Gema OptiMove CR09-C User manual

Rev. 00 1024 602 EN
Operating instructions and Spare parts list
Axis control
OptiMove CR09-C
Translation of the original operating instructions

Rev. 00 12/22
Documentation OptiMove CR09-C
© Copyright 2021 Gema Switzerland GmbH
All rights reserved.
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without the express written consent of Gema Switzerland GmbH.
Gema, EquiFlow, MagicCompact, MagicCylinder, OptiCenter, OptiFlex,
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Switzerland GmbH.
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OptiHopper, OptiMove, OptiSieve, OptiSpeeder, OptiSpray, PCC (Precise
Charge Control), RobotGun, SIT (Smart Inline Technology) and
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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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To the best of our knowledge and belief, the information contained in this
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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.com/patents or
www.gemapowdercoating.us/patents.
Printed in Switzerland
Gema Switzerland GmbH
Mövenstrasse 17
9015 St.Gallen
Switzerland
Phone: [phone]
Email: [e-mail]

Rev. 00 12/22
OptiMove CR09-C Table of contents • 3
Table of contents
About these instructions 7
General information ................................................................................................ 7
Keeping the Manual ................................................................................................ 7
Safety symbols (pictograms) ................................................................................... 7
Structure of Safety Notes ........................................................................... 8
Software version ..................................................................................................... 8
Presentation of the contents ................................................................................... 8
Figure references in the text ...................................................................... 8
Safety 9
Basic safety instructions ......................................................................................... 9
Product specific safety information ......................................................................... 9
Product description 13
Intended use ......................................................................................................... 13
A summary of the directives and standards ............................................. 14
Reasonably foreseeable misuse ........................................................................... 14
Technical Data ...................................................................................................... 15
Versions ................................................................................................... 15
Connectable axes .................................................................................... 15
Electrical data........................................................................................... 15
Dimensions .............................................................................................. 15
Environmental conditions ......................................................................... 16
Sound pressure level ............................................................................... 16
Rating plate .............................................................................................. 16
Design and function .............................................................................................. 17
Overall view.............................................................................................. 17
Function description .............................................................................................. 17
Schematic presentation ........................................................................... 18
Operating elements .................................................................................. 19
Connections – rear side ........................................................................................ 22
Pin assignment ........................................................................................ 23
Scope of delivery................................................................................................... 24
Operating modes................................................................................................... 25
"Manual" operating mode ......................................................................... 25
"Remote" operating mode ........................................................................ 25
Keyboard lock .......................................................................................... 25
Assembly / Connection 27
Assembly guide ..................................................................................................... 27
Connection instructions ......................................................................................... 28
Start-up 29
Preparation for start-up ......................................................................................... 29
Basic conditions ....................................................................................... 29
Measures before initial start-up ............................................................... 29
Electrical wiring and screening concept ................................................... 29

