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Gema OptiMove CR07, Operating Instructions And Spare Parts List

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OptiMove CR07 

Table of contents  

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  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

 

Summary of Contents for OptiMove CR07

Page 1: ...En Translation of the original operating instructions Operating instructions and spare parts list OptiMove CR07 Axis control unit ...

Page 2: ...t 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 be...

Page 3: ...rical 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 ...

Page 4: ...t 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...

Page 5: ... 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 ...

Page 6: ......

Page 7: ...roper 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 conside...

Page 8: ...erally 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...

Page 9: ... 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 info...

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Page 11: ...mponents 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 devi...

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Page 13: ... 12 13 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 ...

Page 14: ...m 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 t...

Page 15: ...Maximum speed 0 6 m s Minimum speed 0 08 m s Acceleration 0 1 2 0 m s 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 ...

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Page 17: ...C 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 equi...

Page 18: ...onfiguration 1 OptiMove 2 3 4 5 6 OptiMove CR07 Axis control unit function 1 Position preset value 4 Frequency converter 2 Regulator 5 Incremental pulse generator 3 RPM preset value 6 AC motor Actual value Position from incremental pulse generator ...

Page 19: ... 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 A3 T7 T8 T9 T5 T6 A1 ...

Page 20: ...nput 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...

Page 21: ...ing 1 2 3 Preset actual value mode dark actual value mode green preset value mode 4 9 Parameter selection display 10 Axis started 11 Axis stopped 12 Axis referencing Remote Remote semiautomatic keyboard lock Remote A1 A2 A3 LED 10 LED 11 LED 12 LED 5 7 9 LED 2 LED 3 LED 4 6 8 LED 1 ...

Page 22: ... running program In this operating mode all display and operating functions are possible by the operating panel such as Program numbers selection Input mode display mode selection Preset value setting in the input mode only in pendulum operation Start Stop Error messages acknowledgement System parameter mode Remote operating mode In the remote operating mode the control unit is controlled by CAN b...

Page 23: ...y set P9 1 for more see Setting the system parameters If the systems parameter P9 1 is set the keyboard lock function can be activated through the remote digital input This is displayed on the operating panel by lighting up of the green Remote LED Only a limited operation is possible by the operating panel namely Start stop referencing axes Input mode display mode selection preset values and actua...

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Page 25: ...Axis power supply 2 3 Axis control signals 2 4 DigitalBus parallel interface 2 5 CAN bus input 2 6 CAN bus output The cable connections have different plugs and cannot be wrongly connected on assembly WARNING Before disconnecting the cables from the sockets always switch off the equipment and disconnect the mains cable ...

Page 26: ...ee operation with high data transmission rates a clear grounding concept is mandatory A uniform grounding potential is a prerequisite for this Exclusively screened cables are to be used for the wiring The cable shield must be connected largely at both ends to the ground WARNING Both ends of the cable shield must be connected generally or as often as possible to the ground otherwise malfunctions ca...

Page 27: ...r Horizontal axis with serial number see Rating plate 18401 xxxx 1012 displayed as 0 1 2 18402 xxxx 940 P7 Holding brake delay time 0 500 ms 100 P8 Communication 0 Digital Bus Error 1 1 CAN Open 2 Digital Bus Error 0 from software version 1 06 P9 Keyboard lock 0 Keyboard lock inactive 1 Keyboard lock active Activate keyboard lock by signal Remote 1 Exception Start stop axes referencing error ackno...

Page 28: ...he booth The upper stroke limit of the OptiMove CR07 Axis control unit is always set at 0 3 meters by the factory In order to set the upper stroke limit system parameter 1 proceed as follows 1 To enter the system parameter mode press and hold the key for 5 seconds The LEDs L1 L3 illuminate 2 Select the parameter P1 on the display A1 by using the keys 3 Set the upper stroke limit value on the displ...

