Gema MultiStar CG10 Guide

Rev. 00 1011 508 EN
Operating instructions and Spare parts list
Gun control unit
MultiStar CG10
Translation of the original operating instructions

Rev. 00 08/17
Documentation MultiStar CG10
© Copyright 2016 Gema Switzerland GmbH
All rights reserved.
This publication is protected by copyright. Unauthorized copying is
prohibited by law. No part of this publication may be reproduced,
photocopied, translated, stored on a retrieval system or transmitted in any
form or by any means for any purpose, neither as a whole nor partially,
without the express written consent of Gema Switzerland GmbH.
Gema, EquiFlow, MagicCompact, MagicCylinder, OptiCenter, OptiFlex,
OptiGun, OptiSelect and OptiStar are registered trademarks of Gema
Switzerland GmbH.
ClassicLine, ClassicStandard, ClassicOpen, DVC (Digital Valve Control),
GemaConnect, MagicControl, MagicPlus, MonoCyclone, MRS,
MultiColor, MultiStar, OptiAir, OptiControl, OptiColor, OptiFeed, OptiFlow,
OptiHopper, OptiMove, OptiSieve, OptiSpeeder, OptiSpray, PCC (Precise
Charge Control), RobotGun, SIT (Smart Inline Technology) und
SuperCorona are trademarks of Gema Switzerland GmbH.
All other product names are trademarks or registered trademarks of their
respective holders.
Reference is made in this manual to different trademarks or registered
trademarks. Such references do not mean that the manufacturers
concerned approve of or are bound in any form by this manual. We have
endeavored to retain the preferred spelling of the trademarks, and
registered trademarks of the copyright holders.
To the best of our knowledge and belief, the information contained in this
publication was correct and valid on the date of publication. Gema
Switzerland GmbH makes no representations or warranties with respect
to the contents or use of this publication, and reserves the right to revise
this publication and make changes to its content without prior notice.
For the latest information about Gema products, visit
www.gemapowdercoating.com.
For patent information, see www.gemapowdercoating.com/patents or
www.gemapowdercoating.us/patents.
Printed in Switzerland
Gema Switzerland GmbH
Mövenstrasse 17
9015 St.Gallen
Switzerland
Phone:[phone]
Fax.: [phone]
E-mail: [email protected]

Rev. 00 08/17
MultiStar CG10 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
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
Reasonably foreseeable misuse...........................................................................12
Technical Data......................................................................................................12
Connectable guns....................................................................................12
Electrical data ..........................................................................................12
Pneumatic data........................................................................................13
Dimensions ..............................................................................................13
Sound pressure level...............................................................................13
Rating plate..............................................................................................13
Powder output (reference values)............................................................14
Air flow rates............................................................................................14
Design and function..............................................................................................15
Overall view..............................................................................................15
Operating elements..................................................................................16
Connections.............................................................................................19
Scope of delivery ..................................................................................................20
Typical properties –Characteristics of the functions............................................21
Operating modes .....................................................................................21
Adjustable programs................................................................................21
Preset coating programs (Easy Mode only).............................................22
Gun activation..........................................................................................22
Gun condition display...............................................................................22
Keyboard lock ..........................................................................................22
Alarm output.............................................................................................23
Background illumination...........................................................................23
Correction factor for the powder output...................................................23
Assembly / Connection 25
Assembly guide.....................................................................................................25
Connection instructions.........................................................................................26
Start-up 27
Preparation for start-up.........................................................................................27
Basic conditions.......................................................................................27

