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Summary of Contents for Gema OptiStar CG06
- Page 1 Operating instructions and spare parts list OptiStar CG06 Automatic gun control unit 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 issue. Gema Switzerland GmbH makes no representations or warranties with respect to the con- tents or use of this publication, and reserves the right to revise this publi- cation and make changes to its content without prior notice.
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Page 3: Table Of Contents
General information ....................13 Software version ....................13 Function description Field of application ....................15 OptiStar CG06 Automatic gun control unit ............15 Typical characteristics ................15 Basic functions ..................16 Additional functions .................. 16 OptiStar CG06 functions - overview ............16 Operating modes .................... - Page 4 Daily start up ......................30 Select the operating mode............... 30 Setting powder output and powder cloud ..........31 OptiStar CG06 gun release ..............32 Setting the electrode rinsing air ............... 33 Setting the shaping air (optional) ............. 33 Powder coating ..................34 Remote control by OptiSelect GM02 manual gun ........
- Page 5 Ordering spare parts ..................... 63 OptiStar CG06 Automatic gun control unit - general ..........64 OptiStar CG06 Automatic gun control unit - inside rear wall ........ 65 OptiStar CG06 - outside rear wall ................. 66 OptiStar CG06-C - inside rear wall ............... 67 OptiStar CG06-C - outside rear wall ..............
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Page 7: General Safety Regulations
Useful tips and other information Conformity of use 1. The OptiStar CG06 Automatic gun control unit is built to the lat- est specification and conforms to the recognized technical safety regulations. It is designed for the normal application of powder coating. -
Page 8: Technical Safety Regulations For Stationary Electrostatic Powder Spraying Equipment
V 09/18 use. The OptiStar CG06 Automatic gun control unit should only be used, maintained and started up by trained personnel, who are informed about and are familiar with the possible hazards in- volved. 4. Start-up (i.e. the execution of a particular operation) is forbidden... -
Page 9: Safety Conscious Working
Safety precautions specified by local legislation must be observed! 8. Only original Gema spare parts should be used, because the ex- plosion protection will also be preserved that way. Damage caused by other parts is not covered by guarantee. -
Page 10: Notes On Special Types Of Hazard
Charging of objects must be avoided - see "Earthing". Grounding/Earthing All electricity conducting parts and machinery found in the workplace (ac- cording to DIN VDE 0745, part 102) must be earthed 1.5 meters either 8 • General safety regulations OptiStar CG06 Automatic gun control unit... -
Page 11: Safety Requirements For Electrostatic Powder Coating
Damage caused by other parts is not covered by guarantee. Repairs must only be carried out by specialists or in Gema workshops. Unauthorized conversions and modifications may lead to injury or dam- age to machinery. The Gema Switzerland GmbH guarantee would no longer be valid. -
Page 12: A Summary Of The Rules And Regulations
14. For your own safety, only use accessories and attachments listed in the operating instructions. The use of other parts can lead to risk of injury. Only original Gema replacement parts should be used. 15. Repairs must only be carried out by specialists and under no cir- cumstances should they be carried out in the operating area. - Page 13 Beuth Verlag GmbH, Burgrafenstrasse 4, 1000 Berlin 30 General secretariat, Rue Bréderode 2, B-1000 Bruxelles, or the appro- priate national committee VDE Verlag GmbH, Bismarckstrasse 33, 1000 Berlin 12 General safety regulations • 11 OptiStar CG06 Automatic gun control unit...
