OptiStar CG13-en
1011 452
En
Operating instructions and spare parts list
OptiStar CG13
Gun control unit
Translation of the original operating instructions
V 01/14
Documentation OptiStar CG13
© 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.
MagicCompact, MagicCylinder, MagicPlus, MagicControl, OptiFlex,
OptiControl, OptiGun, OptiSelect, OptiStar and SuperCorona are
registered trademarks of Gema Switzerland GmbH.
OptiFlow, OptiCenter, OptiMove, OptiSpeeder, OptiFeed, OptiSpray,
OptiSieve, OptiAir, OptiPlus, OptiMaster, MultiTronic, EquiFlow, Precise
Charge Control (PCC), Smart Inline Technology (SIT) and Digital Valve
Control (DVC) 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: +41-71-313 83 00
Fax.: +41-71-313 83 83
E-Mail: [email protected]
V 01/14
Table of contents
General safety regulations
3
Safety symbols (pictograms)................................................................................... 3
Proper use............................................................................................................... 3
Product-specific safety measures ........................................................................... 4
OptiStar CG13 Gun control unit ................................................................. 4
About this manual
5
General information ................................................................................................ 5
Software version ..................................................................................................... 5
Product description
7
Field of application .................................................................................................. 7
Technical data ......................................................................................................... 8
Connectable guns ...................................................................................... 8
Electrical data ............................................................................................ 8
Pneumatic data .......................................................................................... 9
Dimensions ................................................................................................ 9
Powder output (guide values) .................................................................... 9
Air flow rates ............................................................................................ 10
Compatibility and interactions ............................................................................... 10
Design and function .............................................................................................. 11
General view ............................................................................................ 11
Operating elements.................................................................................. 12
Input keys and switches ........................................................................... 14
Connections ............................................................................................. 15
Pin assignment ........................................................................................ 16
Scope of delivery .................................................................................................. 16
Typical properties – Characteristics of the functions ............................................ 17
Operating modes ..................................................................................... 17
Rinsing mode ........................................................................................... 19
Remote control by gun ............................................................................. 19
Monitoring of wearing parts...................................................................... 20
Keyboard lock .......................................................................................... 21
Background illumination ........................................................................... 21
Correction factor for the powder output ................................................... 22
Operation and configuration of the Tribo gun .......................................... 22
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
OptiStar CG13
Table of contents • 1
V 01/14
Operation .............................................................................................................. 32
Select predefined operating mode (Preset mode) .................................. 32
Starting the user-defined operating mode (Program mode).................... 32
Setting powder output and powder cloud ................................................ 33
Setting the electrode rinsing air ............................................................... 34
Setting the fluidization ............................................................................. 34
Setting correction factor for powder output .......................................................... 35
Entering the correction factor .................................................................. 35
Rinsing mode ........................................................................................................ 36
Activating the rinsing function .................................................................. 36
Monitoring of wearing parts and trigger counter ................................................... 38
Trigger counter ........................................................................................ 39
View remaining service life ...................................................................... 39
Deactivation of wearing part monitoring .................................................. 40
Setting the background illumination ..................................................................... 40
Activate/deactivate the program change via remote control ................................ 41
Activate/deactivate the keyboard lock .................................................................. 41
Checking the software version ............................................................................. 41
RAM Reset ........................................................................................................... 42
Shutdown .............................................................................................................. 42
If in disuse for several days ..................................................................... 42
Fault remedying
43
Error diagnosis of the software ............................................................................. 43
General information ................................................................................. 43
Help codes ............................................................................................... 43
Help codes list ......................................................................................... 45
Appearance of errors ............................................................................... 45
Spare parts list
47
Ordering spare parts............................................................................................. 47
OptiStar CG13 Gun control unit............................................................................ 48
OptiStar CG13 – Front plate and power pack ...................................................... 49
OptiStar CG13 – inside rear wall .......................................................................... 50
OptiStar CG13 – Connecting material .................................................................. 51
2 • Table of contents
OptiStar CG13
V 01/14
General safety regulations
This chapter sets out the fundamental safety regulations that must be
followed by the user and third parties using the OptiStar CG13 Gun
control unit.
These safety regulations must be read and understood before the
OptiStar CG13 Gun control unit 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 CG13 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 CG13
for any purposes or substances other than those indicated in our
guidelines.
OptiStar CG13
General safety regulations • 3
V 01/14
3. Observance of the operating, service and maintenance
instructions specified by the manufacturer is also part of
conformity of use. The OptiStar CG13 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 CG13
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 CG13 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 CG13 Gun control unit
The OptiStar CG13 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!
4 • General safety regulations
OptiStar CG13
V 01/14
About this manual
General information
This operating manual contains all the important information you require
for the working with the OptiStar CG13 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 CG13 Gun control
unit with software version starting from 1.99 (see also "Software version
request")!
