Motor unit MTR-DCI. Description MTR-DCI-...-DN. Description en 1209a [763221]

Transcription

1 Motor unit MTR-DCI Description MTR-DCI-...-DN Description en 1209a [763221]

2 Adobe, Reader, DeviceNet, Allen-Bradley, CANopen and CiA are registered brand names of the respective brand holders in certain countries.

3 Contents and general safety instructions Original... de Edition... en 1209a Designation... P.BE-MTR-DCI-DN-EN Order no Festo AG & Co. KG, D Esslingen, 2012 Internet: Reproduction, distribution or sale of this document or communication of its contents to others without express authorization is prohibited. Offenders will be liable for damages. All rights reserved in the event that a patent, utility model or design patent is registered. I

4 Contents and general safety instructions II

5 Contents and general safety instructions Contents Intended use... Safety instructions... Target group... Service... Scope of delivery... Important user instructions... Description of MTR-DCI motor unit... About the version... Product-specific terms and abbreviations... IX X XI XI XI XII XIV XV XVI 1. System overview Positioning with electric drives Fieldbus communication Data exchange using DeviceNet FHPP data profile Components Control and regulation functions Operational safety Dimensional reference system Reference points and positioning range Plus/minus signs and directions Homing Mounting General instructions Dimensions of the motor unit Mounting the electric axes Installation Overview of installation Earthing Power supply III

6 Contents and general safety instructions Power supply requirements Load and logic voltage Serial interface Input for external reference switch Field bus Connecting the higher-order controller Fieldbus cable Fieldbus bit rate and fieldbus length The control panel (type MTR-DCI-...-H2 only) Composition and function of the control panel The menu system Accessing the main menu Selecting a menu command [Diagnostic] menu [Positioning] menu [Positioning] [Move position set] [Positioning] [Demo position table] [Positioning] [Homing] [Settings] menu [Settings] [Axis type] [Settings] [Axis parameter] [Settings] [Homing paramet.] [Settings] [Position set] [Settings] [Password edit] [Settings] [BUS parameter] Menu command [HMI control] IV

7 Contents and general safety instructions 5. Commissioning Commissioning procedure Commissioning with the control panel (MTR-DCI-...-H2 only) Setting the axis type Setting the homing parameters Starting homing Teaching the axis zero point AZ and the software end positions Teaching position set records Test run Setting bus parameters Commissioning with FCT Installing the FCT Procedure Further information on FCT Commissioning a DeviceNet master Overview of commissioning on the Fieldbus Configuration of the DeviceNet master ( I/O configuration ) Festo profile for handling and positioning (FHPP) Supported operating modes Structure of the cyclic I/O data (FHPP standard) Description of the I/O data (record selection) Description of the I/O data (direct task) Description of the control bytes CCON, CPOS, CDIR Description of the status bytes SCON, SPOS, SDIR (RSB) Examples of I/O data V

8 Contents and general safety instructions 5.6 Sequence control according to the FHPP standard Homing Jog mode Teaching via Fieldbus Record selection (Positioning mode) Direct task (Positioning mode, Force mode) Standstill monitoring The Festo Parameter Channel (FPC) Structure of the cyclic I/O data (FHPP-FPC) Request identifiers, response identifiers and error numbers Rules for request-response processing Parameterisation example FHPP finite state machine Establish ready to operate status Positioning Notes on operation Diagnosis and error display Overview of diagnostic options LED status displays Fault messages Overview Description of the messages, warnings, and faults Diagnosis using Fieldbus Overview Diagnostic memory A. Technical appendix... A-1 A.1 Technical data... A-3 A.2 Accessories... A-6 A.3 Motor characteristic curves... A-8 A.4 Conversion of units of measurement... A-14 VI

9 Contents and general safety instructions B. Reference Festo DeviceNet and FHPP... B-1 B.1 DeviceNet Reference (Explicit Messaging)... B-3 B.1.1 Parameter classes... B-3 B.1.2 Object overview (class, attribute, instance)... B-4 B.2 FHPP Reference (I/O messaging)... B-10 B.2.1 Parameter groups... B-10 B.2.2 Object overview (Parameter number (PNU)... B-11 B.2.3 Layout of the parameter entries... B-16 B.2.4 Device data Standard parameters... B-17 B.2.5 Device data Extended parameters... B-18 B.2.6 Diagnosis... B-21 B.2.7 Process data... B-25 B.2.8 Record list... B-27 B.2.9 Project data General... B-31 B.2.10 Project data Force mode... B-33 B.2.11 Project data Teaching... B-34 B.2.12 Project data Jog mode... B-35 B.2.13 Project data Direct mode: (Positioning mode)... B-36 B.2.14 Projectdata Directmode:(Forcemode)... B-37 B.2.15 Axis parameter, electric drive 1 Mechanical... B-38 B.2.16 Axis parameter, electric drives 1 Homing... B-42 B.2.17 Axis parameter, electric drive 1 Controller... B-44 B.2.18 Axis parameter, electric drive 1 Electronic Type plate... B-49 B.2.19 Axis parameter, electric drive 1 Standstill monitoring... B-51 VII

