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Summary of Contents for Gema OptiMove CR07
- Page 1 Operating instructions and spare parts list OptiMove CR07 Axis control unit Translation of the original operating instructions...
- Page 2 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.
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Page 3: Table Of Contents
General data .................... 13 Electrical data ..................13 Dimensions ....................13 Design and function OptiMove CR07 Axis control unit - structure ............15 Function description ....................15 Configuration .................... 16 Operating and display elements, operating modes Display and input buttons ..................17 Operating modes .................... - Page 4 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 2 • Table of contents OptiMove CR07...
- Page 5 V 12/13 Spare parts list 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 ..................
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Page 7: General Safety Regulations
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. -
Page 8: Product-Specific Safety Measures
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. -
Page 9: 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. -
Page 11: 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. -
Page 13: Function Description
V 12/13 Function description OptiMove CR07 Axis control unit Operating panel OptiMove CR07 - operating panel 1 Operating and display elements 2 Power switch ON/OFF OptiMove CR07 Function description • 11... -
Page 14: Field Of Application
V 12/13 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. -
Page 15: Technical Data
V 12/13 Technical data OptiMove CR07 Axis control unit General data OptiMove CR07 Number of axes per control unit Maximum available programs Max. stroke height (theoretical) Maximum speed 0.6 m/s Minimum speed 0.08 m/s Acceleration 0.1-2.0 m/s² Electrical data OptiMove CR07... -
Page 17: Design And Function
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. -
Page 18: Configuration
V 12/13 Configuration OptiMove Actual value "Position" from incremental pulse generator 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 16 • Design and function... -
Page 19: Operating And Display Elements, Operating Modes
In the "Remote" operating mode, only visualization functions are available. T5 T6 WARNING: The input keys should only be pressed with fingertips and under no circumstances with fingernails or hard objects! OptiMove CR07 Operating and display elements, operating modes • 17... - Page 20 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 18 • Operating and display elements, operating modes OptiMove CR07...
- Page 21 Preset- actual value mode (dark = actual value mode / green = preset value mode) 4 - 9 Parameter selection display Axis started Axis stopped Axis referencing Remote Remote, semiautomatic, keyboard lock OptiMove CR07 Operating and display elements, operating modes • 19...
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Page 22: Operating Modes
Manual Remote Semiautomatic Keyboard lock The OptiMove CR07 Axis control unit enables the simply creation of 255 programs with the help of the necessary parameters. "Manual" operating mode The manual operation permits the selection and the start of the travel programs by the operator on the panel. -
Page 23: Keyboard Lock
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 actual values visualization) Error messages acknowledgement OptiMove CR07 Operating and display elements, operating modes • 21... -
Page 25: Commissioning
CAN bus input 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! OptiMove CR07 Commissioning • 23... -
Page 26: Initial Start-Up
Furthermore, the reliability of the unit and the normal processing procedure could be reduced! Setting the system parameters The OptiMove CR07 Axis control unit is adapted with the system parameters to the axis type and the plant-specific characteristics. In order to set the system parameters, proceed as follows: 1. -
Page 27: System Parameters - Overview
3 - 125 kBit/s 0 - 127 CAN-Node ID Default values are marked by bold print WARNING: If an incorrect system parameter is set, this can lead to damage to the axes and/or the booth! OptiMove CR07 Commissioning • 25... -
