Gema OptiStar 4.0 Operating Instructions And Spare Parts List
  1. Manuals
  2. Brands
  3. Gema Manuals
  4. Control Unit
  5. OptiStar 4.0
  6. Operating instructions and spare parts list

Gema OptiStar 4.0 Operating Instructions And Spare Parts List

Gun control unit
Hide thumbs Also See for OptiStar 4.0:
Table of Contents

Advertisement

Quick Links

EN
Rev. 03
1011 529
Operating instructions and Spare parts list
Gun control unit
OptiStar 4.0 (CG21)
Translation of the original operating instructions

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the OptiStar 4.0 and is the answer not in the manual?

Questions and answers

Даур
April 5, 2025

код ошибки H91 что означает

0
1 comments:
Mr. Anderson
April 5, 2025

Error code H91 for the Gema OptiStar 4.0 indicates a communication error between the mainboard and the gun. The cause may be a defective gun, gun cable, or mainboard. The recommended action is to replace the faulty component or contact Gema Service.

This answer is automatically generated

0
Rodulfo B. Giganto
May 8, 2025

Good Day! Our Gema Optistar 4.0 Optiflex Pro no power or no display supply but grounded what is the cause of this problem?

0

Subscribe to Our Youtube Channel

Related Manuals for Gema OptiStar 4.0

Summary of Contents for Gema OptiStar 4.0

  • Page 1 Rev. 03 1011 529 Operating instructions and Spare parts list Gun control unit OptiStar 4.0 (CG21) 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

    Scope of delivery ....................23 Typical properties – Characteristics of the functions ..........23 Operating modes ..................23 Communication with the Gema electrostatic app ........25 Rinsing mode ................... 26 Remote control by gun ................26 Keyboard lock ..................27 Background illumination ................
  • Page 4 Help codes list ..................59 Appearance of errors ................59 Disposal Introduction ......................61 Requirements on personnel carrying out the work ........61 Disposal regulations ................61 Materials ....................61 Disassembly of component groups ..............61 4  Table of contents OptiStar 4.0 (CG21)
  • Page 5 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 Table of contents  5 OptiStar 4.0 (CG21)

  • Page 7: About These Instructions

    General information This operating manual contains all important information which you require for the working with the OptiStar 4.0 (CG21). 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: Structure Of Safety Notes

    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 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 OptiStar 4.0 (CG21)

  • Page 11: Product Description

    Rev. 03 05/20 Product description Intended use This gun control unit is designed exclusively for controlling the Gema powder coating guns (see also in chapter "Technical data"). fig. 1 Observance of the operating, service and maintenance instructions specified by the manufacturer is also part of conformity of use. This...

  • Page 12: A Summary Of The Directives And Standards

    Trade Union information concerning health and 209-052 safety during work (BGI) Reasonably foreseeable misuse – Operation without the proper training – Use with insufficient compressed air quality – Use in connection with unauthorized coating devices or components 12  Product description OptiStar 4.0 (CG21)

  • Page 13: Technical Data

    Rev. 03 05/20 Technische Daten Technical Data Connectable guns OptiStar 4.0 (CG21) connectable OptiSelect Pro Type GM04 OptiSelect Pro Type GM04-CF yes** OptiSelect type GM03 yes* TriboJet yes** The PowerBoost functionality is not available The gun type must be configured (refer to chapter "Typical properties –...

  • Page 14: Pneumatic Data

    Rev. 03 05/20 Pneumatic data OptiStar 4.0 (CG21) Compressed air connection 8 mm Max. input pressure 5.5 bar / 80 psi Max. water vapor content of the 1.3 g/m³ compressed air Max. oil vapor content of the 0.1 mg/m³ compressed air...

  • Page 15: 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. Factory OptiStar 4.0 (CG21) Range setting Flow rate – fluidizing air: –...

  • Page 16: Sound Pressure Level

    Rev. 03 05/20 Sound pressure level OptiStar 4.0 (CG21) 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.

  • Page 17: Compatibility And Interactions

    OptiFlex Dual Gun Kit B, F – OptiFlex Dual Gun Wall Kit B, F Design and function Overall view Fig. 3 Front plate with control and Back panel with interfaces display elements Enclosure Product description  17 OptiStar 4.0 (CG21)

  • Page 18: Operating Elements

    Display of predefined operating modes or display of cleaning mode during cleaning – Display of readiness for pairing the Bluetooth module with a mobile device (green) – Display of an active connection (blue) 18  Product description OptiStar 4.0 (CG21)
  • Page 19 Fluidizing* (display in Nm³/h) 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 Product description  19 OptiStar 4.0 (CG21)
  • Page 20 2 seconds) – Display of the ID number (press for a short time) – Switching on the rinsing mode (PowerClean) with optional PowerClean module – Terminating the rinsing mode (PowerClean) with optional PowerClean module 20  Product description OptiStar 4.0 (CG21)