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Page 14: Product Specific Security Measures
(input and exhaust air) It must be observed, that all components are grounded ac- cording to the local regulations, before start-up 12 • General safety regulations OptiStar CG06 Automatic gun control unit... -
Page 15: About This Manual
General information This operating manual contains all the important information which you re- quire for the working with the OptiStar CG06 Automatic gun control unit. It will safely guide you through the start-up process and give you references and tips for the optimal use of your new powder coating system. -
Page 17: Function Description
V 09/18 Function description Field of application The OptiStar CG06 Automatic gun control unit is designed exclusively for controlling the Gema powder coating guns (see also in chapter "Tech- nical Data"). Any other use, beyond the above mentioned is considered non- conforming. -
Page 18: Basic Functions
Request values for software version and trigger hours coun- Features Keyboard lock, Preset mode, 250 programs, error display and remote control on manual gun (OptiSelect GM02) Options Flow control and shaping air, CAN bus and DigitalBus 16 • Function description OptiStar CG06 Automatic gun control unit... -
Page 19: Operating Modes
V 09/18 Operating modes The OptiStar CG06 Automatic gun control unit can be operated with two operating modes. According to the selected application mode, spray volt- age and spray current are automatically adjusted and limited. Predefined operating mode (Preset mode) -
Page 21: Technical Data
The Tribo gun is not type approved (ATEX). ** Only for enamel powder, the gun is not type approved (ATEX). ATTENTION: The OptiStar CG06 Automatic gun control unit can only be used with the specified gun types! Technical Data • 19... -
Page 22: Electrical Data
1.3 g/m³ Max. oil vapor content of the compressed air 0.1 mg/m³ Dimensions OptiStar CG06 Gun control unit Width 248 mm Depth 250 mm Height 174 mm Weight approx. 5.2 kg 20 • Technical Data OptiStar CG06 Automatic gun control unit... -
Page 23: Air Flow Rates
10.5 Nm³/h (with a parameterized input pressure of 6.5 bar)! The total air consumption with FlowControl and shaping air amounts to max. 15.5 Nm³/h (with a parameterized input pressure of 6.5 bar)! Technical Data • 21 OptiStar CG06 Automatic gun control unit... -
Page 25: Operating And Display Elements
V 09/18 Operating and display elements Display and LEDs OptiStar CG06 Automatic gun control unit - display and LEDs Designation Function Display of actual values, preset values and system param- A1-A4 eters Display of program numbers, error diagnosis codes and... -
Page 26: Input Keys And Switches
Application mode for complicated parts is activated Application mode for recoating parts already coated is ac- tivated Input keys and switches OptiStar CG06 Automatic gun control unit - input keys and switches Designation Function T1-T8 Input keys for preset values and system parameters... -
Page 27: General Information
Lightly touching key T1 indicates the preset values, pushing harder on this key, reduces the powder output. This behavior does not apply to the program select keys, where the program number is directly changed. Operating and display elements • 25 OptiStar CG06 Automatic gun control unit... -
Page 29: Start-Up And Operation
V 09/18 Start-up and operation OptiStar CG06 connections OptiStar CG06 Automatic gun control unit - connections on the rear wall Connection Description 1.1 Air Supply IN Compressed air connection (6-10 bar / 87-145 PSI) 2.1 Power IN Mains cable connection (100-240 VAC) 2.2 Gun... -
Page 30: 2.3 And 2.4 Aux Connections
9. Connect the mains cable to the 2.1 Power IN plug and screw it on Pressure regulator Powder gun after filter (5.5/6.0/6.5 bar) Shaping air (optional) Injector Connecting guide - overview 28 • Start-up and operation OptiStar CG06 Automatic gun control unit... -
Page 31: Cg06 Pin Assignment
Preset values, program number binary value 2 (=64) 8 IN-D7 Preset values, program number binary value 2 (=128) 9 IN-A0 Identification number binary value 2 (=1) 10 IN-A1 Identification number binary value 2 (=2) Start-up and operation • 29 OptiStar CG06 Automatic gun control unit... -
Page 32: Initial Start-Up
Switch on the booth Switch on the powder coating booth according to its operating manual. Daily start up The daily start-up of the OptiStar CG06 Automatic gun control unit takes place by the following steps: Select the operating mode Select the application mode with three predefined modes (Preset mode) or the user-defined program mode with 250 adjustable programs (Pro- gram mode). -
Page 33: Setting Powder Output And Powder Cloud
Setting the total air volume 1. Adjust the total air volume with the keys T3/T4 (see also the injector operating manual) Adjust the total air volume according to the correspond- ing coating requests Start-up and operation • 31 OptiStar CG06 Automatic gun control unit... -
