OptiControl CM03 control unit
Contents
1. OptiControl CM03 switching on 1 The OptiFlex A2 control cabinet is switched on by the main switch 7 2 The OptiControl CMO3 control unit is switched on by the key switch The control voltage is OK when the indicator lamp 6 il luminates The control units in the control cabinet OptiStar Op tiMove etc are thereby put into operation too Main solenoid valve fluidization The main solenoid valve will be switched on and the prefluidization start ed when the three interlocking signals Booth ready Fire protection OK and Grounding control are present on the control unit input Test mode The test mode is started by turning the key switch 5 on Test The pow der guns and reciprocators are switched on immediately The plant can be simply put into operation in this way without external signals must be present on the control unit Attention If the plant is switched on manually no persons may stand near the reciprocators or in the booth Start up e 15 Gema mee Parameterization The various time sequences can be easily set and adapted to all plant specific requirements by the aid of a simple menu control unit P Note Read carefully this section before access to a menu option Standard display gt Stop lt Do not use Set Param lt Set parameter Set Clock lt Do not use Prg Name lt Do not use Parameter input display B2 lt Block number TH 20 00s lt Set time ON TL2. 00 00s lt Set time OFF Ta 00 00s Actual time value 16 e Start up OptiControl CM03 control unit EH Gema Selecting and editing a menu option gt Stop Set Param Set Clock Prg Name Select the Set Param menu with the W key Stop gt Set Param Set Clock Prg Name Press OK Block B1 appears Bl TH 00 50s TL 00 50s Ta 00 00s Press the A key the block B2 appears Info D Quit the program mode Select Block B2 until TH 20 00s Wa 2 ate key B24 with the A key gt TL 00 00s i ch o the norma Ta 00 00s Spay Press OK 2 4 A or W The values can now be TH 2 00s selected and edited with TL 00 00s gt TT lt the arrow keys Ta 00 00s Press OK The new values are saved The editing mode will be quit Note No other menu may be selected otherwise the program becomes unusable for the control unit Attention The control unit continues to process the program in the Parame terization operating mode OptiControl CM03 control unit Start up e 17 Gema Block functions 18 e Start up V 02 13 Working with the menus Block no Designation ak val Set time B2 Prefluidization TH 20 secs T B9 Gap control T 30 secs T B23 Debouncing T 10 secs T level sensor B24 Powder hopper Ta min T empty delay Block B2 prefluidization The prefluidization is started automatically Thereby a valve in the fluidiz ing unit sw
3. editing a menu option 17 Working with the Menus nan nc aan PENNAR ainai 18 le Tea nee EE 18 Block B2 prefluidization eseeeeeeeeeeneeene eseese eeeeeetnnesrnnennssrnnsrnnsrnennnn e 18 Block B9 gap Control 18 Block B23 debouncing the level sensor 18 Block B24 level Control 19 Spare parts list 21 SE nesnese test netr ntn nesn nesr nesnnsennsennnttnsetnnesnnennnsen nenn enn 21 OptiControl CMO3 control unit spare parts et 22 OptiControl CMO3 control unit Table of contents e 1 Gema ei OptiControl CMO3 control unit spare parts 23 2 e Table of contents OptiControl CMO3 control unit EH Gema General safety regulations This chapter sets out the fundamental safety regulations that must be fol lowed by the user and third parties using the OptiControl CMO3 control unit These safety regulations must be read and understood before the Opti Control CMO3 control unit is used Safety symbols pictograms The following warnings with their meanings can be found in the Gema operating instructions The general safety precautions must also be fol lowed as well as the regulations in the operating instructions DANGER Danger due to live electricity 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 equip ment o INFORMATION 1 Useful tips and ot
4. En Operating instructions and spare parts list OptiControl CMO3 control unit TI TI vr Gema Translation of the original operating instructions Gema Gema V 02 13 Documentation OptiControl CMO3 control unit Copyright 2006 Gema Switzerland GmbH All rights reserved This publication is protected by copyright Unauthorized copying is pro hibited by law No part of this publication may be reproduced photocop ied translated stored on a retrieval system or transmitted in any form or by any means for any purpose neither as a whole nor partially without the express written consent of Gema Switzerland GmbH OptiFlex OptiTronic OptiGun EasyTronic EasySelect OptiFlow and SuperCorona are registered trademarks of Gema Switzerland GmbH OptiStar OptiMatic OptiMove OptiMaster OptiPlus MultiTronic and Gematic are trademarks of Gema Switzerland GmbH All other product 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 con cerned approve of or are bound in any form by this manual We have en deavored to retain the preferred spelling of the trademarks and regis tered trademarks of the copyright holders To the best of our knowledge and belief the information contained in this publication was correct and valid on the date of issue Gema Switzerland GmbH