OptiStar CG13
About this manual • 5
V 01/14
Product description
Field of application
The OptiStar CG13 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 CG13 Gun control unit
Reasonably foreseeable misuse
OptiStar CG13
-
Operation without the proper training
-
Use with insufficient compressed air quality and grounding
-
Use in connection with unauthorized coating devices or
components
Product description • 7
V 01/14
Technical data
Connectable guns
OptiStar CG13
connectable
OptiSelect GM03
yes
WARNING:
The OptiStar CG13 gun control unit may only be used with the
specified gun type!
Electrical data
OptiStar CG13
Nominal input voltage
Frequency
Connected load (without vibrator)
50-60 Hz
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)
Connection for rinsing function (valve)
Protection type
Temperature range
Max. surface temperature
Approvals
8 • Product description
100-240 VAC
110/230 VAC
max. 100 W
24 VDC
max. 3 W
IP54
0 °C - +40 °C
(+32 °F - +104 °F)
85 °C (+185 °F)
0102
II 3 (2) D
PTB11 ATEX 5007-2
OptiStar CG13
V 01/14
Pneumatic data
OptiStar CG13
Compressed air connection (on
control unit)
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 CG13
Width
173 mm
Depth
250 mm
Height
177 mm
Weight
approx. 3.9 kg
Powder output (guide values)
General conditions for the OptiFlow Injector
Powder type
Epoxy/polyester
Powder hose length (m)
6
Powder hose Ø (mm)
10
Power hose type
POE with guide strips
Input pressure (bar)
5.5
Correction value C0
Powder output zeroing adjustment
Guide values for OptiStar CG13 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.
3 Nm³/h
Total air
4 Nm³/h
5 Nm³/h
Powder output (g/min)
Powder output
OptiStar CG13
(%)
20
40
60
80
100
85
150
210
270
300
100
185
255
320
360
120
210
280
350
395
Product description • 9
V 01/14
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.
Range
Factory
setting
- OptiFlex B
0-1.0 Nm³/h
0.1 Nm³/h
- OptiFlex F (without AirMover air
requirements)
0-5.0 Nm³/h
1.0 Nm³/h
- OptiFlex 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
OptiStar CG13
Flow rate - fluidizing air
Flow rate total air (at 5.5 bar)
5 Nm³/h
- Conveying air flow rate
0-5.4 Nm³/h
- Supplementary air flow rate
0-4.5 Nm³/h
NOTE:
The total air consumption for the device is determined based on the
3 configured air values (without AirMover air value for OptiFlex F).
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)
Compatibility and interactions
The OptiStar CG13 gun control unit is used for the following manual
equipment from the OptiFlex line:
10 • Product description
-
OptiFlex B/Q (with powder box)
-
OptiFlex F (with fluidized powder hopper)
-
OptiFlex S (with stirrer container)
-
OptiFlex C (with application cup)
-
OptiFlex L (with lab device)
-
OptiFlex W, K (Kits)
-
OptiFlex Dual Gun Kit B, F
-
OptiFlex Dual Gun Wall Kit B, F
OptiStar CG13
V 01/14
Design and function
General view
3
2
1
OptiStar CG13
1
Front plate with control and
display elements
2
Enclosure
3 Back panel with interfaces
Product description • 11
V 01/14
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.
A1 – A4
S1
S4
S7
S9
A5
S12
S13
S15
Displays, Level 1
Designation
Function
A1 – A4
Display of actual values, desired values and system
parameters
Flashes when the possible range is exceeded.
12 • Product description
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 is used as keyboard lock, reduced
operation is possible
S13
Display of vibration/fluidization function
S15
Display of predefined operating modes or display of
rinsing mode during cleaning
OptiStar CG13
V 01/14
S3
S6
S19
Displays and LEDs, Level 2
OptiStar CG13
Designation
Function
S3
Electrode rinsing air (display in Nm³/h)
S6
Fluidizing (display in Nm³/h)
S19
Display illumination (0-8)
Product description • 13
V 01/14
Input keys and switches
T1 / T2
T9
T3 / T4
T5 / T6
T7 / T8
T12
T10 / T11
T16 / T17
T13
T14
T15
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
Switching on and off the fluidization (OptiFlex F)
Switch on/off for vibration and fluidization (OptiFlex B)
T12
Switching on and off the stirrer (OptiFlex S)
Switchover to system parameter mode (Press for at least 5
secs.)
14 • Product description
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
OptiStar CG13
V 01/14
Connections
Compressed air hoses / cables
OptiStar CG13 Connections – Compressed air hoses / cables
Connection
Description
1.1 Main air IN
Compressed air connection
2.1 Power IN
Mains cable connection
2.2 Aux
Vibration motor connection for OptiFlex B
2.3 Gun
Gun cable connection
2.4 Purge
Connection to rinsing module
1.2
Conveying air connection
1.3
Supplementary air connection
1.4
Electrode rinsing air connection
1.5
Fluidizing air connection
Grounding connection
OptiStar CG13
Product description • 15
V 01/14
Pin assignment
Power IN connection
2
PE
3
1
Neutral conductor (power supply)
2
Phase (100-240 VAC)
3
Output vibrator or stirrer
PE
Grounding PE
1
Gun connection
1
4
5
3
PE
2
1
6
Ground
2
Remote control 1 (GM03)
3
Ground
4
Trigger
5
Remote control 2 (GM03)
6
Oscillator
7
Grounding PE
Aux Connection
2
3
1
Neutral conductor
2
Output vibrator, phase
3
1
PE
Not used
Grounding PE
PE
PowerClean (Purge) Connection
3
2
Ground
2
+24 VDC
3
PE
1
1
PE
Not used
Grounding PE
Scope of delivery
16 • Product description
-
Mains cable
-
Quick start instructions and operating manual
OptiStar CG13
V 01/14
Typical properties – Characteristics of the functions
Operating modes
The OptiStar CG13 gun control unit has two operating modes.
