Gema OptiStar 4.0 Guide

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

Rev. 03 05/20
Documentation OptiStar 4.0 (CG21)
© Copyright 2018 Gema Switzerland GmbH
All rights reserved.
This publication is protected by copyright. Unauthorized copying is
prohibited by law. No part of this publication may be reproduced,
photocopied, translated, stored on a retrieval system or transmitted in any
form or by any means for any purpose, neither as a whole nor partially,
without the express written consent of Gema Switzerland GmbH.
Gema, EquiFlow, MagicCompact, MagicCylinder, OptiCenter, OptiFlex,
OptiGun, OptiSelect and OptiStar are registered trademarks of Gema
Switzerland GmbH.
ClassicLine, ClassicStandard, ClassicOpen, DVC (Digital Valve Control),
GemaConnect, MagicControl, MagicPlus, MonoCyclone, MRS,
MultiColor, MultiStar, OptiAir, OptiControl, OptiColor, OptiFeed, OptiFlow,
OptiHopper, OptiMove, OptiSieve, OptiSpeeder, OptiSpray, PCC (Precise
Charge Control), RobotGun, SIT (Smart Inline Technology) und
SuperCorona are trademarks 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 trademarks of the copyright holders.
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.
For the latest information about Gema products, visit
www.gemapowdercoating.com.
For patent information, see www.gemapowdercoating.com/patents or
www.gemapowdercoating.us/patents.
Printed in Switzerland
Gema Switzerland GmbH
Mövenstrasse 17
9015 St.Gallen
Switzerland
Phone:[phone]
Fax.: [phone]
E-mail: [email protected]

Rev. 03 05/20
OptiStar 4.0 (CG21) Table of contents
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3
Table of contents
About these instructions 7
General information ................................................................................................7
Keeping the Manual................................................................................................7
Safety symbols (pictograms)...................................................................................7
Structure of Safety Notes...........................................................................8
Software version .....................................................................................................8
Presentation of the contents...................................................................................8
Figure references in the text......................................................................8
Safety 9
Basic safety instructions .........................................................................................9
Product specific security regulations ......................................................................9
Product description 11
Intended use .........................................................................................................11
A summary of the directives and standards.............................................12
Reasonably foreseeable misuse...........................................................................12
Technical Data......................................................................................................13
Connectable 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 with the Gema electrostatic app ....................................25
Rinsing mode...........................................................................................26
Remote control by gun.............................................................................26
Keyboard lock ..........................................................................................27
Background illumination...........................................................................27
Correction values.....................................................................................28
Operation and configuration of the cup gun.............................................28
Operation and configuration of the Tribo gun..........................................28
Assembly / Connection 29
Assembly guide.....................................................................................................29
Connection instructions.........................................................................................30

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
Table of contents OptiStar 4.0 (CG21)
Start-up 31
Preparation for start-up......................................................................................... 31
Basic conditions....................................................................................... 31
System parameters .............................................................................................. 31
Entering the system parameters ............................................................. 31
Pairing of the Bluetooth module with a mobile device.......................................... 39
Operation 41
Operation.............................................................................................................. 41
Select predefined operating mode (Preset mode) .................................. 41
Starting the individual adjustable programs ............................................ 42
Setting powder output and powder cloud................................................ 42
Setting the electrode rinsing air............................................................... 44
Setting the fluidization ............................................................................. 44
Correction values.................................................................................................. 45
Setting correction factor for powder output .......................................................... 45
Entering the correction values................................................................. 45
Rinsing mode........................................................................................................ 47
Activating the rinsing function.................................................................. 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 schedule............................................................................. 54
Maintenance works.................................................................................. 54
Maintenance / Repairs 55
General information.............................................................................................. 55
Periodic checks .................................................................................................... 55
Repair work........................................................................................................... 55
Fault clearance 57
Error diagnosis of the software............................................................................. 57
General information................................................................................. 57
Help codes............................................................................................... 57
Help codes list......................................................................................... 59
Appearance of errors............................................................................... 59
Disposal 61
Introduction........................................................................................................... 61
Requirements on personnel carrying out the work.................................. 61
Disposal regulations................................................................................ 61
Materials.................................................................................................. 61
Disassembly of component groups...................................................................... 61

Rev. 03 05/20
OptiStar 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

Rev. 03 05/20
OptiStar 4.0 (CG21) About these instructions
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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.
Information about the functional mode of the individual system
components should be referenced in the respective enclosed documents.
Keeping the Manual
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.
WARNING
Indicates a hazardous situation which, if not avoided, could result in
death or serious injury.
CAUTION
Indicates a hazardous situation which, if not avoided, could result in
minor or moderate injury.
ATTENTION
Indicates a potentially harmful situation. If not avoided, the equipment or
something in its surrounding may be damaged.

Rev. 03 05/20
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
About these instructions OptiStar 4.0 (CG21)
ENVIRONMENT
Indicates a potentially harmful situation which, if not avoided, may have
harmful consequences for the environment.
MANDATORY NOTE
Information which must be observed.
NOTICE
Useful information, tips, etc.
Structure of Safety Notes
Every note consists of 4 elements:
–Signal word
–Nature and source of the danger
–Possible 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 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."

Rev. 03 05/20
OptiStar 4.0 (CG21) Safety

9
Safety
Basic safety instructions
–This product is built to the latest specification and conforms to the
recognized technical safety regulations and is designed for the
normal application of powder coating.
–Any other use is considered non-compliant. The manufacturer shall
not be liable for damage resulting from such use; the user bears sole
responsibility for such actions. If this product is to be used for other
purposes or other substances outside of our guidelines then Gema
Switzerland GmbH should be consulted.
–Start-up (i.e. the execution of intended operational tasks) is
forbidden until it has been established that this product has been set
up and wired according to the guidelines for machinery. The
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.
Product specific security regulations
–This product 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.
–The installation work to be done by the customer must be carried out
according to local regulations.
–It must be ensured, that all components are earthed according to the
local regulations before start-up.
For further security information, see the more detailed Gema
safety regulations!

Rev. 03 05/20
10

Safety OptiStar 4.0 (CG21)
WARNING
Working without instructions
Working without instructions or with individual pages from the
instructions 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.