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Summary of Contents for Gema OptiStar CG12-CP
- Page 1 Operating instructions and spare parts list OptiStar CG12-CP 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 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.
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Page 3: Table Of Contents
Table of contents General safety regulations Safety symbols (pictograms) ................... 3 Proper use ....................... 3 Product-specific safety measures ................4 OptiStar CG12-CP Gun control unit ............4 About this manual General information ....................5 Software version ..................... 5 Product description Field of application .................... - Page 4 Spare parts list Ordering spare parts ..................... 55 OptiStar CG12-CP Gun control unit ..............56 OptiStar CG12-CP – Front plate and power pack ..........57 OptiStar CG12-CP – inside rear wall ..............58 OptiStar CG12-CP – inside rear wall ..............59 OptiStar CG12-CP –...
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Page 5: General Safety Regulations
V 12/13 General safety regulations This chapter sets out the fundamental safety regulations that must be followed by the user and third parties using the OptiStar CG12-CP Gun control unit. These safety regulations must be read and understood before the OptiStar CG12-CP is put into operation. -
Page 6: Product-Specific Safety Measures
OptiStar CG12-CP Gun control unit The OptiStar CG12-CP Gun control unit is a constituent part of the equipment and is therefore integrated in the system's safety concept. If it is to be used in a manner outside the scope of the safety concept, then corresponding measures must be taken. -
Page 7: About This Manual
General information This operating manual contains all the important information you require for the working with the OptiStar CG12-CP 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 9: Product Description
V 12/13 Product description Field of application The OptiStar CG12-CP Gun control unit is designed exclusively for controlling the Gema powder coating guns and the OptiSpray AP01 application pump (see also in chapter "Technical data"). Any other use is considered non-compliant. The manufacturer is not... -
Page 10: Technical Data
V 12/13 Technical data Connectable guns OptiStar CG12-CP connectable OptiGun GA03-P WARNING: The OptiStar CG12-CP gun control unit may only be used with the specified gun types! Electrical data OptiStar CG12-CP Nominal input voltage 100-240 VAC Frequency 50-60 Hz Connected load... -
Page 11: Powder Output (Guide Values)
The total air consists of transport air and supplementary air, in relation to the selected powder quantity (in %). As a result the total air volume is maintained constant. OptiStar CG12-CP Transport air flow rate 0-5.4 Nm³/h Spraying air flow rate 0-4.5 Nm³/h... -
Page 12: Design And Function
V 12/13 Design and function General view 1 Front plate with control and 3 Back panel with interfaces display elements 2 Enclosure 10 • Product description OptiStar CG12-CP... -
Page 13: Operating Elements
S12 remote Remote operation mode is used as keyboard lock, reduced operation is possible Gun release System release in network operation S14 system Display of predefined operating modes or display of cleaning mode during cleaning Product description • 11 OptiStar CG12-CP... - Page 14 V 12/13 Displays and LEDs, Level 2 Designation Function Electrode rinsing air (display in Nm³/h) Display illumination (0-8) 12 • Product description OptiStar CG12-CP...
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Page 15: Input Keys And Switches
Switchover to system parameter mode (Press for at least 5 secs.) Preset mode for flat parts (fixed values) Preset mode for complex parts with depressions (fixed values) Preset mode for overcoating parts already coated (fixed values) Power switch On/Off T16/T17 Product description • 13 OptiStar CG12-CP... -
Page 16: Connections
V 12/13 Connections Compressed air hoses / cables OptiStar CG12-CP – Connections - Compressed air hoses / cables Connection Description Compressed air connection 1.1 Main air IN Mains cable connection 2.1 Power IN Gun cable connection 2.2 Gun CAN bus connection (IN) 2.3 Aux... -
Page 17: Pin Assignment
CAN OUT socket with 4 pins (2.4 Aux) Ground 24 VDC CAN high CAN low Enclosure - shield Dense phase pump connection Control signal valve 1-9 IDENT / Recognition REQUEST / Request GND / Ground Enclosure Shield Product description • 15 OptiStar CG12-CP... -
Page 18: Scope Of Delivery
The OptiStar CG12-CP gun control unit has two operating modes. Predefined operating mode (Preset mode) The OptiStar CG12-CP gun control unit has three preset application modes: Application mode for flat parts This application mode is suitable for the coating of simple, flat workpieces without larger cavities. - Page 19 (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: Product description • 17 OptiStar CG12-CP...
