Page 1 Rev. 01 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
Functions available at user level .............. 22 Statistics ........................ 23 System diagnosis ..................23 Machine data ................... 24 Batch management .................. 24 Line management** ................. 25 Power control** ..................26 Daily correction ..................... 27 Table of contents • 3 MagicControl 4.0 (CM40)
Page 4 Injector ........................67 IN pinch valve application pump ................68 OUT pinch valve application pump ............... 68 Application pump, filter ..................69 Application pump, pinch valve diagnostic ............. 69 System service ..................... 70 4 • Table of contents MagicControl 4.0 (CM40)
Page 5 Operating point ..................103 Exhaust air measurement ................... 104 Measurement configuration ..............105 Measuring point ..................106 Measuring procedure ................106 Filter cartridges ....................108 Running-in filter ..................108 Filter cartridge cleaning ................108 Table of contents • 5 MagicControl 4.0 (CM40)
Page 6 Requirements on personnel carrying out the work ........ 115 Disposal regulations ................115 Materials ....................115 Disassembly of component groups ..............116 Spare parts list Ordering spare parts ................... 117 MagicControl CM40 – complete ................. 118 6 • Table of contents MagicControl 4.0 (CM40)
Page 7: About These Instructions
General information This operating manual contains all the 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
Possible consequences of the danger ► Prevention of the danger Software version This document describes the operation of the product MagicControl 4.0 (CM40) with software version starting from CM40_1.4. See chapter "Checking the software version" on page 63. Presentation of the contents Figure references in the text Figure references are used as cross references in the descriptive text.
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
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. Product description • 11 MagicControl 4.0 (CM40)
Page 12: A Summary Of The Directives And Standards
Spray booths for organic coating material - Safety EN 16985 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 Color Screen 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 Two-Finger 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 plant, 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: Statistics
– Optional equipment is marked by double asterisks**. – For additional optional equipment, please contact your Gema sales representative. With its integrated statistics, trend tools and monitoring of wear parts, the plant control offers the user the possibility to analyze important production information to support system optimizations.
Page 24: Machine Data
Manual input of order-related data For further information, see chapter "Batch Management (Basic Version)". Advanced** – Display of powder consumption per batch – Incl. one external scale with terminal – Input of order-related data: 24 • Product description MagicControl 4.0 (CM40)
Page 25: Line Management
Fig. 10: Chronological listing of batches produced Line management** Enables the analysis and efficiency optimization of the powder coating equipment. The most important production parameters are recorded and displayed in daily / weekly / monthly graphs. Product description • 25 MagicControl 4.0 (CM40)
Page 26: Power Control
Real-time measurement and visualization of the power and/or compressed air consumption, as well as the temperature and humidity curve. To use this functionality, appropriate measuring devices must be installed at the supply points of the plant. Fig. 12: 26 • Product description MagicControl 4.0 (CM40)
Page 27: Daily Correction
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 • 27 MagicControl 4.0 (CM40)
Page 28 Rev. 01 12/21 28 • Product description MagicControl 4.0 (CM40)
Page 29: 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. 14: Possibilities of installation Assembly / Connection • 29...
