product description 15
Technische Daten
Technical Data
System
MagicControl CM40
Processor
ARM Cortex-A9 800 MHz
Internal memory
512 MB RAM, 1 GB SLC
Remanent memory
128 kB
Electrical data
MagicControl CM40
Nominal voltage
24 VDC SELV, extra-low safety
voltage
Voltage range
24 VDC acc. to DIN 19240
19.2 - 30.0 VDC 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 A2s
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)
Number of colors
≈ 16.7 million (color depth 24 Bit)
Display surface
344 x 194 mm
Operation
Multifinger touch
Front screen
anti reflex coated, scratch-proof
Rev. 00 08/17
16 Product description MagicControl 4.0 (CM40)
Connections
MagicControl CM40
Ethernet 1
RJ-45 socket, 8-pin, 2 LEDs
(CAT5e/6), LAN1, 10/100 Mbps
Ethernet 2
RJ-45 socket, 8-pin, 2 LEDs
(CAT5e/6), LAN1, 10/100 Mbps
USB host
USB 2.0, not galvanically isolated,
plug type A, full power (500 mA)
USB device
USB 2.0, not galvanically isolated,
plug type B
COM1
RS-232, not galvanically isolated,
SUB-D connector 9-pin
COM2
RS-485, not galvanically isolated,
SUB-D connector 9-pin
CAN
CAN1, not galvanically isolated, SUBD 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 of the device for the purpose of
identification. The rating place contains the following information:
– Type designation
– Version
– Required power supply
– Serial no.
– Arrangement of interfaces and operating elements
Fig. 3: Rating plate
Rev. 00 08/17
MagicControl 4.0 (CM40) Product description 17
Design and function
Operating and display 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
Rev. 00 08/17
18 Product description MagicControl 4.0 (CM40)
Connections and interfaces
Fig. 5: Connections
Connection
Description
1
Ethernet 1
RJ-45 socket, 8-pin, 2 LEDs (CAT5e/6),
LAN1, 10/100 Mbps
2
Ethernet 2
RJ-45 socket, 8-pin, 2 LEDs (CAT5e/6),
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 SDHC according to SDA
specification 2.0
Rev. 00 08/17
MagicControl 4.0 (CM40) Product description 19
Symbols
Fig. 6
Navigation bar
Plant overview
Information bar
-
Mode-dependent bar
Login status bar
Function keys
The function keys are distributed 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
Rev. 00 08/17
20 Product description MagicControl 4.0 (CM40)
Intermediate rinsing
ON/OFF
Gun rinsing ON/OFF
Vibrator 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
Rev. 00 08/17
MagicControl 4.0 (CM40) Product description 21
Operating modes
The plant can be operated in the 3 operating modes automatic (AUTO),
manual (MAN) and cleaning (CLN). The operating modes are selected
using the navigation bar on the operating panel.
Automatic operating mode (AUTO)
Predefined programs are processed in the main operating mode AUTO.
All axes and work processes are controlled by the program. The
operating mode supports gap control.
Automatic operation is only possible if object recognition and a
pulse generator are present.
– The guns and axes start automatically, based on the feedback from
the object recognition
– Dynamic positioning of guns and axes by object recognition
– Coating process is interrupted when the conveyor stops
– Guns can be selected or deselected
– Object changes 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 guns and axes by user
– Coating process is interrupted when the conveyor stops
– Guns can be selected or deselected
– Object change is carried out manually
– Daily correction of the powder output can be modified
– Status display of object recognition
Cleaning operating mode (CLN)
This operating mode allows the user to clean the booth and other plant
components.
– Cleaning procedures for guns, axes and booth
– Cleaning procedures for powder management system are released
Utilization of this operating mode:
– After switching on the equipment, if very high quality is required on
initial coating application
Rev. 00 08/17
22 Product description MagicControl 4.0 (CM40)
– Before every color change
– Before switching off the plant
The higher the requirement for cleanliness, the higher the time
expenditure will be.