Page 29: ... off By switching off the equipment also when the equipment is disconnected from the mains the actual settings are retained Travel to reference point In order that the OptiMove CR07 axes control unit can enter the position of the axis as accurately as possible during operation the triggered axis must first travel to the reference point each time it is switching on The prerequisite for this is that...

Page 30: ...in the reference travel will continue The procedure described above relates to the reference point traveling in manual operation In the automatic operation mode the reference point traveling is triggered with ID no 7 by the DigitalBus and with the corresponding command by the CAN bus Start stop the axis 1 Switch on the axis control unit see also Switch on off the axis control unit 2 If necessary c...

Page 31: ... seconds and then deletes i e the program change has been accepted The new program number is shown on the display A3 The display A1 shows the axis position The corresponding LED remains unlit The display A2 shows the axis speed The corresponding LED remains unlit Displaying the cycle time Only possible in pendulum mode semiautomatic mode 1 Start the axis see also Start stop the axis 2 Press in the...

Page 32: ...standstill NOTE If the system parameter P2 is set to 2 or 4 editing is only possible at a standstill In both cases the modifications are stored in the program memory i e after restarting the OptiMove CR07 Axis control unit the last entered program values are available again NOTE If a program is edited during operation the axis terminates the old command which is still in the memory and takes over ...

Page 33: ... in detail Pendulum operating mode In the pendulum operation mode the axis executes a continuous stroke movement according to the set parameters With the keyboard the different values as well as the start and stop functions can be set in a user friendly way The operator can read the set and current data directly on the display To be equipped for all operating processes up to 255 different programs...

Page 34: ...i e the axis stops in this position 5 Press the key again LEDs and illuminate green 6 Input the desired value for the speed upwards on the display A1 using the keys 7 Input the desired value for the speed downwards on the display A2 using the keys 8 Press the key again or press or or in order to exit the Editing mode Sequence program A sequence program is created by joining a number of individual ...

Page 35: ...er 2 Press the key LED illuminates green The LED in the display area A1 illuminates green too The display A2 remains dark 3 Input the desired value for the desired position on the display A1 using the keys 4 Press the Select key again LED illuminates green 5 Input the desired speed value on the display A1 using the keys 6 Press the Select key again LED illuminates green 7 Input the desired dwell t...

Page 36: ...Move CR07 Programming example positioning Program no 1 Display Input value 1 00 m 0 20 m s 0 s 0 Programming example pendulum movements Program no 1 Program no 2 Display Input value Input value 0 10 m 1 80 m 0 20 m s 0 30 m s 0 s 0 s 2 1 ...

Page 37: ...V 12 13 OptiMove CR07 Axes operating modes 35 Programming example with path time diagram ...

Page 38: ...rating panel namely Referencing axes Program editing when axis is moving Program change when axis is moving Input mode display mode selection preset values and actual values visualization Error messages acknowledgement The program editing requires the same procedure as in the standard semiautomatic operating mode Sequence program X_GunClean The X_GunClean sequence program is based in terms of func...

Page 39: ...n display A1 using the keys Axis travels with the modification The position of the upper reversing point is programmed 4 Press in the display area A2 in order to start the axis LED 2 blinks Axis travels to the lower reversing point 5 Adjust the lower reversing point on display A2 using the keys Axis travels with the modification The position of the lower reversing point is programmed 6 Select the ...

Page 40: ... the axis control unit by pressing 2 Keep pressed the key and at the same time switch on the axis control unit with Keep pressed the key for further 10 seconds The value 255 appears on the display A3 and the LED L3 blinks All other displays remain dark 3 Press the key in order to exit the RAM reset mode Default values after RAM reset Name Default value Preset values Upper position m 0 30 Lower pos...

Page 41: ...p gain 40 P6 Incremental pulse generator adjustment pulse cm 750 P7 Compensation of holding brake delay time ms 100 P8 Communication 0 P9 Keyboard lock 0 P10 Referencing mode 0 P11 CAN Baud rate 3 P12 CAN Node ID 1 NOTE These default values are valid from software version V1 10 ...

Page 42: ......