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
Table of contents MultiStar CG10
System parameters .............................................................................................. 27
Entering the system parameters ............................................................. 27
CAN bus ............................................................................................................... 32
General.................................................................................................... 32
Hardware................................................................................................. 33
Determining user address (Node-ID) and Baud rate............................... 34
Operation 35
Operation.............................................................................................................. 35
Gun activation.......................................................................................... 35
Starting the individual adjustable programs ............................................ 36
Selecting the preset coating programs (Easy Mode only)....................... 37
Setting powder output and powder cloud................................................ 37
Setting the electrode rinsing air............................................................... 38
Gun release............................................................................................. 39
Remote operation................................................................................................. 40
Local operation in remote operating mode.............................................. 40
Transfer to remote operating mode......................................................... 40
System release in network operation................................................................... 40
Correction values.................................................................................................. 41
Entering the correction values................................................................. 41
Powder output/powder hose correction................................................... 42
Correction factor –diagram..................................................................... 44
Daily correction value C2......................................................................... 45
External powder output correction C3 (Easy Mode only)........................ 45
Setting the background illumination ..................................................................... 45
Activate/deactivate the keyboard lock.................................................................. 45
Checking the software version ............................................................................. 46
RAM Reset ........................................................................................................... 46
Decommissioning / Storage 47
Decommissioning................................................................................................. 47
If in disuse for several days..................................................................... 47
Storage conditions................................................................................................ 47
Hazard notes........................................................................................... 47
Type of storage........................................................................................ 47
Storage duration...................................................................................... 47
Space requirements ................................................................................ 47
Physical requirements............................................................................. 48
Maintenance during storage................................................................................. 48
Maintenance schedule............................................................................. 48
Maintenance works.................................................................................. 48
Maintenance / Repairs 49
General information.............................................................................................. 49
Periodic checks .................................................................................................... 49
Repair work........................................................................................................... 49
Fault clearance 51
Error diagnosis of the software............................................................................. 51
General information................................................................................. 51
Help codes............................................................................................... 51
Help codes list......................................................................................... 54
Appearance of errors............................................................................... 54

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MultiStar CG10 Table of contents

5
Disposal 55
Introduction ...........................................................................................................55
Requirements on personnel carrying out the work..................................55
Disposal regulations.................................................................................55
Materials...................................................................................................55
Disassembly of component groups.......................................................................55
Spare parts list 57
Ordering spare parts.............................................................................................57
MultiStar CG10 Gun control unit...........................................................................58
Front plate and power pack ..................................................................................59
Inside back plate...................................................................................................60
Connecting material..............................................................................................61

Rev. 00 08/17
MultiStar CG10 About these instructions

7
About these instructions
General information
This operating manual contains all important information which you
require for the working with the MultiStar CG10. 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 MultiStar CG10
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.
Software version
This document describes the operation of the control unit MultiStar CG10
with software version starting from 1.00.
See chapter "Checking the software version" on page 46.
Presentation of the contents
Figure references in the text
Figure references are used as cross references in the descriptive text.
Example:
"The high voltage (H) created in the gun cascade is guided through the
center electrode."

Rev. 00 08/17
MultiStar CG10 Safety

9
Safety
Basic safety instructions
–This product is built to the latest specification and conforms to the
recognized technical safety regulations and is designed for the
normal application of powder coating.
–Any other use is considered non-compliant. The manufacturer shall
not be liable for damage resulting from such use; the user bears sole
responsibility for such actions. If this product is to be used for other
purposes or other substances outside of our guidelines then Gema
Switzerland GmbH should be consulted.
–Start-up (i.e. the execution of intended operational tasks) is
forbidden until it has been established that this product has been set
up and wired according to the guidelines for machinery. The
standard "Machine safety" must also be observed.
–Unauthorized modifications to the product exempt the manufacturer
from any liability from resulting damage.
–The relevant accident prevention regulations, as well as other
generally recognized safety regulations, occupational health and
structural regulations are to be observed.
–Furthermore, the country-specific safety regulations also must be
observed.
Product specific security regulations
–This product is a constituent part of the equipment and is therefore
integrated in the system's safety concept.
–If it is to be used in a manner outside the scope of the safety
concept, then corresponding measures must be taken.
–The installation work to be done by the customer must be carried out
according to local regulations.
–It must be ensured, that all components are earthed according to the
local regulations before start-up.
For further security information, see the more detailed Gema
safety regulations!

