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.
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.
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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]

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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

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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!

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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")!

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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