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Rev. 01 08/20

OptiStar All-in-One (CG22-C)

Table of contents

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Table of contents

About these instructions

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

Basic safety instructions ......................................................................................... 9

Product specific security regulations ...................................................................... 9

Product description

Intended use ......................................................................................................... 11

A summary of the directives and standards ............................................. 12

Reasonably foreseeable misuse ........................................................................... 12

Technical Data ...................................................................................................... 13

Versions ................................................................................................... 13

Connectable guns .................................................................................... 13

Electrical data .......................................................................................... 13

Pneumatic data ........................................................................................ 14

Dimensions .............................................................................................. 14

Powder output (reference values) ............................................................ 14

Air flow rates ............................................................................................ 15

Environmental conditions ......................................................................... 16

Sound pressure level ............................................................................... 16

Rating plate .............................................................................................. 16

Compatibility and interactions ............................................................................... 17

Design and function .............................................................................................. 17

Overall view.............................................................................................. 17

Operating elements .................................................................................. 18

Menu structure ......................................................................................... 19

Connections ............................................................................................. 20

Scope of delivery .................................................................................................. 21

Typical properties

– Characteristics of the functions ............................................ 22

Communication with the Gema electrostatic app .................................... 23

Rinsing mode ........................................................................................... 24

Correction values ..................................................................................... 24

Assembly / Connection

Assembly guide ..................................................................................................... 25

Connection instructions ......................................................................................... 26

Set-up .................................................................................................................... 27

Start-up

Preparation for start-up ......................................................................................... 29

Содержание CG22-C

Страница 1: ...Rev 01 1011 530 EN Operating instructions and Spare parts list Gun control unit OptiStar All in One CG22 C Translation of the original operating instructions ...

Страница 2: ...arks 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...

Страница 3: ...ably foreseeable misuse 12 Technical Data 13 Versions 13 Connectable guns 13 Electrical data 13 Pneumatic data 14 Dimensions 14 Powder output reference values 14 Air flow rates 15 Environmental conditions 16 Sound pressure level 16 Rating plate 16 Compatibility and interactions 17 Design and function 17 Overall view 17 Operating elements 18 Menu structure 19 Connections 20 Scope of delivery 21 Typ...

Страница 4: ...e in network operation 41 Correction values 42 Entering the correction values 42 Powder output powder hose correction 44 Correction factor diagram 46 Daily correction value C2 46 Rinsing mode 47 Activating the rinsing function 47 Checking the software version 48 Trigger counter 48 RAM Reset 49 Decommissioning Storage 51 Shutdown 51 If in disuse for several days 51 Storage conditions 51 Hazard note...

Страница 5: ...ut the work 59 Disposal regulations 59 Materials 59 Disassembly of component groups 59 Spare parts list 61 Ordering spare parts 61 OptiStar All in One CG22 C gun control unit 62 Compressed air input unit 63 Powder conveying unit 64 Powder conveying unit 65 Block 66 Valve block 67 Connecting material 68 Connecting material 69 ...

Страница 6: ......

Страница 7: ...he 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 inju...

Страница 8: ...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 control unit OptiStar All in One CG22 C with software version starting from 1 00 0 Presentation of the contents Figure references in the text Figur...

Страница 9: ...ry 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 observe...

Страница 10: ...tructions 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 ...

Страница 11: ...plant control then 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 u...

Страница 12: ...European standards EN 50177 Stationary electrostatic application equipment for ignitable liquid coating material Safety requirements EN 50050 2 Electrostatic equipment for areas where there is danger of explosion electrostatic hand held equipment Part 2 Electrostatic hand held spraying equipment EN 12981 Coating plants spray booths for application of organic powder coating material Safety requirem...

Страница 13: ...3 yes OptiSelect Pro Type GM04 yes OptiSelect type GM03 yes ATTENTION The gun control unit may only be used with the specified gun types Electrical data OptiStar Nominal input voltage 100 240 VAC Frequency 50 60 Hz Fluctuations of the power supply 10 Overvoltage category OVC II Connected load 40 VA Nominal output voltage to the gun 12 V Nominal output current to the gun 1 2 A Protection type IP54 ...

