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Gema MultiStar CG10 Operating Instructions And Spare Parts List

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

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Summary of Contents for Gema MultiStar CG10

  • Page 1 Rev. 00 1011 508 Operating instructions and Spare parts list Gun control unit MultiStar CG10 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

    Background illumination ................23 Correction factor for the powder output ........... 23 Assembly / Connection Assembly guide ..................... 25 Connection instructions ..................26 Start-up Preparation for start-up ..................27 Basic conditions ..................27 Table of contents  3 MultiStar CG10...
  • Page 4 Periodic checks ....................49 Repair work ......................49 Fault clearance Error diagnosis of the software ................51 General information ................. 51 Help codes ....................51 Help codes list ..................54 Appearance of errors ................54 4  Table of contents MultiStar CG10...
  • Page 5 Materials ....................55 Disassembly of component groups ............... 55 Spare parts list Ordering spare parts ..................... 57 MultiStar CG10 Gun control unit ................58 Front plate and power pack .................. 59 Inside back plate ....................60 Connecting material ....................61 Table of contents ...

  • Page 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.

  • Page 8: Software Version

    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.

  • 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 MultiStar CG10...

  • Page 11: Product Description

    Rev. 00 08/17 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: Reasonably Foreseeable Misuse

    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 OptiGun GA02 ATTENTION The gun control unit may only be used with the specified gun...

  • Page 13: Pneumatic Data

    Rev. 00 08/17 Pneumatic data MultiStar CG10(-X) Compressed air connection 1/2" hose connection 5.5 bar Input pressure (must be set in the 6.0 bar system parameter P2) 6.5 bar Min. input pressure (while unit in 5.5 bar / 80 psi...

  • Page 14: Powder Output (Reference Values)

    Input pressure (bar) Powder output zeroing Correction value C0 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.

  • Page 15: Design And Function

    The additional control unit is managed by the main control unit. Overall view fig. 3 Front plate with control and Additional unit MultiStar display elements Extend CG10-X Additional panel Back panel with interfaces Product description  15 MultiStar CG10...

  • Page 16: Operating Elements

    Total air volume (display in Nm³/h) 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 CG10...
  • Page 17 Function Electrode rinsing air (display in Nm³/h) Display illumination (0-8) fig. 6: LEDs, Additional panel Designation Function Gun LED: L21..L32 green, red or orange, the color depends on the condition of the corresponding gun Product description  17 MultiStar CG10...
  • Page 18 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 T21..32 Gun selection keys 18  Product description MultiStar CG10...

  • Page 19: Connections

    Rev. 00 08/17 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...

  • Page 20: Scope Of Delivery

    CAN high CAN low Enclosure – shield CAN OUT socket with 4 pins (2.4 Aux) Ground 24 VDC CAN high CAN low Enclosure – shield Scope of delivery – Mains cable – Operating manual 20  Product description MultiStar CG10...

  • Page 21: 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 (20) programs and 3 preset coating programs are automatically stored, without confirmation. Product description  21 MultiStar CG10...

  • Page 22: Preset Coating Programs (Easy Mode Only)

    Display of the desired values of the current program – Display of the actual values – Error acknowledgment An active keyboard lock is indicated by a blinking of the remote display. (see also "Operation – Activate/deactivate the keyboard lock") 22  Product description MultiStar CG10...

  • Page 23: Alarm Output

    The correction factor C0 can be selected such that no powder is output when the powder share is reduced to 0%. (see also "Operation – Setting correction factor for powder output") Product description  23 MultiStar CG10...
  • Page 24 Rev. 00 08/17 24  Product description MultiStar CG10...

  • Page 25: Assembly / Connection

    Rev. 00 08/17 Assembly / Connection Assembly guide The gun control unit is installed in an AS-control cabinet as standard. Please contact Gema for other installation possibilities. fig. 11: AS control cabinet Assembly / Connection  25 MultiStar CG10...

  • Page 26: Connection Instructions

    – Check ground connections with Ohm meter and ensure 1 MOhm 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 CG10...

  • 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 CG10...
  • Page 28 0: P in = 5.5 bar Inlet pressure 1: P in = 6 bar 2: P in = 6.5 bar Unit of 0: Nm³/h measurement 1: scfm (air) 0: Deactivated Interface type 1: Automatic Auto recognition 28  Start-up MultiStar CG10...
  • Page 29 The system parameter P00 is set to 0 when device is starting. – If the parameter is set to 1, each individual gun can be controlled externally via digital inputs. If the signal is not on, the gun cannot be activated (triggered). Start-up  29 MultiStar CG10...
  • Page 30 This parameter is used to determine the measuring unit for all airs (total air and electrode rinsing air). If the parameter is set to 1 (scfm), then all air values are shown in this measuring unit. These lines are displayed in blue. 30  Start-up MultiStar CG10...
  • Page 31 This parameter controls which air volume settings can be controlled by the user. If P07 = 1, conveying air (FL) and supplementary air (ZL) can be controlled separately. The display looks as follows: fig. 17 System parameter P10 fig. 18: System parameter P10 Start-up  31 MultiStar CG10...

  • 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 CG10...

  • Page 33: Hardware

    19: CAN bus – connections PLC control with CAN bus Terminal resistor CAN bus cable – plug assignment fig. 20: CAN bus cable Signal Color white +24 VDC black CAN H black CAN L black Start-up  33 MultiStar CG10...