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10

Safety MultiStar CG10
WARNING
Working without instructions
Working without instructions or with individual pages from the
instructions may result in damage to property and personal injury
if relevant safety information is not observed.
►Before working with the device, organize the required documents
and read the section "Safety regulations".
►Work should only be carried out in accordance with the
instructions of the relevant documents.
►Always work with the complete original document.

Rev. 00 08/17
MultiStar CG10 Product description

11
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
product should only be used, maintained and started up by trained
personnel, who are informed about and are familiar with the possible
hazards involved.
Any other use is considered non-compliant. The manufacturer is not
responsible for any incorrect use and the risks associated with such
actions are assumed by the user alone!
For a better understanding of the interrelationships in powder coating, it is
recommended that the operating instructions for all other components be
read as well, so as to be familiar with their functions too.
fig.
1

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
Product description MultiStar CG10
Reasonably foreseeable misuse
–Operation without the proper training
–Use with insufficient compressed air quality
–Use in connection with unauthorized coating devices or components
Technical Data
Connectable guns
MultiStar CG10(-X)
connectable
OptiGun GA03
yes
OptiGun GA02
yes
ATTENTION
The gun control unit may only be used with the specified gun
types!
Electrical data
MultiStar CG10(-X)
Nominal input voltage
100-240 VAC
Frequency
50-60 Hz
Connected load
300 VA
Nominal output voltage (to the gun)
12 V
Nominal output current (to the gun)
1.2 A
Alarm output (potential-free relay)
max. 2 A / 250 VAC
Temperature range
0 °C - +40 °C
(+32 °F - +104 °F)
Approvals
0102 II (2) D
PTB11 ATEX 5007

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MultiStar CG10 Product description
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13
Pneumatic data
MultiStar CG10(-X)
Compressed air connection
1/2" hose connection
Input pressure (must be set in the
system parameter P2)
5.5 bar
6.0 bar
6.5 bar
Min. input pressure (while unit in
operation)
5.5 bar / 80 psi
Compressed air consumption
6.5 Nm³/h per gun
Max. water vapor content of the
compressed air
1.3 g/m³
Max. oil vapor content of the
compressed air
0.1 mg/m³
Dimensions
MultiStar
CG10
CG10-X
Width
425 mm
425 mm
Depth
320 mm
320 mm
Height
178 mm
178 mm
Weight
approx. 13.2 kg
approx. 12.8
kg
Sound pressure level
MultiStar CG10(-X)
Normal operation
< 60 dB(A)
The sound pressure level was measured while the unit was in operation;
measurements were taken at the most frequent operator positions and at
a height of 1.7 m from the ground.
The specified value is applicable only for this product itself and does not
take into account external noise sources or cleaning impulses.
The sound pressure level may vary, depending on the product
configuration and space constraints.
Rating plate
fig.
2

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14

Product description MultiStar CG10
Powder output (reference values)
General conditions for the OptiFlow Injector
Powder type
Epoxy/polyester
Length of powder hose (m)
12
Powder hose Ø (mm)
11
Type of powder hose
POE with guide strips
Input pressure (bar)
6.0
Correction value C0
Powder output zeroing
adjustment
Guide values for MultiStar CG10 with OptiFlow Injector
IG06
All values in these tables are guide values. Differing environmental
conditions, wear and different powder types can affect the table values.
Total air
3 Nm³/h
4 Nm³/h
5 Nm³/h
Powder output (g/min)
Powder output (%)
20
60
70
80
40
115
140
160
60
175
210
220
80
220
260
270
100
250
300
310
Air flow rates
MultiStar CG10(-X)
per gun
Total air flow rate
0-6.5 Nm³/h
Electrode rinsing air flow rate
0-3.0 Nm³/h
The total air consumption for the device is determined based on
the 2 configured air values multiplied by number of guns.
–These values apply for a control pressure of 6.0 bar!
The max. total air consumption during the coating operation is
< 5,5 Nm³/h per gun:
–Total air = 5 Nm³/h (conveying air + supplementary air)
–Electrode rinsing air = 0,1 Nm³/h (flat jet nozzle)

