Gema OptiStar CG06 Guide

En
Translation of the original operating instructions
Operating instructions and spare parts list
OptiStar CG06
Automatic gun control unit

V 09/18
Documentation OptiStar CG06 Automatic gun control unit
© Copyright 2006 Gema Switzerland GmbH
All rights reserved.
This publication is protected by copyright. Unauthorized copying is pro-
hibited by law. No part of this publication may be reproduced, photocop-
ied, 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.
OptiFlex, OptiTronic, OptiGun, EasyTronic, EasySelect, OptiFlow and
SuperCorona are registered trademarks of Gema Switzerland GmbH.
OptiStar, OptiMatic, OptiMove, OptiMaster, OptiPlus, MultiTronic and
Gematic 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 con-
cerned approve of or are bound in any form by this manual. We have en-
deavored to retain the preferred spelling of the trademarks, and regis-
tered 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 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.
Printed in Switzerland
Gema Switzerland GmbH
Mövenstrasse 17
9015 St. Gallen
Switzerland
Phone: [phone]
Fax.: [phone]
E-Mail: [email protected]
Homepage: www.gemapowdercoating.com

V 09/18
OptiStar CG06 Automatic gun control unit Table of contents • 1
Table of contents
General safety regulations 5
Safety symbols (pictograms) ................................................................................... 5
Conformity of use .................................................................................................... 5
Technical safety regulations for stationary electrostatic powder spraying
equipment ............................................................................................................... 6
General information ................................................................................... 6
Safety conscious working .......................................................................... 7
Individual safety regulations for the operating firm and/or operating
personnel ................................................................................................... 7
Notes on special types of hazard ............................................................... 8
Safety requirements for electrostatic powder coating ................................ 9
A summary of the rules and regulations .................................................. 10
Product specific security measures ...................................................................... 12
About this manual 13
General information .............................................................................................. 13
Software version ................................................................................................... 13
Function description 15
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 .................................................................................................. 17
Predefined operating mode (Preset mode) .............................................. 17
User-defined operating mode (Program mode) ....................................... 17
Technical Data 19
OptiStar CG06 Gun control unit ............................................................................ 19
OptiStar CG06 - versions ......................................................................... 19
Connectable guns .................................................................................... 19
Electrical data .......................................................................................... 20
Pneumatical data ..................................................................................... 20
Dimensions .............................................................................................. 20
Air flow rates ............................................................................................ 21
Operating and display elements 23
Display and LEDs ................................................................................................. 23
Input keys and switches ........................................................................................ 24
General information .............................................................................................. 25
Displaying the programs .......................................................................... 25
Displaying the values ............................................................................... 25

V 09/18
2 • Table of contents OptiStar CG06 Automatic gun control unit
Start-up and operation 27
OptiStar CG06 connections .................................................................................. 27
2.3 and 2.4 Aux connections ................................................................... 28
Connection guide ..................................................................................... 28
CG06 pin assignment .............................................................................. 29
CG06-C(F) pin assignment ...................................................................... 29
CG06-D(F) pin assignment ...................................................................... 29
Initial start-up ........................................................................................................ 30
Setting the device type ............................................................................ 30
Preparing the powder hopper/container .................................................. 30
Switch on the booth ................................................................................. 30
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 ................................... 34
Shut-down ............................................................................................... 34
Saving programs .................................................................................................. 34
Technical explanations concerning high voltage and spray current..................... 35
Characteristic curves of Preset mode ..................................................... 35
Characteristic curve of Program mode .................................................... 35
Additional functions 37
System parameters .............................................................................................. 37
Entering the system parameters ............................................................. 37
Exiting the system parameter mode ........................................................ 38
Trigger counter and software request .................................................................. 38
Keyboard lock ....................................................................................................... 38
Operation with other guns .................................................................................... 39
Configuration of the Tribo gun ................................................................. 39
Operation of the Tribo gun without adapter ............................................. 39
Powder output/powder hose correction ................................................................ 40
Carrying out a powder output correction ................................................. 40
Procedure (powder output correction) ..................................................... 40
Procedure (powder hose correction) ....................................................... 41
Example table for powder output/powder hose correction ...................... 41
Correction factor - diagram ...................................................................... 42
RAM reset ............................................................................................................. 42
Cleaning mode ..................................................................................................... 43
Options 45
FlowControl module .............................................................................................. 45
DigitalBus .............................................................................................................. 46
Controlling the OptiStar control units by a superordinated control unit ... 46
Structure of the 16 bit parallel bus ........................................................... 47
Command table and value ranges .......................................................... 48
Timing diagram ........................................................................................ 48
DigitalBus - allocation .............................................................................. 50
Digital Connector CD02 with connection designations ........................... 51
CAN bus ............................................................................................................... 51
Hardware ................................................................................................. 52
CAN bus cable - plug assignment ........................................................... 52
System release in network operation ...................................................... 53
Determining user address (Node-ID) and Baud rate ............................... 53

