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Rev. 03 05/20

OptiStar 4.0 (CG21)

Start-up



Start-up

Preparation for start-up

The gun control unit always starts up to the last configured
settings.

Basic conditions

When starting up the gun control unit, the following general conditions
impacting the coating results must be taken 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.

Entering the system parameters

Turn on the gun control unit with the

key

Hold

key down for 5 seconds

– The display switches to the following level:

Содержание GG21

Страница 1: ...Rev 03 1011 529 EN Operating instructions and Spare parts list Gun control unit OptiStar 4 0 CG21 Translation of the original operating instructions ...

Страница 2: ...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 trad...

Страница 3: ... guns 13 Electrical data 13 Pneumatic data 14 Dimensions 14 Powder output reference values 14 Air flow rates 15 Environmental conditions 15 Sound pressure level 16 Rating plate 16 Compatibility and interactions 17 Design and function 17 Overall view 17 Operating elements 18 Connections 21 Scope of delivery 23 Typical properties Characteristics of the functions 23 Operating modes 23 Communication w...

Страница 4: ...ion 47 Setting the background illumination 50 Activate deactivate the keyboard lock 50 Checking the software version 50 Checking the trigger time 51 RAM Reset 51 Decommissioning Storage 53 Shutdown 53 If in disuse for several days 53 Storage conditions 53 Hazard notes 53 Type of storage 53 Storage duration 53 Space requirements 53 Physical requirements 54 Maintenance during storage 54 Maintenance ...

Страница 5: ...4 0 CG21 Table of contents 5 Spare parts list 63 Ordering spare parts 63 OptiStar CG21 Gun control unit 64 Front plate and power pack 65 Inside back plate 66 Inside back plate 67 Connecting material 68 Connecting material 69 ...

Страница 6: ......

Страница 7: ... 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 WARNIN...

Страница 8: ...ossible 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 4 0 CG21 with software version starting from 1 00 See chapter Checking the software version on page 50 Presentation of the contents Figure references i...

Страница 9: ...he 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 Pr...

Страница 10: ...tions 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: ...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 co...

Страница 12: ...EU Electromagnetic compatibility EN 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 pow...

Страница 13: ... functions The Tribo gun the gun is not type approved ATEX WARNING The gun control unit may only be used with the specified gun types Electrical data OptiStar 4 0 CG21 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 Connection and ...

Страница 14: ... Epoxy polyester Powder hose Ø mm 11 Type of powder hose POE with guide strips Input pressure bar 5 5 Correction value C0 Powder output zeroing adjustment Guide values for OptiStar with OptiFlow Injector All values in these tables are guide values for new nozzle inserts Differing environmental conditions wear and different powder types can affect the table values Hose internal diameter mm Ø 11 Hos...

Страница 15: ...plementary air flow rate 0 5 5 Nm h The max total air consumption during the coating operation is 5 5 Nm h Total air 5 Nm h conveying air supplementary air Electrode rinsing air 0 1 Nm h flat jet nozzle The total air consumption for the device is determined based on the 3 configured air values without AirMover air value for device type F These values apply for an internal control pressure of 5 5 b...

Страница 16: ...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 ...

Страница 17: ...B Q with powder box OptiFlex F with fluidized powder hopper OptiFlex S with stirrer container OptiFlex C with application cup OptiFlex CF with funnel cup OptiFlex L with lab device OptiFlex W K Kits OptiFlex Dual Gun Kit B F OptiFlex Dual Gun Wall Kit B F Design and function Overall view Fig 3 1 Front plate with control and display elements 2 Enclosure 3 Back panel with interfaces ...

Страница 18: ...e 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 Nm h S7 High voltage display in kV S9 Spraying current display in µA S12 remote Remote operation mode no local operation possible Remote operation mode is used as keyboard lock reduced operation is possible S13 Activation of vibration fluidizatio...

Страница 19: ...s Level 2 Designation Function S3 Electrode rinsing air display in Nm h S6 Fluidizing display in Nm h S19 Display background illumination 0 8 The value for this function cannot be set for the OptiSelect Pro GM04 CF gun type Input keys and switches fig 6 Input keys and switches ...

Страница 20: ...ver to system parameter mode press for at least 5 secs T13 Preset mode for flat parts fixed values T14 Preset mode for complex parts with depressions fixed values T15 Preset mode for overcoating parts already coated fixed values T16 T17 Power switch On Off T18 Activation of the pairing readiness from the Bluetooth module to the mobile device press for at least 2 seconds Display of the ID number pr...

Страница 21: ... air IN Compressed air connection 2 1 Power IN Mains cable connection 2 2 Aux Vibration motor connection for equipment type B 2 3 Gun Gun cable connection 2 4 Power Clean Connection to rinsing module 1 2 Conveying air connection 1 3 Supplementary air connection 1 4 Electrode rinsing air connection 1 5 Fluid air connection Grounding connection ...

