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Gema MagicControl 4.0 Operating Instructions Manual

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EN
Rev. 00
1011 534
Operating instructions and Spare parts list
System control
MagicControl 4.0 (CM40)
Translation of the original operating instructions

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Summary of Contents for Gema MagicControl 4.0

  • Page 1 Rev. 00 1011 534 Operating instructions and Spare parts list System control MagicControl 4.0 (CM40) Translation of the original operating instructions...
  • Page 2 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.

  • Page 3: Table Of Contents

    Operating data management (LM) ................ 23 Daily correction ..................... 23 Assembly / Connection Mounting instructions .................... 25 Inserting the SD card .................... 26 Inserting SD card ..................26 Removing SD card ................... 26 Table of contents  3 MagicControl 4.0 (CM40)
  • Page 4 SD card – data backup ................67 Powder output/powder hose correction ........... 67 Correction factor – diagram ..............70 Repair work ......................70 Fault clearance Main page error display ..................71 Faults ........................72 Diagnostic ......................72 4  Table of contents MagicControl 4.0 (CM40)
  • Page 5 Requirements on personnel carrying out the work ........77 Disposal regulations ................. 77 Materials ....................77 Disassembly of component groups ............... 78 Spare parts list Ordering spare parts ..................... 79 MagicControl CM40 – complete ................80 Table of contents  5 MagicControl 4.0 (CM40)

  • Page 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.

  • Page 8: Structure Of Safety Notes

    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." 8  About these instructions MagicControl 4.0 (CM40)

  • Page 9: Safety

    If this product is to be used for other purposes or other substances outside of our guidelines then Gema Switzerland GmbH should be consulted.
  • Page 10 ► 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. 10  Safety MagicControl 4.0 (CM40)

  • Page 11: Product Description

    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. Product description  11 MagicControl 4.0 (CM40)
  • Page 12 Coating plants – spray booths for application of EN 12981 organic powder coating material - Safety requirements Recognized safety-related regulations Electrostatic coating 764 / DGUV Information Trade Union information concerning health and 209-052 safety during work (BGI) 12  Product description MagicControl 4.0 (CM40)

  • Page 13: Reasonably Foreseeable Misuse

    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 Product description  13 MagicControl 4.0 (CM40)

  • Page 14: Scope Of Delivery

    Installation in control cabinet or on stands MagicControl CM40 Monitor 15.6" SD card Number of guns Number of stations Number of axes from ZA04 Axis type from XT09 Scope of delivery – SD card – Operating manual 14  Product description MagicControl 4.0 (CM40)

  • Page 15: Technical Data

    Screen diagonal 15.6" Resolution 1366 x 768 pixels (WXGA) ≈ 16.7 million (color depth 24 Bit) Number of colors Display surface 344 x 194 mm Operation Multifinger touch Front screen anti reflex coated, scratch-proof Product description  15 MagicControl 4.0 (CM40)

  • Page 16: Connections

    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 16  Product description MagicControl 4.0 (CM40)

  • Page 17: Design And Function

    Display, touch sensor Acquisition of the actuation of the operating elements shown on the display. Operated by touch using fingers. Slot for SD card SD card slot Exits the visualization program CTRL button Product description  17 MagicControl 4.0 (CM40)

  • Page 18: Connections And Interfaces

    9-pin RS-485, not galvanically isolated, SUB-D COM2 connector 9-pin CAN1, not galvanically isolated, SUB-D connector 9-pin MSTB plug connector, 3-pin Power supply SDSC or SDHC according to SDA SD card slot specification 2.0 18  Product description MagicControl 4.0 (CM40)

  • Page 19: Symbols

    Filter ON/OFF or Powder management High/Low frequency Guns ON/OFF ﴾= Squeegee ON/OFF powder﴿ Guns‐External cleaning Floor blow-off ON/OFF ON/OFF Axes move to reference Axes ON/OFF position Safety grid (access Reference axes release ON/OFF) Start/Cancel Product description  19 MagicControl 4.0 (CM40)

  • Page 20: Meaning Of The Colors

    Border color Red = Error Guns and axes black/grey = present, but not active orange = active state e.g. gun sprays powder, axis running = Error 20  Product description MagicControl 4.0 (CM40)

  • Page 21: Operating Modes

    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 Product description  21 MagicControl 4.0 (CM40)

  • Page 22: User Levels And Access

    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) –...