Predefined operating mode (Preset mode)
The OptiStar CG13 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 threedimensional 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.
OptiStar CG13
Product description • 17
V 01/14
Adjustable operating mode (Program mode)
In this operating mode, 20 individually definable programs (P01-P20) 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 20 programs and 3 application modes
are automatically stored, without confirmation!
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
powder accumulation 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:
18 • Product description
OptiStar CG13
V 01/14
Rinsing mode
The PowerClean mode is used to blow powder accumulations and
moisture out of the powder hose, injector, and gun using compressed air.
The device provides three rinsing modes:
-
simple rinsing mode (without optional PowerClean module)
-
PowerClean™ mod (with optional PowerClean module)
-
rinsing mode for OptiFlex 2 Q equipment
The desired rinsing mode must be set in the system parameter P01 (see
"Entering the system parameters").
NOTE:
The rinsing mode can only be activated from standby mode, namely
by pressing the P key on the gun remote control or the
corresponding keys on the gun control unit.
The rinsing mode is signalized by a circling LCD segment on the display:
The actual rinsing procedure is started and stopped by pressing the gun
trigger. Once the rinsing mode is quit, the unit automatically returns to the
last program.
Remote control by gun
NOTE:
The remote control is blocked as long as the keyboard lock is
activated or while in system parameterization mode.
Various functions can be remotely controlled using the buttons on the
rear side of the powder gun (OptiSelect GM03 gun type):
-
Modify the powder output (press the Λ or V key on the gun)
The powder output will be increased or decreased
accordingly
-
Change programs (press the Λ or V key on the gun) It is
switching between programs P01-P20. This function must be
activated first, in order to use it - see "Activate/deactivate the
program change via remote control".)
NOTE:
Pressing one of the keys calls up the desired values instead of the
actual values!
-
OptiStar CG13
Switch to PowerClean mode (Press P button). Only if system
parameter P01 = 1
Product description • 19
V 01/14
Monitoring of wearing parts
Wearing parts have a limited service life. The OptiStar CG13 gun control
unit offers functionality to monitor the service life of up to four wearing
parts using a reverse counter:
NOTE:
The order of wearing parts to be monitored as well as the service
life can be set as needed by the operator.
Example table:
No.
Wearing part
1
Insert sleeve
2
Powder hose
3
Electrode holder
4
Pulverizing element
To better explain this function, a few terms relevant to this process must
first be explained:
20 • Product description
Service life
Operating time after which wearing parts should
be replaced (defined by the operator).
Minus days
Number of hours past the selected service life
that the wearing part has continued to be used.
Operating life
Effective time during which the wearing part was
in operation = service life plus minus days, if any
Remaining
service life
displayed value (where not in the minus range)
-
The service life monitoring can be activated/deactivated for
each wearing part (see also "Initial start-up - Monitoring of
wearing parts")
-
By default all monitoring is deactivated and must be activated
by the operator
-
Query the remaining service life
-
Reset the operating time
-
Unit used for display of service life / operating time: 1 day
(x.x), range: 0.1 – 500 days
OptiStar CG13
V 01/14
Keyboard lock
The OptiStar CG13 gun control unit has a keyboard lock to prevent
modification of individual parameter values kV, µA etc.) within the
operating modes (Program and Preset). Following is not affected by the
keyboard lock:
-
Program selection
-
Display of desired values of the current program
-
Displaying the actual values
-
Error acknowledgement
An active keyboard lock is indicated by a blinking of the remote display.
(see also "Initial start-up - Activate/deactivate the keyboard lock")
The keyboard lock status remains stored, when switching the equipment
off and on. The keyboard lock is cancelled if a RAM reset is performed.
Background illumination
Brightness
8 different brightness settings are available for the display. The setting
remains in place when the machine is switched on/off.
Auto Power Save mode
The background illumination is reduced automatically if the control unit is
inactive for 5 minutes.
OptiStar CG13
Product description • 21
V 01/14
Correction factor for the powder output
The OptiStar CG13 gun control unit enables a zeroing out of the powder
output. This allows for compensation to different powder hose lengths
connecting to the pistol.