The cleaning of the components is partially automated, however, some of
them must be cleaned manually.
During cleaning, no objects may be present in the booth and no
objects may enter the booth.
User levels and access
The plant control offers the possibility to define the access rights of the
different users. Access is only possible after entering the appropriate
password. Certain functions are available depending on the user level,
which is defined in advance.
The software 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 groups
Administ
rator
Service
Supervis
or
Operator
Painter
The panel can be used without any
limitation
– – –
–
Level for specialized Gema staff
– – –
Configuration possible
– – –
–
Plant parameters can be modified
–
–
Correction values can be modified
–
–
Sequence control programs can be
modified
–
–
Application parameters can be modified
(axes, guns, pretravel/overtravel, daily
correction)
–
The user can rename or copy the
existing application data
–
The user can activate the existing
application data
Rev. 00 08/17
MagicControl 4.0 (CM40) Product description 23
User
Admin
Gema
Service
user 1
user 2
user 3
User level
0 1 2 3 4
If no user is logged on to the panel,
operation is locked
– – – – –
Operating data management (LM)
With its integrated statistics, trend tools and monitoring of wearing parts,
the plant control offers the user the possibility to analyze important
production information and thereby support future system optimizations.
Machine utilization statistics give the user insight into usage and
performance of the plant, powder consumption and the total area of the
coated parts.
The software-based timer in the control unit gives information about how
long the control unit has been in operation, or how long it has been
operated with this control unit.
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 modifying the programmed
values. The daily correction has the same effect 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. 7:
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
adjusting the basic program.
– To compensate for differences in ambient conditions
(summer/winter).
Rev. 00 08/17
24 Product description MagicControl 4.0 (CM40)
Rev. 00 08/17
MagicControl 4.0 (CM40) Assembly / 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
Rev. 00 08/17
26 Assembly / Connection MagicControl 4.0 (CM40)
Inserting the SD card
The SD card contains the actual operating system and all important
application information. In order for the operating panel to function
properly, the SD card must be inserted before the plant is started.
The slot for inserting the SD card is located on the side of the operating
panel.
ATTENTION
Data loss
A voltage drop or removal of the SD card while it is being written to
can lead to data 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 incorrect insertion.
1. Do not use force when inserting.
2. Push the SD card into the slot until it clicks into place.
Removing SD card
1. Push the SD card all the way into the SD card slot.
2. Pull the SD card out of the SD card slot.
3. Store the SD card in its packaging for protection.
Rev. 00 08/17
MagicControl 4.0 (CM40) Start-up 27
Start-up
Preparation for start-up
Basic conditions
When starting up the plant control, the following general conditions
impacting the coating results must be taken into consideration:
– Gun control units, axes and all other system components correctly
connected
– Guns correctly connected
– Corresponding power and compressed air supply available
– Powder preparation and powder quality
General information
The plant control is pre-parameterized, configured and tested at the
Gema factory. This 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 operation, for
everything else refer to the "Technical Manual".
Job-related object and process data are managed in the "Coating
programs" menu and in the corresponding submenus.
Depending on the access level of the user who is logged on, parameters
can be edited or only displayed. Some parameters are reserved
exclusively for Gema Service.
Rev. 00 08/17
28 Start-up MagicControl 4.0 (CM40)
CAN bus
General
The plant control is a CAN master system. Together with CAN slave
participants, it forms the network.
The wiring 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.
Rev. 00 08/17
MagicControl 4.0 (CM40) Operation 29
Operation
Operation
During the initial commissioning of 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:
Rev. 00 08/17
30 Operation MagicControl 4.0 (CM40)
Fig. 10: Main page (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
Rev. 00 08/17
MagicControl 4.0 (CM40) Operation 31
Fig. 13:
7. Press the key.
– The following screen is displayed:
Fig. 14:
The following functions are available:
– Modify and manage coating programs 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.
