Gema OptiStar All-in-One Operating Instructions And Spare Parts List
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Gema OptiStar All-in-One Operating Instructions And Spare Parts List

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

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Summary of Contents for Gema OptiStar All-in-One

  • Page 1 Rev. 01 1011 530 Operating instructions and Spare parts list Gun control unit OptiStar All-in-One (CG22-C) 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

    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 .....................
  • Page 4 Periodic checks ....................53 Repair work ......................53 Fault clearance Error diagnosis of the software ................55 General information ................. 55 Help codes ....................55 Help codes list ..................58 Appearance of errors ................58 4  Table of contents OptiStar All-in-One (CG22-C)
  • Page 5 Materials ....................59 Disassembly of component groups ............... 59 Spare parts list 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 ........................

  • Page 7: About These Instructions

    General information This operating manual contains all important information which you require for the working with the OptiStar All-in-One (CG22-C). 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

    Figure references in the text Figure references are used as cross references in the descriptive text. Example: "The high voltage (H) created in the gun cascade is guided through the center electrode." 8  About these instructions OptiStar All-in-One (CG22-C)

  • 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 All-in-One (CG22-C)

  • Page 11: Product Description

    Rev. 01 08/20 Product description Intended use This gun control unit is designed exclusively for controlling the Gema powder coating guns as well as for the powder transport by means of the integrated injector (see also in chapter "Technical data").

  • Page 12: A Summary Of The Directives And Standards

    Operation without the proper training – Use with insufficient compressed air quality – Use in connection with unauthorized coating devices or components – Use of enameled powder – Use of moist powder – Incorrectly assembled individual parts 12  Product description OptiStar All-in-One (CG22-C)

  • Page 13: Technical Data

    Versions OptiStar CAN bus All-in-One CG22-C The equipment designation is indicated on the type plate. Connectable guns OptiStar All-in-One (CG22-C) connectable OptiGun type GA03 OptiSelect Pro Type GM04 OptiSelect type GM03 ATTENTION The gun control unit may only be used with the specified gun...

  • Page 14: Pneumatic Data

    Rev. 01 08/20 Pneumatic data OptiStar All-in-One (CG22-C) Compressed air connection Quick coupling 5.5 bar Input pressure (must be set in the 6.0 bar system parameter P2) 6.5 bar Max. input pressure 7-8 bar / 101-116 psi Min. input pressure (while unit in 5.5 bar / 80 psi...

  • 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. OptiStar All-in-One (CG22-C) Conveying air flow rate 0-5.5 Nm³/h Supplementary air flow rate 0-5.5 Nm³/h...

  • Page 16: Environmental Conditions

    Rev. 01 08/20 Environmental conditions OptiStar All-in-One (CG22-C) Utilization in the interior Height up to 2 000 m +5 °C - +40 °C Temperature range (+41 °F - +104 °F) Max. surface temperature +85 °C (+185 °F) 80 % for temperatures to 31 °C,...

  • Page 17: 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 Front plate with control and Back panel with interfaces display elements Injector Enclosure Product description  17 OptiStar All-in-One (CG22-C)

  • Page 18: Operating Elements

    (blinks) – Display of an active connection System release via external release Remote operation mode, no local operation possible – Remote operation mode is used as keyboard lock, reduced operation is possible 18  Product description OptiStar All-in-One (CG22-C)

  • Page 19: Menu Structure

    Parameters) Values) Powder output P00-P12 C0, C1, C2, Pairing Bluetooth Software version C4, C5 (Software version) Total air Rotate the display Trigger counter (Trigger time) High voltage RAM Reset Spray current Electrode rinsing Product description  19 OptiStar All-in-One (CG22-C)

  • Page 20: Connections

    Compressed air hoses / cables fig. 6: Connections Connection Description Powder hose connection Gun cable connection CAN bus connection (OUT) Mains cable connection Compressed air connection Grounding connection CAN bus connection (IN) Electrode rinsing air connection 20  Product description OptiStar All-in-One (CG22-C)

  • Page 21: Scope Of Delivery

    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 – Quick-start guide and operating manual Product description  21 OptiStar All-in-One (CG22-C)

  • Page 22: Typical Properties - Characteristics Of The Functions

    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. 22  Product description OptiStar All-in-One (CG22-C)

  • Page 23: Communication With The Gema Electrostatic App

    Rev. 01 08/20 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 24: Rinsing Mode

    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 in the plant). 24  Product description OptiStar All-in-One (CG22-C)

  • Page 25: Assembly / Connection

    Rev. 01 08/20 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 Assembly / Connection  25 OptiStar All-in-One (CG22-C)