5. bg the OptiControl CMO3 control unit key switch for maintenance pur poses The whole powder coating equipment must be switched off with the main switch on the OptiFlex control cabinet red on a yellow base which should normally be locked with a small padlock OptiControl CM03 control unit Function description e 9 V 02 13 Technical data OptiControl CMO3 control unit OptiControl CMO3 control unit General information Gema OptiControl CM03 Max number of OptiStar control units 14 Max number of OptiMove control units 4 Electrical data OptiControl CM03 Nominal input voltage 100 240 VAC Frequency 50 60 Hz Control current circuit 24 VDC Temperature range Ben Protection type IP54 Approval C Ex 13D ATEX Zone 22 Technical data e 11 EH Gema Operating and display elements OptiControl CMO3 control unit Front view 1 2 3 4 5 6 7 un eq be ne ow OptiControl CMOS front view 1 Indicator lamp Powder hopper full green 2 Indicator lamp Powder hopper empty red 3 Push button indicator lamp Alarm OFF red 4 Key switch for system release ON OFF 5 Key switch for control voltage STOP ON Test 6 Indicator lamp Control ON green 7 Equipment main switch OptiControl CMO3 control unit Operating and display elements e 13 Start up EH Gema OptiControl CMO3 control unit A OptiControl CMO3 control unit Switching on
6. efluidization If the level sensor is covered the Powder hopper full lamp 1 illuminates If the level sensor is uncovered for more than 60 secs the indicator lamp ex pires The output Fresh powder required will be activated and the alarm horn rings at the same time The alarm horn can be acknowledged with the Alarm OFF 3 key the horn switches off and the Alarm OFF 3 button illuminates After the level sensor is covered with powder the pro cedure can start again Start up e 19 EH Gema Spare parts list Ordering spare parts When ordering spare parts for powder coating equipment please indicate the following specifications Type and serial number of your powder coating equipment Order number quantity and description of each spare part Example Type OptiControl CMO3 control unit Serial number 1234 5678 Order no 203 386 1 piece Clamp Y 18 15 mm When ordering cable or hose material the required length must also be given The spare part numbers of this yard meter ware is always marked with an The wear parts are always marked with a All dimensions of plastic hoses are specified with the external and inter nal diameter Example 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 haz ardous location approval will be preserved that way The use of spare parts from other manufacturers will invalidate the Gema
7. guar antee conditions OptiControl CMO3 control unit Spare parts list e 21 Gema N OptiControl CMO3 control unit spare parts list 1 Power pack Logo Power 24 VDC 1 3 A 263 915 2 Siemens relay Logo 24RC 8 IN 4 OUT 266 949 3 Siemens relay Logo 24R 4 IN 4 OUT additional module 266 957 4 Indicator lamp green 230 V 267 104 5 Indicator lamp red 230 V 267 090 6 Push button red 267 880 7 key switch 2 raster 268 020 8 Key switch 3 raster 264 440 9 Main switch 25A 245 690 22 e Spare parts list OptiControl CMO03 control unit V 02 13 OptiControl CMO3 control unit spare parts LA Up Um SIEMENS OptiControl CMO3 spare parts Wu l A Gema 0 Note Further information will be found in the plant specific wiring dia gram and in the corresponding parts list OptiControl CMO3 control unit Spare parts list e 23
8. he operator when a powder shortage occurs Various displays in the front door inform about the cur rent operating status The OptiControl CMO3 control unit is intended exclusively for controlling functions in electrostatic powder coating equipments Any other use is considered as non conform The manufacturer is not responsible for any damage resulting from this the risk for this is 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 oth er components so as to be familiar with their functions too Note A perfect functioning of the axes reciprocator control units and the gun control units requires the correct setting of the corresponding system parameters see therefore the corresponding operating in structions Function description e 7 Gema mere OptiControl CMO3 control unit Overview OptiControl CMO3 control unit overview 1 Chain conveyor 2 Workpiece object 3 Ext control unit 4 Booth recovery system 5 Fire protection 6 Start light barrier 7 Level sensor 8 Powder hopper Possible configuration A possible configuration of the OptiControl CMO3 control unit with the subordinated components is shown in the following table OptiControl CMO3 control unit Component Function release OptiStar Po
9. her information Conformity of use 1 The OptiControl CMOS control unit is built to the latest specifica tion and conforms to the recognized technical safety regulations It is designed for the normal application of powder coating 2 Any other use is considered as non conform The manufacturer is not responsible for damage resulting from improper use of this equipment the end user alone is responsible If the OptiControl CMO03 control unit is to be used for other purposes or other sub stances outside of our guidelines then Gema Switzerland GmbH should be consulted 3 Observance of the operating service and maintenance instruc tions specified by the manufacturer is also part of conformity of OptiControl CMO3 control unit General safety regulations e 3 Gema V 02 13 use The OptiControl CMO3 control unit should only be used maintained and started up by trained personnel who are in formed 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 OptiControl CMO3 control unit has been set up and wired according to the guidelines for machinery 98 37 EG EN 60204 1 machine safety must also be observed 5 Unauthorized modifications to OptiControl CMO3 control unit ex empts the manufacturer from any liability from resulting damage 6 The relevant accident prevention regulations as well as other generally recog