  • Page 21: Connections

    Vibration motor connection for equipment type B 2.3 Gun Gun cable connection 2.4 Power Connection to rinsing module Clean Conveying air connection Supplementary air connection Electrode rinsing air connection Fluid air connection Grounding connection Product description  21 OptiStar 4.0 (CG21)
  • Page 22 Neutral conductor Output vibrator, phase Not used PE grounding Gun connection Ground Remote control 1 (GM03) Ground Trigger Remote control 2 (GM03) Oscillator PE grounding PowerClean Connection Ground +24 VDC Not used PE grounding 22  Product description OptiStar 4.0 (CG21)

  • Page 23: Scope Of Delivery

    This application mode is suitable for the overcoating of workpieces which are already coated. In this operating modes, current (µA) and high voltage (kV) are preset, while powder and air volumes can be set and stored for each application mode. Product description  23 OptiStar 4.0 (CG21)
  • Page 24 The control unit automatically switches to PowerBoost mode when the spray voltage value above 100 kV is selected. The high voltage and spray current values and their symbols are depicted in red: fig. 11: PowerBoost Mode 24  Product description OptiStar 4.0 (CG21)

  • Page 25: Communication With The Gema Electrostatic App

    Rev. 03 05/20 Communication with the Gema electrostatic app The control unit is prepared for communication* with the Gema electrostatic app. The electrostatic app is optimized for mobile devices with a screen diagonal up to 15 cm (6"). The app enables customers to improve their productivity by providing the...

  • Page 26: Rinsing Mode

    P12. – Modify the powder output (press the Λ or V key on the gun. The powder output will be increased or decreased accordingly) – Switch to PowerClean mode (Press P button) 26  Product description OptiStar 4.0 (CG21)

  • Page 27: Keyboard Lock

    The keyboard lock is cancelled if a RAM reset is performed. Background illumination Brightness 8 different brightness settings are available for the display. The setting remains in place when the machine is switched on/off. Product description  27 OptiStar 4.0 (CG21)

  • Page 28: Correction Values

    The settings are also retained if the device type is changed. The Tribo gun mode can also be deactivated using the procedure mentioned above. The charging current (µA) is displayed in the main menu during coating process: fig. 15: 28  Product description OptiStar 4.0 (CG21)

  • Page 29: Assembly / Connection

    Rev. 03 05/20 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 Assembly / Connection  29 OptiStar 4.0 (CG21)

  • Page 30: 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! 30  Assembly / Connection OptiStar 4.0 (CG21)

  • Page 31: Start-Up

    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  31 OptiStar 4.0 (CG21)
  • Page 32 3: Automatic device (CG20/CG20-C) Device type 4: Stirrer device with S Fd fluidization (CG21) 5: Application pump (CG23-P) 6: Application pump + CAN bus (CG24-CP) 7: Cup gun unit Type CF with GM04-CF gun (CG21) 32  Start-up OptiStar 4.0 (CG21)
  • Page 33 2: Powder output +/- PowerBoost (Activation) is not overwritten, if a Memory Reset is performed Default values are marked by bold print. Press key to quit the system parameter mode. The display switches to the standard level Start-up  33 OptiStar 4.0 (CG21)
  • Page 34 (trigger). The T12 key turns the The T12 key turns the vibration On and Off fluidization On and Off. Stirrer device Stirrer On during (type S) triggering 34  Start-up OptiStar 4.0 (CG21)
  • Page 35 19: System parameter P01 See chapter "Rinsing mode" on page 47. P01 parameter Description value Manual equipment without PowerClean module Manual equipment with PowerClean module Type Q Manual coating equipment with PowerClean module Start-up  35 OptiStar 4.0 (CG21)
  • Page 36 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. 36  Start-up OptiStar 4.0 (CG21)
  • Page 37 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 Start-up ...
  • Page 38 Activating/Deactivating the rinse mode Program change +/- Activating/Deactivating the rinse mode Change the powder output +/- Activation of the PowerBoost function ATTENTION: This value must not be selected when operating devices type "Q Dual Gun"! 38  Start-up OptiStar 4.0 (CG21)

  • Page 39: Pairing Of The Bluetooth Module With A Mobile Device

    The communication partners exchange key data so that they automatically recognize each other next time. More information on how to use Gema's E-app can be found in a separate manual. Start-up  39 OptiStar 4.0 (CG21)
  • Page 40 Rev. 03 05/20 40  Start-up OptiStar 4.0 (CG21)

  • Page 41: Operation

    Application mode Preset kV Preset µA flat parts complicated parts overcoat The air values for total air, powder output and electrode rinsing air can be individually defined and are saved in the programs. Operation  41 OptiStar 4.0 (CG21)

  • Page 42: Starting The Individual Adjustable Programs

    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 42  Operation OptiStar 4.0 (CG21)
  • Page 43 To achieve maximum efficiency, we recommend avoided an overly high powder volume where possible! Check fluidization of the powder in the powder container Point the gun into the booth, switch the gun on and visually check the powder output Operation  43 OptiStar 4.0 (CG21)

  • Page 44: Setting The Electrode Rinsing Air

    If in this display level is no operation for 3 seconds, the device switches back to the first display level – The powder should only be touched gently, but should be "cooked" regularly and is also to be stirred using a rod Close again the cover 44  Operation OptiStar 4.0 (CG21)