Страница 14: ...5 bar 80 psi Max water vapor content of the compressed air 1 3 g m ISO 8573 1 Class 3 4 Max oil vapor content of the compressed air oil water 0 1 mg m ISO 8573 1 Class 2 Dimensions OptiStar All in One CG22 C Width 390 mm Depth 40 mm Height 350 mm Weight approx 4 9 kg Powder output reference values General conditions for the OptiFlow Injector Powder type Epoxy polyester Powder hose Ø mm 11 Type of ...

Страница 15: ... 290 350 235 270 185 220 100 340 405 280 320 220 260 Air flow rates The total air consists of conveying air and supplementary air in relation to the selected powder quantity in As a result the total air volume is maintained constant OptiStar All in One CG22 C Conveying air flow rate 0 5 5 Nm h Supplementary air flow rate 0 5 5 Nm h Electrode rinsing air flow rate 0 5 0 Nm h The total air consumpti...

Страница 16: ...egree of pollution of the intended environment 2 in accordance with DIN EN 61010 1 Sound pressure level OptiStar All in One CG22 C 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 do...

Страница 17: ...7 Compatibility and interactions The gun control is used with following types of OptiCenter OptiCenter All in One Type OC06 Design and function Overall view fig 3 1 Front plate with control and display elements 2 Enclosure 3 Back panel with interfaces 4 Injector ...

Страница 18: ...t display in Total air volume display in Nm h High voltage display in kV Spraying current display in µA Electrode rinsing air display in Nm h 2 Gun release 3 Display of readiness for pairing the Bluetooth module with a mobile device blinks Display of an active connection 4 System release via external release 5 Remote operation mode no local operation possible Remote operation mode is used as keybo...

Страница 19: ...t value Switchover to the menu level press for at least 3 secs 3 Key UP 4 Key DOWN Menu structure Start display Programs Menu level Application parameters System parameters System Parameters Correction values Correction Values Settings Settings Information INFO Powder output P00 P12 C0 C1 C2 C4 C5 Pairing Bluetooth Software version Software version Total air Rotate the display Trigger counter Trig...

Страница 20: ...Compressed air hoses cables fig 6 Connections Connection Description 1 Powder hose connection 2 Gun cable connection 3 CAN bus connection OUT 4 Mains cable connection 5 Compressed air connection 6 Grounding connection 7 CAN bus connection IN 8 Electrode rinsing air connection ...

Страница 21: ...lease 100 240 VAC PE PE grounding Gun connection 1 Ground 2 INTERCOM 3 Ground 4 Trigger 5 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 Quick start guide and operating manual ...

Страница 22: ...The values for current high voltage powder output total air and electrode rinsing air can be set as needed for a given application Precise Control of spraying Current PCC Mode For coating components with both complex and simple geometries a spraying current of below 10 µA can be selected to prevent unintended overcoating on the simpler surfaces This is especially important in combination with high...

Страница 23: ...trieved at any time Statistics and cost estimates of the order are generated automatically Maintenance can be scheduled Setup This configures the OptiStar control unit The OptiStar can be controlled individually or as a participant in a group System information and diagnostic data can easily be retrieved and sent as e mail Service Enables direct access to the operating instructions of the system c...

Страница 24: ... activated via the CAN bus connection See chapter Rinsing mode on page 47 The actual rinsing procedure is started and stopped by the superordinated control unit Once the rinsing mode is quit the unit automatically returns to the last program Correction values The Gun control unit can be adapted with the correction values optimally to local conditions e g the adjustment of different powder outputs ...

Страница 25: ...ar All in One CG22 C Assembly Connection 25 Assembly Connection Assembly guide The gun control unit is mounted into place using 2xM4 screws on the front side Please contact Gema for other installation possibilities fig 8 ...

Страница 26: ...ent on page 21 fig 9 Connecting guide overview 1 Gun cable 2 Powder hose 3 Electrode rinsing air hose 6 OptiStar Control unit 7 Injector 8 Power supply 9 Grounding connection Connect grounding cable to the booth or the suspension arrangement 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 provi...

Страница 27: ...Rev 01 08 20 OptiStar All in One CG22 C Assembly Connection 27 Set up Usually this control unit is used in automatic plants fig 10 OptiStar All in One in OptiCenter ...

Страница 28: ...Rev 01 08 20 28 Assembly Connection OptiStar All in One CG22 C ...