Страница 22: ...e 100 240 VAC 3 Output vibrator or stirrer PE PE grounding Aux Connection 1 Neutral conductor 2 Output vibrator phase 3 Not used PE PE grounding Gun connection 1 Ground 2 Remote control 1 GM03 3 Ground 4 Trigger 5 Remote control 2 GM03 6 Oscillator 7 PE grounding PowerClean Connection 1 Ground 2 24 VDC 3 Not used PE PE grounding ...

Страница 23: ...on mode for flat parts This application mode is suitable for the coating of simple flat workpieces without larger cavities Application mode for complicated parts This application mode is suitable for the coating of three dimensional workpieces with complex shapes e g profiles Application mode for recoating parts already coated This application mode is suitable for the overcoating of workpieces whi...

Страница 24: ...ent unintended overcoating on the simpler surfaces This is especially important in combination with high loading powders such as metallic The controller automatically switches into PCC mode This allows for very fast yet highly precise control The high voltage and spray current values and their symbols are depicted in red Fig 10 PCC mode Maximum coating performance PowerBoost Mode For maximum coati...

Страница 25: ... 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 components and to the Gema website ...

Страница 26: ...ndby mode namely by pressing the P key on the gun remote control or the key on the gun control unit See chapter Rinsing mode on page 47 The rinsing mode is signalized by a circling LCD segment on the display fig 12 Rinsing mode active The rinsing procedure is stopped by pressing the gun trigger Once the cleaning mode is quit the unit automatically returns to the last program Remote control by gun ...

Страница 27: ...eyboard lock The gun control unit has a keyboard lock to prevent modification of individual parameter values kV µA etc within the operating modes Program and Preset Following is not affected by the keyboard lock Program selection 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 di...

Страница 28: ...he cup gun type OptiSelect Pro GM04 CF can be connected to the manual gun control unit The gun control must first be set to this gun type in system parameter P00 before start up See chapter System parameters on page 31 Operation and configuration of the Tribo gun The Tribo gun can be connected to the manual gun control unit The Tribo gun can be configured by holding the keys T5 and T6 when switchi...

Страница 29: ...tiStar 4 0 CG21 Assembly Connection 29 Assembly Connection Assembly guide The gun control unit is mounted into place using 2xM6 screws on the front side Please contact Gema for other installation possibilities Fig 16 ...

Страница 30: ...ntrol signal cable 8 Injector 9 PowerClean module Option 10 Compressed air hose 11 Fluidizing air hose 12 Maintenance unit 13 OptiStar Control unit 14 Rinsing air hose Use clamp to connect grounding cable to the cabin 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...

Страница 31: ... taken 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 Entering the system parameters 1 Turn on the gun control unit with the ON key ...

Страница 32: ... with the T1 or T2 key Selection is cyclical i e after the last system parameter the first starts again and vice versa 6 Select parameter values according to the following table No Description Values Display P001 Device type 0 Fluidizing device type F CG21 F 1 Box device with vibrator Type B CG21 B 2 Stirrer device Type S CG21 S 3 Automatic device CG20 CG20 C A 4 Stirrer device with fluidization C...

Страница 33: ...tting 0 Standard PA GL 1 Advanced FL ZL Std Adv P10 Log level 0 1 2 3 4 5 LoG P11 Bluetooth ID no 0 Bluetooth deactivated 1 255 blid P12 Remote Manual Gun 0 Powder output PowerClean Activation PAC 1 Program change PowerClean Activation PrC 2 Powder output PowerBoost Activation PAb 1 is not overwritten if a Memory Reset is performed Default values are marked by bold print 7 Press key to quit the sy...

Страница 34: ...to fluidizing box or stirrer types These sub types differ in the control of the vibrator output and the behavior of the fluidizing air Device type Function AUX Output Fluidizing air function Fluidizing device type F Always Off The gun trigger switches the fluidization on The T12 key turns the fluidization On and Off Box device type B Vibration On during triggering wake for 30 seconds Fluidizing ai...

Страница 35: ...h trigger The T12 key also activates or deactivates the fluidization Cup gun device type CF Always Off Fluidizing air always switched off System parameter P01 rinsing mode fig 19 System parameter P01 See chapter Rinsing mode on page 47 P01 parameter value Description 0 Manual equipment without PowerClean module 1 Manual equipment with PowerClean module 2 Type Q Manual coating equipment with PowerC...

Страница 36: ...ing unit These lines are displayed in blue System parameter P10 fig 21 System parameter P10 The device can export log reports of the program run to an SD card for test purposes and for finding defects If an SD card is inserted during the switching on procedure the log messages are also recorded onto the SD card The data are record in the MESSAGES LOG file in the root directory Once this file reach...