Rev. 00 08/17
32 Operation MagicControl 4.0 (CM40)
9. Press the key
– Axes are referenced
10. Select operating mode:
Automatic operation mode
Manual operation mode
Cleaning
11. Put all other plant components, 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)
Rev. 00 08/17
MagicControl 4.0 (CM40) Operation 33
Fig. 16: Coating programs
Confirm program selection
Copy data
Insert data
Exit screen
Scroll bar
Delete entry in search field
Data search 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 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 must be
checked according to the plant specific solution
Rev. 00 08/17
34 Operation MagicControl 4.0 (CM40)
Fig. 17: Program change per station
– The plant is ready for production
2. For internal program changes, the number must be entered in the
input field
– The plant is ready for production
Gap control
A pulse generator must be installed and be functioning for the
displacement measurement.
In automatic 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 parts pass through the object
recognition:
– The motor is switched to the operating mode (operating power)
– The gun controls are switched on again
Manual mode
1. Press the key to select manual operation mode
Rev. 00 08/17
MagicControl 4.0 (CM40) Operation 35
Fig. 18: Manual operation mode
2. Load the desired coating program (See chapter "Load coating
programs" on page 44.)
The plant control is now ready for production.
3. Axes and guns can be switched on/off manually by the user.
Guns start independently from the conveyor
Axes and guns can be switched on/off both in automatic and manual
mode independently of object 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 the effective
position which is entered in the control. This can lead to collision
or faulty coating without due care and consideration.
► This function may only be used by trained personnel.
1. Press the key
The key turns orange and the activated conveyor is simulated.
Setting the daily correction
The powder output is corrected in percent for all guns per station.
Setting values/range
Default
50 - 150%
100%
Rev. 00 08/17
36 Operation MagicControl 4.0 (CM40)
This means that the current powder output value is multiplied 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. 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:
Rev. 00 08/17
MagicControl 4.0 (CM40) Operation 37
– Booth floor cleaning works with increased cleaning frequency
2. Close the booth doors (if available)
– For automatic closing doors, press the arrow key
–
Otherwise close the doors manually
Fig. 20:
– Axes move into the cleaning positions 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 inside of the hose, the guns and nozzles can be
cleaned manually if necessary
Rev. 00 08/17
38 Operation MagicControl 4.0 (CM40)
7. Press the key to fully extend the guns from the booth.
8. Press the key to move the guns into the booth.
9. Continue to follow the cleaning steps of the powder management
system
10. Open cabin doors and close flaps (if present)
11. Booth floor cleaning 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 operation again.
4. Select the operating mode and coat
or
5. End production and switch off the plant
Rev. 00 08/17
MagicControl 4.0 (CM40) Operation 39
Working interruptions or coating breaks
If the coating process is interrupted for a longer period of 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.
Rev. 00 08/17
40 Operation MagicControl 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:
Rev. 00 08/17
MagicControl 4.0 (CM40) Operation 41
Fig. 25: Application data – Guns
Station
Gun activated/deactivated
Powder output
Total air
High voltage
Spray current
Electrode rinsing air
Pretravel = gun ON in front of the object
(values values are set in the configuration menu)
Overtravel = gun OFF after the object
(values values are set in the configuration menu)
Gun spays/does 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. Touch the corresponding input field to change the parameters of the
respective gun
Edit axis values, select or deselect axes
1. Press the key
The following page is displayed:
Rev. 00 08/17
42 Operation MagicControl 4.0 (CM40)
Fig. 26: Application data – Axes
Station
Axis activated/deactivated
Upper reversing point – fix position. Caution: Collision danger!
Lower reversing point
Speed
Spray distance: Gun tip - object (controlled by object width
recognition) – fix position. Caution: Collision danger!
Pretravel = axis ON in front of the object
(values values are set in the configuration menu)
Overtravel = axis OFF after the object
(values 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 without saving, any changes are discarded
Changes per station or all stations
Error description
Auto: Axis moves according to object recognition and spray
distance
Manual: Axis moves to the specified position
2. Press the corresponding axis key
Rev. 00 08/17
MagicControl 4.0 (CM40) Operation 43
The key turns orange and the axis is selected.