  • Page 45: Correction Values

    (e.g. the adjustment of different powder 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.
  • Page 46 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. Correction value and range for the type CF cup unit Press the The display returns to the first level display. 46  Operation OptiStar 4.0 (CG21)

  • Page 47: Rinsing Mode

    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. Detach the injector START = Operation  47 OptiStar 4.0 (CG21)
  • Page 48 Manual equipment with optional PowerClean module (system parameter P01= 1 or P01=2) The rinsing mode can only be activated from standby mode (main menu display, no powder conveying). START = 48  Operation OptiStar 4.0 (CG21)
  • Page 49 Manual PowerClean impulse by pressing the gun trigger a (manual) second time STOP = OR the cleaning mode is terminated automatically. After completion of the PowerClean procedure, the controller switches back to coating mode. Operation  49 OptiStar 4.0 (CG21)

  • Page 50: Setting The Background Illumination

    The keyboard lock is cancelled by pressing the same key combination Checking the software version Press these two keys at the same time – The status display is shown as long as the keys are held. 50  Operation OptiStar 4.0 (CG21)

  • Page 51: Checking The Trigger Time

    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. Operation  51 OptiStar 4.0 (CG21)
  • Page 52 Rev. 03 05/20 52  Operation OptiStar 4.0 (CG21)

  • Page 53: 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  53 OptiStar 4.0 (CG21)

  • Page 54: 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. 54  Decommissioning / Storage OptiStar 4.0 (CG21)

  • Page 55: 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 56 Rev. 03 05/20 56  Maintenance / Repairs OptiStar 4.0 (CG21)

  • Page 57: Fault Clearance

    Here is a list of all possible help codes for this Gun control unit: Code Description Criteria Remedy Pneumatics: – PowerClean valve not connect or replace connected – Valve defective Contact a Gema service PowerClean valve – Connection cable center defective – Mainboard defective Fault clearance  57 OptiStar 4.0 (CG21)
  • Page 58 Rev. 03 05/20 Code Description Criteria Remedy Solenoid coil current lower than Contact a Gema service preset limiting value center Trigger valve Valve defective, main board or cable defective The preset value for Lower supplementary air Supplementary air supplementary air is too high...

  • Page 59: Help Codes List

    Rev. 03 05/20 Code Description Criteria Remedy Supplementary air Throttle motor or needle Contact a Gema service reference position not jammed, limit switch defective, center found error in motor throttle Electrode rinsing air Throttle motor or needle Contact a Gema service...
  • Page 60 Rev. 03 05/20 60  Fault clearance OptiStar 4.0 (CG21)

  • Page 61: 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 62 Rev. 03 05/20 62  Disposal OptiStar 4.0 (CG21)

  • Page 63: 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  63 OptiStar 4.0 (CG21)

  • Page 64: Optistar Cg21 Gun Control Unit

    OptiStar CG21 gun control unit – complete, without item 4 1015 203 Front plate – complete, see corresponding spare parts list Enclosure Backplate – complete, see corresponding spare parts list Cover 1015 249 4 ––––– fig. 24 64  Spare parts list OptiStar 4.0 (CG21)

  • Page 65: Front Plate And Power Pack

    Membrane keypad with carrier plate 1015 217 Spacer sleeve – Ø 3.6/7x5 mm Display 1015 220 Washer – Ø 3.2/7x0.5 mm Locknut – M3 Power pack – 24 VDC 1009 849 Fig. 25 Spare parts list  65 OptiStar 4.0 (CG21)

  • Page 66: Inside Back Plate

    1001 521 Fluidizing pad – 1/8" 237 264 Screw – M4x16 mm 1013 925 Plastic tube – Ø 8/6 mm 103 152* Motor throttle – complete 1008 012 * Please indicate length 66  Spare parts list OptiStar 4.0 (CG21)

  • Page 67: Inside Back Plate

    Rev. 03 05/20 Inside back plate fig. 26: OptiStar CG21 Spare parts list  67 OptiStar 4.0 (CG21)

  • Page 68: Connecting Material

    Mains cable – Schuko 382 485 Mains cable – USA 382 507 Mains cable – GB 382 515 Mains cable – AUS 382 523 Mains cable – China 1000 993 * Please indicate length 68  Spare parts list OptiStar 4.0 (CG21)

  • Page 69: Connecting Material

    Rev. 03 05/20 Connecting material fig. 27 Spare parts list  69 OptiStar 4.0 (CG21)
  • Page 71 Guidelines, European ........12 Standards, European ........12 Start-up ............31 Storage ............53 Storage conditions ........... 53 Input keys and switches ........19 Intended use ............ 11 Typical characteristics ........23 Maintenance ............. 55 Index  71 OptiStar 4.0 (CG21)
  • Page 72 Rev. 03 05/20 72  Index OptiStar 4.0 (CG21)
  • Page 74 Rev. 03...

This manual is also suitable for:

Gg21

Table of Contents

Save PDF