Страница 37: ...paired from a level of detail of 4 System parameter P11 Bluetooth ID no fig 22 System parameter P11 The Bluetooth ID number is determined with this parameter An individual Bluetooth ID number must be assigned to each pistol control unit that is to be accessed via the Gema electrostatic app System parameter P12 Remote Manual Gun fig 23 System parameter P12 ...

Страница 38: ...tion 0 Change the powder output Activating Deactivating the rinse mode 1 Program change Activating Deactivating the rinse mode 2 Change the powder output Activation of the PowerBoost function ATTENTION This value must not be selected when operating devices type Q Dual Gun ...

Страница 39: ... an app distribution platform or Keyword gema e app ID number set in system parameter P11 Bluetooth activated on mobile device To use Gema s E app proceed as follows 1 Start the E app 2 Keep the key on the control unit pressed for two seconds 3 Press 4 Select OptiStar the control unit is now paired The communication partners exchange key data so that they automatically recognize each other next ti...

Страница 40: ...Rev 03 05 20 40 Start up OptiStar 4 0 CG21 ...

Страница 41: ... control unit with the ON key 2 Press the corresponding application key The arrow above the desired button lights up The pre defined application modes have preset values for high voltage and spray current Application mode Preset kV Preset µA flat parts 100 100 complicated parts 100 22 overcoat 100 10 3 The air values for total air powder output and electrode rinsing air can be individually defined...

Страница 42: ...g air 0 1 Nm h Fluidizing air 1 0 Nm h for device type F 0 1 Nm h for device type B and S Setting powder output and powder cloud The powder output depends on the selected powder output in and the powder cloud on the selected total air volume As a factory default value a powder rate of 50 and a total air volume of 4 Nm h are recommended If values are entered that the gun control unit cannot impleme...

Страница 43: ... coating thickness Factory default setting of 50 is recommended for initial operation The total air volume is thereby kept constant automatically by the control unit To achieve maximum efficiency we recommend avoided an overly high powder volume where possible 2 Check fluidization of the powder in the powder container 3 Point the gun into the booth switch the gun on and visually check the powder o...

Страница 44: ...s on the powder type the air humidity and the ambient temperature Fluidizing and vibration start by switching on the control unit Procedure 1 Configure AirMover by opening the ball valve complete and adjusting with the flow control valve equipment type F only 2 Open the powder container cover equipment type F only 3 Press the key The second display level will be shown 4 Adjust the fluidizing air w...

Страница 45: ...ON 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 Setting correction factor for powder output Entering the correction values 1 Hold key down for 5 seconds The display switches to the following level 2 Press the key The display switches...

Страница 46: ...ng to the following table Corr value Description Range2 Default value1 C0 Powder output 0 5 3 0 1 0 0 0 3 03 0 03 1 The correction value is set to its default value if the default value changes when the P00 device type is changed 2 The correction value is set to its default value if it is outside of the value range after the P00 device type has been changed 3 Correction value and range for the typ...

Страница 47: ...ment without optional PowerClean module system parameter P01 0 The rinsing mode can only be activated from standby mode main menu display no powder conveying On manual coating equipment type F the injector must be disconnected prior to cleaning procedure on type B the suction unit must be lifted and on type S the powder container must be empty 1 Detach the injector 2 OR 3 START ...

Страница 48: ...de is exited if the automatic rinsing sequence has finished Manual manual The operator controls the number and length of the PowerClean impulse by pressing the gun trigger a second time 4 STOP OR OR the cleaning mode is terminated automatically After completion of the PowerClean procedure the controller switches back to coating mode Manual equipment with optional PowerClean module system parameter...

Страница 49: ...cleaning of other components such as the fluid intake unit powder container etc The rinsing mode is exited if the automatic rinsing sequence has finished Manual manual The operator controls the number and length of the PowerClean impulse by pressing the gun trigger a second time 3 STOP OR OR the cleaning mode is terminated automatically After completion of the PowerClean procedure the controller s...

Страница 50: ...ed brightness Activate deactivate the keyboard lock 1 Hold key pressed 2 Press the corresponding key The keyboard lock will be activated The remote display blinks 3 The keyboard lock is cancelled by pressing the same key combination Checking the software version 1 Press these two keys at the same time The status display is shown as long as the keys are held ...

Страница 51: ...settings of the gun control unit All parameters except P00 and correction values as well as all user defined values in the Program mode and Preset mode will be overwritten with factory default values An active keyboard lock will be deactivated By resetting the RAM all user made settings will be set to factory default 1 Switch off the device 2 Press the key and hold it 3 Switch on the control unit ...