V 09/18
OptiStar CG06 Automatic gun control unit Table of contents • 3
Schematic diagrams 55
OptiStar CG06 - pneumatic diagram..................................................................... 55
OptiStar CG06 - electrical diagram ....................................................................... 56
Troubleshooting 57
Repairing the electrical part of the control unit ..................................................... 57
Replacing the fuse(s) ............................................................................... 57
Replacing the power supply board .......................................................... 57
Replace the front plate ............................................................................. 58
Repairing the pneumatic part ................................................................................ 59
Replacing the pneumatic part .................................................................. 59
Removing the pneumatic hoses .............................................................. 59
Fitting the pneumatic hoses ..................................................................... 59
Error diagnosis of the software ............................................................................. 59
General information ................................................................................. 59
Help codes ............................................................................................... 60
Help codes list .......................................................................................... 62
Appearance of errors ............................................................................... 62
Spare parts list 63
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 ..................................................................... 68
OptiStar CG06-CF - inside rear wall ..................................................................... 69
OptiStar CG06-CF - outside rear wall ................................................................... 70
OptiStar CG06-D - inside rear wall ....................................................................... 71
OptiStar CG06-D - outside rear wall ..................................................................... 72
OptiStar CG06-DF - inside rear wall ..................................................................... 73
OptiStar CG06-DF - outside rear wall ................................................................... 74
OptiStar CG06 - enclosure and power pack ......................................................... 75
OptiStar CG06 - front plate ................................................................................... 76

V 09/18
OptiStar CG06 Automatic gun control unit General safety regulations • 5
General safety regulations
This chapter sets out the fundamental safety regulations that must be fol-
lowed by the user and third parties using the OptiStar CG06 Automatic
gun control unit.
These safety regulations must be read and understood before the Op-
tiStar CG06 Automatic gun control unit is used.
Safety symbols (pictograms)
The following warnings with their meanings can be found in the Gema
operating instructions. The general safety precautions must also be fol-
lowed as well as the regulations in the operating instructions.
DANGER!
Danger due to live electricity or moving parts. Possible consequences:
Death or serious injury
ATTENTION!
Improper use of the equipment could damage the machine or cause it to
malfunction. Possible consequences: minor injuries or damage to equip-
ment
NOTE!
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.
2. Any other use is considered as non-conform. The manufacturer
is not responsible for damage resulting from improper use of this
equipment; the end-user alone is responsible. If the OptiStar
CG06 Automatic gun control unit is to be used for other purposes
or other substances outside of our guidelines then Gema Swit-
zerland GmbH should be consulted.
3. Observance of the operating, service and maintenance instruc-
tions specified by the manufacturer is also part of conformity of

V 09/18
6 • General safety regulations OptiStar CG06 Automatic gun control unit
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
until it has been established that the OptiStar CG06 Automatic
gun control unit has been set up and wired according to the
guidelines for machinery (2006/42 EG). EN 60204-1 (machine
safety) must also be observed.
5. Unauthorized modifications to OptiStar CG06 Automatic gun con-
trol unit exempt the manufacturer from any liability from resulting
damage.
6. The relevant accident prevention regulations, as well as other
generally recognized safety regulations, occupational health and
structural regulations are to be observed.
7. Furthermore the country-specific safety regulations must be ob-
served.
Explosion protection Protection type Temperature class
II (2) 3 D IP54 T6 (zone 21)
Technical safety regulations for stationary electrostat-
ic powder spraying equipment
General information
The powder spraying equipment from Gema is designed with safety in
mind and is built according to the latest technological specifications. This
equipment can be dangerous if it is not used for its specified purpose.
Consequently it should be noted that there exists a danger to life and
limb of the user or third party, a danger of damage to the equipment and
other machinery belonging to the user and a hazard to the efficient op-
eration of the equipment.
1. The powder spraying equipment should only be started up and
used once the operating instructions have been carefully studied.
Improper use of the controlling device can lead to accidents, mal-
function or damage to the control itself.
2. Before every start-up check the equipment for operational safety
(regular servicing is essential)!
3. Safety regulations BGI 764 and VDE regulations DIN VDE 0147,
Part 1, must be observed for safe operation.
4. Safety precautions specified by local legislation must be ob-
served.
5. The plug must be disconnected before the machine is opened for
repair.
6. The plug and socket connection between the powder spraying
equipment and the mains network should only be taken out when
the power is switched off.