The correction factor C0 can be selected such that no powder is output
when the powder share is reduced to 0%. (see also "Initial start-up Setting correction factor for powder output")
Operation and configuration of the Tribo gun
The Tribo gun can be connected to the OptiStar CG13 manual gun
control unit. The Tribo gun can be configured by holding the keys T5 and
T6 when switching on. The selected adjustment remains stored, when
the device is switched off. The settings are also retained if the device
type is changed. The Tribo pistol mode can also be deactivated using the
procedure mentioned above.
The charging current (µA) is displayed in the main menu during coating
process:
22 • Product description
OptiStar CG13
V 01/14
Commissioning
Preparation for start-up
Basic conditions
When starting up the OptiStar CG13 gun control unit, the following
general conditions impacting the coating results must be taken into
consideration:
-
Gun control unit correctly connected
-
Gun correctly connected
-
Corresponding power and compressed air supply available
-
Powder preparation and powder quality
Mounting instructions
The OptiStar CG13 gun control unit is mounted into place using 2xM6
screws on the front side.
OptiStar CG13
Commissioning • 23
V 01/14
Connection instructions
Gun
Maintenance unit
6 - 10 bar
5.5 bar
Fluidizing
air hose
Injector
PowerClean
module
(Option)
Connection instructions - overview
1.
2.
NOTE:
Use clamp to connect grounding cable to the cabin or the
suspension arrangement. Check ground connections with Ohm
meter and ensure 1 MOhm or less!
3.
24 • Commissioning
4.
OptiStar CG13
V 01/14
5.
6.
7.
8.
9.
10.
NOTE:
The compressed air must be free of oil and water!
NOTE:
If no vibration motor (OptiFlex B) is connected, close the 2.2 Aux
output with the provided dust protection cap!
If no PowerClean module is connected, close also the 2.4 Purge
connection with the provided dust protection cap!
OptiStar CG13
Commissioning • 25
V 01/14
Initial start-up
NOTE:
The gun control unit always starts up to the last configured
settings.
System parameters
The OptiStar CG13 Gun control unit is configured by using the system
parameters. This configuration will be saved in the equipment memory.
Entering the system parameters
1. Turn on the gun control unit with the ON key
2. Hold
key down for 5 seconds
The display switches to the following level:
T1 / T2
A1
A3
T5 / T6
3. The system parameter number is shown in the display A1
with a P placed in front
4. Set the corresponding system parameter value with the T5
or T6 key.
The value of the adjusted system parameter appears on
corresponding display A3
5. Browse to the next or previous system parameter with the T1
or T2 key
6. Select parameter values according to the following table
OptiStar CG13
Initial start-up • 27
V 01/14
NOTE:
The system parameter P00 of the manual unit may not be set to 3
(automatic device)!
A wrong parameterization leads to various malfunctions!
No.
P001)
P01
Values
Description
Device type
Rinsing mode
Display
0:
Fluidizing device Type
F (CG13)
F
1:
Box device with vibrator
Type B (CG13)
b
2:
Stirrer device Type S
(CG13)
S
3:
Automatic device
(CG08/C) 2)
A
4:
Manual device with
fluidization (CG13)
S Fd
5:
Application pump
2)
(CG11-P)
6:
Application pump +
2)
CAN-Bus (CG12-CP)
0:
no PowerClean
module present
PowerClean module
present
PowerClean module
present (OptiFlex 2 Q)
1:
2:
P03
Unit of
measurement (air)
0:
1:
P10
Log level
0, 1, 2, 3, 4, 5
P
CP
Nm³/h
scfm
1)
is not overwritten, if a Memory Reset is performed
2)
Not available for manual units
nn3
SCF
LoG
Default values are marked by bold print.
key to quit the system parameter mode
7. Press
The display switches to the standard level
28 • Initial start-up
OptiStar CG13
V 01/14
System parameter P00 (device type)
NOTE:
If the control unit is supplied as a component of an OptiFlex 2
complete unit, then the corresponding system parameter is set
correctly by the factory!
NOTE:
A wrong parameterization leads to various malfunctions!
► The system parameter P00 must be set to 0, 1, 2, or 4!
Manual devices are subdivided into fluidizing, box or stirrer types. These
sub-types differ in the control of the vibrator output and the behavior of
the fluidizing air.
Device type
Function AUX Output
Fluidizing air function
Fluidizing device
(type F)
Always Off (no vibration)
The gun trigger switches
the fluidization on
The T12 key turns the
fluidization On and Off
Box device (type
B)
OptiStar CG13
Vibration On during
triggering, wake for 30
seconds
Fluidizing air switches on
parallel to the main
solenoid valve (trigger)
The T12 key turns the
vibration On and Off
The T12 key turns the
fluidization On and Off
Stirrer device (type
S)
Stirrer On during
triggering
Stirrer device with
fluidization
(OptiFlex S Fd)
Stirrer On during
triggering
Fluidizing air switched On
and Off with trigger
The T12 key also
activates or deactivates
the fluidization
Initial start-up • 29
V 01/14
System parameter P01 (rinsing mode)
The system parameter P01 is set to 0 when device is starting.