Page 30: 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. 30 • Assembly / Connection MagicControl 4.0 (CM40)
Page 31: 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 32: Can Bus
All actual values (process data) – All control values – All system parameters (except Baud rate and CAN address) – All error messages – All other parameters such as software version, daily correction, powder output correction etc. 32 • Start-up MagicControl 4.0 (CM40)
Page 33: Operation
Turn the main switch to the ON position. – The plant control is started up to the start page. Fig. 15: Start page Touch the screen – The screen switches to the main page: Operation • 33 MagicControl 4.0 (CM40)
Page 34 Press the Select key to log in with your user name and password Fig. 17: User selection Select the desired user profile and confirm by pressing the Press the Password key Fig. 18: Password input Enter password and confirm by pressing RET 34 • Operation MagicControl 4.0 (CM40)
Page 35 Turn the key switch to turn on the control voltage. – The indicator lamp lights up. Operation • 35 MagicControl 4.0 (CM40)
Page 36: 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. 21: Automatic operation mode Press the symbol to load coating programs (for more information, see below) 36 • Operation MagicControl 4.0 (CM40)
Page 37: 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 • 37 MagicControl 4.0 (CM40)
Page 38: Gap Control
= 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 38 • Operation MagicControl 4.0 (CM40)
Page 39: Manual Mode
This can lead to collision or faulty coating without due care and consideration. ► This function may only be used by trained personnel. Press the The key turns orange and the activated conveyor is simulated. Operation • 39 MagicControl 4.0 (CM40)
Page 40: Setting The Daily Correction
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: 40 • Operation MagicControl 4.0 (CM40)
Page 41 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 • 41 MagicControl 4.0 (CM40)
Page 42: 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 42 • Operation MagicControl 4.0 (CM40)
Page 43: Working Interruptions Or Coating Breaks
To exit Cleaning mode, press and hold the key for 2 seconds. Fig. 28: The display changes to this screen Fig. 29: Turn the key switch to 0 to turn off the control voltage. – The indicator lamp goes out. Operation • 43 MagicControl 4.0 (CM40)
Page 44: Coating Data
Fig. 30: Start page Turn the main switch to the OFF position Coating Data Edit gun values, select or deselect Press the – The following page is displayed: Fig. 31: Application data – Guns 44 • Operation MagicControl 4.0 (CM40)
Page 45: 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 • 45 MagicControl 4.0 (CM40)
Page 46 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 46 • Operation MagicControl 4.0 (CM40)
Page 47: 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 • 47 MagicControl 4.0 (CM40)
Page 48: 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 48 • Operation MagicControl 4.0 (CM40)
Page 49: Naming Coating Programs
Data is copied to the current coating program Fig. 37: Naming a coating program Naming coating programs Touch the desired table entry. – The line is highlighted. Only lines which are highlighted can be changed, clicking on Operation • 49 MagicControl 4.0 (CM40)
Page 50: Search Coating Programs
A keyboard opens to search for coating programs by alphanumeric entry. fig. 39: – Only coating programs that match the search are listed. Pay attention to upper and lower case as well as spaces! 50 • Operation MagicControl 4.0 (CM40)
Page 51: User Administration
By clicking on the symbol in the log-in status bar , if another user has previously logged off Fig. 40: Login Log in by user selection Log in by entering user name Enter user password Confirm Cancel Log-in status: User logged in Operation • 51 MagicControl 4.0 (CM40)
Page 52 The screen switches to the next page: Fig. 42: 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 52 • Operation MagicControl 4.0 (CM40)
Page 53 Enter user name and confirm by pressing RET Press the Password key Fig. 44: Log-in – Password input Enter password and confirm by pressing RET Fig. 45: Press the key. – The following screen is displayed: Operation • 53 MagicControl 4.0 (CM40)
Page 54: 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: 54 • Operation MagicControl 4.0 (CM40)
Page 55 The following page is displayed: Fig. 48: Settings Press the – The following page is displayed: Fig. 49: Press the “User” key – A keyboard opens to enter the name of the new user. Operation • 55 MagicControl 4.0 (CM40)
Page 56 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. 56 • Operation MagicControl 4.0 (CM40)
Page 57 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 • 57 MagicControl 4.0 (CM40)
Page 58 Enter the user name to be deleted Press the RET key to confirm Press the “···” key – A corresponding dialog opens. Fig. 56: Select the user to be deleted using the arrow keys (<<, <, >, >>). 58 • Operation MagicControl 4.0 (CM40)
Page 59 The following page is displayed: Fig. 57: Change user password In the Settings menu, press the The following page is displayed: Fig. 58: Press the “Password” key – A keyboard opens to enter the last password used. Operation • 59 MagicControl 4.0 (CM40)
Page 60 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. 60: Press the 60 • Operation MagicControl 4.0 (CM40)
Page 61 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 • 61 MagicControl 4.0 (CM40)
Page 62 The following page is displayed: Fig. 64: Press the LANGUAGE key – The following page is displayed: Fig. 65: Select desired language – The change takes effect immediately and the control switches to the previous page 62 • Operation MagicControl 4.0 (CM40)
Page 63: Checking The Software Version
Rev. 01 12/21 Checking the software version Push the button Push the button Push the button – The following page with the actual software version is displayed: Operation • 63 MagicControl 4.0 (CM40)
Page 64 Rev. 01 12/21 64 • Operation MagicControl 4.0 (CM40)
Page 65: System Diagnosis
Fig. 66: Main menu with overview of the maintenance status of the plant Display • Overview of wear parts service life • Maintenance scheduling Displayed states Green Wear parts OK Orange < 10% remaining service life overdue part change, error message System diagnosis • 65 MagicControl 4.0 (CM40)
Page 66: Displayed Values
Rev. 01 12/21 Displayed values Service life An estimated service life of each part is set by Gema (basic setting). The service life can be adjusted by the customer in user level 2 (user1) to suit requirements. Actual value As soon as the guns are switched on, the actual value counter starts counting up.