  • 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 OptiStar All-in-One (CG22-C)

  • Page 27: Set-Up

    Rev. 01 08/20 Set-up Usually, this control unit is used in automatic plants. fig. 10: OptiStar All-in-One in OptiCenter Assembly / Connection  27 OptiStar All-in-One (CG22-C)
  • Page 28 Rev. 01 08/20 28  Assembly / Connection OptiStar All-in-One (CG22-C)

  • Page 29: Start-Up

    These values can be adjusted and requested manually or by remote interface (CAN). Entering the system parameters Switch on the gun control unit Hold key down for 3 seconds Start-up  29 OptiStar All-in-One (CG22-C)
  • Page 30 1: P in = 6 bar (Input pressure) 2: P in = 6.5 bar Air unit 0: Nm³/h m³/h (air measurement unit) 1: scfm SCFM Bus interface 0: Deactivated (Interface type) 1: Automatic recognition Auto 30  Start-up OptiStar All-in-One (CG22-C)
  • Page 31 Scroll to the next or previous system parameter with the Selection is cyclical, i.e. after the last system parameter, the first starts again and vice versa. Press key to quit the system parameter mode. – The display switches to the START screen Start-up  31 OptiStar All-in-One (CG22-C)
  • Page 32 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. This value is set to 0 in network operation.

  • Page 33: Pairing Of The Bluetooth Module With A Mobile Device

    – the control unit is now paired. 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. CAN bus General The control unit is a simple CANopen slave.
  • Page 34 11: CAN bus – connections PLC control with CAN bus Terminal resistor CAN bus cable – plug assignment fig. 12: CAN bus cable Signal Color white +24 VDC black CAN H black CAN L black 34  Start-up OptiStar All-in-One (CG22-C)

  • Page 35: 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. Start-up  35 OptiStar All-in-One (CG22-C)
  • Page 36 Rev. 01 08/20 36  Start-up OptiStar All-in-One (CG22-C)

  • Page 37: Operation

    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 Change the application parameters Switch on the gun control unit Press the Operation  37 OptiStar All-in-One (CG22-C)
  • Page 38 Scroll to the next or previous parameter with the Selection is cyclical, i.e. after the last parameter, the first starts again and vice versa. Press key to quit the application parameter mode. – The display switches to the START screen 38  Operation OptiStar All-in-One (CG22-C)

  • Page 39: Setting Powder Output And Powder Cloud

    To achieve maximum efficiency, we recommend avoided an overly high powder volume where possible! Check fluidization of the powder in the powder container Switch the gun on and visually check the powder output Operation  39 OptiStar All-in-One (CG22-C)

  • Page 40: Setting The Electrode Rinsing Air

    Rev. 01 08/20 Setting the electrode rinsing air Adjust the correct electrode rinsing air according to the applied nozzles (deflector plate, flat jet nozzle) ≈ 0.1 Nm³/h ≈ 0.5 Nm³/h too much electrode rinsing air 40  Operation OptiStar All-in-One (CG22-C)

  • Page 41: Remote Operation

    Trigger Gun connected External release Release on mains plug Gun release System System Command via Remote Interface enable logic release Gun ON/OFF Command via Remote Interface Error lock Device error System lock Parameter input Operation  41 OptiStar All-in-One (CG22-C)

  • Page 42: 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 43 Scroll to the next or previous correction value with the Selection is cyclical, i.e. after the last correction value, the first starts again and vice versa. Press key to quit the correction values mode. – The display switches to the START screen Operation  43 OptiStar All-in-One (CG22-C)

  • Page 44: Powder Output/Powder Hose Correction

    The display switches to the START screen Powder hose correction – procedure Set the powder output to 80 (%) Put the measuring bag over the gun nozzle and fasten it. Switch on the gun for 60 seconds 44  Operation OptiStar All-in-One (CG22-C)
  • Page 45 12 g etc. Powder hose correction C1 Before After correction correction C1=100 % 200 g C1=100 % 200 g C1=100 % 250 g C1=80% 200 g C1=100 % 280 g C1=71% 200 g etc. Operation  45 OptiStar All-in-One (CG22-C)

  • Page 46: Correction Factor - Diagram

    – 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! 46  Operation OptiStar All-in-One (CG22-C)

  • Page 47: Rinsing Mode

    During the “Powder hose cleaning with constant air volume” mode, there is no airflow increasing step by step. The maximum values are set immediately. The rinsing mode is exited: – if the rinsing sequence has finished Operation  47 OptiStar All-in-One (CG22-C)