P01
parameter
value
Description
Manual equipment without PowerClean module:
0
P key on the gun switches from the remote control of
powder output to the remote control of program change!
The simple rinsing mode cannot be activated directly on
the gun but by pressing the corresponding keys on the
gun control unit.
Manual equipment with PowerClean module:
1
The rinsing mode is started by pressing the P key on
the gun, and the rinsing procedure is started by
pressing the gun trigger.
OptiFlex 2 Q Manual coating equipment
2
The rinsing mode and the rinsing procedure are started
immediately after pressing the P key or the external
push button (without pressing the gun trigger).
System parameter P03 (measuring unit)
This parameter is used to determine the measuring unit for all airs (total
air and electrode rinsing air). If the parameter is set to 1 (scfm), then all
air values are shown in this measuring unit. These lines are displayed in
blue.
30 • Initial start-up
OptiStar CG13
V 01/14
System parameter P10 (Log messages)
The device can export log reports of the program run to an SD card for
test purposes and for finding defects.
If an SD card is inserted during the switching on procedure, the log
messages are also recorded onto the SD card. The data are record in the
MESSAGES.LOG file in the root directory. Once this file reaches a size
of 32 MB, it is renamed as MESSAGES.1 and a new MESSAGES.LOG
file is then created.
P10 parameter
value
Level of detail of reports
0
no messages
1
few details
...
5
all messages
NOTE:
Real time timings can be impaired from a level of detail of 4.
OptiStar CG13
Initial start-up • 31
V 01/14
Operation
NOTE:
During the initial commissioning of the device, it is recommended
that the functional check be performed without powder!
Select predefined operating mode (Preset mode)
1. Turn on the gun control unit with the ON key
2. Press the corresponding application key
the arrow above the pressed key is switched on
The pre-defined application modes have preset values for
high voltage and spray current:
Application mode
Preset µA
Preset kV
(flat parts)
100
100
(complex parts)
22
100
(overcoated)
10
100
3. The air values for total air, powder output and electrode
rinsing air can be individually defined and are saved in the
programs.
Starting the user-defined operating mode
(Program mode)
1. Turn on the gun control unit with the ON key
2. Press
program key
3. Select desired program (01-20)
Program 20 active
4. Change coating parameters as required
NOTE:
Programs 01-20 are automatically saved.
32 • Initial start-up
OptiStar CG13
V 01/14
Description
Presetting
Powder output
0%
Total air
0 Nm³/h
High voltage
0 kV
Spray current
0 µA
Electrode rinsing air
0.1 Nm³/h
Fluidizing air
1.0 Nm³/h (for OptiFlex-F)
0.1 Nm³/h (for OptiFlex-B and S)
Setting powder output and powder cloud
The powder output depends on the selected powder output (in %) and
the selected total air volume.
Setting the total air volume
1.
Adjust the total air volume with the T3/T4 keys (see also the
gun / injector operating manual)
-
Adjust the total air volume according to the
corresponding coating requests
Setting the powder output
1.
or
Adjust the powder output volume (e.g. according to the
desired coating thickness)
-
Factory default setting of 50% is recommended for initial
operation. The total air volume is thereby kept constant
automatically by the control unit.
NOTE:
As a factory default value, a powder rate of 50% and a total air
volume of 4 Nm³/h are recommended.
If values are entered that the equipment cannot implement, then the
operator is informed of this by a blinking in the relevant display and
a temporary error message!
2. Check fluidization of the powder in the powder container
3. Point the gun into the booth, press the gun trigger and
visually check the powder output
OptiStar CG13
Initial start-up • 33
V 01/14
Setting the electrode rinsing air
1.
2.
Press the key T9 (SELECT)
The second display level will be shown
Adjust the correct electrode rinsing air according to the
applied nozzles (deflector plate, flat jet nozzle)
NOTE:
By using flat jet nozzles, the factory default value is approx. 0.3
Nm³/h, by using round jet nozzles with air-rinsed deflector plates,
the factory default value is approx. 0.5 Nm³/h!
3. If in this display level is no operation for 3 seconds, the first
display level is switched over independently
Setting the fluidization
The fluidization can be adjusted on the OptiFlex 2 B, OptiFlex 2 Q,
OptiFlex 2 F and OptiFlex 2 S manual units.
The powder fluidization depends on the powder type, the air humidity and
the ambient temperature. Fluidizing and vibration start by switching on
the control unit.
Procedure:
1. Configure AirMover by opening the ball valve complete and
adjusting with the flow control valve (OptiFlex 2 F only)
2. Open the powder container cover
3.
4.
