Gema MagicControl 4.0 - Assembly; Connection; Installation & SD Card

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Rev. 01 12/21

MagicControl 4.0 (CM40) 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.

: Possibilities of installation

Main Page

Table of Contents3
About These Instructions7
General Information7
Keeping the Manual7
Safety Symbols (Pictograms)7
Structure of Safety Notes8
Software Version8
Presentation of the Contents8
Safety9
Basic Safety Instructions9
Product Specific Security Regulations9
Product Description11
Intended Use11
A Summary of the Directives and Standards12
Reasonably Foreseeable Misuse13
Powder Circuit13
Typical Characteristics13
Scope of Delivery14
Technical Data15
System15
Electrical Data15
Dimensions15
Display15
Connections16
Environmental Conditions16
Rating Plate16
Design and Function17
Operating and Display Elements17
Connections and Interfaces18
Symbols19
Meaning of the Colors20
Operating Modes21
Automatic Operating Mode (AUTO)21
Manual Operating Mode (MAN)21
Cleaning Operating Mode (CLN)21
User Levels and Access22
Functions Available at User Level22
Statistics23
System Diagnosis23
Machine Data24
Batch Management24
Line Management25
Power Control26
Daily Correction27
Assembly / Connection29
Mounting Instructions29
Inserting the SD Card30
Inserting SD Card30
Removing SD Card30
Start-Up31
Preparation for Start-Up31
Basic Conditions31
General Information31
CAN Bus32
General32
Operation33
Starting the Plant33
Automatic Operation Mode36
Plants with Program Change Per Station (Internal or External)37
Gap Control38
Manual Mode39
Guns Start Independently from the Conveyor39
Setting the Daily Correction40
Cleaning Operation Mode40
Safety Grid Function42
Working Interruptions or Coating Breaks43
Switching off the Plant43
Coating Data44
Edit Gun Values, Select or Deselect44
Edit Axis Values, Select or Deselect Axes45
Coating Programs47
Load Coating Programs48
Creating Coating Programs48
Copy and Insert Coating Programs48
Naming Coating Programs49
Search Coating Programs50
User Administration51
Status Display51
Login51
Log-Out54
Change User54
User Profile54
Checking the Software Version63
System Diagnosis65
Introduction65
Display65
Displayed States65
Displayed Values66
Electrode Holder66
Gun Nozzle67
Powder Hose67
Injector67
IN Pinch Valve Application Pump68
OUT Pinch Valve Application Pump68
Application Pump, Filter69
Application Pump, Pinch Valve Diagnostic69
System Service70
Machine Data71
Description71
Batch Management (Basic Version)73
Introduction73
Operation73
Maintenance / Repairs75
General Information75
Periodic Checks75
Cleaning and Maintenance75
Repairs76
Storage and Transport76
SD Card - Data Backup77
Powder Output/Powder Hose Correction77
Correction Factor - Diagram81
Repair Work81
Diagnostic83
Description83
General84
Powder Guns85
Axes86
Inputs/Outputs87
CAN Bus88
Standard Interface89
Application Pump90
Exhaust Air91
After Filter Pressure Monitoring93
Introduction93
Typical Characteristics94
Description of the Pressure Switches94
Pressure Switch Overview95
Display of the Pressure Values in Magiccontrol CM4096
Configuration97
1503 After Filter Type97
1504 Volume Flow97
1561 Meter above Sea Level97
1562 Temperature98
Opticontrol ISC08 Adjustment Instructions99
ATEX: Stop Powder99
Alarm100
Operating Point100
Opticontrol ISC09 Adjustment Instructions101
Introduction101
Calibration When Operating with Frequency Converter101
Alarm102
Operating Point103
Exhaust Air Measurement104
Measurement Configuration105
Measuring Point106
Measuring Procedure106
Filter Cartridges108
Running-In Filter108
Filter Cartridge Cleaning108
Filter Cartridge Aging108
Filter Cartridge Replacement109
Operation109
Error Messages109
Behavior When ATEX Differential Pressure Is Reached110
Fault Clearance111
Main Page Error Display111
Faults112
Decommissioning / Storage113
Shutdown113
Storage Conditions113
Hazard Notes113
Type of Storage113
Storage Duration113
Space Requirements113
Physical Requirements113
Maintenance During Storage114
Maintenance Schedule114
Maintenance Works114
Disposal115
Introduction115
Requirements on Personnel Carrying out the Work115
Disposal Regulations115
Materials115
Disassembly of Component Groups116
Spare Parts List117
Ordering Spare Parts117
Magiccontrol CM40 - Complete118

Gema MagicControl 4.0 - Assembly; Connection; Installation & SD Card

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