Страница 29: ... into consideration Gun control unit correctly connected Gun correctly connected Corresponding power and compressed air supply available Powder preparation and powder quality System parameters The Gun control unit is configured by using the system parameters This configuration will be saved in the equipment memory These values can be adjusted and requested manually or by remote interface CAN Enter...

Страница 30: ...s according to the following table No Description Values Display P001 Application Device type 3 Automatic device CG22 C C P02 Pressure Input pressure 0 P in 5 5 bar 1 P in 6 bar 2 P in 6 5 bar 5 5 6 0 6 5 P03 Air unit air measurement unit 0 Nm h 1 scfm m h SCFM P04 Bus interface Interface type 0 Deactivated 1 Automatic recognition OFF Auto ...

Страница 31: ...1 Gun release is not changed Keep gun state 2 Gun release always active Always enabled P10 Log level 0 1 2 3 4 5 P11 BLE Devid Bluetooth ID no 0 Bluetooth deactivated 1 255 P12 Rmt Ctrl Remote control 0 Powder output Cleaning activation 1 Program change Cleaning activation PA Clean Prog Clean 1 is not overwritten if a Memory Reset is performed Default values are marked by bold print 5 Scroll to th...

Страница 32: ... messages are also recorded onto the SD card The data are record in 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 Parameter value Level of detail of reports 0 no messages 1 few details 5 all messages Real time timings can be impaired from a level of detail of 4 System parameter P11 Bluetoot...

Страница 33: ...ach other next time More information on how to use Gema s E app can be found in a separate manual CAN bus General The control unit is a simple CANopen slave It operates in a network with a central control unit Master Communication takes place exclusively between the Master and the Slaves Following data can be accessed by CANopen All desired values process data All actual values process data All co...

Страница 34: ...ptiStar no 1 OptiStar no 2 CAN bus participant no 127 max fig 11 CAN bus connections 1 PLC control with CAN bus 2 Terminal resistor CAN bus cable plug assignment fig 12 CAN bus cable Pin Signal Color 1 GND white 2 24 VDC black 3 CAN H black 4 CAN L black ...

Страница 35: ... the Node ID value can be set by editing the system parameter P06 Node ID system parameter P06 CAN Node ID 1 127 P06 value CAN Node ID 1 127 1 127 Baud rate system parameter P05 P05 value Baud rate 0 20 kbit s 1 50 kbit s 2 100 kbit s 3 125 kbit s 4 250 kbit s 5 500 kbit s 6 800 kbit s 7 1 Mbit s Default value of system parameter P05 3 The Baud rate is selected with 125 kbits as default This setti...

Страница 36: ...Rev 01 08 20 36 Start up OptiStar All in One CG22 C ...

Страница 37: ... Program 001 active 2 Select the desired program number 001 250 using or key 3 Change the application parameters as required Programs 001 250 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 Nm h High voltage 80 kV Spray current 20 µA Electrode rinsing air 0 1 Nm h Change the application parame...

Страница 38: ...sponding value with the or key 4 Scroll to the next or previous parameter with the or key Selection is cyclical i e after the last parameter the first starts again and vice versa 5 Press key to quit the application parameter mode The display switches to the START screen ...

Страница 39: ...ry error message Setting the total air volume 1 Adjust the total air volume according to the corresponding coating requests correct powder cloud too little total air Setting the powder output 1 Adjust the powder output volume e g according to the desired coating thickness much powder little powder Factory default setting of 50 is recommended for initial operation The total air volume is thereby ke...

Страница 40: ...tion OptiStar All in One CG22 C Setting the electrode rinsing air 1 Adjust the correct electrode rinsing air according to the applied nozzles deflector plate flat jet nozzle 0 1 Nm h 0 5 Nm h too much electrode rinsing air ...

Страница 41: ...ting and vice versa the powder output will cease so that the device is in a defined mode after transfer Remote operating mode is signaled by the symbol REMOTE System release in network operation 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 Signal Designation Trigger Gun connected System re...

Страница 42: ...owder outputs in the plant ATTENTION Incorrectly set correction values can lead to coating errors The plant was optimally set by the Gema service engineer at the first start up Changes of correction values may only be made by Gema trained personnel Entering the correction values 1 Switch on the gun control unit 2 Hold key down for 3 seconds 3 Set the corresponding correction value with the or key ...