Page 34: Optistar Cg06 Gun Release
60% is recommended for initial spraying. The total air volume is maintained constant automatically 3. Release the OptiStar CG06 control unit by superordinated control unit (external release signal) 4. Activate the gun with the key T16, the LED L7 illuminates 5. -
Page 35: Setting The Electrode Rinsing Air
The second display level is switched over 2. Adjust the shaping air with the keys T5/T6 If this display level is not operated for 3 seconds, the first display level is switched over independently Start-up and operation • 33 OptiStar CG06 Automatic gun control unit... -
Page 36: Powder Coating
By pressing one of the keys, the preset values will be displayed versus the actual values! Shut-down The shut-down of the OptiStar CG06 Automatic gun control unit takes place in following steps: 1. Switch off externally by superordinated control unit, or on the control unit with key T16 (local operation) 2. -
Page 37: Technical Explanations Concerning High Voltage And Spray Current
The operator can optimize the values for his application by utilizing the ranges below (see diagram). Characteristic curve of Program mode Spray current (µA) Start-up and operation • 35 OptiStar CG06 Automatic gun control unit... -
Page 39: Additional Functions
V 09/18 Additional functions System parameters The OptiStar CG06 Automatic gun control unit is configured with the sys- tem parameters. The values will be saved in the equipment memory. These values can be adjusted and requested manually or by remote in- terface (CAN). -
Page 40: Exiting The System Parameter Mode
The status display is shown as long as a key is held. Keyboard lock The OptiStar CG06 Automatic Gun control unit contains a keyboard lock, which prevents changing individual values for each parameter (kV, µA etc.) within an application mode (Preset or Program). The following is not affect-... -
Page 41: Operation With Other Guns
If a memory reset takes place, the keyboard lock will be can- celled. On the OptiStar CG06 Automatic gun control unit (automatic device), an external interlocking by remote input can also be utilized. These two lock- ing features are independent, which means, if the local interlocking is de- activated, the external interlocking remains activated and vice versa. -
Page 42: Powder Output/Powder Hose Correction
V 09/18 Powder output/powder hose correction The OptiStar CG06 Automatic gun control unit can be adjusted with cor- rection values optimal to local conditions (for example the adjustment of different powder outputs in the plant, caused by different powder hose lengths and geometry to the guns.) -
Page 43: Procedure (Powder Hose Correction)
200 g/min 200 g/min (200/250) x 10 gr. 12 gr. 250 g/min 200 g/min 100 = 80% (200/280) x 0 gr. 12 gr. 280 g/min 200 g/min 100 = 71% etc. Additional functions • 41 OptiStar CG06 Automatic gun control unit... -
Page 44: Correction Factor - Diagram
RAM reset The RAM reset enables a restore of factory settings of the OptiStar CG06 gun control unit. All user-defined values in Program and Preset mode will be set to factory default. The adjusted device type in system parameter P0 remains stored in memory and an active keyboard lock will be deac- tivated. -
Page 45: Cleaning Mode
DigitalBus or CAN bus. NOTE: The injector must be disconnected from the pickup tube or powder hopper prior to cleaning procedure! The cleaning mode is terminated by pressing the program key T12. Additional functions • 43 OptiStar CG06 Automatic gun control unit... -
Page 47: Options
Highest regulating dynamics Micro controller based air volume calibration High air volume regulation range - total air up to 6.5 Nm³/h (C0 = 1.8 dm³/h, powder output = 80%) FlowControl module Options • 45 OptiStar CG06 Automatic gun control unit... -
Page 48: Digitalbus
Error mess. bus 1-bit Error Strobe 2 System ON/OFF PLC control OptiStar 2 digital Remote/Manual input / output Error Strobe 12 System ON/OFF OptiStar 14 Remote/Manual Error Controlling by a superordinated control unit 46 • Options OptiStar CG06 Automatic gun control unit... -
Page 49: Structure Of The 16 Bit Parallel Bus
Error - Digital output composite error message, indicates all errors which are present in the control unit (error list, can be deleted locally). Error polarity = acc. to System parameter P8 Options • 47 OptiStar CG06 Automatic gun control unit... -
Page 50: Command Table And Value Ranges
(D8 is not needed for these value ranges, must be left on 0) Timing diagram The following timing must be respected by the external control when communicating by DigitalBus: Timing diagram 48 • Options OptiStar CG06 Automatic gun control unit... - Page 51 200 µs (2 ms) Strobe = 0; wait_strobe_pulse_500 µs(); Strobe = 1; If a following command wants to be sent, a break of at least 5 ms must take place. Options • 49 OptiStar CG06 Automatic gun control unit...