Press the key T9 (SELECT)
The second display level will be shown
Adjust the fluidizing air with the keys T5/T6
-
If in this display level is no operation for 3 seconds, the
device switches back to the first display level
-
The powder should only be touched gently, but should
be "cooked" regularly and is also to be stirred using a rod
5. Close again the cover
34 • Initial start-up
OptiStar CG13
V 01/14
Setting correction factor for powder output
Entering the correction factor
1. Hold
key down for 5 seconds
The display switches to the following level:
key
2. Press
The display switches to the following level:
T1 / T2
A1
T3 / T4
A2
3. The value of the correction factor C0 is displayed
4. Set the corresponding correction value with the T3 or T4 key.
The value of the adjusted correction factor appears on
corresponding display A2
5. Select correction values according to the following table
Corr.value
C0
Description
Powder output (dm³/h)
Range2)
Default
value
0.5-3.0
1.0
1)
1) The correction value is set to its default value if the default value changes when the
P00 device type is changed.
2) The correction value is set to its default value if it is outside of the value range after the
P00 device type has been changed.
OptiStar CG13
Initial start-up • 35
V 01/14
6. Press
key
Display returns to the first level display.
Rinsing mode
The rinsing mode enables blowing off powder accumulations in the
powder hose with preset air pressure. This function is a two steps
process to activate.
Activating the rinsing function
Manual equipment without PowerClean module (system
parameter P01=0)
The rinsing mode can only be activated from standby mode (main menu
display, no powder conveying).
NOTE:
The injector must be detached prior to rinsing procedure!
1. Detach the injector
2. Press these two keys at the same time for 3 seconds
3.
36 • Initial start-up
OptiStar CG13
V 01/14
= automatically
= manually
4.
Procedure
Effect
- The automatic rinsing process is started
automatic
manual
- Injector, powder hose, gun and spray nozzle are purged
using compressed air
- The automated PowerClean function enables parallel
cleaning of other components, such as the fluid intake
unit, powder container, etc.
- The operator controls the number and length of the
PowerClean impulse by pressing the pistol trigger a
second time
The rinsing mode is exited:
-
if the automatic rinsing sequence has finished
-
if no operation is started within 15 s
The active manual rinsing function is terminated immediately when
exiting this mode.
The rinsing mode can be terminated with the same key combination, if
required.
After completion of the PowerClean procedure, the controller switches
back to coating mode.
Manual equipment with optional PowerClean module
(system parameter P01=1)
The rinsing mode can only be activated from standby mode (main menu
display, no powder conveying).
1.
2.
= automatically
= manually
3.
OptiStar CG13
Initial start-up • 37
V 01/14
Procedure
Effect
- The automatic rinsing process is started
- Injector, powder hose, gun and spray nozzle are purged
using compressed air
automatic
- The automated PowerClean function enables parallel
cleaning of other components, such as the fluid intake
unit, powder container, etc.
- The operator controls the number and length of the
PowerClean impulse by pressing the pistol trigger a
second time
manual
The rinsing mode is exited:
-
if the automatic rinsing sequence has finished
-
if no operation is started within 15 s
The active manual rinsing function is terminated immediately when
exiting this mode.
The rinsing mode can be terminated with the same key combination, if
required.
After completion of the PowerClean procedure, the controller switches
back to coating mode.
Monitoring of wearing parts and trigger counter
1. Press
key 2x
The display switches to the following level:
A5
and
at same time
2. Press
Monitoring is activated
During the first activation a value of 0.1 is shown as the start
value. If monitoring has already been activated at some
earlier point, then the last stored value is displayed.
3. Set the desired service life for each wearing part using the
or
4. The reverse counter is then activated and runs only during
active coating
38 • Initial start-up
OptiStar CG13
V 01/14
5. If the selected service life is exceeded, the service symbol
appears on the display. The coating procedure is not affected
by this.
Trigger counter
The trigger counter (total time in days of trigger time) is shown in the
display A5.
The trigger counter can't be reset!
View remaining service life
1. Press
key 2x
The display switches to the wearing part monitoring level
Display of remaining service life:
range 0.1 – 500 days
< or >
adjustment of
service life
Quit wearing
parts monitoring
< and >:
Deactivation of
monitoring
Service life
expired
negative value:
display blinks
< and >:
Activation of
montioring
Monitoring
deactivated
Display example for wearing part no. 3:
OptiStar CG13
Read minus days
-7.5 days
Selected service life
200 days
Operating life
207.5 days
Initial start-up • 39
V 01/14
Deactivation of wearing part monitoring
1. Press
and
key simultaneously
Monitoring is deactivated.
Setting the background illumination
1. Press
key
The display switches to the following level:
2.
40 • Initial start-up
Select the desired brightness
OptiStar CG13
V 01/14
Activate/deactivate the program change via remote
control
The remote control function has been set in the factory to change the
powder output only.
If the operator prefers the possibility to switch between the programs, this
function is to be activated/deactivated either on the control unit or on the
gun directly.
NOTE:
This function is activated/deactivated in depending on the system
parameter P01:
► P01=0
by pressing the P key on the gun directly
► P01=1
on the gun control unit
Activate/deactivate the program change function on the
gun control unit
1. Hold
key pressed
key
2. Press
The display flashes once, and the program change function is
activated/deactivated
Activate/deactivate the keyboard lock
1. Hold
key pressed
key
2. Press
The keyboard lock is activated. The remote display blinks.