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Page 20: Rinsing Mode
The rinsing mode is signalized by a circling LCD segment on the display: 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. 18 • Product description OptiStar CG12-CP... -
Page 21: Monitoring Of Wearing Parts
V 12/13 Monitoring of wearing parts Wearing parts have a limited service life. The OptiStar CG12-CP gun control unit offers functionality to monitor the service life of up to four wearing parts using a reverse counter: NOTE: The order of wearing parts to be monitored as well as the service life can be set as needed by the operator. -
Page 22: Keyboard Lock
V 12/13 Keyboard lock The OptiStar CG12-CP 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... -
Page 23: Correction Factor For The Powder Output C0
V 12/13 Correction factor for the powder output C0 The OptiStar CG12-CP gun control unit enables a zeroing out of the powder output. This allows for compensation to the suction area. The correction factor C0 can be selected such that barely visible powder is output when the powder share is reduced to 0%. -
Page 25: Commissioning
Gun control unit correctly connected Gun correctly connected Corresponding power and compressed air supply available Powder preparation and powder quality Mounting instructions The OptiStar CG12-CP gun control unit is mounted into place using 2xM6 screws on the front side. Commissioning • 23 OptiStar CG12-CP... -
Page 26: Connection Instructions
Electrode rinsing air Transport air hose hose Powder hose Control signal cable Gun cable Dense phase pump Pinch valve air Powder hopper Spraying air hose Compressed air hose Hose coupling Ø 8/6 – Ø 6/4 mm 24 • Commissioning OptiStar CG12-CP... - Page 27 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! NOTE: The compressed air must be free of oil and water! Commissioning • 25 OptiStar CG12-CP...
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Page 29: Initial Start-Up
The gun control unit always starts up to the last configured settings. System parameters The OptiStar CG12-CP 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). - Page 30 Log level is not overwritten, if a Memory Reset is performed Default values are marked by bold print. 7. Press key to quit the system parameter mode The display switches to the standard level 28 • Initial start-up OptiStar CG12-CP...
- Page 31 V 12/13 System parameter P00 If the OptiStar CG12-CP gun control unit is equipped with the CAN bus- option, this device type is recognized automatically. The system parameter P0 is set to 3 when device is starting. NOTE: A wrong parameterization leads to various malfunctions! ►...
- Page 32 32 MB, it is renamed as MESSAGES.1 and a new MESSAGES.LOG file is then created. Parameter value Level of detail of reports no messages few details all messages NOTE: Real time timings can be impaired from a level of detail of 4. 30 • Initial start-up OptiStar CG12-CP...
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Page 33: Operation
3. Select desired program (001-250) Program 250 active 4. Change coating parameters as required NOTE: Programs 001-250 are preset at the factory but can be modified at any time, after which they are automatically stored. Initial start-up • 31 OptiStar CG12-CP... -
Page 34: Setting Powder Output And Powder Cloud
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 output 32 • Initial start-up OptiStar CG12-CP... - Page 35 The spraying air (ZL) will be set in accordance to the calculated transport air (TL) and the adjusted total air volume (GL). Formula: GL = ZL + TL Airflows in the OptiGun GA03-P automatic powder gun Initial start-up • 33 OptiStar CG12-CP...
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Page 36: Setting The Electrode Rinsing Air
Filter element 2 backpressure Pinch valves set pressure 2.5 bar, Conveying mode: 2.0-2.5 % Pinch valves set pressure 3.0 bar, Conveying mode: 2.5-3.0 % (bei laufender Applikationspumpe wird alle 8 s der Mittelwert ausgegeben) 34 • Initial start-up OptiStar CG12-CP... - Page 37 Description Unit Current transport air Nm³/h Current spraying air Nm³/h 1) Depending on the unit set, airflows are displayed in Nm³/h or scfm. 4. Press key 2x The display switches to the main level Initial start-up • 35 OptiStar CG12-CP...
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Page 38: Correction Values
V 12/13 Correction values The OptiStar OptiStar CG12-CP 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). Entering the correction values 1. Hold key down for 5 seconds The display switches to the following level: 2. -
Page 39: Powder Output/Powder Hose Correction
A2 display, and set it to 20 (ms) with the keys T3/T4, if necessary. 5. Check the correction value for maximum powder output C1 on the A2 display, and set it to 100 (%), if necessary. Initial start-up • 37 OptiStar CG12-CP... - Page 40 Powder output correction C0 before after correction correction C0=20 ms 20 gr. 8 gr. C0=17 ms C0=20 ms 10 gr. 10 gr. C0=20 ms C0=20 ms 0 gr. 8 gr. C0=22 ms etc. 38 • Initial start-up OptiStar CG12-CP...
- Page 41 1.0 - 1.3 Correction value C4 NOTE: The C4 correction value can only be adjusted for analysis purposes during any repairs which may be carried out! C4 must be re-set to 6.0 before being reused! Initial start-up • 39 OptiStar CG12-CP...