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Page 52: Digitalbus - Allocation
V 09/18 DigitalBus - allocation SYSTEM STROBE REMOTE ERROR ACTIVE NOTE: I and Q are not intended as plug annotation by plug supplier! 50 • Options OptiStar CG06 Automatic gun control unit... -
Page 53: Digital Connector Cd02 With Connection Designations
Digital Connector CD02 with connection desig- nations The interface between the OptiStar CG06 Automatic gun control unit and the PLC control unit is given by the Digital Connector CD02. All parallel interface signals of up to 12 devices are fed connection-friendly on plugs. -
Page 54: Hardware
PLC control unit with CAN bus Terminal resistor CAN bus - connections CAN bus cable - plug assignment Signal Color white +24 VDC brown CAN H green CAN L yellow CAN bus cable 52 • Options OptiStar CG06 Automatic gun control unit... -
Page 55: System Release In Network Operation
500 m from the first to the last CAN bus client. If longer cables are used, select a lower Baud rate. Node ID - system parameter P6 CAN Node-ID 1-127 Value P6 CAN Node-ID 1-127 1-127 Options • 53 OptiStar CG06 Automatic gun control unit... -
Page 57: Schematic Diagrams
Throttle motors (optional) Conveying air (FL) Supplementary air (ZL) Input pressure 5.5 / 6.0 / 6.5 Nm³/h Electrode rinsing air (EL) Shaping air (SHA) (optional) OptiStar CG06 - pneumatic diagram Schematic diagrams • 55 OptiStar CG06 Automatic gun control unit... -
Page 58: Optistar Cg06 - Electrical Diagram
OptiStar CG06 - electrical diagram CG06 DISPLAY CG06 MAINBOARD KEYBOARD POWER SUPPLY DC OUT POWER IN OptiStar CG06 - electrical diagram - part 1 CG06 MAINBOARD FLOWCONTROL DIGITALBUS MODULE CANBUS MODULE OptiStar CG06 - electrical diagram - part 2 56 • Schematic diagrams... -
Page 59: Troubleshooting
4. Place the new board on the standoffs, press them into the board and snap into mounting bracket within enclosure. Re- connect the plugs 5. Reassemble the control unit in reverse order as described and install it 6. Reconnect the mains cable Troubleshooting • 57 OptiStar CG06 Automatic gun control unit... -
Page 60: Replace The Front Plate
NOTE: The motor plugs are to be put in according to the annotation! 5. Reconnect the mains cable NOTE: If there are any problems or uncertainties, please contact a Gema service center! Power input Power pack Input (AC) -
Page 61: Repairing The Pneumatic Part
Error diagnosis of the software General information The correct function of the OptiStar CG06 Automatic gun control unit is constantly monitored. If the equipment software determines a fault, an er- ror message is indicated with an error code. Following is monitored:... -
Page 62: Help Codes
Reduce daily correction value The theoretical value for convey- Limit conveying air to conveying ing air falls below minimum air minimum Conveying air range lower devi- ation Total air is smaller than mini- 60 • Troubleshooting OptiStar CG06 Automatic gun control unit... - Page 63 Overflow on transmission buffer. Messages are produced faster than they can be sent Node Guarding message is Master failed missing longer than 2 seconds. Connection to master failed Troubleshooting • 61 OptiStar CG06 Automatic gun control unit...
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Page 64: Help Codes List
It is possible that an error appears just shortly, but after the acknowl- edgement it will disappear. In this case, switch off the OptiStar control unit and switch it on again (reset by restarting). 62 • Troubleshooting OptiStar CG06 Automatic gun control unit... -
Page 65: Spare Parts List
Ø 8/6 mm, 8 mm outside diameter (o/d) / 6 mm inside diameter (i/d) ATTENTION! Only original Gema spare parts should be used, because the haz- ardous location approval will be preserved that way! The use of spare parts from other manufacturers will invalidate the Gema guar- antee conditions! Spare parts list •... -
