Gema OptiMove CR07 Guide

En
Translation of the original operating instructions
Operating instructions and spare parts list
OptiMove CR07
Axis control unit

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Documentation OptiMove CR07 Axis control unit
© Copyright 2012 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,
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Charge Control (PCC), Smart Inline Technology (SIT) and Digital Valve
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All other product names are trademarks or registered trademarks of their
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Reference is made in this manual to different trademarks or registered
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Fax.: [phone]
E-Mail: [email protected]

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OptiMove CR07 Table of contents • 1
Table of contents
General safety regulations 5
Safety symbols (pictograms)...................................................................................5
Proper use...............................................................................................................5
Product-specific safety measures ........................................................................... 6
OptiMove CR07 Axis control unit...............................................................6
Special security measures ......................................................................................7
About this manual 9
General information ................................................................................................9
Function description 11
OptiMove CR07 Axis control unit .......................................................................... 11
Operating panel .......................................................................................11
Field of application ................................................................................................12
Technical data 13
OptiMove CR07 Axis control unit .......................................................................... 13
General data ............................................................................................13
Electrical data ..........................................................................................13
Dimensions ..............................................................................................13
Design and function 15
OptiMove CR07 Axis control unit - structure.........................................................15
Function description..............................................................................................15
Configuration............................................................................................16
Operating and display elements, operating modes 17
Display and input buttons...................................................................................... 17
Operating modes ..................................................................................................20
"Manual" operating mode.........................................................................20
"Remote" operating mode........................................................................20
Keyboard lock ..........................................................................................21
Commissioning 23
Connections - rear side.........................................................................................23
Initial start-up.........................................................................................................24
Measures before initial start-up................................................................24
Electrical wiring and screening concept...................................................24
Setting the system parameters .............................................................................24
System parameters - overview ................................................................25
System parameter P1: setting the upper stroke limit ...............................26
Operation 27
Operating the axis control unit ..............................................................................27
Switch on/off the axes control unit ........................................................................27

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2 • Table of contents OptiMove CR07
Travel to reference point....................................................................................... 27
Start/stop the axis................................................................................................. 28
Program change ................................................................................................... 29
Displaying the cycle time ...................................................................................... 29
Edit programs ....................................................................................................... 30
Axes operating modes 31
General information .............................................................................................. 31
Pendulum operating mode ................................................................................... 31
Editing/setting .......................................................................................... 32
Sequence program ............................................................................................... 32
Structure of a program step (procedure step) ......................................... 33
Programming example - positioning........................................................ 34
Programming example - pendulum movements ..................................... 34
Programming example with path-time diagram....................................... 35
Semiautomatic pendulum operating mode........................................................... 36
Sequence program X_GunClean ......................................................................... 36
Setup .................................................................................................................... 37
Setup mode by keyboard (pendulum operating mode / semiautomatic
mode)....................................................................................................... 37
Setup mode by keyboard (sequence program)....................................... 37
RAM reset............................................................................................................. 38
Entering the RAM reset mode ................................................................. 38
Default values after RAM reset ............................................................... 38
DigitalBus parallel interface 41
Overview............................................................................................................... 41
16 bits parallel bus structure ................................................................... 42
Command table and value ranges .......................................................... 44
Control sequence ................................................................................................. 45
Control sequence for program number change (identification number 6)45
Control sequence for program parameter (identification numbers 0-5) .. 45
Data transfer............................................................................................ 45
Software description ............................................................................................. 46
Program procedure diagram ................................................................... 46
Digital Connector CD02 with connection designations ........................................ 47
CAN bus 49
General information .............................................................................................. 49
Hardware .............................................................................................................. 49
CAN bus cable - plug assignment ........................................................... 49
Setting the user address (ID Number)..................................................... 50
Setting the Baud rate............................................................................... 50
Fault remedying 51
General information .............................................................................................. 51
Hardware 53
Pin allocations ...................................................................................................... 53
Plug 2.1 - Power IN ................................................................................. 53
Plug 2.2 - Drive supply ............................................................................ 53
Plug 2.3 - Drive I/O .................................................................................. 53
Plug 2.4 – Aux DigitalBus parallel interface ............................................ 54
Plug 2.5 - CAN bus IN ............................................................................. 54
Plug 2.6 - CAN bus OUT ......................................................................... 55