  • Page 23: Operating Data Management (Lm)

    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). Product description  23 MagicControl 4.0 (CM40)
  • Page 24 Rev. 00 08/17 24  Product description MagicControl 4.0 (CM40)

  • Page 25: Assembly / Connection

    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 Assembly / Connection  25...

  • Page 26: Inserting The Sd Card

    Removing SD card Push the SD card all the way into the SD card slot. Pull the SD card out of the SD card slot. Store the SD card in its packaging for protection. 26  Assembly / Connection MagicControl 4.0 (CM40)

  • Page 27: Start-Up

    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".

  • Page 28: Can Bus

    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. 28  Start-up MagicControl 4.0 (CM40)

  • Page 29: Operation

    – The plant control starts the operating system, the PLC control and the operating software to the start page. Fig. 9: Start page Touch the screen – The screen switches to the main page: Operation  29 MagicControl 4.0 (CM40)
  • Page 30 Press the Select key to log in with your user name and password Fig. 11: User selection Select the desired user profile and confirm by pressing the Press the Password key Fig. 12: Password input Enter password and confirm by pressing RET 30  Operation MagicControl 4.0 (CM40)
  • Page 31 In some cases, the frequency converter must also be started up and the control units supplied with power. Turn the key switch to turn on the control voltage. – The indicator lamp lights up. Operation  31 MagicControl 4.0 (CM40)

  • Page 32: Automatic Operation Mode

    If some plant components are not yet ready for operation, a message will be displayed. Automatic operation mode Press the key to select automatic operation mode Fig. 15: Automatic operation mode Press the symbol to load coating objects (for more information, see below) 32  Operation MagicControl 4.0 (CM40)

  • Page 33: Plants With Program Change Per Station (Internal Or External)

    Plants with program change per station (internal or external) For plants with internal or external program change, proceed as follows: For external program changes, the number in the middle must be checked according to the plant specific solution Operation  33 MagicControl 4.0 (CM40)

  • Page 34: Gap Control

    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 Press the key to select manual operation mode 34  Operation MagicControl 4.0 (CM40)

  • Page 35: Guns Start Independently From The Conveyor

    Press the 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% Operation  35 MagicControl 4.0 (CM40)

  • Page 36: Cleaning Operation Mode

    If several stations are present, press + to enlarge the window Enter desired value (max. 150, min. 50) Press the RET key to confirm Cleaning operation mode Press the The following page is displayed: 36  Operation MagicControl 4.0 (CM40)
  • Page 37 Follow the cleaning steps of the respective powder management system (MagicCenter, OptiCenter or Powder Center) After cleaning the inside of the hose, the guns and nozzles can be cleaned manually if necessary Operation  37 MagicControl 4.0 (CM40)

  • Page 38: Safety Grid Function

    After the cleaning/maintenance work has been completed, press the – The safety grid is locked again. Press the – Axes are ready for operation again. Select the operating mode and coat End production and switch off the plant 38  Operation MagicControl 4.0 (CM40)

  • Page 39: Working Interruptions Or Coating Breaks

    To exit Cleaning mode, press and hold the key for 2 seconds. Fig. 22: The display changes to this screen Fig. 23: Turn the key switch to 0 to turn off the control voltage. – The indicator lamp goes out. Operation  39 MagicControl 4.0 (CM40)

  • Page 40: Application Data

    2 seconds Fig. 24: Start page Turn the main switch to the OFF position Application data Edit gun values, select or deselect Press the – The following page is displayed: 40  Operation MagicControl 4.0 (CM40)

