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Gema MultiStar XL CG28-C Operating Instructions And Spare Parts List

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Rev. 00
1027 034
Operating instructions and Spare parts list
Gun control unit
MultiStar XL CG28-C
Translation of the original operating instructions

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Summary of Contents for Gema MultiStar XL CG28-C

  • Page 1 Rev. 00 1027 034 Operating instructions and Spare parts list Gun control unit MultiStar XL CG28-C 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

    Basic conditions ..................27 System parameter ....................27 Entering the system parameters .............. 27 CAN bus ........................ 32 General ....................32 Hardware ....................33 Determining device address (Node-ID) and Baud rate ......34 Table of contents • 3 MultiStar XL CG28-C...
  • Page 4 Help codes list ..................59 Appearance of errors ................59 Disposal Introduction ......................61 Requirements on personnel carrying out the work ........61 Disposal regulations ................61 Materials ....................61 Disassembly of component groups ..............61 4 • Table of contents MultiStar XL CG28-C...
  • Page 5 MultiStar XL CG 28-C Gun control unit ..............64 Front plate ......................65 Power pack - complete ..................66 Connecting material ....................67 Pneumatic unit - OptiCenter .................. 68 AirController - complete ..................69 Index Table of contents • 5 MultiStar XL CG28-C...

  • Page 7: About These Instructions

    General information This operating manual contains all the important information that is needed to operate the MultiStar XL CG28-C. 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: Software Version

    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 electrode. 8 • About these instructions MultiStar XL CG28-C...

  • 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. – 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.

  • Page 10: Product Specific Security 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! 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.

  • Page 11: Product Description

    Rev. 00 01/25 Product description Intended use The Gun control unit is designed exclusively for controlling the Gema powder coating guns (see also in chapter "Technical data"). Observance of the operating, service and maintenance instructions specified by the manufacturer is also part of conformity of use. This...

  • Page 12: A Summary Of The Directives And Standards

    Trade Union information concerning health and 209-052 safety during work (BGI) Reasonably foreseeable misuse – Operation without the proper training – Use with insufficient compressed air quality – Use in connection with unauthorized coating devices or components 12 • Product description MultiStar XL CG28-C...

  • Page 13: Technical Data

    Rev. 00 01/25 Technical Data Connectable guns MultiStar XL CG28-C connectable OptiGun GA03 NOTICE The gun control unit may only be used with the specified gun types! Electrical data MultiStar XL CG28-C Nominal input voltage 100–240 V AC Frequency 50-60 Hz...

  • Page 14: Rating Plate

    See applicable operating instructions for the OptiFlow injector used. Guide values for MultiStar CG28 with OptiFlow Injector See applicable operating instructions for the OptiFlow injector used. Air flow rates MultiStar XL CG28-C per gun Total air flow rate 0-6.5 Nm³/h Electrode rinsing air flow rate 0-2.0 Nm³/h The total air consumption for the device is determined based on the 2 configured air values multiplied by number of guns.

  • Page 15: Design And Function

    The application parameters (high voltage, electricity and powder output) can be programmed easily and quickly using a central entry and display field. Overall view Fig. 3: MultiStar XL CG28-C Front plate with control and ON/OFF switch display elements Back panel with interfaces...

  • Page 16: Operating Elements

    High voltage (display in kV) Spraying current (display in µA) Remote operation mode, no local operation S12 remote possible Gun release S14 system System release via plant signal Display of preset coating programs 16 • Product description MultiStar XL CG28-C...
  • Page 17 Rev. 00 01/25 Fig. 5: Displays and LEDs, Level 2 Designation Function Electrode rinsing air (display in Nm³/h) Display illumination (0-8) Product description • 17 MultiStar XL CG28-C...

  • Page 18: Input Keys And Switches

    Switchover to system parameter mode (press for at least 5 secs.) Preset mode for flat parts Preset mode for complex parts with depressions Preset mode for overcoating parts already coated Power switch On/Off Activation of the hose rinsing function 18 • Product description MultiStar XL CG28-C...

