1011 515
En
Translation of the original operating instructions
Operating instructions and spare parts list
Axis control
OptiMove CR08
Страница 1: ...1011 515 En Translation of the original operating instructions Operating instructions and spare parts list Axis control OptiMove CR08 ...
Страница 2: ...ct 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 b...
Страница 3: ...hnical data 10 Connectable axes 10 General data 10 Electrical data 11 Dimensions 11 Design and function 13 Structure 13 Function description 13 Configuration 14 Operating and display elements operating modes 15 Display and input buttons 15 Operating modes 18 Manual operating mode 18 Keyboard lock 18 Start up 19 Connections rear side 19 Initial start up 20 Measures before initial start up 20 Electr...
Страница 4: ...positioning 30 Programming example pendulum movements 30 Programming example with path time diagram 31 Semiautomatic pendulum operating mode 32 RAM reset 32 Entering the RAM reset mode 32 Default values after RAM reset 33 CAN bus 35 General information 35 Hardware 35 CAN bus cable plug assignment 35 Troubleshooting 37 General information 37 Hardware 39 Pin allocations 39 Plug 2 1 Power IN 39 Plug ...
Страница 5: ... Keeping the Manual Please keep this Manual ready for later use or if there should be any queries 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 Safety symbols pictograms The following warnings with their meanings can be fou...
Страница 6: ...injury ATTENTION Indicates a potentially harmful situation which if not avoided the equipment or something in its surrounding may be damaged ENVIRONMENT Indicates a potentially harmful situation which if not avoided may have harmful consequences for the environment MANDATORY NOTE Information which must be observed NOTE Useful information tips etc Software version This document describes the operat...
Страница 7: ...ng 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 ...
Страница 8: ...test run 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 The voltage supply of the axis is guaranteed by the OptiMove CR08 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 ...
Страница 9: ...ng 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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Страница 11: ...V 02 16 OptiMove CR08 Product description 9 Product description OptiMove CR08 axis control unit Operating panel fig 1 Operating panel 1 Operating and display elements 2 Power switch ON OFF ...
Страница 12: ...rrect 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 to read completely the operating instructions of the other components so as to be familiar with their functions too Reasonably foreseeable misuse Operation without the proper training Use in connection with unauthorized coating ...
Страница 13: ...ge 230 VAC Tolerance 10 10 Frequency 50 60 Hz Control current circuit 24 VDC Fuse F1 10 AT Power consumption 0 6 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 CR08 Width 173 mm Depth 212 mm Height 177 mm Weight 3 kg ...
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Страница 15: ...nsists of an OptiMove control unit a servo regulator and an axis with synchronous motor The servo regulator receives the supply voltage and the control signals directly from the OptiMove axis control unit The OptiMove CR08 axis control unit contains the visualization input unit and sequence control for the control of an axis with synchronous motor and position regulator The drive motor is equipped...
Страница 16: ...V 02 16 14 Design and function OptiMove CR08 Configuration fig 2 Schematic presentation 1 Axis control 2 Position regulator 3 Pulse generator wiring 4 Motor cables 5 Drive motor ...
Страница 17: ...lay 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 fig 3 Display and input buttons ATTENTION The input keys may be damaged if they are pressed with fingernails or hard objects Input keys should only be pressed wi...
Страница 18: ...t position below speed downwards A3 Displays the selected program number or the error code Keys Meaning Start axis T7 Stop axis T8 Press and hold 5 seconds system parameter Start reference point travel T9 Input keys for desired values and system parameters increase value Input keys for desired values and system parameters decrease value T5 T6 Input keys for program number error acknowledgment Acti...
Страница 19: ...splay elements operating modes 17 fig 4 LEDs LED Meaning 1 2 3 Preset actual value mode dark actual value mode green desired value mode 4 9 Parameter selection display 10 Axis started 11 Axis stopped 12 Axis referencing Remote Keyboard lock ...
Страница 20: ...anel such as Program numbers selection Input mode display mode selection Desired value setting in the input mode only in pendulum operation Start Stop Error messages acknowledgement System parameter mode Keyboard lock In the Keyboard lock operating mode the control unit operating panel is locked The prerequisite for it is that the System parameter P9 must already have been correctly set P9 1 for m...
Страница 21: ...nections rear side 2 1 Power supply 2 2 Axis power supply 2 6 CAN bus output The cable connections have different plugs and cannot be wrongly connected on assembly Before disconnecting the cables from the sockets always switch off the equipment and disconnect the mains cable ...
Страница 22: ...by an electrics specialist For trouble free 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 ATTENTION Malfunctions during operation Bad or no grounding affects the reliability and ...
Страница 23: ...is and or the booth If an incorrect system parameter is set this can lead to damage to the axes and or the booth Input correct parameter values Name Description Values Remark P1 Upper stroke limit 0 00 5 00 m 0 50 m P2 Operating mode 1 Pendulum operation 2 Sequence program 3 Semiautomatic pendulum operation P3 Acceleration 0 10 2 00 m s2 1 80 m s2 P4 max speed 0 08 0 60 m s 0 60 m s Default values...