  • Page 41: Edit Axis Values, Select Or Deselect Axes

    Only guns which are activated can be switched on. Touch the corresponding input field to change the parameters of the respective gun Edit axis values, select or deselect axes Press the The following page is displayed: Operation  41 MagicControl 4.0 (CM40)
  • Page 42 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 Press the corresponding axis key 42  Operation MagicControl 4.0 (CM40)

  • Page 43: Coating Programs

    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 Operation  43 MagicControl 4.0 (CM40)

  • Page 44: Load Coating Programs

    Copy any existing program, preferably a related similar one, so that you do not have to make many changes Insert Load Edit coating programs Copy and insert coating programs Select coating program 44  Operation MagicControl 4.0 (CM40)
  • Page 45 Select the coating program to which the data shall be copied from the clipboard Fig. 30: Press the The following security prompt is displayed: Fig. 31: Confirm – Data is copied to the current coating program Fig. 32: Naming a coating program Operation  45 MagicControl 4.0 (CM40)

  • Page 46: Naming Coating Programs

    Enter object name Press the RET key to confirm Search coating programs Search by name Press the search field (7) – A keyboard opens to search for coating programs by alphanumeric entry. Fig. 34: 46  Operation MagicControl 4.0 (CM40)

  • Page 47: User Administration

    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 Operation  47 MagicControl 4.0 (CM40)
  • Page 48 The screen switches to the next page: Fig. 37: Log-in – User selection Select the desired user profile and confirm by pressing the Alternatively, the user can enter their name directly by pressing the User 48  Operation MagicControl 4.0 (CM40)
  • Page 49 Enter user name and confirm by pressing RET Press the Password key Fig. 39: Log-in – Password input Enter password and confirm by pressing RET Fig. 40: Press the key. – The following screen is displayed: Operation  49 MagicControl 4.0 (CM40)

  • Page 50: Log-Out

    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 Press the The following page is displayed: 50  Operation MagicControl 4.0 (CM40)
  • Page 51 Rev. 00 08/17 Fig. 42: Press the – The following page is displayed: Fig. 43: Settings Press the – The following page is displayed: Fig. 44: Press the “User” key Operation  51 MagicControl 4.0 (CM40)
  • Page 52 Press the MARK key: the selected group is marked with * – Press the RET key to confirm Press the “New password” key – A keyboard opens to enter a password for the new user. 52  Operation MagicControl 4.0 (CM40)
  • Page 53 The new user now appears in the list of available users and can be deleted or changed at any time. Delete users In the Settings menu, press the – The following page is displayed: Operation  53 MagicControl 4.0 (CM40)
  • Page 54 A keyboard opens to enter the user name to be deleted. Fig. 50: Enter the user name to be deleted Press the RET key to confirm Press the “···” key – A corresponding dialog opens. Fig. 51: 54  Operation MagicControl 4.0 (CM40)
  • Page 55 The following page is displayed: Fig. 52: Change user password In the Settings menu, press the The following page is displayed: Fig. 53: Press the “Password” key – A keyboard opens to enter the last password used. Operation  55 MagicControl 4.0 (CM40)
  • Page 56 A keyboard opens and the new password must be entered again. Press the RET key to confirm 10. Press the Search users This function is used to display all created and active users. Press the The following page is displayed: Fig. 55: 56  Operation MagicControl 4.0 (CM40)
  • Page 57 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. Press the The following page is displayed: Operation  57 MagicControl 4.0 (CM40)
  • Page 58 The following page is displayed: Fig. 59: Press the LANGUAGE key – The following page is displayed: Fig. 60: Select desired language – The change takes effect immediately and the control switches to the previous page 58  Operation MagicControl 4.0 (CM40)
  • Page 59 Rev. 00 08/17 Operation  59 MagicControl 4.0 (CM40)
  • Page 60 Rev. 00 08/17 60  Operation MagicControl 4.0 (CM40)

  • Page 61: Maintenance / Repairs

    ► 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. Maintenance / Repairs  61 MagicControl 4.0 (CM40)

  • Page 62: Repairs

    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.