  • Page 19: Connections

    CAN bus connection (OUT) Communication cable connection to AirController Trigger Connection Group triggering Error output connection Err OUT (OUT) Gun 1.1 – 6.6 Gun cable connection Grounding connection Fig. 7: Connections - MultiStar XL CG28-C Product description • 19 MultiStar XL CG28-C...
  • Page 20 Main solenoid valve Main valve connection CA1 – CA6 Solenoid valves connections SA1 – SA6 (18x) EA1 – EA6 CA1+4 CA2+5 CA3+6 Pressure regulator SA1+4 connections (7x) SA2+5 SA3+6 EA1-6 Fig. 8: Connections - AirController 20 • Product description MultiStar XL CG28-C...
  • Page 21 SA1 – SA6 Connection - Electrode rinsing air to guns 1.1 – EA1 – EA6 CA1+4 CA2+5 CA3+6 SA1+4 Connection - Pressure regulator SA2+5 SA3+6 EA1-6 Main valve Connection - Main solenoid valve Product description • 21 MultiStar XL CG28-C...

  • Page 22: Pin Assignment

    24 V DC CAN high CAN low Enclosure – shield Connection Trigger IN max. 24VDC Group trigger 1 Group trigger 2 Group trigger 3 Group trigger 4 Group trigger 5 Group trigger 6 22 • Product description MultiStar XL CG28-C...

  • Page 23: Scope Of Delivery

    Rev. 00 01/25 Connection Error OUT max. 24VDC (potential-free) empty Connection COM PE grounding 24 V DC Ground COM high COM low Scope of delivery – Mains cable – Operating manual Product description • 23 MultiStar XL CG28-C...

  • Page 24: Typical Properties - Characteristics Of The Functions

    The values for current, high voltage, powder output, total air and electrode rinsing air can be set as needed for a given application. The settings defined in the 250 programs and 3 application modes are automatically stored, without confirmation! 24 • Product description MultiStar XL CG28-C...

  • Page 25: Assembly / Connection

    Rev. 00 01/25 Assembly / Connection Assembly guide The gun control unit is installed in an OptiCenter as standard. Fig. 11: OptiCenter OC09 (example) Assembly / Connection • 25 MultiStar XL CG28-C...

  • Page 26: Connection Instructions

    Check ground connections with Ohm meter and ensure 1 kOhm or less. The compressed air must be free of oil and water! Close the unused connections with the provided dust protection caps! 26 • Assembly / Connection MultiStar XL CG28-C...

  • Page 27: Start-Up

    (CAN). Entering the system parameters Turn on the gun control unit with the ON key Hold key down for 5 seconds – The display switches to the following level: Start-up • 27 MultiStar XL CG28-C...
  • Page 28 2 5 0 5: 500 kbit/s 5 0 0 6: 800 kbit/s 8 0 0 7: 1 Mbit/s 1 0 0 0 CAN Node ID 1-127 Log level 0, 1, 2, 3, 4, 5 28 • Start-up MultiStar XL CG28-C...

  • Page 29: System Parameter P00

    If the parameter is set to 2, the gun groups can be controlled via digital inputs from an external group trigger. If the signal is not on, the gun groups cannot be activated (triggered). Start-up • 29 MultiStar XL CG28-C...
  • Page 30 SD card. The data is written to the MESSAGES.LOG file in the root directory. Once this file reaches a size of 32 MB, it is renamed as MESSAGES.1 and a new MESSAGES.LOG file is then created. 30 • Start-up MultiStar XL CG28-C...
  • Page 31 Rev. 00 01/25 Parameter Level of detail of reports value no messages few details all messages Real time timings can be impaired from a level of detail of 4. Start-up • 31 MultiStar XL CG28-C...

  • 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 special parameters such as software version, daily correction, powder output correction etc. 32 • Start-up MultiStar XL CG28-C...

  • Page 33: Hardware

    The MultiStar control units are connected to the central PLC control unit via CAN bus cables. The second CAN bus output is fitted with a terminating plug in order to terminate the network correctly. Fig. 15: CAN bus – connections Start-up • 33 MultiStar XL CG28-C...

  • Page 34: Determining Device Address (Node-Id) And Baud Rate

    The Baud rate is selected with 125 kbits as default. This setting permits a maximum cable length of approx. 500 m from the first to the last CAN bus user. If longer cables are used, select a lower Baud rate. 34 • Start-up MultiStar XL CG28-C...

  • Page 35: Operation

    Programs 001-250 (01-20) are preset at the factory but can be modified at any time, after which they are automatically stored. Description Presetting Powder output Total air 4.0 Nm³/h High voltage 80 kV Spray current 20 µA Electrode rinsing air 0.1 Nm³/h Operation • 35 MultiStar XL CG28-C...