10. itches alternately on and off for 0 5 sec The prefluidization du ration depends on the powder type the air humidity and the ambient temperature The default time is preset on 20 secs After the elapse of this time the fluidizing air can be set on the OptiAir fluidizing unit see therefore the corresponding user manual B2 f Le scha Bee ee START PAUSE B2 prefluidization Block B9 gap control The powder guns and reciprocators start with a light barrier signal on the booth entry If no objects pass through the light barrier during a preset time the powder guns and reciprocators will be stopped The default time is preset on 30 secs The plant will restart as soon as further objects pass through the light barrier If there is a chain conveyor stop the guns and reciprocators are switched off The elapsed time between two objects will be hold and keeps running by the next start Block B23 debouncing the level sensor The fluidized powder actuates many impulses on the level sensor There fore a debouncing time is set e the level sensor must be covered or uncovered for a time until the operating procedure will be continued The debouncing time depends on the powder type however it should not be selected too short OptiControl CMO3 control unit OptiControl CMO3 control unit Pen Gema Block B24 level control The level control will be activated after the pr
11. makes no representations or warranties with respect to the con tents or use of this publication and reserves the right to revise this publi cation and make changes to its content without prior notice Printed in Switzerland Gema Switzerland GmbH M venstrasse 17 9015 St Gallen Switzerland Phone 41 71 313 83 00 Fax 41 71 313 83 83 E Mail info gema eu com Homepage www gemapowdercoating com ns Gema Table of contents General safety regulations 3 Safety symbols Dichograme mann 3 Conformity Of Use nun ie are Ait weave ae ri 3 Product specific security Measures nen 4 OptiControl CMO3 control unt 4 About this manual 5 Generallinformation u diva 5 Function description 7 Field of application ul 7 OptiControl CMO3 control unt 8 OINA E EE e ue SE de fe aie Seances 8 Possible confiouraiton nenn 8 FUNCUONS Laia 9 Interlocking signals ooooononnnnnnnncnnnncnn nana cana n cnc 9 Technical data 11 OptiControl CMO3 control unt 11 General Information sauna deinen 11 Electrical datas EE 11 Operating and display elements 13 OptiControl CMO3 control unt 13 TED IOWA da E 13 Start up 15 OptiControl CMO3 control unt 15 SWITCHING ON EE 15 Main solenoid valve fluidization ocococccicicinininoninicinininonininininanininanass 15 RE 15 Parameotelz alteran ibi toilet 16 elle Elte Bel 16 Parameter input display 20um44nnnnnnnnannnnnnnannnnnnnannnnnnnannnnnnnnannn nn 16 Selecting and
12. nized safety regulations occupational health and structural regulations are to be observed 7 Furthermore the country specific safety regulations must be ob served Product specific security measures 4 e General safety regulations OptiControl CMO3 control unit The OptiControl CMO3 control unit is constituent part of the system and is thus integrated into the safety system of the plant For the use outside of the safety concept corresponding measures must be taken Note For further information see the more detailed Gema safety regula tions OptiControl CMO3 control unit e Gema About this manual General information OptiControl CMO3 control unit This operating manual contains all the important information which you require for the working with the OptiControl CMOS3 control unit It will safe ly 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 reciprocators booths powder gun control units powder guns etc should be referenced to their corresponding documents About this manual e 5 EH Gema Function description Field of application OptiControl CMO3 control unit The OptiControl CMO3 control unit enables a semiautomatic operation in the OptiFlex A2 control system The control unit assumes switching func tions monitors the powder hopper and alerts t
13. wder guns OptiMove Reciprocators OptiFeed Powder transport OptiAir Level sensor Light barrier Start Stop Fluidizing and Airmover Powder level in the powder hopper Object recognition Interlockings Booth etc Main solenoid valve Compressed air supply Alarm Powder shortage 8 e Function description OptiControl CMO3 control unit EH Gema Functions OptiMove OptiStar control units release switch on power supply Main solenoid valve release Fluidization controlled by fluidizing unit Fresh powder requirement Powder full display Powder empty display Control of the alarm horn Reciprocators and powder guns signal Start Stop e Note The OptiControl CMO3 control unit functions are explicitly described in the chapter Start up Interlocking signals In order to control the operation of the electrostatic powder coating equipment it is absolutely necessary to have some interlocking functions The OptiControl CMO3 control unit assumes these interlocking functions Chain conveyor Powder recovery equipment Fire protection Grounding check Non control and non potential contacts permit an individual adaptation to all plant specific requirements All OptiFlex components incl OptiMove can be switched on and off with the key switch of the OptiControl CMO3 control unit main operation switch Attention It is not permitted to switch off the powder coating equipment with
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