Страница 43: ...n value 40 100 100 C2 Daily correction value 50 150 100 C4 Threshold value Suction section clogged mbar 200 5 70 C5 Threshold value Powder hose clogged mbar 30 70 50 5 Scroll to the next or previous correction value with the or key Selection is cyclical i e after the last correction value the first starts again and vice versa 6 Press key to quit the correction values mode The display switches to t...

Страница 44: ...imum powder output C1 and set it to 100 if necessary For the next steps a measuring bag is necessary for weighing the powder output Do not forget to note the dead weight of the measuring bag 7 Put the measuring bag over the gun nozzle and fasten it Switch on the gun for 60 seconds 8 After this time has elapsed switch off the gun remove the measuring bag and weigh it The powder output should be bet...

Страница 45: ...culated values C1 for each individual gun in the table and enter the values to the control unit therefore repeat the steps 2 and 3 Example table for powder offset and powder hose correction Gun Powder offset correction C0 No Before correction After correction 1 C0 1 8 Nm h 20 g C0 1 7 Nm h 12 g 2 C0 1 8 Nm h 10 g C0 1 8 Nm h 13 g 3 C0 1 8 Nm h 0 g C0 2 6 Nm h 12 g etc Gun Powder hose correction C1...

Страница 46: ...ing fig 13 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 Daily correction value C2 The daily correction value C2 can be used to allow higher or lower powder volumes ...

Страница 47: ...als are present 1 Select the desired rinsing function on the MagicControl 4 0 Rinsing function A Powder hose cleaning with increasing air volume B Powder hose cleaning with constant air volume 2 During the Powder hose cleaning with increasing air volume mode all airflows are increased step by step after starting the rinsing procedure and then they remain at the maximum Time s 0 1 2 3 4 Conveying a...

Страница 48: ... Select the submenu INFO in the MAIN MENU The actual software version is displayed Trigger counter 1 Select the submenu INFO in the MAIN MENU 2 Press or for switching to the next display The trigger counter total time in days of trigger time is shown The trigger counter can t be reset ...

Страница 49: ...rs except P00 and correction values as well as all user defined values will be overwritten with factory default values By resetting the RAM all user made settings will be set to factory default 1 Select the submenu Settings in the MAIN MENU 2 Press or for switching to the corresponding display All values are reset The control unit must be set up again ...

Страница 50: ...Rev 01 08 20 50 Operation OptiStar All in One CG22 C ...

Страница 51: ... powder conveying see therefore the corresponding user manuals 3 Turn off the compressed air main supply Storage conditions Hazard notes There is no danger to personnel or the environment if the unit is stored properly Type of storage For safety reasons the product should only be stored in a horizontal position Storage duration If the physical conditions are maintained the unit can be stored indef...

Страница 52: ...uirements 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 ...

Страница 53: ...cting cables and hoses The corresponding parts should be replaced immediately if any damage to cables or hoses is discovered All plugs must be properly tightened 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 dan...

Страница 54: ...Rev 01 08 20 54 Maintenance Repairs OptiStar All in One CG22 C ...

Страница 55: ...eir appearance Each error in the list must be individually acknowledged with the key The errors are displayed in the order of their appearance Here is a list of all possible help codes for this Gun control unit Code Description Criteria Remedy Pneumatics 1 H06 Trigger valve Solenoid coil current lower than preset limiting value Valve defective main board or cable defective Contact a Gema service c...

Страница 56: ... defective The control unit is switched off Contact a Gema service center Power supply H20 Voltage supply error Mainboard Mainboard defective Contact a Gema service center H21 Supply undervoltage Power pack defective or overloaded Contact a Gema service center H22 Wrong internal system clock Backup battery is empty Contact Gema Service EEPROM equipment memory H24 EEPROM content invalid EEPROM erro...

Страница 57: ...r clogged No negative pressure on suction side present Check the powder hose H52 Pinch valve Solenoid coil current lower than preset limiting value Valve defective main board or cable defective Contact a Gema service center H53 Cleaning solenoid valve suction side Solenoid coil current lower than preset limiting value Valve defective main board or cable defective Contact a Gema service center H54 ...

Страница 58: ...center H70 Electrode rinsing air position lost Lost steps limit switch defective throttle motor defective Contact a Gema service center Communication mainboard gun H91 Communication error mainboard gun Gun gun cable or Mainboard defective Replace or contact Gema Service Help codes list The last appeared four errors are stored in a list by the software If an error appears which is already in the li...

