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

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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.

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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."

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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!

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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.

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OptiStar 4.0 (CG21) Product description
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11
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
product should only be used, maintained and started up by trained
personnel, who are informed about and are familiar with the possible
hazards involved.
Any other use is considered non-compliant. The manufacturer is not
responsible for any incorrect use and the risks associated with such
actions are assumed by the user alone!
For a better understanding of the interrelationships in powder coating, it is
recommended that the operating instructions for all other components be
read as well, so as to be familiar with their functions too!

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12

Product description OptiStar 4.0 (CG21)
A summary of the directives and standards
This product was built according to the current state of the art. The
product is subject to the European directives and complies with the
following standards.
The product is suitable for the intended purpose and can be used in the
appropriate areas.
For further information, also refer to the enclosed Declaration of
Conformity.
European directives RL
EG-RL
2006/42/EU
Machinery
EG-RL
2014/34/EU
Equipment and Protective Systems in Potentially
Explosive Atmospheres (ATEX)
EG-RL
2014/30/EU
Electromagnetic compatibility
EN European standards
EN 50177
Stationary electrostatic application equipment for
ignitable liquid coating material - Safety requirements
EN 50050-2
Electrostatic equipment for areas where there is
danger of explosion - electrostatic hand held
equipment
Part 2: Electrostatic hand-held spraying equipment
EN 12981
Coating plants –spray booths for application of
organic powder coating material - Safety
requirements
Recognized safety-related regulations
764 / DGUV
Information
209-052
Electrostatic coating
Trade Union information concerning health and
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

Rev. 03 05/20
OptiStar 4.0 (CG21) Product description
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13
TechnischeDaten
Technical Data
Connectable guns
OptiStar 4.0 (CG21)
connectable
OptiSelect Pro Type GM04
yes
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 –Characteristics of the functions").
The Tribo gun the gun is not type approved (ATEX).
WARNING
The gun control unit may only be used with the specified gun
types!
Electrical data
OptiStar 4.0 (CG21)
Nominal input voltage
100-240 VAC
Frequency
50-60 Hz
Fluctuations of the power supply
± 10 %
Overvoltage category
OVC II
Connected load
40 VA
Nominal output voltage (to the gun)
12 V
Nominal output current (to the gun)
1.2 A
Connection and output for vibrator (on
Aux output)
110/230 VAC
max. 100 W
Connection for rinsing function (valve)
24 VDC
max. 3 W
Protection type
IP54
Approvals
0102 II 3 (2) D
PTB17 ATEX 5002

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14

Product description OptiStar 4.0 (CG21)
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
compressed air
1.3 g/m³
Max. oil vapor content of the
compressed air
0.1 mg/m³
Dimensions
OptiStar
Width
173 mm
Depth
250 mm
Height
177 mm
Weight
approx. 2.6 kg
Powder output (reference values)
General conditions for the OptiFlow Injector
Powder type
Epoxy/polyester
Powder hose Ø (mm)
11
Type of powder hose
POE with guide strips
Input pressure (bar)
5.5
Correction value C0
Powder output zeroing
adjustment
Guide values for OptiStar with OptiFlow Injector
All values in these tables are guide values for new nozzle inserts.
Differing environmental conditions, wear and different powder types can
affect the table values.
Hose internal diameter (mm)
Ø 11
Hose length (m)
6
12
18
Total air volume (Nm³/h)
3.5
5.5
3.5
5.5
3.5
5.5
Powder output (g/min)
Powder output (%)
20
90
105
65
75
45
60
40
170
205
135
150
100
120
60
235
280
185
215
145
170
80
290
350
235
270
185
220
100
340
405
280
320
220
260

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OptiStar 4.0 (CG21) Product description