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OptiMove CR07 Table of contents • 3
Spare parts list 57
Ordering spare parts .............................................................................................57
OptiMove CR07 – Front plate and power pack.....................................................58
OptiMove CR07 – Front plate and power pack.....................................................59
OptiMove CR07 – Rear panel...............................................................................60
OptiMove CR07 – Rear panel...............................................................................61
Appendix - program table......................................................................................62

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OptiMove CR07 General safety regulations • 5
General safety regulations
This chapter sets out the fundamental safety regulations that must be
followed by the user and third parties using the OptiMove CR07.
These safety regulations must be read and understood before the
OptiMove CR07 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 OptiMove CR07 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 OptiMove CR07
for any purposes or substances other than those indicated in our
guidelines.
3. Observance of the operating, service and maintenance
instructions specified by the manufacturer is also part of
conformity of use. The OptiMove CR07 should only be used,

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6 • General safety regulations OptiM ove CR07
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 a particular operation) is forbidden
until it has been established that the OptiMove CR07 axis control
unit has been set up and wired according to the guidelines for
machinery (2006/42 EG). EN 60204-1 (machine safety) must
also be observed.
5. Unauthorized modifications to the OptiMove CR07 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.
Explosion
protection Protection type Temperature class
II 3D IP54 85 °C
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.
OptiMove CR07 Axis control unit
The OptiMove CR07 axis 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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OptiMove CR07 General safety regulations • 7
Special security measures
1. It must be ensured, that all components are earthed according
to the local regulations before start-up.
2. The OptiMove CR07 axis control unit should be switched on
and operated only after carefully reading these operating
instructions. Incorrect operation of the axis control unit can
lead to accidents, malfunctions or damage to the plant.
WARNING!
The power of the axes is very much stronger than that of a human
being! All axes must be secured against access during operation
(see local regulations). Never stand under the Z carriage when the
reciprocator is not operating!
3. The installation work to be done by the customer must be
carried out according to local regulations.
4. The plugs and sockets of the axis control unit and the power
unit of the Reciprocator should only be unplugged when the
power supply is disconnected
5. The connecting cables between the control unit and the axis
must be laid in such a way, that they cannot be damaged
during axis operation. Please observe the local safety
regulations!
6. The maximum upper stroke limit of the reciprocator must
always be set with reference to the maximum height of the
booth gun slots. If an incorrect (too high) stroke limit is set,
this can lead to damage to the reciprocator and/or the booth!
WARNING:
During a test run, it must be guaranteed that the unit is not
damaged by the test! In particular, the limitations of the stroke
range have to be observed (for further information, see chapter
"System parameter P1 - Setting the upper mechanical stop")!
7. The voltage supply of the axis is guaranteed by the OptiMove
CR07 Axis control unit. The supply voltage amounts to 230
VAC and must always be conducted in the emergency stop
circuit. In case of an emergency, the voltage supply to the
motor may be interrupted with the emergency stop switch.
8. When repairing the axis, both the CR07 Axis control unit and
the axis must be disconnected from the mains according to
the local safety regulations!
9. Repairs may be done only by authorized Gema service
centers. Unauthorized conversions and modifications can
lead to injuries and damage to the equipment. The Gema
Switzerland GmbH guarantee would no longer be valid.
10. We point out that the customer himself is responsible for the
safe operation of the equipment. Gema Switzerland GmbH is
in no way responsible for any resulting damage.

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OptiMove CR07 About this manual • 9
About this manual
General information
This operating manual contains all the important information you require
for the working with the OptiMove CR07 axis 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 function mode of the individual system components
- booth, axis, gun control unit, powder gun or powder injector - should be
referenced to their enclosed corresponding 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.