Page 66: Optistar Cg06 Automatic Gun Control Unit - General
1001 460 OptiStar CG06-C Gun control unit - complete (with CAN bus) 1001 461 OptiStar CG06-CF Gun control unit - complete (with CAN bus / FlowControl) OptiStar CG06-D Gun control unit - complete (with DigitalBus) 1001 462 OptiStar CG06-DF Gun control unit - complete (with DigitalBus / FlowControl) -
Page 67: Optistar Cg06 Automatic Gun Control Unit - Inside Rear Wall
Fluidizing pad - 1/8"a 262 315 Screw-in nipple - 1/8"a, Ø 6 mm Throttle motor - complete 1000 064 OptiStar CG06 Automatic gun control unit - inside rear wall Spare parts list • 65 OptiStar CG06 Automatic gun control unit... -
Page 68: Optistar Cg06 - Outside Rear Wall
V 09/18 OptiStar CG06 - outside rear wall Rear wall (aluminum) 1000 070 Rear wall (steel sheet) 1005 099 Shake proof washer - A type, M6 200 450 Milled nut - M6 200 433 Screw plug - complete 1001 789 Hose connection - complete, Ø... -
Page 69: Optistar Cg06-C - Inside Rear Wall
V 09/18 OptiStar CG06-C - inside rear wall CAN bus module - complete 1001 274 1001 686 Washer - Ø 6.4/12.5x1.6 mm 215 279 Hexagon screw - M6x30 mm Fluidizing pad - 1/8"a 237 264 Lock washer - M3 R... -
Page 70: Optistar Cg06-C - Outside Rear Wall
V 09/18 OptiStar CG06-C - outside rear wall Rear wall (aluminum) 1000 070 Rear wall (steel sheet) 1005 099 Cap screw - M3x10 mm 216 739 Washer - Ø 6.4/12.5x1.6 mm 1001 686 Cap screw - M6x10 mm 205 214 Lock nut - M18x0.75 mm... -
Page 71: Optistar Cg06-Cf - Inside Rear Wall
V 09/18 OptiStar CG06-CF - inside rear wall CAN bus module - complete 1001 274 1000 076 FlowControl - complete 1001 686 Washer - Ø 6.4/12.5x1.6 mm Hexagon screw - M6x30 mm 215 279 Fluidizing pad - 1/8"a 237 264... -
Page 72: Optistar Cg06-Cf - Outside Rear Wall
V 09/18 OptiStar CG06-CF - outside rear wall Rear wall (aluminum) 1000 070 Rear wall (steel sheet) 1005 099 Cap screw - M3x10 mm 216 739 Washer - Ø 4.3/9x0.8 mm 1002 093 Cap screw - M4x12 mm 216 798 Hose connection - complete, Ø... -
Page 73: Optistar Cg06-D - Inside Rear Wall
V 09/18 OptiStar CG06-D - inside rear wall DigitalBus module - complete 1001 309 1001 686 Washer - Ø 6.4/12.5x1.6 mm 215 279 Hexagon screw - M6x30 mm Fluidizing pad - 1/8"a 237 264 Screw-in nipple - 1/8"a, Ø 6 mm... -
Page 74: Optistar Cg06-D - Outside Rear Wall
V 09/18 OptiStar CG06-D - outside rear wall Rear wall (aluminum) 1000 070 Rear wall (steel sheet) 1005 099 Cap screw - M3x10 mm 216 739 Cap screw - M6x10 mm 205 214 Washer - Ø 6.4/12.5x1.6 mm 1001 686... -
Page 75: Optistar Cg06-Df - Inside Rear Wall
V 09/18 OptiStar CG06-DF - inside rear wall DigitalBus module - complete 1001 309 1000 076 FlowControl - complete 1001 686 Washer - Ø 6.4/12.5x1.6 mm Hexagon screw - M6x30 mm 215 279 Fluidizing pad - 1/8"a 237 264 Throttle motor - complete... -
Page 76: Optistar Cg06-Df - Outside Rear Wall
V 09/18 OptiStar CG06-DF - outside rear wall Rear wall (aluminum) 1000 070 Rear wall (steel sheet) 1005 099 Cap screw - M3x10 mm 216 739 Washer - Ø 4.3/9x0.8 mm 1002 093 Cap screw - M4x12 mm 216 798 Hose connection - complete, Ø... -
Page 77: Optistar Cg06 - Enclosure And Power Pack
V 09/18 OptiStar CG06 - enclosure and power pack Enclosure - CG06 control unit 1001 435 374 059 Power pack - 15 VDC 1000 388 Mainboard power supply Mainboard power supply 1001 178 Spacer - Ø 4, Ø 4.8/4.8 mm, PA... -
Page 78: Optistar Cg06 - Front Plate
Spacer sleeve - Ø 3.2/6x6 mm Spacer sleeve - Ø 3.2/6x15 mm 1001 926 230 251 Compression spring - 0.5x6.3x13.5 mm 1000 400 Special screw OptiStar CG06 - front plate 76 • Spare parts list OptiStar CG06 Automatic gun control unit... - Page 79 V 09/18 Spare parts list • 77 OptiStar CG06 Automatic gun control unit...
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