Page 28: System Parameter P1: Setting The Upper Stroke Limit
The maximum stroke height is limited by the corresponding height of the used reciprocator or by the maximum height of the gun slots in the booth. The upper stroke limit of the OptiMove CR07 Axis control unit is always set at 0.3 meters by the factory. -
Page 29: Operation
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... -
Page 30: Start/Stop The Axis
The axis is started, and the selected program is activated. The corresponding LED illuminates 4. Press the key. The axis is stopped The display A1 shows the actual axis position. The corresponding LED remains unlit 28 • Operation OptiMove CR07... -
Page 31: Program Change
(pendulum movement) 3. Read off the cycle time and use it in the program for the calculation of the optimal sine curve OptiMove CR07 Operation • 29... -
Page 32: Edit Programs
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! -
Page 33: Axes Operating Modes
Axes operating modes General information The OptiMove CR07 Axis control unit is universally used for all Gema axes. To be ideally equipped for all conditions, the operating mode can be set in the system parameter mode P2. The following axes operating... -
Page 34: Editing/Setting
X axis. NOTE! The prerequisite for the programming of sequence programs is that the system parameter P2 is already set correctly P2=2 (see also "Setting the system parameters")! 32 • Axes operating modes OptiMove CR07... -
Page 35: Structure Of A Program Step (Procedure Step)
9. Input the address of the following program on the display A1 using the keys 0 = no further program step 10. Press the key again, or press or , in order to exit the Editing mode OptiMove CR07 Axes operating modes • 33... -
Page 36: Programming Example - Positioning
Program no. 1 Display Input value 1.00 m 0.20 m/s 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 34 • Axes operating modes OptiMove CR07... -
Page 37: Programming Example With Path-Time Diagram
V 12/13 Programming example with path-time diagram OptiMove CR07 Axes operating modes • 35... -
Page 38: Semiautomatic Pendulum Operating Mode
P2 = 4 - X-GunClean Program 1 - 253 Sequence program Start Stop Dwell time Dwell time Program 254 - 255 Start Pause Start Stop The program editing requires the same procedure as in the sequence program. 36 • Axes operating modes OptiMove CR07... -
Page 39: Setup
The axis travels to the position of the first program step 3. On the display A1, adjust the positions using the keys LED 1 blinks Axis travels with the modification The position of the first program step is programmed OptiMove CR07 Axes operating modes • 37... -
Page 40: Ram Reset
Speed downwards [m/s] System parameters P1 - Upper stroke limit (also applied as travel position 0.30 for horizontal axis) P2 - Operating mode 1.50 P3 - Acceleration [m/s 0.60 P4 - Max. speed [m/s] 38 • Axes operating modes OptiMove CR07... - Page 41 P7 - Compensation of holding brake delay time [ms] P8 - Communication P9 - Keyboard lock P10 - Referencing mode P11 - CAN-Baud rate P12 - CAN-Node ID NOTE! These default values are valid from software version V1.10! OptiMove CR07 Axes operating modes • 39...
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Page 43: Digitalbus Parallel Interface
PLC Control Strobe 2 System On / Off Digital OptiMove Remote / Manuell Input / Output Error Strobe 12 OptiMove System On / Off Remote / Manuell Error Controlling by superordinated control unit OptiMove CR07 DigitalBus parallel interface • 41... -
Page 44: 16 Bits Parallel Bus Structure
V 12/13 16 bits parallel bus structure Program D8 D7 D6 D5 D4 D3 D2 D1 D0 A2 A1 A0 Remote System Strobe Error active Value Command Input Output Output Data Control Status Data bits (Data) The data bus width is 12 bits. The first 9 bits are used to transfer the data for the different operating parameters to the control unit. - Page 45 Program 1 - 253 Sequence program Start Stop Dwell time Dwell time Program 254 - 255 Start Pause Start Stop NOTE! By traveling to a reference point, the output always remains on "low"! OptiMove CR07 DigitalBus parallel interface • 43...