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 4.0 (CG21)
Range
Factory
setting
Flow rate –fluidizing air:
–Device type B
0-1.0 Nm³/h
0.1 Nm³/h
–Device type F (without AirMover
air requirements) / L
0-5.0 Nm³/h
1.0 Nm³/h
–Device type S (with optional fluid
plate)
0-1.0 Nm³/h
0.1 Nm³/h
Electrode rinsing air flow rate
0-5.0 Nm³/h
0.1 Nm³/h
Flow rate total air (at 5.5 bar)
5 Nm³/h
–Conveying air flow rate
0-5.5 Nm³/h
–Supplementary air flow rate
0-5.5 Nm³/h
The max. total air consumption during the coating operation is
< 5,5 Nm³/h:
–Total air = 5 Nm³/h (conveying air + supplementary air)
–Electrode rinsing air = 0,1 Nm³/h (flat jet nozzle)
The total air consumption for the device is determined based on
the 3 configured air values (without AirMover air value for device
type F).
–These values apply for an internal control pressure of 5.5 bar!
Environmental conditions
OptiStar 4.0 (CG21)
Utilization
in the interior
Height
up to 2 000 m
Temperature range
+5 °C - +40 °C
(+41 °F - +104 °F)
Max. surface temperature
+85 °C (+185 °F)
Maximum relative humidity
80 % for temperatures to 31 °C,
linearly decreasing to 50 %
relative humidity at 40 °C
Environment
not for wet environment
Degree of pollution of the
intended environment
2 (in accordance with DIN EN
61010-1)

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16

Product description OptiStar 4.0 (CG21)
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.
The specified value is applicable only for this product itself and does not
take into account external noise sources or cleaning impulses.
The sound pressure level may vary, depending on the product
configuration and space constraints.
Rating plate
fig.
2

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OptiStar 4.0 (CG21) Product description

17
Compatibility and interactions
The gun control unit is used for the following manual equipment from the
OptiFlex line:
–OptiFlex B/Q (with powder box)
–OptiFlex F (with fluidized powder hopper)
–OptiFlex S (with stirrer container)
–OptiFlex C (with application cup)
–OptiFlex CF (with funnel cup)
–OptiFlex L (with lab device)
–OptiFlex W, K (Kits)
–OptiFlex Dual Gun Kit B, F
–OptiFlex Dual Gun Wall Kit B, F
Design and function
Overall view
Fig.
3
1 Front plate with control and
display elements
2 Enclosure
3 Back panel with interfaces

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
Product description OptiStar 4.0 (CG21)
Operating elements
Displays
The desired and actual values are distributed across several
levels.
–The key is used to switch between the levels.
–If no controls are used within 6 s, the device automatically
returns to level 1.
fig.
4
: Displays, Level 1
Designation
Function
A1-A4
Display of actual values, desired values and system
parameters
–Flashes if the possible range is exceeded.
A5
Display of program numbers, error diagnosis codes
and status information
S1
Powder output (display in %)
S4
Total air volume (display in Nm³/h)
S7
High voltage (display in kV)
S9
Spraying current (display in µA)
S12 remote
Remote operation mode, no local operation possible
–Remote operation mode is used as keyboard
lock, reduced operation is possible
S13
Activation of vibration/fluidization
S15
Display of predefined operating modes or display of
cleaning mode during cleaning
S20
–Display of readiness for pairing the Bluetooth
module with a mobile device (green)
–Display of an active connection (blue)

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OptiStar 4.0 (CG21) Product description
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19
fig.
5
: Displays and LEDs, Level 2
Designation
Function
S3
Electrode rinsing air* (display in Nm³/h)
S6
Fluidizing* (display in Nm³/h)
S19
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

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
Product description OptiStar 4.0 (CG21)
Designation
Function
T1-T8
Input keys for desired values and system
parameters
T9
Switch between display levels
T10-T11
Program change
T12
–Switching on and off the fluidization
(equipment type F)
–Switch on/off for vibration and fluidization
(equipment type B)
–Switching on and off the stirrer (equipment
type S)
–Switchover to system parameter mode (press
for at least 5 secs.)
T13
Preset mode for flat parts (fixed values)
T14
Preset mode for complex parts with depressions
(fixed values)
T15
Preset mode for overcoating parts already coated
(fixed values)
T16/T17
Power switch On/Off
T18
–Activation of the pairing readiness from the
Bluetooth module to the mobile device (press
for at least 2 seconds)
–Display of the ID number (press for a short
time)
T19
–Switching on the rinsing mode (PowerClean)
with optional PowerClean module
–Terminating the rinsing mode (PowerClean)
with optional PowerClean module