  • Page 63: Operating Data Management (Lm)

    Operating data management (LM) The display shows the hours (h) with a definition of 1/100 h = 0.6 mins. Press the The following page is displayed: Fig. 61: Machine utilization Press the Maintenance / Repairs  63 MagicControl 4.0 (CM40)

  • Page 64: System Diagnosis

    Powder consumption based on output volume and average transfer efficiency Number of color changes Color change System diagnosis Display of wearing parts status and maintenance time Press the The following page is displayed: 64  Maintenance / Repairs MagicControl 4.0 (CM40)
  • Page 65 -> see profile for maintenance interval Min.% value Max.% value Leave current page or return to main menu ► Press the The following page is displayed: Fig. 64: Injector safety nozzle Powder hoses Electrode holder Maintenance / Repairs  65 MagicControl 4.0 (CM40)

  • Page 66: Customer Profile

    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 66  Maintenance / Repairs MagicControl 4.0 (CM40)

  • Page 67: Sd Card - Data Backup

    Powder output correction – procedure Press the The following page is displayed: Fig. 66: Press the The following page is displayed: Maintenance / Repairs  67 MagicControl 4.0 (CM40)
  • Page 68 Set the total air to 4.0 (Nm³/h) on the (4) display. Set the powder output to 0 (%) on the (3) display Check the correction value for minimum powder output C0 on the (5) display, and set it to 1.8 (Nm³/h) if necessary 68  Maintenance / Repairs MagicControl 4.0 (CM40)
  • Page 69 C0=1.8 Nm³/h 20 g C0=1.7 Nm³/h 12 g C0=1.8 Nm³/h 10 g C0=1.8 Nm³/h 13 g C0=1.8 Nm³/h C0=2.6 Nm³/h 12 g etc. Powder hose correction C1 Before After correction correction Maintenance / Repairs  69 MagicControl 4.0 (CM40)

  • Page 70: Correction Factor - Diagram

    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.

  • Page 71: Fault Clearance

    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 Fault clearance  71 MagicControl 4.0 (CM40)

  • Page 72: Faults

    Switch off the control voltage and switch it on again after 10 seconds, otherwise restart the plant. Diagnostic Press the The following page is displayed: Fig. 71: Press the The following page is displayed: 72  Fault clearance MagicControl 4.0 (CM40)
  • Page 73 Rev. 00 08/17 Fig. 72: General information: Light grids, axes, guns, objects Gun settings Digital inputs and outputs CAN bus addresses Interfaces Application pumps Exit screen Fault clearance  73 MagicControl 4.0 (CM40)
  • Page 74 Rev. 00 08/17 74  Fault clearance MagicControl 4.0 (CM40)

  • Page 75: Decommissioning / Storage

    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! Decommissioning / Storage  75 MagicControl 4.0 (CM40)

  • Page 76: Maintenance During Storage

    Rev. 00 08/17 Maintenance during storage Maintenance schedule No maintenance schedule is necessary. Maintenance works During long-term storage, periodically perform a visual check. 76  Decommissioning / Storage MagicControl 4.0 (CM40)

  • Page 77: Disposal

    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.

  • Page 78: Disassembly Of Component Groups

    Risk of fatal injury from electric shock if touched ► Only trained, authorized staff may open the electrical compartment ► Observe the safety symbols Disconnect the mains supply and supply cables. Remove all product covers. The product is now prepared for disassembly. 78  Disposal MagicControl 4.0 (CM40)

  • Page 79: Spare Parts List

    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! Spare parts list  79 MagicControl 4.0 (CM40)

  • Page 80: Magiccontrol Cm40 - Complete

    Rev. 00 08/17 MagicControl CM40 – complete Micro Touch Panel MC 15.6" – complete (without pos. 2) 1015 320 SD card – 4 GB on request Fig. 73: MagicControl CM40 80  Spare parts list MagicControl 4.0 (CM40)
  • Page 81 Start-up ............27 Storage ............75 Guidelines, European ........12 Storage conditions ........... 75 Intended use ............ 11 User levels access ............22 functions available ........22 Maintenance ............. 61 Maintenance during storage ......76 Index  81 MagicControl 4.0 (CM40)
  • Page 82 Rev. 00...

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