Page 67: Gun Nozzle
Service life of the powder hose per gun Basic setting = 1500 hours Injector By tapping the corresponding key or by changing pages (►) you can access the status overview of the injectors. System diagnosis • 67 MagicControl 4.0 (CM40)
Page 68: In Pinch Valve Application Pump
By tapping the corresponding key or by changing pages (►) you can access the status overview of the OUT pinch valves. Fig. 72: Service life of the OUT pinch valve of the application pumps 68 • System diagnosis MagicControl 4.0 (CM40)
Page 69: Application Pump, Filter
Interval An interval between 2 pinch valve diagnoses of 16.00 hours is entered by Gema as a basic value. The pinch valve diagnostic of the application pumps takes place automatically after the powder hose rinsing. When the time has expired without a color change, the following message appears: “Pinch valve diagnostic required”...
Page 70: System Service
Depending on the service carried out on the plant, service can enter a future date here and confirm with the reset button. User Level 1 (GemaService) has access rights. In addition the message “System service required” appears on the main screen. 70 • System diagnosis MagicControl 4.0 (CM40)
Page 71: Machine Data
Time during which the CM40 is in automatic Automatic mode Time during which the CM40 is in manual Manual mode Time during which the CM40 is in cleaning Cleaning mode Time during which the CM40 is in standby Switch-off mode Machine data • 71 MagicControl 4.0 (CM40)
Page 72 Number of activated conveyor stops (by Number of stops operator, conveyor system, system error) After filter running time After filter Coating time (trigger time) Axis running time Axis Fig. 77: Gun and axis operating hours screen 72 • Machine data MagicControl 4.0 (CM40)
Page 73: Batch Management (Basic Version)
(Fig. 78). Batch management calculates the total time and powder consumption from the data entered and adds them to a report (Fig. 79). Fig. 78: Input mask Batch Management (Basic Version) • 73 MagicControl 4.0 (CM40)
Page 74 Fig. 79: Chronological listing of batches produced Optionally, the saved Batch Management files can be copied to a computer or file server via an ftp://-path – for more information refer to the document “Advanced Batch Management”. 74 • Batch Management (Basic Version) MagicControl 4.0 (CM40)
Page 75: 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 • 75 MagicControl 4.0 (CM40)
Page 76: 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 77: Sd Card - Data Backup
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. Maintenance / Repairs • 77 MagicControl 4.0 (CM40)
Page 78 Rev. 01 12/21 Powder output correction – procedure Press the The following page is displayed: Fig. 80: Press the The following page is displayed: Fig. 81: Press the The following page is displayed: 78 • Maintenance / Repairs MagicControl 4.0 (CM40)
Page 79 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 Maintenance / Repairs • 79 MagicControl 4.0 (CM40)
Page 80 Powder hose correction C1 Before After correction correction C1=100 % 200 g C1=100 % 200 g C1=100 % 250 g C1=80% 200 g C1=100 % 280 g C1=71% 200 g etc. 80 • Maintenance / Repairs MagicControl 4.0 (CM40)
Page 81: Correction Factor - Diagram
Repair work In the event of malfunctions or faults, the product must be checked and repaired at an authorized Gema service location. The repairs must only be performed by an authorized specialist. Improper interventions can result in serious danger for user or the equipment and may result in loss of warranty! Maintenance / Repairs •...
Page 82 Rev. 01 12/21 82 • Maintenance / Repairs MagicControl 4.0 (CM40)
Page 83: Diagnostic
Activation of the pinch valve diagnostic of the application pumps – Switching the remote operation of the gun control units on/off Exhaust air – Display of the current pressure values of the after filter – “Running-in filter cartridges” function Diagnostic • 83 MagicControl 4.0 (CM40)
Page 84: General
Fig. 84: “General” diagnosis screen This screen displays: – Light grid segments – Gun status – Axis status and position – Current object per station – States of scanner zones – Code plate information 84 • Diagnostic MagicControl 4.0 (CM40)
Page 85: Powder Guns
The current software version of the OptiStar gun control units is displayed. The firmware update for CG22 and CG24-CP from firmware version 0.21.0 and higher is done automatically. Firmware download status: Download is active. Diagnostic • 85 MagicControl 4.0 (CM40)
Page 86: Axes
Fig. 86: “Axes” diagnosis screen This diagnosis page is used exclusively for swivel axes. Swivel axes are a Gema product that is very rarely used. Swivel axes are used when a customer has coating objects that are tilted at a precisely defined angle. In this case one axis with a positive angle and one axis with a negative angle can be used.
