Gema OptiStar CG08-C Guide

1010 771 En
Translation of the original operating instructions
Operating instructions and spare parts list
OptiStar CG08(-C)
Gun control unit

V 02/18
Documentation OptiStar CG08(-C)
© Copyright 2010 Gema Switzerland GmbH
All rights reserved.
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prohibited by law. No part of this publication may be reproduced,
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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
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concerned approve of or are bound in any form by this manual. We have
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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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www.gemapowdercoating.us/patents.
Printed in Switzerland
Gema Switzerland GmbH
Mövenstrasse 17
9015 St.Gallen
Switzerland
Phone:[phone]
Fax.: [phone]
E-mail: [email protected]

V 02/18
OptiStar CG08(-C) Table of contents •1
Table of contents
General safety regulations 3
Safety symbols (pictograms)...................................................................................3
Proper use...............................................................................................................3
Product-specific safety measures ........................................................................... 4
OptiStar CG08 Gun control unit.................................................................4
About this manual 5
General information ................................................................................................5
Software version .....................................................................................................5
Product description 7
Field of application ..................................................................................................7
Technical data.........................................................................................................8
OptiStar CG08 - versions...........................................................................8
Connectable guns ......................................................................................8
Electrical data ............................................................................................ 8
Pneumatic data ..........................................................................................9
Dimensions ................................................................................................9
Powder output (guide values) ....................................................................9
Air flow rates ............................................................................................10
Design and function ..............................................................................................11
General view ............................................................................................11
Operating elements..................................................................................12
Input keys and switches...........................................................................14
Connections .............................................................................................15
Pin assignment ........................................................................................16
CG08-C pin assignment...........................................................................16
Scope of delivery ..................................................................................................16
Typical properties – Characteristics of the functions ............................................17
Operating modes .....................................................................................17
Rinsing mode ...........................................................................................18
Monitoring of wearing parts......................................................................19
Keyboard lock ..........................................................................................20
Background illumination...........................................................................20
Correction factor for the powder output ...................................................21
Commissioning 23
Preparation for start-up .........................................................................................23
Basic conditions .......................................................................................23
Mounting instructions ............................................................................................23
Connection instructions.........................................................................................24
Initial start-up 27
System parameters...............................................................................................27
Entering the system parameters..............................................................27
Operation ..............................................................................................................31

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2 •Table of contents OptiStar CG08(-C)
Select predefined operating mode (Preset mode) .................................. 31
Starting the user-defined operating mode (Program mode).................... 31
Setting powder output and powder cloud ................................................ 32
Setting the electrode rinsing air............................................................... 33
Correction values.................................................................................................. 33
Entering the correction values................................................................. 33
Powder output/powder hose correction................................................... 34
Correction factor - diagram...................................................................... 36
Cleaning mode ..................................................................................................... 37
Activating the cleaning function............................................................... 37
Monitoring of wearing parts and trigger counter................................................... 38
Trigger counter ........................................................................................ 38
View remaining service life ...................................................................... 39
Deactivation of wearing part monitoring .................................................. 40
Setting the background illumination ..................................................................... 40
Activate/deactivate the keyboard lock .................................................................. 41
Checking the software version ............................................................................. 41
RAM Reset ........................................................................................................... 41
Shutdown.............................................................................................................. 42
If in disuse for several days ..................................................................... 42
CAN bus 43
Hardware ................................................................................................. 43
CAN bus cable - plug assignment ........................................................... 44
System release in network operation ...................................................... 44
Determining user address (Node-ID) and Baud rate............................... 44
Fault remedying 47
Error diagnosis of the software............................................................................. 47
General information ................................................................................. 47
Help codes............................................................................................... 47
Help codes list ......................................................................................... 49
Appearance of errors............................................................................... 49
Spare parts list 51
Ordering spare parts............................................................................................. 51
OptiStar CG08(-C) Gun control unit ..................................................................... 52
OptiStar CG08(-C) – Front plate and power pack ................................................ 53
OptiStar CG08(-C) – inside rear wall.................................................................... 54
OptiStar CG08(-C) connections............................................................................ 55

V 02/18
OptiStar CG08(-C) General safety regulations •3
General safety regulations
This chapter sets out the fundamental safety regulations that must be
followed by the user and third parties using the OptiStar CG08(-C) Gun
control unit.
These safety regulations must be read and understood before the
OptiStar CG08(-C) is put into operation.
Safety symbols (pictograms)
The following warnings with their meanings can be found in the Gema
Switzerland operating instructions. The general safety precautions must
also be followed as well as the regulations in the operating instructions.
DANGER!
Danger due to electrically live or moving parts. Possible consequences:
death or serious injury
WARNING!
Improper use of the equipment could damage the machine or cause it to
malfunction. Possible consequences: minor injuries or damage to
equipment
INFORMATION!
Useful tips and other information
Proper use
1. The OptiStar CG08(-C) is built to the latest specification and
conforms to the recognized technical safety regulations and is
designed for the normal application of powder coating.
2. 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. Gema Switzerland
GmbH must be consulted prior to any use of the OptiStar CG08(-
C) for any purposes or substances other than those indicated in
our guidelines.