– Only selected axes can be started.
3. Press the key
– Start axes
4. Press the key
– Stop axes
5. Touch the input field to change the 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 available for editing
Rev. 00 08/17
44 Operation MagicControl 4.0 (CM40)
Load coating programs
1. Press the symbol
Fig. 28
2. Select coating program
3. Press the key
– The selected program is loaded
Creating coating programs
If 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
Rev. 00 08/17
MagicControl 4.0 (CM40) Operation 45
Fig. 29:
2. Press the key
– Data 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
Rev. 00 08/17
46 Operation MagicControl 4.0 (CM40)
Naming coating programs
1. Touch the desired table entry.
– The line is highlighted.
Only lines which are highlighted can 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:
Rev. 00 08/17
MagicControl 4.0 (CM40) Operation 47
– Only coating programs that match the search are listed.
Pay attention to upper and lower case as well as spaces!
Search by numbers
1. Press the number field (8)
– A keyboard opens to search for coating programs by numerical
input.
– 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 in by user selection
Log in by entering user name
Enter user password
Rev. 00 08/17
48 Operation MagicControl 4.0 (CM40)
Confirm
Cancel
Log-in status:
User logged in
User logged 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
Rev. 00 08/17
MagicControl 4.0 (CM40) Operation 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:
Rev. 00 08/17
50 Operation MagicControl 4.0 (CM40)
Fig. 41:
Log-out
The user can log out in two ways:
– By switching off the plant (See chapter "Switching off the plant" on
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:
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
Rev. 00 08/17
52 Operation MagicControl 4.0 (CM40)
– A keyboard opens to enter the name of the new user.
Fig. 45:
5. Enter user name
6. Press the RET key to confirm
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.
Rev. 00 08/17
MagicControl 4.0 (CM40) Operation 53
Fig. 47:
10. Enter password
11. Press the RET key to confirm
12. Press the “Confirm 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:
Rev. 00 08/17
54 Operation MagicControl 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:
Rev. 00 08/17
MagicControl 4.0 (CM40) Operation 55
6. Select the user to be deleted 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.
Rev. 00 08/17
56 Operation MagicControl 4.0 (CM40)
Fig. 54:
3. Enter the last password used
4. Press the RET key to confirm
5. Press the “New password” key
– 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:
Rev. 00 08/17
MagicControl 4.0 (CM40) Operation 57
2. Press the key
– The following page is displayed:
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:
Rev. 00 08/17
58 Operation MagicControl 4.0 (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
Rev. 00 08/17
MagicControl 4.0 (CM40) Operation 59
Rev. 00 08/17
60 Operation MagicControl 4.0 (CM40)
Rev. 00 08/17
MagicControl 4.0 (CM40) Maintenance / Repairs 61
Maintenance / Repairs
General information
The product was designed for a maintenance-free operation.
Periodic checks
The periodic checks include examining all connecting cables.
The corresponding parts should be replaced immediately if any damage
to cables is discovered.
All plugs must be properly tightened.
If an error message or maintenance message occurs, the causes must be
examined and remedied promptly.
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 (e.g. knife).
► Do not use any aggressive or abrasive cleaning agent or solvent.
► Ensure liquids do not enter the operating panel (risk of short
circuit) and no damage is caused to the operating panel
► Clean the touch screen surface carefully with a clean, soft, damp
cloth.
Rev. 00 08/17
62 Maintenance / Repairs MagicControl 4.0 (CM40)
Battery
The built-in battery for buffering the real-time clock is maintenance-free
and designed for a buffer time with the power switched off while
maintaining the ambient conditions of typically 10 years at 25 °C (77 °F).
Repairs
For repairs, please contact Gema Technical Support.
ATTENTION
Destruction of the operating panel
The operating panel may only be opened by the manufacturer or an
authorized body.