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MultiStar CG10 Product description
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15
Design and function
The Control unit is an intelligent gun control, which permits to control
completely up to 12 powder guns at the same time.
The gun control unit is composed of a main control unit (for the control of
up to 6 guns) and an optional additional control unit, MultiStar Extend, (for
the control of up to 6 additional guns). The application parameters (high
voltage, electricity and powder output) can be programmed easily and
quickly using a central entry and display field. The additional control unit
is managed by the main control unit.
Overall view
fig.
3
1 Front plate with control and
display elements
2 Additional panel
3 Additional unit MultiStar
Extend CG10-X
4 Back panel with interfaces

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
Product description MultiStar CG10
Operating elements
Displays
The desired and actual values are distributed across several
levels.
–The "sel" key is used to switch between the levels.
–If no controls are used within 6 s, the device automatically
returns to level 1.
fig.
4
: Displays, Level 1
Designation
Function
A1-A4
Display of actual values, desired values and
system parameters
–Flashes if the possible range is exceeded.
A5
Display of program numbers, error diagnosis
codes and status information
S1
Powder output (display in %)
S4
Total air volume (display in Nm³/h)
S7
High voltage (display in kV)
S9
Spraying current (display in µA)
S12 remote
Remote operation mode, no local operation
possible
S13
Gun release
S14 system
System release via plant signal
S15
Display of preset coating programs

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MultiStar CG10 Product description

17
fig.
5
: Displays and LEDs, Level 2
Designation
Function
S3
Electrode rinsing air (display in Nm³/h)
S19
Display illumination (0-8)
fig.
6
: LEDs, Additional panel
Designation
Function
L21..L32
Gun LED:
green, red or orange, the color depends on the
condition of the corresponding gun

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
Product description MultiStar CG10
Input keys and switches
fig.
7
: Input keys and switches
Designation
Function
T1-T8
Input keys for desired values and system
parameters
T9 (Select)
Switch between display levels
T10-T11
Program change
T12
Gun release
Switchover to system parameter mode (press for at
least 5 secs.)
T13
Preset mode for flat parts
T14
Preset mode for complex parts with depressions
T15
Preset mode for overcoating parts already coated
T16
Power switch On/Off
T21..32
Gun selection keys

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MultiStar CG10 Product description
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19
Connections
Compressed air hoses / cables
fig.
8
: MultiStar CG10 / Extend Connections –Compressed air hoses /
cables
Connection
Description
1.1 Main air IN
Compressed air connection
2.1 Power IN
Mains cable connection
Gun 1-12
Gun cable connection
2.3 Aux
CAN bus connection (IN)
2.4 Aux
CAN bus connection (OUT)
2.5 Ext
Communication cable connection
X
Cable lead-through:
- Alarm output
- Digital Input for individual gun triggering
Electrode rinsing air connection
Supplementary air connection
Conveying air connection
Grounding connection

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
Product description MultiStar CG10
Pin assignment
Power IN connection
1
Neutral conductor (power supply)
2
Phase (100-240 VAC)
3
System input ON/OFF (100-240 VAC)
PE
PE grounding
Gun connection
1
Ground
2
empty
3
empty
4
empty
5
empty
6
Oscillator
7
PE grounding
CAN IN plug with 4 pins (2.3 Aux)
1
Ground
2
24 VDC
3
CAN high
4
CAN low
Enclosure –shield
CAN OUT socket with 4 pins (2.4 Aux)
1
Ground
2
24 VDC
3
CAN high
4
CAN low
Enclosure –shield
Scope of delivery
–Mains cable
–Operating manual