V 09/18
OptiStar CG06 Automatic gun control unit General safety regulations • 7
7. The connecting cable between the controlling device and the
spray gun must be set up so that it cannot be damaged during
operation. 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.
9. If Gema powder spraying equipment is used in conjunction with
machinery from other manufacturers then their safety regulations
must also be taken into account.
10. Before starting work familiarize yourself with all installations and
operating elements, as well as with their functions! Familiariza-
tion during operation is too late!
11. Caution must be exercised when working with a powder/air mix-
ture! A powder/air mixture in the right concentration is flammable!
Smoking is forbidden in the entire plant area!
12. As a general rule for all powder spraying installations, persons
with pacemakers should never enter high voltage areas or areas
with electromagnetic fields. Persons with pacemakers should not
enter areas with powder spraying installations!
ATTENTION!
We emphasize that the customer himself is responsible for the safe
operation of equipment. Gema is in no way responsible for any re-
sulting damages!
Safety conscious working
Each person responsible for the assembly, start-up, operation, service
and repair of powder spraying equipment must have read and under-
stood the operating instructions and the "Safety regulations" chapter. The
operator must ensure that the user has had the appropriate training for
powder spraying equipment and is aware of the possible sources of dan-
ger.
The control units for the spray guns must only be set up and used in zone
22. The spray guns are permitted in the zone 21 created by them.
The powder spraying equipment should only be used by trained and au-
thorized personnel. This applies to modifications to the electrical equip-
ment, which should only be carried out by a specialist.
The operating instructions and the necessary closing down procedures
must be followed before any work is carried out concerning the set-up,
start-up, operation, modification, operating conditions, mode of operation,
servicing, inspection or repairs.
The powder spray equipment can be turned off by using the main switch
or failing that, the emergency shut-down. Individual components can be
turned off during operation by using the appropriate switches.
Individual safety regulations for the operating
firm and/or operating personnel
1. Any operating method which will negatively influence the tech-
nical safety of the powder spraying equipment is to be avoided.

V 09/18
8 • General safety regulations OptiStar CG06 Automatic gun control unit
2. The operator should care about no non-authorized personnel
works on the powder spraying equipment (e.g. this also includes
using the equipment for non-conform work).
3. For dangerous materials, the employer has to provide an operat-
ing instructions manual for specifying the dangers arising for hu-
mans and environment by handling dangerous materials, as well
as the necessary preventive measures and behavior rules. The
operating instructions manual has to be written in an under-
standable form and in the language of the persons employed,
and has to be announced in a suitable place in the working area.
4. The operator is under obligation to check the powder spraying
equipment at least once every shift for signs of external damage,
defects or changes (including the operating characteristics)
which could influence safety and to report them immediately.
5. The operator is obliged to check that the powder spraying
equipment is only operated when in satisfactory condition.
6. As far as it is necessary, the operating firm must ensure that the
operating personnel wear protective clothing (e.g. facemasks).
7. The operating firm must guarantee cleanliness and an overview
of the workplace with suitable instructions and checks in and
around the powder spraying equipment.
8. No safety devices should be dismantled or put out of operation. If
the dismantling of a safety device for set-up, repair or servicing is
necessary, reassembly of the safety devices must take place
immediately after the maintenance or repair work is finished. The
powder spraying device must be turned off while servicing is car-
ried out. The operator must train and commit the responsible
personnel to this.
9. Activities such as checking powder fluidization or checking the
high voltage spray gun etc. must be carried out with the powder
spraying equipment switched on.
Notes on special types of hazard
Power
It is necessary to refer once more to the danger of life from high voltage
current if the shut-down procedures are not observed. High voltage
equipment must not be opened - the plug must first be taken out - other-
wise there is danger of electric shock.
Powder
Powder/air mixtures can be ignited by sparks. There must be sufficient
ventilation in the powder coating booth. Powder lying on the floor around
the powder spraying device is a potentially dangerous source of slipping.
Static charges
Static charges can have the following consequences: Charges to people,
electric shocks, sparking. 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