  • Page 48: Checking The Software Version

    Select the submenu INFO in the MAIN MENU Press 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! 48  Operation OptiStar All-in-One (CG22-C)

  • Page 49: Ram Reset

    By resetting the RAM, all user-made settings will be set to factory default! Select the submenu Settings in the MAIN MENU Press for switching to the corresponding display – All values are reset. The control unit must be set-up again. Operation  49 OptiStar All-in-One (CG22-C)
  • Page 50 Rev. 01 08/20 50  Operation OptiStar All-in-One (CG22-C)

  • Page 51: 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  51 OptiStar All-in-One (CG22-C)

  • Page 52: 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. 52  Decommissioning / Storage OptiStar All-in-One (CG22-C)

  • Page 53: 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 54 Rev. 01 08/20 54  Maintenance / Repairs OptiStar All-in-One (CG22-C)

  • Page 55: Fault Clearance

    Here is a list of all possible help codes for this Gun control unit: Code Description Criteria Remedy Pneumatics 1: 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...
  • Page 56 Conveying air range minimum lower deviation Total air is smaller than minimum High voltage: No vibrations in the oscillator, Contact a Gema service Gun error cable break, oscillator or gun is center defective Cable or cascade defective. The Contact a Gema service Gun Overload control unit is switched off.
  • Page 57 Rev. 01 08/20 Code Description Criteria Remedy The message to be sent has no Contact a Gema service more place in the transmission center Overflow on transmission buffer. Messages are produced faster than they can be sent. Node Guarding message is...

  • Page 58: Help Codes List

    Rev. 01 08/20 Code Description Criteria Remedy Electrode rinsing air Short circuit in limit switch, motor Contact a Gema service throttle does not move throttle defective center Conveying air position Lost steps, limit switch defective, Contact a Gema service lost...

  • Page 59: 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 60 Rev. 01 08/20 60  Disposal OptiStar All-in-One (CG22-C)

  • Page 61: 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  61 OptiStar All-in-One (CG22-C)

  • Page 62: Optistar All-In-One (Cg22-C) Gun Control Unit

    OptiStar All-in-One (CG22-C) gun control unit OptiStar All-in-One (CG22-C) gun control unit – complete 1018 600 OptiStar All-in-One (CG22-C) gun control unit – complete, without item 1 1016 670 Powder conveying unit – complete, see corresponding spare parts list Valve block – complete, see corresponding spare parts list Countersunk-head screw –...

  • Page 63: Compressed Air Input Unit

    Quick release connection – Ø 4 mm 1016 793 Silencer – 1/8" 1016 606 Sensor hose 1018 795 Compressed air hose 1018 794 * Please indicate length # Wearing part fig. 15: Spare parts list  63 OptiStar All-in-One (CG22-C)

  • Page 64: Powder Conveying Unit

    Screw – M4x12 mm 1018 914 O-ring – Ø 16x2 mm 1007 794# O-ring – Ø 17x1.5 mm 1003 709 IG08 Interface – complete 1018 901 Quick release connection – Ø 6 mm 1018 917 64  Spare parts list OptiStar All-in-One (CG22-C)

  • Page 65: Powder Conveying Unit

    Rev. 01 08/20 Powder conveying unit fig. 16: Spare parts list  65 OptiStar All-in-One (CG22-C)

  • Page 66: Block

    1018 616 O-ring – Ø 11x1.5 mm 1000 532 Throttle valve – complete 1016 590 Screw – M3x10 mm 1018 782 Compressed air hose 1018 794 * Please indicate length # Wearing part 66  Spare parts list OptiStar All-in-One (CG22-C)

  • Page 67: Valve Block

    Rev. 01 08/20 Valve block fig. 17: Spare parts list  67 OptiStar All-in-One (CG22-C)

  • Page 68: 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 Mains cable – see enclosed wiring diagram * Please indicate length 68  Spare parts list OptiStar All-in-One (CG22-C)

  • Page 69: Connecting Material

    Rev. 01 08/20 Connecting material fig. 18 Spare parts list  69 OptiStar All-in-One (CG22-C)
  • Page 71 Start-up ............29 Figure references in the text ......8 Storage ............51 Storage conditions ........... 51 Guidelines, European ........12 Typical characteristics ........22 Intended use ............ 11 Versions ............13 Maintenance ............. 53 Index  71 OptiStar All-in-One (CG22-C)
  • Page 72 Rev. 01 08/20 72  Index OptiStar All-in-One (CG22-C)
  • Page 74 Rev. 01...

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