► Operate the operating panel only with the housing completely
closed.
Use appropriate packaging when transporting.
Storage and transport
ATTENTION
UV light
Plastics become brittle under the influence of UV light. This
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 switch on the operating panel when condensation is
present.
► If condensation is present and the operating panel has been
exposed to climatic fluctuations, allow the operating panel to
adjust to room temperature before commissioning.
► Do not expose the operating panel to direct heat radiation from
heaters.
Observe the ambient conditions when transporting and storing the
operating panel.
The maximum ambient temperature for storage and transport must not
exceed the specified value:
Rev. 00 08/17
MagicControl 4.0 (CM40) Maintenance / Repairs 63
Climatic ambient conditions
Air pressure (operation)
795 - 1080 hPa
max. 2000 m ü. NHN
Temperature (operation)
± 0 – +50 °C (+32 – +122 °F)
Temperature (storage / transport)
-20 – + 60 °C (-4 – +140 °F)
Air humidity
Relative air humidity 10 - 95 %
Condensation
Non-condensing
Whilst the operating panel has a robust design, the built-in components
are sensitive to excessive vibrations and/or shocks.
The operating 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 may only be switched on after it is fully
dry.
Operating data management (LM)
The display shows the hours (h) with a definition of 1/100 h = 0.6 mins.
1. Press the key
The following page is displayed:
Fig. 61:
Machine utilization
1. Press the key
Rev. 00 08/17
64 Maintenance / Repairs MagicControl 4.0 (CM40)
The following page is displayed:
Fig. 62:
Overall equipment
effectiveness
Display of operating times and coating
results of the plant
Powder coating
Total productive coating time based on
spray and axis movement times
Color change
Total time in color change mode
Auxiliary process
time
Total time takes into account conveyor
stop, object 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 [m²] based on the area
output and triggering times of the guns.
Powder consumption
Trend towards powder consumption [kg]
based on output volume and average
transfer efficiency
Color change
Number of color changes
System diagnosis
Display of wearing parts status and maintenance time
1. Press the key
The following page is displayed:
Rev. 00 08/17
MagicControl 4.0 (CM40) Maintenance / Repairs 65
Fig. 63:
Wearing part
Status
100% = As new
Min.% = lowest value of individual 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
Rev. 00 08/17
66 Maintenance / Repairs MagicControl 4.0 (CM40)
Gun nozzles
Next page
Gun group selection
Gun
Desired, input values for the service life in hours:
Injector safety nozzle Input range 1 - 200
Powder hose Input range 1 - 3000
Gun electrode Input range 1 - 700
Gun nozzle Input range 1 - 700
Individual value input or per group if gun 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 of all guns
Percentage of sprayed powder on the component
Average area output of the guns
Date input of the next maintenance date due
Rev. 00 08/17
MagicControl 4.0 (CM40) Maintenance / Repairs 67
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 "Technical Manual".
Some operating systems do not display individual files. This is
often the case with “autoexec.bat” files, for example.
– When copying the data, make sure that all data is visible and
copied.
– If in doubt, contact your IT department.
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 fields (see "Example table
for powder output/powder hose correction"), so that, if a possible system
reset takes place, an access to these data can take place.
Powder output correction – procedure
1. Press the key
The following page is displayed:
Fig. 66:
2. Press the key
The following page is displayed:
Rev. 00 08/17
68 Maintenance / Repairs MagicControl 4.0 (CM40)
Fig. 67:
3. Press the key
The following page is displayed:
Fig. 68: Powder output/powder hose correction
Station
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 (Nm³/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 (Nm³/h) if necessary
Rev. 00 08/17
MagicControl 4.0 (CM40) Maintenance / Repairs 69
6. Check the correction value for maximum powder output C1 on the
(6) display, and set 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
10-15 gr
10. If no powder is expelled from the gun, increase the minimum powder
output value C0 (range 0.5-3.0 Nm³/h)
11. If too much powder is expelled from the gun, decrease the minimum
powder output value C0 (range 0.5-3.0 Nm³/h)
12. Repeat steps 7 and 8, 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 in the table
Calculate the powder output correction according to 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 Nm³/h
20 g
C0=1.7 Nm³/h
12 g 2 C0=1.8 Nm³/h
10 g
C0=1.8 Nm³/h
13 g 3 C0=1.8 Nm³/h
0 g
C0=2.6 Nm³/h
12 g
etc. Gun
Powder hose correction C1
No.