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4 • Table of contents OptiMove CR09-C
System parameters .............................................................................................. 30
Entering the system parameters ............................................................. 30
CAN bus ............................................................................................................... 34
General information ................................................................................. 34
Hardware ................................................................................................. 35
Determining device address (Node-ID) and Baud rate ........................... 36
DigitalBus parallel interface .................................................................................. 37
Overview .................................................................................................. 37
16 bits parallel bus structure.................................................................... 37
Command table and value ranges .......................................................... 39
Control sequence .................................................................................... 39
Software description ................................................................................ 41
Digital Connector CD02 with connection designations ........................... 42
Operation 43
Operation .............................................................................................................. 43
Operating the axis control unit .............................................................................. 43
Switch on/off the axis control unit ......................................................................... 43
Travel to reference point ....................................................................................... 44
Start/stop the axis ................................................................................................. 44
Program change ................................................................................................... 45
Displaying the cycle time ...................................................................................... 45
Edit programs ....................................................................................................... 45
Axes operating modes 47
General ................................................................................................................. 47
Pendulum operating mode ................................................................................... 47
Editing/Setting ......................................................................................... 48
Sequence program ............................................................................................... 48
Structure of a program step (procedure step) ......................................... 49
Programming example – positioning ....................................................... 50
Programming example – pendulum movements ..................................... 50
Programming example with path-time diagram ....................................... 51
Semiautomatic pendulum operating mode ........................................................... 51
Sequence program X_GunClean ......................................................................... 52
Setup .................................................................................................................... 52
Setup mode by keyboard (pendulum operating mode / semiautomatic
mode) ....................................................................................................... 52
Setup mode by keyboard (sequence program) ....................................... 53
Memory Reset ...................................................................................................... 54
Default values after RAM reset ............................................................... 54
Checking the software version ............................................................................. 55
Query of the hour counter ..................................................................................... 55
Decommissioning / Storage 57
Shutdown .............................................................................................................. 57
If in disuse for several days ..................................................................... 57
Storage conditions ................................................................................................ 57
Hazard notes ........................................................................................... 57
Type of storage ........................................................................................ 57
Storage duration ...................................................................................... 57
Space requirements ................................................................................ 57
Physical requirements ............................................................................. 58
Maintenance during storage ................................................................................. 58
Maintenance schedule ............................................................................. 58
Maintenance works .................................................................................. 58

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OptiMove CR09-C Table of contents • 5
Maintenance / Repairs 59
General information .............................................................................................. 59
Periodic checks ..................................................................................................... 59
Repair work ........................................................................................................... 59
Fault clearance 61
Software error diagnostics .................................................................................... 61
General information ................................................................................. 61
Help codes list .......................................................................................... 61
Appearance of errors ............................................................................... 61
Help codes ............................................................................................... 61
Disposal 65
Introduction ........................................................................................................... 65
Requirements on personnel carrying out the work .................................. 65
Disposal regulations ................................................................................. 65
Materials ................................................................................................... 65
Disassembly of component groups ....................................................................... 65
Spare parts list 67
Ordering spare parts ............................................................................................. 67
OptiMove CR09-C axis control unit....................................................................... 68
Front plate ............................................................................................................. 69
Rear wall ............................................................................................................... 70
Connecting material .............................................................................................. 71
Appendix – program table ..................................................................................... 72

Rev. 00 12/22
OptiMove CR09-C About these instructions • 7
About these instructions
General information
This operating manual contains all the important information which you
require for the working with the OptiMove CR09-C. It will safely guide you
through the start-up process and give you references and tips for the
optimal use when working with your powder coating system.
Information about the functional mode of the individual system
components should be referenced in the respective enclosed documents.
Keeping the Manual
Please keep this Manual ready for later use or if there should be any
queries.
Safety symbols (pictograms)
The following warnings with their meanings can be found in the Gema
instructions. The general safety precautions must also be followed as well
as the regulations in the relevant instructions.
DANGER
Indicates a hazardous situation which, if not avoided, will result in death
or serious injury.
WARNING
Indicates a hazardous situation which, if not avoided, could result in
death or serious injury.
CAUTION
Indicates a hazardous situation which, if not avoided, could result in
minor or moderate injury.
ATTENTION
Indicates a potentially harmful situation. If not avoided, the equipment or
something in its surrounding may be damaged.

Rev. 00 12/22
8 • About these instructions OptiMove CR09-C
ENVIRONMENT
Indicates a potentially harmful situation which, if not avoided, may have
harmful consequences for the environment.
MANDATORY NOTE
Information which must be observed.
NOTICE
Useful information, tips, etc.
Structure of Safety Notes
Every note consists of 4 elements:
– Signal word
– Nature and source of the danger
– Possible consequences of the danger
– Prevention of the danger
SIGNAL WORD
Nature and source of the hazard!
Possible consequences of the danger
► Prevention of the danger
Software version
This document describes the operation of the product OptiMove CR09-C
with software version starting from 0.04.0.
See chapter "Checking the software version" on page 55.
Presentation of the contents
Figure references in the text
Figure references are used as cross references in the descriptive text.
Example:
"The high voltage (H) created in the gun cascade is guided through the
center electrode."