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4 •General safety regulations OptiStar CG08(-C)
3. Observance of the operating, service and maintenance
instructions specified by the manufacturer is also part of
conformity of use. The OptiStar CG08(-C) should only be used,
maintained and started up by trained personnel, who are
informed about and are familiar with the possible hazards
involved.
4. Start-up (i.e. the execution of intended operational tasks) is
forbidden until it has been established that the OptiStar CG08(-
C) has been set up and wired according to the guidelines for
machinery (2006/42 EC). EN 60204-1 (machine safety) must
also be observed.
5. Unauthorized modifications to the OptiStar CG08(-C) 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 also must be
observed.
Product-specific safety measures
- Installation work performed by the customer must be carried
out according to local regulations.
- All components must be grounded according to the local
regulations before start-up.
OptiStar CG08 Gun control unit
The OptiStar CG08(-C) 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.
NOTE:
For further security information, see the more detailed Gema safety
regulations!

V 02/18
OptiStar CG08(-C) About this manual •5
About this manual
General information
This operating manual contains all the important information you require
for the working with the OptiStar CG08(-C) 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.
Information about the functional mode of the individual system
components - booth, gun and powder injector - should be referenced in
the respective enclosed documents.
DANGER:
Working without operating instructions
Working without operating instructions or with individual pages
from the operating 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.
Software version
This document describes the operation of the OptiStar CG08(-C) Gun
control unit with software version starting from 2.00 (see also "Software
version request")!

V 02/18
OptiStar CG08(-C) Product description •7
Product description
Field of application
The OptiStar CG08(-C) Gun control unit is designed exclusively for
controlling the Gema powder coating guns (see also in chapter
"Technical data").
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!
OptiStar CG08(-C) Gun control unit
Reasonably foreseeable misuse
- Operation without the proper training
- Use with insufficient compressed air quality and grounding
- Use in connection with unauthorized coating devices or
components

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8 •Product description OptiStar CG08(-C)
Technical data
OptiStar CG08 - versions
OptiStar CAN bus
CG08 no
CG08-C yes
The equipment designation is indicated on the type plate.
Connectable guns
OptiStar CG08(-C) connectable
OptiGun GA03 yes
WARNING:
The OptiStar CG08(-C) gun control unit may only be used with the
specified gun types!
Electrical data
OptiStar CG08(-C)
Nominal input voltage 100-240 VAC
Frequency 50-60 Hz
Connected load 40 VA
Nominal output voltage (to the gun) 12 V
Nominal output current (to the gun) 1.2 A
Protection type IP54
Temperature range 0 °C - +40 °C
(+32 °F - +104 °F)
Max. surface temperature 85 °C (+185 °F)
Approvals 0102 II 3 (2) D
PTB11 ATEX 5007-2

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OptiStar CG08(-C) Product description •9
Pneumatic data
OptiStar CG08(-C)
Compressed air connection Quick coupling
Input pressure (must be set in the system
parameter P2)
5.5 bar
6.0 bar
6.5 bar
Max. input pressure 10 bar / 145 psi
Min. input pressure (while unit in operation) 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 CG08(-C)
Width 173 mm
Depth 250 mm
Height 177 mm
Weight approx. 3.7 kg
Powder output (guide values)
General conditions for the OptiFlow Injector
Powder type Epoxy/polyester
Powder hose length (m) 12
Powder hose Ø (mm) 11
Power hose type POE with guide strips
Input pressure (bar) 5.5
Correction value C0 Powder output zeroing adjustment
Guide values for OptiStar CG08 with OptiFlow Injector IG06
All values in these tables are guide values. Differing environmental
conditions, wear and different powder types can affect the table values.
Total air 3 Nm³/h 4 Nm³/h 5 Nm³/h
Powder output (g/min)
Powder output (%) 20 60 70 80
40 115 140 160
60 175 210 220
80 220 260 270
100 250 300 310