Before
correction
After
correction
Rev. 00 08/17
70 Maintenance / Repairs MagicControl 4.0 (CM40)
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. 69: 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 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 by an authorized specialist.
Improper tampering can result in serious danger for user and equipment.
Rev. 00 08/17
MagicControl 4.0 (CM40) Fault clearance 71
Fault clearance
Main 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
Rev. 00 08/17
72 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.
Diagnostic
1. Press the key
The following page is displayed:
Fig. 71:
2. Press the key
The following page is displayed:
Rev. 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
Rev. 00 08/17
74 Fault clearance MagicControl 4.0 (CM40)
Rev. 00 08/17
MagicControl 4.0 (CM40) Decommissioning / Storage 75
Decommissioning / Storage
Shutdown
1. End the coating procedure
2. Switch off the control unit
The adjustments for high voltage, powder output volume and
electrode rinsing air remain stored.
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 requirements
The space requirements correspond to the size of the product.
There are no special requirements concerning distance to neighboring
equipment.
Physical requirements
Storage must be inside a dry building at a temperature between +5 and
+50 °C. Do not expose to direct sunlight!
Rev. 00 08/17
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.
Rev. 00 08/17
MagicControl 4.0 (CM40) Disposal 77
Disposal
Introduction
Requirements on personnel carrying out the
work
The disposal of the product is to be carried out by the owner or operator.
When disposing of components that are not manufactured by Gema, the
instructions in the respective manufacturer’s documentation must be
observed.
Disposal regulations
The product must be disassembled and disposed of properly 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.
WARNING
Risk of explosion: Lithium battery
If improperly handled, there is a risk of explosion due to the lithium
battery installed in the operating panel.
► Ensure the operating panel is disposed of properly.
The recyclable materials should be taken to your local recycling
center.
Operating panels that are no longer required must be disposed of
properly in accordance with local regulations.
Rev. 00 08/17
78 Disposal MagicControl 4.0 (CM40)
Disassembly of component groups
WARNING
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.
Rev. 00 08/17
MagicControl 4.0 (CM40) Spare parts list 79
Spare parts list
Ordering spare parts
When ordering spare parts for powder coating equipment, please indicate
the following specifications:
– Type and serial number of your powder coating equipment
– Order number, quantity and description of each spare part
Example:
– Type OptiGun GA03 automatic powder gun
Serial number 1234 5678
– Order no. 203 386, 1 piece, Clamp – Ø 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 using the spare parts from other manufacturers the
explosion protection is no longer guaranteed. If any damage is
caused by this use all guarantee claims become invalid!
► Only original Gema spare parts should be used!
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
Rev. 00 08/17
MagicControl 4.0 (CM40) Index 81
Index
A
About these instructions ..................................... 7
Assembly .......................................................... 25
B
Basic safety instructions ..................................... 9
C
Connection ....................................................... 25
Connections
Interfaces ...................................................... 18
D
Decommissioning ............................................. 75
Design and function ......................................... 17
Disassembly of component groups .................. 78
Disposal ............................................................ 77
Disposal regulations ......................................... 77
F
Fault clearance ................................................. 71
Faults ................................................................ 72
Figure references in 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
Spare parts list ................................................. 79
Standards, European ....................................... 12
Start-up ............................................................ 27
Storage ............................................................ 75
Storage conditions ........................................... 75
U
User levels
access .......................................................... 22
functions available ....................................... 22
Rev. 00
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