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Page 42: Cleaning Mode
Cleaning the hose to the gun In this cleaning program (key T14), the powder hose to the gun will be cleaned with several air blasts. During this time, the pinch valve on the suction side remains closed. 40 • Initial start-up OptiStar CG12-CP... -
Page 43: Monitoring Of Wearing Parts And Trigger Counter
4. The reverse counter is then activated and runs only during active coating 5. If the selected service life is exceeded, the service symbol appears on the display. The coating procedure is not affected by this. Initial start-up • 41 OptiStar CG12-CP... -
Page 44: Trigger Counter
< and >: Activation of montioring Monitoring deactivated Display example for wearing part no. 3: -7.5 days Read minus days 200 days Selected service life 207.5 days Operating life 42 • Initial start-up OptiStar CG12-CP... -
Page 45: Deactivation Of Wearing Part Monitoring
V 12/13 Deactivation of wearing part monitoring 1. Press key simultaneously Monitoring is deactivated. Setting the background illumination 1. Press The display switches to the following level: Select the desired brightness Initial start-up • 43 OptiStar CG12-CP... -
Page 46: Activate/Deactivate The Keyboard Lock
By resetting the RAM, all user-made settings will be set to factory default! 1. Switch off the control unit 2. Press the key and hold it 3. Switch on the control unit, the CLR display blinks 4. Wait for approximately 5 seconds, until CLR disappears 44 • Initial start-up OptiStar CG12-CP... -
Page 47: Shutdown
If in disuse for several days 1. Separate from power mains 2. Clean the coating equipment (see the corresponding operating manual) 3. Turn off the compressed air main supply Initial start-up • 45 OptiStar CG12-CP... -
Page 49: Can Bus
V 12/13 CAN bus The OptiStar CG12-CP Gun control unit, fitted with a CAN bus interface, 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. -
Page 50: Can Bus Cable - Plug Assignment
The release is determined due to the several internal and external signals. Signal Designation Ext. Release System signal on mains plug Trigger Gun connected System Gun release Local or command via Remote Interface release Error Lock Device error System Lock Parameter input 48 • CAN bus OptiStar CG12-CP... -
Page 51: Determining User Address (Node-Id) And Baud Rate
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 P06 CAN Node-ID 1-127 P06 value CAN Node-ID 1-127 1-127 CAN bus • 49 OptiStar CG12-CP... -
Page 53: Fault Remedying
Here is a list of all possible help codes for the OptiStar CG12-CPOptiStar CG12-CP Gun control unit: Code Description Criteria Remedy Pneumatics: Solenoid coil current lower than contact Gema Service preset limiting value Trigger valve Valve defective, main board or cable defective Fault remedying • 51 OptiStar CG12-CP... - Page 54 Total air is smaller than minimum High voltage: No vibrations in the oscillator, cable contact Gema Service Gun error break, oscillator or gun is defective Offset spray current Grounded current measurement contact Gema Service measurement...
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Page 55: Help Codes List
Gema Service measurement cause: Hardware defective The unit is configured as pump Check System parameter P0, No AP01 interface control unit, but there is no pump otherwise contact a Gema interface service center Communication -Gun: Mainboard Communication error Mainboard defective... -
Page 57: Spare Parts List
Ø 8/6 mm, 8 mm outside diameter (o/d) / 6 mm inside diameter (i/d) WARNING! Only original Gema spare parts should be used, because the explosion protection will also be preserved that way. The use of spare parts from other manufacturers will invalidate the Gema guarantee conditions! Spare parts list •... -
Page 58: Optistar Cg12-Cp Gun Control Unit
V 12/13 OptiStar CG12-CP Gun control unit 1009 301 OptiStar CG12-CP Gun control unit – complete Cover 1008 301 OptiStar CG12-CP Gun control unit 56 • Spare parts list OptiStar CG12-CP... -
Page 59: Optistar Cg12-Cp - Front Plate And Power Pack
V 12/13 OptiStar CG12-CP – Front plate and power pack Front plate - complete (pos. 1-12) 1009 860 Front plate with foil keyboard (pos. 5-8) 1009 859 OptiStar Mainboard V2.0 - complete 1009 844 Spacer sleeve - Ø 3.1/6x15 mm PCB Powerboard V2.0... -
Page 60: Optistar Cg12-Cp - Inside Rear Wall
V 12/13 OptiStar CG12-CP – inside rear wall Rear panel gasket 1007 033 CAN bus module - complete 1009 068 Adjusting elbow - Ø 8/Ø 8 mm 1001 031 Solenoid valve - Ø 8-Ø 8 mm, NW 3.4, 24 VDC... -
Page 61: Optistar Cg12-Cp - Inside Rear Wall
V 12/13 OptiStar CG12-CP – inside rear wall OptiStar CG12-CP – inside rear wall Spare parts list • 59 OptiStar CG12-CP... -
Page 62: Optistar Cg12-Cp - Connections
V 12/13 OptiStar CG12-CP – Connections Quick release connection – NW5, Ø 6 mm 200 840 Hose - Ø 6/4 mm 103 144* Nut with kink protection – M12x1 mm, Ø 8 mm 201 316 Spraying air hose - Ø 8/6 mm (black) 103 756* Quick release coupling for spraying air hose - NW5-Ø... -
Page 63: Optistar Cg12-Cp - Connections
V 12/13 OptiStar CG12-CP – Connections OptiStar CG12-CP – Connections Spare parts list • 61 OptiStar CG12-CP...
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