  • Page 36: Select Predefined Operating Mode (Preset Mode)

    Setting the total air volume Adjust the total air volume on the gun control unit with the T3/T4 keys – Adjust the total air volume according to the corresponding coating requests 36 • Operation MultiStar XL CG28-C...

  • Page 37: Setting The Powder Output

    Setting the electrode rinsing air Press the key. The second display level will be shown. Adjust the correct electrode rinsing air according to the applied nozzles (deflector plate, flat jet nozzle) Operation • 37 MultiStar XL CG28-C...

  • Page 38: Gun Release

    Gun release In order that the guns can spray powder, some system-relevant conditions must be complied, and no error may be present. MultiStar XL CG28-C without bus connection: External release signal is present. The corresponding symbol is displayed: Press the...

  • Page 39: Group Triggering With P00

    Rev. 00 01/25 Group triggering with P00 Trigger via MultiStar XL CG28-C - Spar display Prerequisites – The gun groups in system parameters P11 - P16 are activated accordingly (ON/OFF). – External release signal is present. Hold key down for 5 seconds.
  • Page 40 Guns start to spray. Trigger via CAN - Can display Hold key down for 5 seconds. The display switches to the following level: Press right key 1x. The display switches to the following level: 40 • Operation MultiStar XL CG28-C...
  • Page 41 Rev. 00 01/25 Press the key: The corresponding symbol is displayed: Guns start to spray. Operation • 41 MultiStar XL CG28-C...
  • Page 42 Trigger via ext. group triggering - Din display Hold key down for 5 seconds. The display switches to the following level: Press right key 2x. The display switches to the following level: Press the key: The corresponding symbol is displayed: 42 • Operation MultiStar XL CG28-C...

  • Page 43: Can Operatin Mode

    Remote operating mode is signaled by the symbol S12 (remote). System enable function The system release logic starts and stops the powder conveying and high voltage. The release is determined due to the several internal and external signals. Operation • 43 MultiStar XL CG28-C...

  • Page 44: Correction Values

    The display switches to the following level: The correction factor number is shown in the display A1 with a C placed in front Set the corresponding correction value with the T3 or T4 key. 44 • Operation MultiStar XL CG28-C...

  • Page 45: Powder Output/Powder Hose Correction

    Set the total air to 4.0 (Nm³/h) on the A2 display. Set the powder output to 00 (%) on the A1 display To enter the system parameter mode, press the key longer than 5 seconds. Operation • 45 MultiStar XL CG28-C...

  • Page 46: Powder Hose Correction - Procedure

    C1 (%) = x 100 measured powder output 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) 46 • Operation MultiStar XL CG28-C...

  • Page 47: Example Table For Powder Offset And Powder Hose Correction

    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! Operation • 47 MultiStar XL CG28-C...

  • Page 48: Daily Correction Value C2

    The guns are flushed via the OptiCenter. Setting the background illumination Press the The display switches to the following level: Select the desired brightness Activate/deactivate the keyboard lock Hold key pressed Press the corresponding key: 48 • Operation MultiStar XL CG28-C...

  • Page 49: Checking The Software Version

    Program mode and Preset mode will be overwritten with factory default values. An active keyboard lock will be deactivated. By resetting the RAM, all user-made settings will be set to factory default! Operation • 49 MultiStar XL CG28-C...
  • Page 50 Switch on the control unit, the CLR display blinks Wait for approximately 5 seconds until CLR disappears Release the – All values are reset. The device must be set-up again. 50 • Operation MultiStar XL CG28-C...

  • Page 51: Decommissioning / Storage

    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. Decommissioning / Storage • 51 MultiStar XL CG28-C...

  • Page 52: Physical Requirements

    Storage must be inside a dry building at a temperature between +5 and +50 °C. Do not expose to direct sunlight! Maintenance during storage Maintenance schedule No maintenance schedule is necessary. Maintenance works During long-term storage, periodically perform a visual check. 52 • Decommissioning / Storage MultiStar XL CG28-C...

  • Page 53: Maintenance / Repairs

    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 54 Rev. 00 01/25 54 • Maintenance / Repairs MultiStar XL CG28-C...