3. The keyboard lock is cancelled by pressing the same key
combination
Checking the software version
1. Press these two keys at the same time
2.
The status display is shown as long as the keys are held.
OptiStar CG13
Initial start-up • 41
V 01/14
RAM Reset
The RAM reset enables a restore of factory settings of the OptiStar CG13
gun control unit. All parameters (except P00) and correction values as
well as all user-defined values in the Program mode and Preset mode will
be overwritten with factory default. An active keyboard lock will be
deactivated.
NOTE:
By resetting the RAM, all user-made settings will be set to factory
default!
1. Switch off the control unit
2. Press the
key and hold it
3. Switch on the control unit, the CLR display blinks
4. Wait for approximately 5 seconds, until CLR disappears
5. Release the
key
6. All values are reset. The control unit must be set-up again.
Shutdown
1. Release gun trigger
2. Switch off the control unit
NOTE:
The adjustments for high voltage, powder output volume and
electrode rinsing air remain stored
If in disuse for several days
1. Separate from power mains
2. Clean the coating equipment (see the corresponding
operating manual)
3. Turn off the compressed air main supply
42 • Initial start-up
OptiStar CG13
V 01/14
Fault remedying
Error diagnosis of the software
General information
The correct function of the OptiStar CG13 Gun control unit is constantly
monitored. If the equipment software determines a fault, an error
message is indicated with a help code. Following is monitored:
-
High voltage technology
-
Pneumatic system
-
Power supply
Help codes
The error diagnosis codes (help codes) are shown in rot on the A5
display.
T10/T11
The help codes are stored in an error list in the order of their appearance.
Each error in the list must be individually acknowledged with the keys
T10 or T11.
The errors are displayed in the order of their appearance. The T10 and
T11 keys cannot be used for other functions, as long as an error code is
still shown.
Here is a list of all possible help codes for the OptiStar CG13 Gun control
unit:
Code
Description
Criteria
Remedy
- Purge valve not connected
connect or replace
Pneumatics:
H05
Purge valve
- Valve defective
- Connection cable defective
contact Gema Service
- Mainboard defective
OptiStar CG13
Fault remedying • 43
V 01/14
Code
Description
H06
Trigger valve
H07
Supplementary air flow too
high
(Setting of supplementary
air on the display)
H08
Conveying air volume too
high (setting of powder
share on the display)
H09
Powder output higher than
100%
H10
Conveying air range lower
deviation
Criteria
Remedy
Solenoid coil current lower than
preset limiting value
contact Gema Service
Valve defective, main board or cable
defective
The preset value for supplementary
air is too high compared to the
conveying air setting
Lower supplementary air value
or increase value for conveying
air to equalize air volumes to the
injector, delete error code
The preset value for conveying air is
too high compared to the
supplementary air setting
Lower conveying air value or
increase value for
supplementary air to equalize air
volumes to the injector, delete
error code
The powder output multiplied by the
powder hose length factor and daily
correction value is greater than 100%
Reduce powder output
Daily correction value too large
Reduce daily correction value
The theoretical value for conveying
air falls below minimum
Limit conveying air to its
minimum value
Total air is smaller than minimum
High voltage:
H11
Gun error
No vibrations in the oscillator, cable
break, oscillator or gun is defective
contact Gema Service
H13
Intermediate circuit voltage
too high
Mainboard defective, device is
switched off
contact Gema Service
H14
Offset spray current
measurement
Grounded current measurement
contact Gema Service
Power pack defective or overloaded
contact Gema Service
Power supply:
H21
Supply undervoltage
EEPROM (equipment memory):
H24
EEPROM content invalid
EEPROM error
contact Gema Service
H25
Timeout during EEPROM
writing
EEPROM error
contact Gema Service
Values not correctly stored
in EEPROM during
switching off
EEPROM error
contact Gema Service
H26
H27
EEPROM verification
erroneous
EEPROM error
contact Gema Service
Throttle motors:
Conveying air reference
position not found
Throttle motor or needle jammed, limit
switch defective, error in motor
throttle
contact Gema Service
H60
Supplementary air
reference position not
found
Throttle motor or needle jammed, limit
switch defective, error in motor
throttle
contact Gema Service
H61
Electrode rinsing air
reference position not
found
Throttle motor or needle jammed, limit
switch defective, error in motor
throttle
contact Gema Service
H62
H64
Conveying air throttle does
not move
Short circuit in limit switch, motor
throttle defective
contact Gema Service
H65
Supplementary air throttle
does not move
Short circuit in limit switch, motor
throttle defective
contact Gema Service
44 • Fault remedying
OptiStar CG13
V 01/14
Code
Description
Criteria
Remedy
H66
Electrode rinsing air throttle
does not move
Short circuit in limit switch, motor
throttle defective
contact Gema Service
H68
Conveying air position lost
Lost steps, limit switch defective,
throttle motor defective
contact Gema Service
H69
Supplementary air position
lost
Lost steps, limit switch defective,
throttle motor defective
contact Gema Service
H70
Electrode rinsing air
position lost
Lost steps, limit switch defective,
throttle motor defective
contact Gema Service
H71
Fluidizing air position lost
Lost steps, limit switch defective,
throttle motor defective
contact Gema Service
Mainboard defective
contact Gema Service
Gun not connected
connect
Gun, gun cable or Mainboard
defective
Replace or contact Gema
Service
Mainboard defective
contact Gema Service
Communication Mainboard-Gun:
H90
Communication error
Mainboard
H91
Communication error
Mainboard-Gun
H92
Communication error
Mainboard
Help codes list
The last appeared four errors are stored in a list by the software. If an
error appears, which is already in the list, he will not be listed again.