Страница 24: ... the booth The upper stroke limit of the OptiMove CR08 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 dis...
Страница 25: ...ey The device is switched 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 CR08 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 prer...
Страница 26: ...ol unit see also Switch on off the axis control unit 2 If necessary change to another program see also Program change 3 Press the key The axis is started and the selected program is activated The corresponding LED illuminates 4 Press the key Axis is stopped The display A1 shows the actual axis position The corresponding LED remains unlit Program change The program change can be done via keyboard m...
Страница 27: ...s been traveled the measured cycle time is shown and updated after each further cycle pendulum movement 3 Read off the cycle time and use it in the program for the calculation of the optimal sine curve Edit programs In the Edit program mode the input parameter values can be selected or changed All program data must be determined Therefore use the program tables in the appendix of this operating ma...
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Страница 29: ...ulum 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 can be stored ...
Страница 30: ...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 ...
Страница 31: ...ber 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 ...
Страница 32: ...Move CR08 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 ...
Страница 33: ...V 02 16 OptiMove CR08 Axes operating modes 31 Programming example with path time diagram ...
Страница 34: ...s see section Pin allocation During operation the axis cannot be stopped with the stop key Only a limited operation is possible by the operating 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 proce...
Страница 35: ...Default value Desired values Upper position m 0 50 Lower position m 0 00 Speed upwards m s 0 20 Speed downwards m s 0 20 System parameters P1 Upper stroke limit also applied as travel position for horizontal axis 0 50 P2 Operating mode 1 P3 Acceleration m s 1 80 P4 Max speed m s 0 60 ...
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Страница 37: ... used exclusively to communicate with the servo regulator Hardware The OptiMove control unit is connected to the ZA10 vertical axis via a 4 pin CAN bus cable The vertical axis must be fitted with a terminal plug with terminal resistor CAN bus cable plug assignment fig 6 CAN bus cable Pin Signal Color 1 GND white 2 24 VDC black 3 CAN H black 4 CAN L black ...
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Страница 39: ...iption Action Axis H02 Tracking error too large In order to prevent a larger tracking error the speed must be reduced H05 Desired travel position is larger than the defined end position system parameter P1 Travel position must be limited according to SP1 H08 Mechanical stop not detected during the reference travel H09 Speed value larger than system parameter P4 Limit speed according to system para...
Страница 40: ...connected H41 Too many errors during sending ERROR_PASSIVE H42 Overflow on data reception H43 Overflow on transmission H44 Master failed Stop axis soft stop Servo H50 Servo error message EMCY Stop axis H51 Servo warning message EMCY Stop axis H52 Servo error message during reference travel Stop axis H53 Servo error reaction Stop axis H54 Servo communication error SDO transfer failed wrong PDO data...
Страница 41: ... 2 1 Power IN Pin Function 1 Neutral conductor 2 Phase 230 VAC 3 Axis start 230 VAC PE Ground Plug 2 2 Drive supply Pin Function 1 Neutral conductor 2 Phase 3 Not connected PE Ground Plug 2 6 CAN bus OUT Pin Function 1 GND 2 24 VDC 3 CAN_H 4 CAN_L Enclosure Shield ...
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Страница 43: ...rdering 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 ATTENTION Use of non original Gema spare parts When using the spare pa...
Страница 44: ...complete 1014 198 3 1 EPROM program version V x x current software 1014 201 4 Spacer sleeve Ø 3 4 6x6 5 mm 1001 925 5 Display complete 1010 293 7 Front plate gasket 1007 042 8 Front frame complete incl pos 8 1 1007 048 8 1 Special screw 1007 019 9 Special screw M4x20 7 mm 1003 000 10 Toothed lock washer Ø 5 3 10x0 6 mm 1002 999 11 Screw M4x6 mm 221 767 12 Washer Ø 3 2 7x0 5 mm 201 944 13 Locknut M...
Страница 45: ... 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 5 Dust protection cap for connector socket 265 446 6 Screw M4x16 mm 1013 925 7 Fuse holder 200 131 8 Fuse 10 AT 200 174 9 Safety strap for relay socket 1001 063 10 Freewheeling diode for relay 258 075 11 Relay 24 VDC 10 A 2UK 1002 915 12 Relay socket 251 135 fig 8 Rear wall ...
Страница 46: ...V 02 16 44 Spare parts list OptiMove CR08 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 36 ...
Страница 47: ...V 02 16 OptiMove CR08 Spare parts list 45 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 131 ...
Страница 48: ...V 02 16 46 Spare parts list OptiMove CR08 132 133 134 135 136 137 138 139 140 141 142 143 144 145 146 147 148 149 150 201 202 203 204 205 206 207 208 209 210 211 212 213 214 215 216 ...
Страница 49: ...V 02 16 OptiMove CR08 Spare parts list 47 217 218 219 220 221 222 223 224 225 226 227 228 229 230 231 232 233 234 235 236 237 238 239 240 241 242 243 244 245 246 247 248 249 250 ...