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Page 46: Command Table And Value Ranges
V 12/13 Command table and value ranges Pendulum Sequence Command Value operation program Designation Unit Resolution code A0:A2 range P2=1 P2=2 P2=3 P2=4 Upper position 0.00 - 5.00 0.01 Lower position 0.00 - 5.00 0.01 Speed upwards 0.08 - 0.60 0.01 Speed downwards 0.08 - 0.60... -
Page 47: Control Sequence
The Data bus is read in for data validation 3 times and the results compared, 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. OptiMove CR07 DigitalBus parallel interface • 45... -
Page 48: Software Description
V 12/13 Software description For each OptiMove Axis control unit, one strobe signal and one error signal exists. The data signals 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. -
Page 49: Digital Connector Cd02 With Connection Designations
V 12/13 Digital Connector CD02 with connection designations The interface between the OptiMove CR07 Axis control unit and the PLC is given by the Digital Connector CD02. All parallel interface signals of up to 12 devices are fed connection-friendly on plugs. -
Page 51: Can Bus
V 12/13 CAN bus General information The OptiMove CR07 Axis control unit is fitted with a CAN bus interface as standard, and can be operated as a simple CANopen slave in a network with a central control unit (Master). The communication between the users in the network takes place by CAN bus, therefore each existent component must be classified with an individual user address (Node-ID = identification number). -
Page 52: Setting The User Address (Id Number)
500 m from the first to the last CAN bus client. If longer cables are used, select a lower Baud rate. 4. Press the key, in order to exit the system parameter mode 50 • CAN bus OptiMove CR07... -
Page 53: Fault Remedying
Limit speed according to system parameter P4 Axis position not correctly stored during Axis position = Upper end stop. Axis can only switching off travel downwards. Frequency converter error Emergency stop Axis cannot be started, because not referenced OptiMove CR07 Fault remedying • 51... - Page 54 Too many errors during sending (ERROR_PASSIVE) Overflow on data reception Overflow on transmission Master failed Stop axis (soft stop) Data outside the value range Reject data Invalid Node ID set Node ID = 127 52 • Fault remedying OptiMove CR07...
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Page 55: Hardware
Plug 2.3 - Drive I/O Function GND frequency converter 24 V frequency converter Frequency converter error RPM preset value Motor right running (UP) Motor left running (DOWN) Reserve Reserve 24 VDC OptiMove Motor brake Proximity switch Reserve OptiMove CR07 Hardware • 53... -
Page 56: Plug 2.4 - Aux Digitalbus Parallel Interface
Preset values, program no. Binary value 9 GND_External 1 OUT Error, axis not referenced 2 OUT Program_Active 24VDC_Extern 24 VDC digital outputs Enclosure Shield Shield Plug 2.5 - CAN bus IN Function 24 VDC CAN_H CAN_L Enclosure Shield 54 • Hardware OptiMove CR07... -
Page 57: Plug 2.6 - Can Bus Out
V 12/13 Plug 2.6 - CAN bus OUT Function 24 VDC CAN_H CAN_L Enclosure Shield OptiMove CR07 Hardware • 55... -
Page 59: Spare Parts List
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... -
Page 60: Optimove Cr07 - Front Plate And Power Pack
V 12/13 OptiMove CR07 – Front plate and power pack OptiMove CR07 Axis control unit - complete 1010 550 1010 540 Front plate - complete (pos. 1-13) Front plate with foil keyboard (pos. 1-6) 1010 539 Front frame - complete (incl. pos. 1.1) -
Page 61: Optimove Cr07 - Front Plate And Power Pack
V 12/13 OptiMove CR07 – Front plate and power pack OptiMove CR07 – Front plate and power pack OptiMove CR07 Spare parts list • 59... -
Page 62: Optimove Cr07 - Rear Panel
V 12/13 OptiMove CR07 – Rear panel Rear panel gasket 1007 033 Relay socket 251 135 Relay – 24 VDC/10 A, 2UK 1002 915 Freewheeling diode for relay 258 075 Safety strap for relay socket 1001 063 Fuse holder 200 131... -
Page 63: Optimove Cr07 - Rear Panel
V 12/13 OptiMove CR07 – Rear panel OptiMove CR07 – Rear panel OptiMove CR07 Spare parts list • 61... -
Page 64: Appendix - Program Table
V 12/13 Appendix - program table 62 • Spare parts list OptiMove CR07... - Page 65 V 12/13 120 X position OptiMove CR07 Spare parts list • 63...
- Page 66 V 12/13 64 • Spare parts list OptiMove CR07...
- Page 67 V 12/13 OptiMove CR07 Spare parts list • 65...
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