Page 43: ...he digital inputs are subdivided into a data bus consisting of 12 bits and a control bus consisting of 3 bits The digital outputs consist of the error message bit and the program active bit Digital Input Output Strobe 1 System On Off Remote Manuell Error Strobe 2 System On Off Remote Manuell Strobe 12 System On Off Remote Manuell Error Error Controlling by superordinated control unit PLC Control D...

Page 44: ...For inputs there are 3 control bits available Axis Start Start Stop axis Strobe Data transfer activation Remote Operating mode Status bits Status For outputs there are 2 status bits available Error Axis not referenced Program active Status bit 1 Status bit 1 has assigned two functions 1 After switching on an impulse of 0 1 s is present that means the axis has to be referenced OptiMove ON 2 The com...

Page 45: ...ns on low Dwell time Dwell time Dwell time Dwell time Start Stop Start End Start Stop lower reversing point Start Stop Pause Start Stop Start End Pause Start Stop Program 1 253 Program 254 255 P2 1 Pendulum operating mode P2 2 sequence program P2 3 Pendulum operating mode semiautomatic P2 4 X GunClean Sequence program ...

Page 46: ... 0 08 0 60 m s 0 01 X X 3 Speed downwards 0 08 0 60 m s 0 01 X 4 Dwell time 0 5 00 s 0 01 X 5 Following program address 0 255 1 X 6 Program no 1 255 1 X X 7 Start travel to reference point 0 1 1 X X X is used in the respective mode NOTE If a program is edited during operation the axis terminates the old command which is still in the memory and takes over the new program values by the next cycle ch...

Page 47: ...ompared after every negative Strobe flank If an error occurs the digital output Error is set at high and the error message H30 is shown on display A3 DATA STABLE Data bus Strobe signal OptiMove Composite error message Error low correct transmission Composite error message Error high incorrect transmission DATA STABLE Reading and processing Ts 20 ms Ts 100 ms Ts 20 ms DATA STABLE Data bus Strobe si...

Page 48: ...nals and the identification number signals are used in common for all OptiMove control units The OptiMove control unit takes over the data with the negative flank of the strobe signal Explanation The simultaneous transmission of identical data to all OptiMove units only occurs on the negative flank of all strobe signals Example of a PLC program Program procedure diagram ...

Page 49: ...arallel interface signals of up to 12 devices are fed connection friendly on plugs The exact plug assignment for the connection to the PLC is evident in the following illustration 1 3 5 7 9 11 2 4 6 8 10 12 X3 X4 X2 X5 X1 1 2 3 Digital Connector CD02 X5 1 12 Strobe 13 24 Start axis X4 1 12 D8 13 24 Remote Man X3 1 12 Prog aktiv 13 24 Error not referenced X2 1 8 13 20 D0 D7 9 11 21 23 A0 A2 X1 1 GN...

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Page 51: ...dentification number The allocation is described in the section Setting the user address ID number The transmission speed setting is determined by adjusting the Baud rate see therefore Setting the Baud rate Hardware The OptiMove control units are connected to the central PLC control unit with 4 pin CAN bus cables The last bus client is fitted with a terminal plug with terminal resistor in order to...

Page 52: ... the numbers of other existing users Setting the Baud rate 1 To enter the system parameter mode press and hold the key for 5 seconds The LEDs L1 L3 illuminate 2 Select the parameter P11 on the display A1 by using the keys 3 Select a value between 0 and 7 on the display A2 using the keys Set value P11 CAN Baud rate 0 20 kBit s 1 50 kBit s 2 100 kBit s 3 125 kBit s Default 4 250 kBit s 5 500 kBit s ...

Page 53: ...Emergency stop Axis must be referenced again H04 Wrong encoder rotating direction Emergency stop Axis must be referenced again H05 Desired travel position is larger then the defined end position system parameter P1 Travel position must be limited according to SP1 H06 Lower end stop overrun Emergency stop Axis can only travel upwards Axis must be referenced again H07 Proximity switch signal is perm...