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10 •Product description OptiStar CG08(-C)
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 CG08(-C)
Conveying air flow rate 0-5.4 Nm³/h
Supplementary air flow rate 0-4.5 Nm³/h
Electrode rinsing air flow rate 0-3.0 Nm³/h
NOTE:
The total air consumption for the device is determined based on the
3 configured air values.
These values apply for an internal control pressure of 5.5 bar!
NOTE:
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)

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OptiStar CG08(-C) Product description •11
Design and function
General view
1 Front plate with control and
display elements
3 Back panel with interfaces
2 Enclosure
2
3
1

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12 •Product description OptiStar CG08(-C)
Operating elements
Display and input buttons
NOTE:
For easier operation of the control unit, the preset and actual values
are distributed across several levels. The "sel" key is used to switch
between the levels. If no controls are used within 6 s, the device
automatically returns to level 1.
Displays, Level 1
Designation Function
A1-A4 Display of actual values, desired values and system
parameters
Flashes when 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 Gun release
S14 system System release in network operation
S15 Display of predefined operating modes or display of
cleaning mode during cleaning
S1
S4
S7
S9
S15
A1 – A4
A5
S13
S12
S14

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OptiStar CG08(-C) Product description •13
Displays and LEDs, Level 2
Designation Function
S3 Electrode rinsing air (display in Nm³/h)
S19 Display illumination (0-8)
S3
S19

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14 •Product description OptiStar CG08(-C)
Input keys and switches
Input keys and switches
Designation Function
T1-T8 Input keys for desired values and system parameters
T9 (Select) Switch between display levels
T10-T11 Program change
T12 Gun release
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
T12
T1 / T2
T3 / T4
T5 / T6
T7 / T8
T10/T11
T16/T17
T9
T13 T14 T15

V 02/18
OptiStar CG08(-C) Product description •15
Connections
Compressed air hoses / cables
OptiStar CG08-C – Connections - Compressed air hoses / cables
Connection Description
1.1 Main air IN Compressed air connection
2.1 Power IN Mains cable connection
2.2 Gun Gun cable connection
2.3 Aux CAN bus connection (IN)
2.4 Aux CAN bus connection (OUT)
1.4 Electrode rinsing air connection
1.3 Supplementary air connection
1.2 Conveying air connection
Grounding connection

V 02/18
16 •Product description OptiStar CG08(-C)
Pin assignment
Power IN connection
1 Neutral conductor (power supply)
2 Phase (100-240 VAC)
3 System input ON/OFF (100-240 VAC)
PE Grounding PE
Gun connection
1 Ground
2 Remote control 1 (GM03)
3 Ground
4 Trigger
5 Remote control 2 (GM03)
6 Oscillator
7 Grounding PE
CG08-C pin assignment
CAN IN plug with 4 pins (2.3 Aux)
1 Ground
2 24 VDC
3 CAN high
4 CAN low
Enclosure - shield
CAN OUT socket with 4 pins (2.4 Aux)
1 Ground
2 24 VDC
3 CAN high
4 CAN low
Enclosure - shield
Scope of delivery
- Mains cable
- Quick start instructions and operating manual
PE 3
1
2
3
1
2
4
5 PE
6
4
3 2
1
1
2 3
4

V 02/18
OptiStar CG08(-C) Product description •17
Typical properties – Characteristics of the functions
Operating modes
The OptiStar CG08(-C) gun control unit has two operating modes.
Predefined operating mode (Preset mode)
The OptiStar CG08(-C) 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.
- Application mode for complex parts
This application mode is suitable for the coating of three-
dimensional workpieces with complex shapes (e.g. profiles).
- Application mode for recoating parts already coated
This application mode is suitable for the overcoating of
workpieces which are already coated.
In this operating modes, current (µA) and high voltage (kV) are preset, while
powder and air volumes can be set and stored for each application mode.
Adjustable operating mode (Program mode)
In this operating mode, 250 individually definable programs (P001-P250)
are available. These programs are automatically saved and can be
recalled again as the application requires.
The values for current, high voltage, powder output, total air and
electrode rinsing air can be set as needed for a given application.
NOTE:
The settings defined in the 250 programs and 3 application modes
are automatically stored, without confirmation!

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18 •Product description OptiStar CG08(-C)
Precise Control of spraying Current (PCC Mode)
For coating components with both complex and simple geometries, a
spraying current of below 10 µA can be selected to prevent unintended
overcoating on the simpler surfaces. This is especially important in
combination with high loading powders (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:
Rinsing mode
The PowerClean mode is used to blow powder accumulations and
moisture out of the powder hose, injector, and gun using compressed air.
NOTE:
The rinsing mode can only be activated from standby mode, namely
by pressing the corresponding keys on the gun control unit or also
by an optional bus connection such as CAN bus.
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.