Page 87: Inputs/Outputs
The same functionality is provided for all digital outputs. When exiting the “Inputs/outputs” screen, the outputs are no longer overwritten. The inputs remain set as temporarily programmed. This functionality is deactivated when the system is switched on again. Diagnostic • 87 MagicControl 4.0 (CM40)
Page 88: Can Bus
Rev. 01 12/21 CAN bus Fig. 89: “CAB bus” diagnosis screen This screen displays the current CAN bus users in orange color. By clicking on the question mark symbol you can display the CAN address overview. 88 • Diagnostic MagicControl 4.0 (CM40)
Page 89: Standard Interface
Rev. 01 12/21 Standard interface Fig. 90: “Interface” diagnosis screen This page is used to monitor the current information on the interface. Diagnostic • 89 MagicControl 4.0 (CM40)
Page 90: Application Pump
– For all other “Start” keys, a pinch valve diagnostic of the corresponding application pump is triggered. – The diagnostic function is only enabled if the OC07(OC03) has been cleaned beforehand. 90 • Diagnostic MagicControl 4.0 (CM40)
Page 91: Exhaust Air
Rev. 01 12/21 Exhaust air Fig. 92: “Exhaust air” diagnosis screen This page is used to observe the after filter differential pressures. A detailed description can be found in the document “LF pressure monitoring”. Diagnostic • 91 MagicControl 4.0 (CM40)
Page 92 Rev. 01 12/21 92 • Diagnostic MagicControl 4.0 (CM40)
Page 93: After Filter Pressure Monitoring
The EN 16985 standard requires redundant back pressure and differential pressure monitoring. See EN16985:2018(D) Fig. 93: Locking of the technical ventilation with the interface to the application system Booth Differential pressure monitor Compressed air valve Dynamic pressure indicator After filter pressure monitoring • 93 MagicControl 4.0 (CM40)
Page 94: Typical Characteristics
– The differential pressure monitor measures the actual differential pressure of the filter cartridges (filter resistance). – The pressure is displayed on the CM40 control at Filter cartridges Δp: Actual value. 94 • After filter pressure monitoring MagicControl 4.0 (CM40)
Page 95: Pressure Switch Overview
“ATEX: Stop powder” Electrical pressure switch Pressure switch is set to: Differential pressure monitor Fan Δp Δp fan “ATEX: Stop powder” Fig. 94: Overview of all pressure switches with designations and intended use After filter pressure monitoring • 95 MagicControl 4.0 (CM40)
Page 96: Display Of The Pressure Values In Magiccontrol Cm40
Fig. 95: Pressure monitoring pneumatic diagram Display of the pressure values in MagicControl CM40 After logging in to User level 1, the Exhaust Air page can be opened. Fig. 96: Note: 96 • After filter pressure monitoring MagicControl 4.0 (CM40)
Page 97: Configuration
A higher sea level means thinner air and therefore a higher exhaust air setting is required. After filter pressure monitoring • 97 MagicControl 4.0 (CM40)
Page 98: 1562 Temperature
A higher temperature means thinner air and therefore a higher exhaust air level is required. ID no. Setting values / range Default 5 – 40[ºC] 1562 20[ºC] 98 • After filter pressure monitoring MagicControl 4.0 (CM40)
Page 99: Opticontrol Isc08 Adjustment Instructions
The LED lights up as soon as the defined pressure is reached or exceeded. Important: The M = Mode key must not be pressed. 315B1 / 315 B3 – The M key is used to adjust the zero point deviation After filter pressure monitoring • 99 MagicControl 4.0 (CM40)
Page 100: Alarm
(in this example 12,000 m³/h) Δp “operating point” Enter actual value under manually. 100 • After filter pressure monitoring MagicControl 4.0 (CM40)
Page 101: Opticontrol Isc09 Adjustment Instructions
(in this example 9,600 m³/h) Δp ATEX: Stop powder Enter the actual value of the manually under 6. After filter pressure monitoring • 101 MagicControl 4.0 (CM40)
Page 102: Alarm
(in this example 10,800 m³/h) Δp “Alarm” Enter actual value of system pressure manually under 102 • After filter pressure monitoring MagicControl 4.0 (CM40)
Page 103: Operating Point