Page 54: ...top Store axis position current program number and axis status Stop the system H23 EEPROM content invalid Load factory configuration DigitalBus H30 Data validation error Reject data H31 Data outside the value range Reject data H32 Data reception overflow Reject data CAN bus H40 Permanent CAN bus error BUS_OFF i e no power supply or cable is not connected H41 Too many errors during sending ERROR_PA...

Page 55: ...g 2 2 Drive supply Pin Function 1 Neutral conductor 2 Phase 3 Not connected PE Ground Plug 2 3 Drive I O Pin Function 1 GND frequency converter 2 24 V frequency converter 3 Frequency converter error 4 RPM preset value 5 Motor right running UP 6 Motor left running DOWN 7 Reserve 8 Reserve 9 24 VDC OptiMove 10 Motor brake 11 Proximity switch 12 Reserve 13 B 14 B ...

Page 56: ... values program no Binary value 6 G D6 Preset values program no Binary value 7 H D7 Preset values program no Binary value 8 I A0 Identification number Binary value 1 K A1 Identification number Binary value 2 L A2 Identification number Binary value 3 M 12 IN Axis_Start N 13 IN Strobe data transfer from data bus O 14 IN Remote manual P D8 Preset values program no Binary value 9 R GND_External GND S ...

Page 57: ...V 12 13 OptiMove CR07 Hardware 55 Plug 2 6 CAN bus OUT Pin Function 1 GND 2 24 VDC 3 CAN_H 4 CAN_L Enclosure Shield ...

Page 58: ......

Page 59: ...ce Clamp Ø 18 15 mm 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 shoul...

Page 60: ... 1 Special screw 1007 019 2 Special screw M4x20 7 mm 1003 000 3 Front plate gasket 1007 042 5 Screw M4x6 mm 221 767 6 Toothed lock washer Ø 5 3 106x0 6 mm 1002 999 7 Display complete 1010 293 8 Spacer sleeve Ø 3 4 6x6 5 mm 1001 925 9 Spacer sleeve Ø 3 6 7x5 mm 247 758 10 Main board V1 0 complete 1010 290 10 1 EPROM program version V x x current software 1000 610 11 Spacer 263 508 12 Locknut M3 262...

Page 61: ...V 12 13 OptiMove CR07 Spare parts list 59 OptiMove CR07 Front plate and power pack OptiMove CR07 Front plate and power pack 2 3 4 8 10 14 5 7 1 6 12 13 11 13 12 9 ...

Page 62: ...ction complete 1010 739 13 CAN bus IN connection complete 387 541 14 Connection to axis power supply complete 1010 740 15 CAN bus OUT connection complete 387 550 Mains cable for ZAxx L 20 m 1000 280 Signal cable for ZAxx L 20 m 1000 281 Optional features not shown CAN bus cable 0 50 m 1002 655 CAN bus cable 4 50 m 387 592 CAN bus cable 5 50 m 388 521 CAN bus cable 6 50 m 388 530 Bus terminal resis...

Page 63: ...V 12 13 OptiMove CR07 Spare parts list 61 OptiMove CR07 Rear panel OptiMove CR07 Rear panel 9 9 8 10 4 5 3 2 6 7 1 11 13 15 12 14 ...

Page 64: ...V 12 13 62 Spare parts list OptiMove CR07 Appendix program table 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 ...

Page 65: ...V 12 13 OptiMove CR07 Spare parts list 63 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 X position ...

Page 66: ...V 12 13 64 Spare parts list OptiMove CR07 131 132 133 134 135 136 137 138 139 140 141 142 143 144 145 146 147 148 149 150 201 202 203 204 205 206 207 208 209 210 211 212 213 214 215 ...

Page 67: ...V 12 13 OptiMove CR07 Spare parts list 65 216 217 218 219 220 221 222 223 224 225 226 227 228 229 230 231 232 233 234 235 236 237 238 239 240 241 242 243 244 245 246 247 248 249 250 ...

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