Страница 59: ...f properly at the end of its service life When disposing of the product the applicable local and regional laws directives and environmental regulations must be complied with Materials The materials must be sorted according to material groups and taken to the appropriate collection points Disassembly of component groups WARNING Live components Risk of fatal injury from electric shock if touched Onl...

Страница 60: ...Rev 01 08 20 60 Disposal OptiStar All in One CG22 C ...

Страница 61: ... Ø 18 15 mm When ordering cable or hose material the required length must also be given The spare part numbers of this bulk stock is always marked with an Wearing parts are always marked with a All dimensions of plastic hoses are specified with the external and internal diameter Example Ø 8 6 mm 8 mm outside diameter o d 6 mm inside diameter i d ATTENTION Use of non original Gema spare parts When ...

Страница 62: ...hout item 1 1016 670 1 Powder conveying unit complete see corresponding spare parts list 2 Valve block complete see corresponding spare parts list 3 Countersunk head screw M4x8 mm 1016 664 4 Compressed air input unit complete see corresponding spare parts list 5 Backplate complete see corresponding spare parts list 6 PT screw 3x8 mm 1017 424 7 Display module complete 1016 657 8 Mainboard with powe...

Страница 63: ...se connection Ø 8 mm 1015 379 2 Plug connection 1016 148 3 Solenoid valve 1015 382 4 PT screw 4x16 mm 1018 919 5 Screw M3x6 mm 1018 785 6 Quick release connection Ø 4 mm 1016 793 7 Silencer 1 8 1016 606 8 Sensor hose 1018 795 10 Compressed air hose 1018 794 Please indicate length Wearing part fig 15 ...

Страница 64: ...plete incl pos 7 1 1014 806 7 1 O ring Ø 11 1x1 6 mm 1017 002 Sensor module complete 1018 906 8 Screw M4x30 mm 1018 915 9 O ring Ø 15x1 5 mm 261 564 10 Filter cover 1018 909 11 Filter tube 1018 908 12 Adapter nipple complete 1018 604 13 O ring Ø 12x2 mm 235 725 Pinch valve module complete 1018 904 15 Pinch valve hose DN7 5 1018 610 16 Screw M4x12 mm 1018 914 17 O ring Ø 16x2 mm 1007 794 18 O ring ...

Страница 65: ...Rev 01 08 20 OptiStar All in One CG22 C Spare parts list 65 Powder conveying unit fig 16 ...

Страница 66: ... screw 4x10 mm 1018 918 4 Quick release connection Ø 8 mm 1015 379 5 Supplementary air flow restrictor complete 1018 615 6 Supplementary air flow restrictor 1018 616 7 O ring Ø 11x1 5 mm 1000 532 8 Throttle valve complete 1016 590 9 Screw M3x10 mm 1018 782 10 Compressed air hose 1018 794 Please indicate length Wearing part ...

Страница 67: ...Rev 01 08 20 OptiStar All in One CG22 C Spare parts list 67 Valve block fig 17 ...

Страница 68: ...ing screw 1018 927 3 Screw M2 5x5 mm 1018 926 4 Gun cable see also spare parts list of the gun 5 CAN bus cable 0 5 m 1002 655 CAN bus cable 4 5 m 387 592 CAN bus cable 5 5 m 388 521 CAN bus cable 6 0 m 388 530 5 1 Bus terminal resistor not shown 387 606 9 Mains cable see enclosed wiring diagram Please indicate length ...

Страница 69: ...Rev 01 08 20 OptiStar All in One CG22 C Spare parts list 69 Connecting material fig 18 ...

Страница 70: ......

Страница 71: ...Fault clearance 55 Figure references in the text 8 G Guidelines European 12 I Intended use 11 M Maintenance 53 Maintenance during storage 52 O Operating elements 18 Displays 18 Input keys 19 Operation 37 Overall view 17 P PCC mode 22 Periodic checks 53 Pictograms 7 Pin assignment 21 Pneumatic data 14 Powder output reference values 14 Presentation of the contents 8 Product description 11 Product sp...

Страница 72: ...Rev 01 08 20 72 Index OptiStar All in One CG22 C ...

Страница 73: ......

Страница 74: ...Rev 01 ...

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