Rev. 00 12/22
OptiMove CR09-C Safety • 9
Safety
Basic safety instructions
– This product is built to the latest specification and conforms to the
recognized technical safety regulations and is designed for the
normal application of powder coating.
– 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. If this product is to be used for other
purposes or other substances outside of our guidelines then Gema
Switzerland GmbH should be consulted.
– Start-up (i.e. the execution of intended operational tasks) is
forbidden until it has been established that this product has been set
up and wired according to the guidelines for machinery. The
standard "Machine safety" must also be observed.
– Unauthorized modifications to the product exempt the manufacturer
from any liability from resulting damage.
– The relevant accident prevention regulations, as well as other
generally recognized safety regulations, occupational health and
structural regulations are to be observed.
– Furthermore, the country-specific safety regulations also must be
observed.
Product specific safety information
– This product 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.
– 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.

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10 • Safety OptiMove CR09-C
WARNING
The power of the axes is 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!
– The plugs and sockets of the axis control unit and the power unit of
the vertical axis should only be unplugged when the power supply is
disconnected.
– The connecting cables between the control unit and the axis must be
laid in such a way, that they cannot be damaged during axes
operation. Please observe the local safety regulations!
– The maximum upper stroke limit of the vertical axis 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 vertical axis and/or the booth!
ATTENTION
The equipment may be damaged during a test run!
► In particular, the limitations of the stroke range have to be
observed (for further information, see chapter "System parameter
P01 – Setting the upper mechanical stop")!
– The voltage supply of the axis is guaranteed by the 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.
– When repairing the axis, both the axis control unit and the axis must
be disconnected from the mains according to the local safety
regulations!
– Repairs may only be carried out 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.
– 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.
For further information, see the more detailed Gema safety
regulations.

Rev. 00 12/22
OptiMove CR09-C Safety • 11
WARNING
Working without instructions
Working without instructions or with individual pages from the
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.

Rev. 00 12/22
12 • Safety OptiMove CR09-C

Rev. 00 12/22
OptiMove CR09-C Product description • 13
Product description
Intended use
The axis control unit is designed exclusively for operating electrically
driven axes in electrostatic powder coating equipments.
Fig. 1: Axis control OptiMove CR09-C
Observance of the operating, service and maintenance instructions
specified by the manufacturer is also part of the intended use. This
product should only be used, maintained and started up by trained
personnel, who are informed about and are familiar with the possible
hazards involved.
Any other use is not considered as intended use. 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.

Rev. 00 12/22
14 • Product description OptiMove CR09-C
A summary of the directives and standards
This product was built according to the current state of the art. The
product is subject to the European directives and complies with the
following standards.
The product is suitable for the intended purpose and can be used in the
appropriate areas.
For further information, also refer to the enclosed Declaration of
Conformity.
European directives RL
EG-RL
2006/42/EU
Machinery
EG-RL
2014/34/EU
Equipment and Protective Systems in Potentially
Explosive Atmospheres (ATEX)
EG-RL
2014/30/EU
Electromagnetic compatibility
EN European standards
EN 50177
Stationary electrostatic application equipment for
ignitable liquid coating material - Safety requirements
Recognized safety-related regulations
BGI 764 /
DGUV
Information
209-052
Electrostatic coating
Trade Union information concerning health and
safety during work (BGI)
Reasonably foreseeable misuse
– Operation without the proper training
– Use in connection with unauthorized devices or components