Press the Teach key to store the set frequency. The afterfilter is now ready for operation. The speed is readjusted by 0.1 Fan Δp Hz each time when the changes by 10 PA. After filter pressure monitoring • 103 MagicControl 4.0 (CM40)
Page 104: Exhaust Air Measurement
Hertz. The entire display area adapts to the new operating point value. 25 steps Exhaust air measurement For exhaust air measurement we recommend the Testo 405i hot wire anemometer, which is both economical and practical. 104 • After filter pressure monitoring MagicControl 4.0 (CM40)
Page 105: Measurement Configuration
We recommend the “Temporal” variant. With this variant, the exhaust air volume is measured over a defined time period. A measuring time of 60 seconds produces a precise result. • Measurement direction = Exhaust air After filter pressure monitoring • 105 MagicControl 4.0 (CM40)
Page 106: Measuring Point
– Tests have shown that the measurement is most accurate if the measurement is only made in the center of the pipe. The results are displayed in the Smart Probes app. 106 • After filter pressure monitoring MagicControl 4.0 (CM40)
Page 107 Rev. 01 12/21 The results can be exported as a report in various formats. After filter pressure monitoring • 107 MagicControl 4.0 (CM40)
Page 108: Filter Cartridges
As soon as the alarm 15071 Fan 1 minimum exhaust air appears, the operating point must be readjusted by opening the throttle valve until the “Fan display value on the CM40 display reaches the differential pressure ∆p operating point”. 108 • After filter pressure monitoring MagicControl 4.0 (CM40)
Page 109: Filter Cartridge Replacement
At the same time as the alarm message 15071 appears, the 4 pressure monitors also trigger: – Fan ∆p (Actual value 1) Differential pressure monitor (315B1) – Fan ∆p (Actual value 2) Differential pressure monitor (315B3) After filter pressure monitoring • 109 MagicControl 4.0 (CM40)
Page 110: Behavior When Atex Differential Pressure Is Reached
The “System” signal of the automatic and manual gun control units switches off. – Main solenoid valve switches off – Cleaning mode not possible ▪ A pop-up window appears when the cleaning button is pressed. 110 • After filter pressure monitoring MagicControl 4.0 (CM40)
Page 111: Fault Clearance
The following screen is displayed: Fig. 98: Error display Selected error message Error description Error number Display error history Delete error history (keep pressed for 2 seconds) Acknowledge error Exit current page Help codes list Fault clearance • 111 MagicControl 4.0 (CM40)
Page 112: Faults
(see also CAN bus Operating Manual or – Control is in an the respective axis). undefined state Switch off the control voltage and switch it on again after 10 seconds, otherwise restart the plant. 112 • Fault clearance MagicControl 4.0 (CM40)
Page 113: 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 • 113 MagicControl 4.0 (CM40)
Page 114: Maintenance During Storage
Rev. 01 12/21 Maintenance during storage Maintenance schedule No maintenance schedule is necessary. Maintenance works During long-term storage, periodically perform a visual check. 114 • Decommissioning / Storage MagicControl 4.0 (CM40)
Page 115: 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 116: 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. 116 • Disposal MagicControl 4.0 (CM40)
Page 117: 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 warrantee claims become invalid! ► Only original Gema spare parts should be used! Spare parts list • 117 MagicControl 4.0 (CM40)
Page 118: Magiccontrol Cm40 - Complete
Rev. 01 12/21 MagicControl CM40 – complete Micro Touch Panel MC 15.6" – complete (without pos. 2) 1015 320 SD card – 4 GB on request Fig. 99: MagicControl CM40 118 • Spare parts list MagicControl 4.0 (CM40)
Page 119 Storage ............113 Guidelines, European ........12 Storage conditions ......... 113 Intended use ............ 11 User levels access ............22 functions available ........22 Maintenance ............. 75 Maintenance during storage ......114 Spare parts list • 119 MagicControl 4.0 (CM40)
Page 120 Rev. 01...

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