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OptiMove CR07 Function description • 11
Function description
OptiMove CR07 Axis control unit
Operating panel
OptiMove CR07 - operating panel
1 Operating and display elements
2 Power switch ON/OFF
1
2

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12 • Function description OptiMove CR07
Field of application
The OptiMove CR07 Axis control unit is designed exclusively for
operating electrically driven axes in electrostatic powder coating
equipments. 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.
The start-up (i.e. the start of intended operation) is forbidden until it is
determined that the control unit and the equipment are installed and
connected according to the machine guideline (2006/42/EG). EN 60204-1
(machine safety) must also be observed.
For a better understanding of the interrelationships in powder coating, it
is recommended to read completely the operating instructions of the
other components, so as to be familiar with their functions too!

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OptiMove CR07 Technical data • 13
Technical data
OptiMove CR07 Axis control unit
General data
OptiMove CR07
Number of axes per control unit 1
Maximum available programs 255
Max. stroke height (theoretical) 5 m
Maximum speed 0.6 m/s
Minimum speed 0.08 m/s
Acceleration 0.1-2.0 m/s²
Electrical data
OptiMove CR07
Nominal input voltage 230 VAC
Tolerance +10% / -10%
Frequency 50/60 Hz
Control current circuit 24 VDC
Fuse F1 10 AT
Power consumption 1.1 kW
Protection type IP54
Operating temperature 0°C - +40°C
(+32°F - +104°F)
Storing temperature -20°C - +70°C
(-4°F - +158°F)
Dimensions
OptiMove CR07
Width 173 mm
Depth 212 mm
Height 177 mm
Weight 3 kg

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OptiMove CR07 Design and function • 15
Design and function
OptiMove CR07 Axis control unit - structure
The OptiMove CR07 Axis control unit is available as an enclosure version
for building into an AS0x control system.
Function description
The OptiMove CR07 Axis control unit is used in axis control systems. A
complete axis control system consists of an OptiMove control unit, a
frequency converter and an axis with AC motor. The frequency converter
receives the supply voltage and the control signals directly from the
OptiMove axis control unit.
The OptiMove CR07 axis control unit contains the regulation,
visualization and input unit and is responsible for the exact positioning
adjustment of the carriage by evaluating the signal from the reciprocator
incremental pulse generator in the axis.
The drive motor is equipped with an electrical retaining brake. When the
axes control unit holds an axis position (axis standstill), the holding brake
will be activated and the frequency transformer released with a time
delay (motor without current).

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16 • Design and function OptiMove CR07
Configuration
1
OptiMove
234
56
OptiMove CR07 Axis control unit - function
1 Position preset value 4 Frequency converter
2 Regulator 5 Incremental pulse generator
3 RPM preset value 6ACmotor
Actual value "Position" from
incremental pulse generator

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OptiMove CR07 Operating and display elements, operating modes • 17
Operating and display elements,
operating modes
Display and input buttons
The control unit is operated by a foil keyboard with input and display
elements. All displays (A1-A3) are 7 segment displays and all LEDs are
green.
In the "Manual" operating mode, all operation functions are released with
the foil keyboard. In the "Remote" operating mode, only visualization
functions are available.
WARNING:
The input keys should only be pressed with fingertips and under no
circumstances with fingernails or hard objects!
A2
A
3
T7 T8 T9
T5 T6
A1

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18 • Operating and display elements, operating modes OptiMove CR07
Display Meaning
A1
Actual value display (axis position)
Preset value input (position above, speed upwards, dwell time,
program address)
A2 Actual value display (axis speed)
Preset value input (position below, speed downwards)
A3 Displays the selected program number or the error code
Keys Meaning
Start axis (T7)
Stop axis (T8)
press for 5 seconds = system parameter
Start reference point travel (T9)
Input keys for preset values and system parameters (increase
value)
Input keys for preset values and system parameters (decrease
value)
T5, T6 Input keys for program number, error acknowledgment
Activate display mode (select desired value input LED 4 - LED
9)