Rev. 00 12/22
OptiMove CR09-C Product description • 15
Technische Dat en
Technical Data
Versions
System integration via CAN bus
OptiMove CR09-C
yes
The equipment designation is indicated on the type plate.
Connectable axes
OptiMove CR09-C
connectable
ZA08
yes
XT11
yes
ZA10
No
ATTENTION
The axis control may only be used with the specified axis types!
Electrical data
OptiMove CR09-C
Nominal input voltage
100 - 240 VAC
Frequency
50-60 Hz
Fluctuations of the power supply
± 10 %
Overvoltage category
OVC II
Connected load
40 VA
Fuse F1
10 AT
Power consumption
0.6 kW
Protection type
IP54
Approvals
II 3D
Dimensions
OptiMove CR09-C
Width
173 mm
Depth
250 mm
Height
177 mm
Weight
approx. 2.5 kg

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16 • Product description OptiMove CR09-C
Environmental conditions
OptiMove CR09-C
Utilization
in the interior
Height
up to 2 000 m
Temperature range
+5 °C - +40 °C
(+41 °F - +104 °F)
Max. surface temperature
+85 °C (+185 °F)
Maximum relative humidity
80 % for temperatures to 31 °C,
linearly decreasing to 50 %
relative humidity at 40 °C
Environment
not for wet environment
Degree of pollution of the
intended environment
2 (in accordance with DIN EN
61010-1)
Sound pressure level
OptiMove CR09-C
Normal operation
< 60 dB(A)
The sound pressure level was measured while the unit was in operation;
measurements were taken at the most frequent operator positions and at
a height of 1.7 m from the ground.
The specified value is applicable only for this product itself and does not
take into account external noise sources or cleaning impulses.
The sound pressure level may vary, depending on the product
configuration and space constraints.
Rating plate
Fig. 2

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OptiMove CR09-C Product description • 17
Design and function
The axis control unit is available as an enclosure version for building into
an ASxx control system.
Overall view
Fig. 3
1 Front plate with control and
display elements
2 Enclosure
3 Back panel with interfaces
Function description
The 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 asynchronous motor. The frequency converter
receives the supply voltage and the control signals directly from the
OptiMove axis control unit.
The axis control unit contains the visualization, input unit and sequence
control for the control of an axis with motor and frequency converter.
The drive motor is equipped with an electrical retaining brake. The holding
brake is activated if the axis control is disconnected from mains.

Rev. 00 12/22
18 • Product description OptiMove CR09-C
Schematic presentation
Fig. 4: Schematic presentation
1 Axis control
2 Frequency converter
3 Pulse generator wiring
4 Pulse generator
5 Motor cables
6 Drive motor
7 Signal line
8 Axis adapter

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OptiMove CR09-C Product description • 19
Operating elements
The control unit is operated by a foil keyboard with input and display
elements.
In the "Manual" operating mode, all operation functions are released with
the foil keyboard. In the "Remote" operating mode, only visualization
functions are available.
Display
The desired and actual values are distributed across several
levels.
– The key is used to switch between the levels.
– Certain levels* are only visible in certain axis operating modes
(See chapter "System parameters" on page 30.).
Fig. 5: Displays, Level 1
Designation
Function
A1
Display of actual values / desired values and
system parameters
Level 1
– Position of the axis while traveling or at a
standstill
Level 2
– Axis upper position
Level 3
– Speed upwards
Level 4*
– Dwell time
Level 5*
– Number of the following program
– Parameter number
A2
– Parameter designation

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20 • Product description OptiMove CR09-C
Designation
Function
A3
Display of actual values / desired values and
parameter values
Level 1
– Speed while traveling
Level 2
– Axis lower position
Level 3
– Speed downwards
A5
Display of program numbers, error diagnosis
codes and status information
S1-S4
Upper position, speed upwards, dwell time
S6-S9
Lower position, speed downwards, following
program
S10
Display background illumination (0-8)
S12 remote
Remote operation mode, no local operation
possible
– Remote operation mode is used as
keyboard lock, reduced operation is
possible
S13
Axis is running / not running
S15-17
Displays the axis status