Appearance of errors
It is possible that an error is only displayed for a short time, but after the
acknowledgement it will disappear. In this case, it's recommended to
switch off the control unit and switch it on again (reset by restarting).
OptiStar CG13
Fault remedying • 45
V 01/14
Spare parts list
Ordering spare parts
When ordering spare parts for powder coating equipment, please indicate
the following specifications:
-
Type and serial number of your powder coating
equipment
-
Order number, quantity and description of each spare
part
-
Type OptiStar CG13
Serial number 1234 5678
-
Order no. 203 386, 1 piece, Clamp - Ø 18/15 mm
Example:
When ordering cable or hose material, the required length must also be
given. The spare part numbers of this bulk stock is always marked with
an *.
Wearing parts are always marked with a #.
All dimensions of plastic hoses are specified with the external and
internal diameter:
Example:
Ø 8/6 mm, 8 mm outside diameter (o/d) / 6 mm inside diameter (i/d)
WARNING!
Only original Gema spare parts should be used, because the
explosion protection will also be preserved that way. The use of
spare parts from other manufacturers will invalidate the Gema
guarantee conditions!
OptiStar CG13
Spare parts list • 47
V 01/14
OptiStar CG13 Gun control unit
1
OptiStar CG13 Gun control unit – complete
1009 971
2
Cover
1008 301
1
OptiStar CG13 Gun control unit
2
48 • Spare parts list
OptiStar CG13
V 01/14
OptiStar CG13 – Front plate and power pack
Front plate - complete (pos. 1-12)
1009 860
Front plate with foil keyboard (pos. 5-8)
1009 859
1
OptiStar Mainboard V2.0 – complete
1009 844
2
Spacer sleeve – Ø 3.1/6x15 mm
3
PCB Powerboard V2.0
4
Spacer sleeve – Ø 3.2/6x7 mm
5
Front frame - complete (incl. pos. 5.1)
1007 048
Special screw
1007 019
6
Special screw – M4x20/7 mm
1003 000
7
Front plate gasket
1007 042
9
Spacer sleeve – Ø 3.6/7x5 mm
5.1
1009 865
10
Display
11
Washer – Ø 3.2/7x0.5 mm
12
Locknut – M3
13
Power pack – 24 VDC
12
1007 044
1009 849
11
10
9
8
7
6
13
1
2
3
4
5
OptiStar CG13 – Front plate and power pack
OptiStar CG13
Spare parts list • 49
V 01/14
OptiStar CG13 – inside rear wall
1
Rear panel gasket
1007 033
2
Motor throttle – complete
1008 012
3
T-piece – 1/4"a- Ø 8- Ø 8 mm
1008 040
4
Solenoid valve - Ø 8-Ø 8 mm, NW 3.4, 24 VDC
1003 914
5
Motor throttle - complete
1000 064
6
Plastic tube - Ø 8/6 mm
103 152*
7
Fluidizing pad - 1/8"a
237 264
8
Cap screw - M4x16 mm
216 801
* Please indicate length
8
7
1
6
5
2
3
5
5
4
OptiStar CG13 – inside rear wall
50 • Spare parts list
OptiStar CG13
V 01/14
OptiStar CG13 – Connecting material
1
1.1
2
Quick release connection – NW5, Ø 6 mm
200 840
Hose - Ø 6/4 mm
100 854*
Nut with kink protection – M12x1 mm, Ø 8 mm
201 316
2.1
Supplementary air hose - Ø 8/6 mm (black)
2.2
Quick release coupling for supplementary air hose - NW5-Ø 8 mm
261 637
Nut with kink protection – M12x1 mm, Ø 8 mm
201 316
3
103 756*
3.1
Conveying air hose - Ø 8/6 mm (red)
103 500*
3.2
Quick release coupling for conveying air hose - NW5-Ø 8 mm
4
Hose - Ø 8/6 mm
5
Quick release connection - NW 5, Ø 6 mm
5.1
6
261 645
103 756*
200 840
Hose - Ø 6/4 mm
100 854*
PowerClean module cable – 1 m (option)
1009 879
PowerClean module cable – 15 m (option)
1009 880
7
Power cable (country-specific)
8
Vibrator cable (constituent part of vibrator)
* Please indicate length
8
7
6
1
5
2
3
4
OptiStar CG13 – Connections
OptiStar CG13
Spare parts list • 51
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