Gema MagicControl 4.0 Guide

Rev. 01 1011 534 EN
Operating instructions and Spare parts list
System control
MagicControl 4.0 (CM40)
Translation of the original operating instructions

Rev. 01 12/21
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
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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:[phone]
Fax.: [phone]
E-mail: [email protected]

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MagicControl 4.0 (CM40) Table of contents
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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.............................................12
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
Statistics................................................................................................................23
System diagnosis.....................................................................................23
Machine data ...........................................................................................24
Batch management..................................................................................24
Line management** .................................................................................25
Power control** ........................................................................................26
Daily correction .....................................................................................................27

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Table of contents MagicControl 4.0 (CM40)
Assembly / Connection 29
Mounting instructions............................................................................................ 29
Inserting the SD card............................................................................................ 30
Inserting SD card..................................................................................... 30
Removing SD card .................................................................................. 30
Start-up 31
Preparation for start-up......................................................................................... 31
Basic conditions....................................................................................... 31
General information.............................................................................................. 31
CAN bus ............................................................................................................... 32
General.................................................................................................... 32
Operation 33
Operation.............................................................................................................. 33
Starting the plant .................................................................................................. 33
Automatic operation mode.................................................................................... 36
Plants with program change per station (internal or external)................. 37
Gap control.............................................................................................. 38
Manual mode........................................................................................................ 39
Guns start independently from the conveyor........................................... 39
Setting the daily correction................................................................................... 40
Cleaning operation mode ..................................................................................... 40
Safety grid function.................................................................................. 42
Working interruptions or coating breaks............................................................... 43
Switching off the plant .......................................................................................... 43
Coating Data......................................................................................................... 44
Edit gun values, select or deselect.......................................................... 44
Edit axis values, select or deselect axes................................................. 45
Coating programs................................................................................................. 47
Load coating programs............................................................................ 48
Creating coating programs...................................................................... 48
Copy and insert coating programs .......................................................... 48
Naming coating programs....................................................................... 49
Search coating programs ........................................................................ 50
User administration............................................................................................... 51
Status display.......................................................................................... 51
Login........................................................................................................ 51
Log-out..................................................................................................... 54
Change user............................................................................................ 54
User profile .............................................................................................. 54
Checking the software version ............................................................................. 63
System diagnosis 65
Introduction........................................................................................................... 65
Display..................................................................................................... 65
Displayed states...................................................................................... 65
Displayed values ..................................................................................... 66
Electrode holder ................................................................................................... 66
Gun nozzle............................................................................................................ 67
Powder hose......................................................................................................... 67
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

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MagicControl 4.0 (CM40) Table of contents
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Machine data 71
Description............................................................................................................71
Batch Management (Basic Version) 73
Introduction ...........................................................................................................73
Operation ..............................................................................................................73
Maintenance / Repairs 75
General information ..............................................................................................75
Periodic checks.....................................................................................................75
Cleaning and maintenance......................................................................75
Repairs.....................................................................................................76
Storage and transport..............................................................................76
SD card –data backup ............................................................................77
Powder output/powder hose correction...................................................77
Correction factor –diagram .....................................................................81
Repair work...........................................................................................................81
Diagnostic 83
Description............................................................................................................83
General .................................................................................................................84
Powder guns.........................................................................................................85
Axes......................................................................................................................86
Inputs/outputs........................................................................................................87
CAN bus................................................................................................................88
Standard interface.................................................................................................89
Application pump...................................................................................................90
Exhaust air............................................................................................................91
After filter pressure monitoring 93
Introduction ...........................................................................................................93
Typical characteristics..............................................................................94
Description of the pressure switches....................................................................94
Pressure switch overview .....................................................................................95
Display of the pressure values in MagicControl CM40.........................................96
Configuration.........................................................................................................97
1503 After filter type...............................................................................97
1504 Volume flow ..................................................................................97
1561 Meter above sea level...................................................................97
1562 Temperature .................................................................................98
OptiControl ISC08 Adjustment instructions ..........................................................99
ATEX: Stop powder .................................................................................99
Alarm......................................................................................................100
Operating point ......................................................................................100
OptiControl ISC09 Adjustment instructions ........................................................101
Introduction ............................................................................................101
Calibration when operating with frequency converter............................101
Alarm......................................................................................................102
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

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Table of contents MagicControl 4.0 (CM40)
Filter cartridge aging..............................................................................108
Filter cartridge replacement................................................................................ 109
Operation............................................................................................................ 109
Error messages ..................................................................................................109
Behavior when ATEX differential pressure is reached.......................... 110
Fault clearance 111
Main page error display...................................................................................... 111
Faults.................................................................................................................. 112
Decommissioning / Storage 113
Shutdown............................................................................................................113
Storage conditions.............................................................................................. 113
Hazard notes......................................................................................... 113
Type of storage...................................................................................... 113
Storage duration.................................................................................... 113
Space requirements .............................................................................. 113
Physical requirements........................................................................... 113
Maintenance during storage............................................................................... 114
Maintenance schedule........................................................................... 114
Maintenance works................................................................................ 114
Disposal 115
Introduction......................................................................................................... 115
Requirements on personnel carrying out the work................................ 115
Disposal regulations.............................................................................. 115
Materials................................................................................................ 115
Disassembly of component groups.................................................................... 116
Spare parts list 117
Ordering spare parts...........................................................................................117
MagicControl CM40 –complete......................................................................... 118

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MagicControl 4.0 (CM40) About these instructions
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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.
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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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 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.
Example:
"The high voltage (H) created in the gun cascade is guided through the
center electrode."

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MagicControl 4.0 (CM40) Safety
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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!

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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.