  • Page 34: Determining User 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 client. If longer cables are used, select a lower Baud rate. 34  Start-up MultiStar CG10...

  • Page 35: Operation

    Pressing T12 and T10 simultaneously displays the number of usable guns: fig. 22: Number of usable guns If the user activates a gun which is above the usable number, the display shows the text "no GUN Left". Operation  35 MultiStar CG10...

  • Page 36: Starting The Individual Adjustable Programs

    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 60 % Total air 4.0 Nm³/h High voltage 80 kV Spray current 20 µA Electrode rinsing air 0.1 Nm³/h 36  Operation MultiStar CG10...

  • Page 37: Selecting The Preset Coating Programs (Easy Mode Only)

    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 Operation  37 MultiStar CG10...

  • Page 38: Setting The Electrode Rinsing Air

    Point the gun into the booth, switch the gun on and visually check 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) 38  Operation MultiStar CG10...

  • Page 39: 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 CG10 without bus connection: External release signal is present. The corresponding symbol is displayed: Press the...

  • Page 40: Remote Operation

    Signal Designation Trigger Gun connected External release Release on mains plug System System Gun release on control unit enable logic release Gun release Command via Remote Interface Error lock Device error System lock Parameter input 40  Operation MultiStar CG10...

  • Page 41: Correction Values

    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. The value of the adjusted correction factor appears on corresponding display A2 Operation  41 MultiStar CG10...

  • Page 42: 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. 42  Operation MultiStar CG10...
  • Page 43 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) Operation  43 MultiStar CG10...

  • Page 44: Correction Factor - Diagram

    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. 44  Operation MultiStar CG10...

  • Page 45: Daily Correction Value C2

    Select the desired brightness Activate/deactivate the keyboard lock Hold key pressed Press the corresponding key: – The keyboard lock will be activated. The remote display blinks. The keyboard lock is cancelled by pressing the same key combination Operation  45 MultiStar CG10...

  • Page 46: Checking The Software Version

    Switch on the control unit, the CLR display blinks Wait for approximately 5 seconds until CLR disappears Release the – All values are reset. The control unit must be set-up again. 46  Operation MultiStar CG10...

  • Page 47: 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  47 MultiStar CG10...

  • Page 48: 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. 48  Decommissioning / Storage MultiStar CG10...

  • Page 49: Maintenance / Repairs

    Repair work In the event of malfunctions or faults, the product must be checked and repaired by an authorized Gema service workshop. The repairs must only be performed by an authorized specialist. Improper tampering can result in serious danger for user and equipment.
  • Page 50 Rev. 00 08/17 50  Maintenance / Repairs MultiStar CG10...

  • Page 51: Fault Clearance

    For error codes which are not related to a specific gun, for example a defect in the trigger valve, the error code appears on the display only. Here is a list of all possible help codes for this Gun control unit: Fault clearance  51 MultiStar CG10...
  • Page 52 Main unit Additional unit High voltage Code Description Criteria Remedy Pneumatics: Solenoid coil current lower than Contact a Gema service H105 Trigger valve MU preset limiting value center Valve defective, main board or H205 Trigger valve AU cable defective The powder output multiplied by...
  • Page 53 Rev. 00 08/17 Code Description Criteria Remedy EEPROM verification Contact a Gema service EEPROM error erroneous center CAN bus: The CAN controller changes into Connect the cable, BUS OFF condition. otherwise contact Gema Permanent CAN bus service error No power supply or cable is not connected.

  • Page 54: Help Codes List

    Rev. 00 08/17 Code Description Criteria Remedy Supplementary air Lost steps, limit switch defective, Contact a Gema service position lost throttle motor defective center Electrode rinsing air Lost steps, limit switch defective, Contact a Gema service position lost throttle motor defective...

  • Page 55: 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 56 Rev. 00 08/17 56  Disposal MultiStar CG10...

  • Page 57: 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 guarantee claims become invalid! ► Only original Gema spare parts should be used! Spare parts list  57 MultiStar CG10...

  • Page 58: Multistar Cg10 Gun Control Unit

    Rev. 00 08/17 MultiStar CG10 Gun control unit Main control unit MultiStar CG10 – complete 1011 601 Additional control unit MultiStar Extend CG10-X – complete 1011 602 fig. 24: MultiStar CG10 58  Spare parts list MultiStar CG10...

  • Page 59: Front Plate And Power Pack

    PCB – complete 1011 557 Illuminated push button – complete 1012 840 Power pack – 24 VDC 1011 565 PCB Controller Board – complete 1011 554 fig. 25: Front plate and power pack Spare parts list  59 MultiStar CG10...

  • Page 60: Inside Back Plate

    Plug – Ø 10 mm 1011 615 Gun connection – complete, with cable 1011 570 Fuse – 5 AT 200 166# * Please indicate length # Wearing part fig. 26: Inside back plate 60  Spare parts list MultiStar CG10...

  • Page 61: Connecting Material

    CAN bus cable – 5.5 m 388 521 CAN bus cable – 6.0 m 388 530 Bus terminal resistor (not shown) 387 606 Communication cable – 0,6 m 1011 607 * Please indicate length fig. 27 Spare parts list  61 MultiStar CG10...
  • Page 63 Figure references in the text ......8 Scope of delivery ..........20 Spare parts list ..........57 Start-up ............27 Storage ............47 Maintenance ............. 49 Storage conditions ........... 47 Maintenance during storage ......48 Index  63 MultiStar CG10...
  • Page 64 Rev. 00...

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