Страница 52: ...Rev 03 05 20 52 Operation OptiStar 4 0 CG21 ...

Страница 53: ...er 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 indefinite...

Страница 54: ...ments 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 55: ... 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 danger f...

Страница 56: ...Rev 03 05 20 56 Maintenance Repairs OptiStar 4 0 CG21 ...

Страница 57: ...n in red on the A5 display The help codes are stored in an error list in the order of their appearance Each error in the list must be individually acknowledged with the keys T10 or T11 The errors are displayed in the order of their appearance The T10 and T11 keys cannot be used for other functions as long as an error code is still shown Here is a list of all possible help codes for this Gun contro...

Страница 58: ...rrection value H10 Conveying air range lower deviation The theoretical value for conveying air falls below minimum Total air is smaller than minimum Limit conveying air to its minimum value High voltage H11 Gun error No vibrations in the oscillator cable break oscillator or gun is defective Contact a Gema service center H13 Gun Overload Cable or cascade defective The control unit is switched off C...

Страница 59: ...g air throttle does not move Short circuit in limit switch motor throttle defective Contact a Gema service center H68 Conveying air position lost Lost steps limit switch defective throttle motor defective Contact a Gema service center H69 Supplementary air position lost Lost steps limit switch defective throttle motor defective Contact a Gema service center H70 Electrode rinsing air position lost ...

Страница 60: ...Rev 03 05 20 60 Fault clearance OptiStar 4 0 CG21 ...

Страница 61: ...operly 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 Only tr...

Страница 62: ...Rev 03 05 20 62 Disposal OptiStar 4 0 CG21 ...

Страница 63: ...8 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 usin...

Страница 64: ...21 OptiStar CG21 Gun control unit OptiStar CG21 gun control unit complete without item 4 1015 203 1 Front plate complete see corresponding spare parts list 2 Enclosure 3 Backplate complete see corresponding spare parts list 4 Cover 1015 249 4 fig 24 ...

Страница 65: ...e 1015 221 2 Spacer sleeve Ø 3 1 6x15 mm 3 PCB Powerboard complete 1015 223 4 Spacer sleeve Ø 3 2 6x7 mm 5 Front frame complete incl pos 5 1 1015 232 5 1 Screw 1007 019 6 Screw M4x16 mm 1013 925 7 Front plate gasket 1015 236 8 Membrane keypad with carrier plate 1015 217 9 Spacer sleeve Ø 3 6 7x5 mm 10 Display 1015 220 11 Washer Ø 3 2 7x0 5 mm 12 Locknut M3 13 Power pack 24 VDC 1009 849 Fig 25 ...

Страница 66: ...72 3 T piece 1 4 Ø 8 Ø 8 mm 1008 040 4 Solenoid valve Ø 8 Ø 8 mm 24 VDC 1003 914 5 O ring Ø 12x1 5 mm NBR70 261 416 6 Motor throttle complete 1000 064 7 O ring Ø 8x4 mm NBR70 1001 521 8 Fluidizing pad 1 8 237 264 9 Screw M4x16 mm 1013 925 10 Plastic tube Ø 8 6 mm 103 152 11 Motor throttle complete 1008 012 Please indicate length ...

Страница 67: ...Rev 03 05 20 OptiStar 4 0 CG21 Spare parts list 67 Inside back plate fig 26 OptiStar CG21 ...

Страница 68: ... 3 1 Conveying air hose Ø 8 6 mm red 103 500 3 2 Quick release coupling for conveying air hose NW5 Ø 8 mm 261 645 4 Quick release connection NW5 Ø 8 mm 203 181 4 1 Hose Ø 8 6 mm 103 756 5 Quick release connection NW 5 Ø 6 mm 200 840 5 1 Hose Ø 6 4 mm 100 854 6 Vibrator cable constituent part of vibrator 8 PowerClean module cable 1 m option 1009 879 PowerClean module cable 15 m option 1009 880 9 Ma...

Страница 69: ...Rev 03 05 20 OptiStar 4 0 CG21 Spare parts list 69 Connecting material fig 27 ...

Страница 70: ......

Страница 71: ...pean 12 I Input keys and switches 19 Intended use 11 M Maintenance 55 Maintenance during storage 54 O Operating elements 18 Displays 18 Input keys and switches 19 Operating modes 23 Operation 41 Overall view 17 P PCC mode 24 Periodic checks 55 Pictograms 7 Pin assignment 22 Pneumatic data 14 Powder output reference values 14 PowerBoost Mode 24 Presentation of the contents 8 Preset mode 23 Product ...

Страница 72: ...Rev 03 05 20 72 Index OptiStar 4 0 CG21 ...

Страница 73: ......

Страница 74: ...Rev 03 ...

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