  • Page 55: Fault Clearance

    T11 keys cannot be used for other functions, as long as an error code is still shown. For four-digit help codes, the last 2 numbers refer to the corresponding guns/gun controllers. Example: H111 = guns 1.1 H166 = guns 6.6 H413 = GunController 3 Fault clearance • 55 MultiStar XL CG28-C...
  • Page 56 Gun group: 1 Overvoltage intermediate circuit intermediate circuit voltage Contact Gema Service voltage overvoltage Gun group: 2 Overvoltage intermediate circuit voltage intermediate circuit Contact Gema Service voltage overvoltage Gun group: 3 56 • Fault clearance MultiStar XL CG28-C...
  • Page 57 Messages are produced faster than they can be sent. Node Guarding message is Check the connection to missing longer than 2 seconds. the Master, otherwise master failed Connection to master failed. contact Gema service Fault clearance • 57 MultiStar XL CG28-C...
  • Page 58 Message” received the “Boot Up Message”. otherwise contact Gema service Communication Mainboard-Gun: H311 – Authentication error of Gun, gun cable or Circuit board Replace or contact Gema guns 1.1 - 6.6 H366 defective Service Internal device communication: Firmware update H400...

  • Page 59: Help Codes List

    It is possible that a help code is only displayed for a short time, but after the acknowledgment it will disappear. In this case, it's recommended to switch off the device and switch it on again (reset by restarting). Fault clearance • 59 MultiStar XL CG28-C...
  • Page 60 Rev. 00 01/25 60 • Fault clearance MultiStar XL CG28-C...

  • Page 61: 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 62 Rev. 00 01/25 62 • Disposal MultiStar XL CG28-C...

  • Page 63: Spare Parts List

    Ø 8/6 mm, 8 mm outside diameter (o/d) / 6 mm inside diameter (i/d) WARNING Use of non-original Gema spare parts Use of Non-Gema replacement spare parts may invalidate some or all approval certificates and accreditations; and the user assumes all explosion risks associated with use of these parts. Use of these replacement spare parts may void any and all warranty claims.

  • Page 64: Multistar Xl Cg 28-C Gun Control Unit

    MultiStar XL CG 28-C Gun control unit – complete 1028100 Illuminated push button – yellow 262820 LED module – 24 V, white 1005427 Fixing flange 262838 Standard auxiliary switch 262854 Fig. 17: MultiStar XL CG28-C Gun control unit 64 • Spare parts list MultiStar XL CG28-C...

  • Page 65: Front Plate

    1015220 Spacer – ø6x3.4x21.5 mm 1015215 MultiStar Mainboard – complete 1027546 Locknut – M3 262498 Washer – ø3,2/7x0,5 mm 201944 Spacer sleeve – ø3.1/6x15 mm 261548 Fig. 18: Front plate - complete Spare parts list • 65 MultiStar XL CG28-C...

  • Page 66: Power Pack - Complete

    Rev. 00 01/25 Power pack - complete Gun control unit mounting plate - complete 1028085 Gun control board (GunController) - complete 1027551 Power pack – 600W 24VDC 1028083 Fig. 19: Power pack - complete 66 • Spare parts list MultiStar XL CG28-C...

  • Page 67: Connecting Material

    CAN bus cable – 5.5 m 388521 CAN bus cable – 6.0 m 388530 Power supply cable extension – 4 m 1027572 Mains cable – 6 m 390119 Fig. 20: Connecting material Spare parts list • 67 MultiStar XL CG28-C...

  • Page 68: Pneumatic Unit - Opticenter

    E/P-Pressure regulator – NW5 4-20 mA 266787 Silencer – 1/8A 251305 Solenoid valve – 1" NW24 without coil 1005592 Valve coil for solenoid valve – 24VDC 1005119 Fig. 21: Pneumatic unit - OptiCenter 68 • Spare parts list MultiStar XL CG28-C...

  • Page 69: Aircontroller - Complete

    AirController board – complete 1027555 Hexagon shakeproof nut – M5 1005188 Power pack – 600W 24VDC 1028083 Countersunk screw – M4x6 mm 1028046 * Please indicate length # Wearing part Fig. 22: AirController - complete Spare parts list • 69 MultiStar XL CG28-C...
  • Page 71 Scope of delivery ..........23 Shutdown ............51 Guidelines, European ........12 Spare parts list ..........63 Standards, European ........12 Start-up ............27 Maintenance ............. 53 Storage ............51 Maintenance during storage......52 Storage conditions ........... 51 Index • 71 MultiStar XL CG28-C...
  • Page 72 Rev. 00...

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