10 Contents and general safety instructions C. The Command Interpreter (CI)... C-1 C.1 Data transmission... C-3 C.1.1 Procedure... C-3 C.1.2 Structure of the CI commands... C-5 C.1.3 Checking the data... C-9 C.2 CI Reference... C-11 C.2.1 Object overview (Index, Subindex)... C-11 C.2.2 Layout of the parameter entries... C-18 C.2.3 Communication Profile Area (1xxxh)... C-19 C.2.4 Manufacturer Specific Profile Area (2xxxh)... C-20 C.2.5 Standardised Device Profile Area (6xxxh)... C-26 D. Index... D-1 VIII

11 Contents and general safety instructions Intended use The MTR-DCI-... motor unit is an intelligent servo motor consisting of DC motor, planetary gear, encoder and integrated control electronics (position controller). The MTR-DCI has been optimised for use with Festo axes (e.g. DMES-... or DNCE-...). This manual deals with the basic functions of the MTR-DCI and controlling this via the Fieldbus DeviceNet interface. The Fieldbus interface supports the Festo Fieldbus profile for handling and positioning (FHPP). The MTR-DCI and the connectable modules and cables may only be used as follows: Asintended In industrial applications In perfect technical condition In their original state without unauthorised modifications (with the exception of the conversions or modifications described in the documentation supplied with the product). Follow the safety instructions and adhere to the intended use of each sub-assembly and module as described in the documentation. Please observe the standards specified in the relevant chapters, the regulations of professional associations, the technical monitoring group (TÜV), the VDE regulations and the relevant national and local regulations. Be mindful of the limit values of all additional components (e. g. sensors, actuators). IX

12 Contents and general safety instructions Safety instructions When commissioning and programming positioning systems, you must observe the safety regulations in this manual as well as those in the operating instructions for the other components used. The user must make sure that nobody is in the operating range of the connected actuators or axis system. Access to thepossibledangerareamustbepreventedbysuitable measures such as protective screens and warning signs. Warning Electrical axes can move with high force and at high speed. Collisions can lead to serious injury to human beings and damage to components. Make sure that nobody can reach into the operating range of the axes or other connected actuators and that no objects lie in the positioning range while the system is still connected to a power supply. Warning Faults in parameterisation can cause injury to human beings and damage to property. Only enable the controller once the axis system has been installed and parameterised by technically qualified staff. X

13 Contents and general safety instructions Target group This manual is intended exclusively for technicians trained in control and automation technology, who have experience in installing, commissioning, programming and diagnosing positioning systems. Service Please consult your local Festo Service or write to the following address if you have any technical problems: Scopeofdelivery The following items are supplied with the MTR-DCI motor unit: Motor unit with integrated controller, optionally with control panel Operating package on CD-ROM: User documentation (descriptions) Festo Configuration Tool with MTR-DCI plug-in User documentation (quick reference guide) Available as accessories (see Appendix A.2): Connecting cable and fieldbus plug Programming cable User documentation in paper form. XI

14 Contents and general safety instructions Important user instructions Danger categories This manual contains instructions on the possible dangers which can occur if the product is not used correctly. These instructions are marked (Warning, Caution, etc), printed on a shaded background and marked additionally with a pictogram. A distinction is made between the following danger warnings: Warning... means that failure to observe this instruction may result in serious personal injury or damage to property. Caution... means that failure to observe this instruction may result in personal injury or damage to property. Note... means that failure to observe this instruction may result in damage to property. Electrostatically sensitive devices: Incorrect handling can result in damage to components. XII

15 Contents and general safety instructions Identifying special information The following pictograms mark passages in the text which contain special information. Pictograms Information: Recommendations, tips and references to other sources of information Accessories: Information on necessary or useful accessories Environment: Information on the environment-friendly use of the products Text designations The bullet indicates activities which may be carried out in any order. 1. Figures denote activities which must be carried out in the numerical order specified. Hyphens indicate general activities. XIII

16 Contents and general safety instructions Description of MTR-DCI motor unit This description contains information on the mode of operation, as well as on assembly, installation and commissioning of electric valve actuators with motor unit type MTR-DCI-...-DN (DeviceNet interface). Information on additional components, e. g. the reference switches, can be found in the operating instructions supplied with the product in question. Type Designation Content Operating package with brief description and descriptions (and commissioning software) on CD-ROM Description Help system for software Operating instructions, if present Further manuals P.BP-MTR-DCI Motor unit of type MTR-DCI with DeviceNet interface P.BE-MTR-DCI-DN-... Festo Configuration Tool help (contained in FCT software) Drives e.g. DMES-... / DNCE-... Motor unit MTR-DCI with other communications interfaces e.g. P.BE-MTR-DCI-IO-... P.BE-MTR-DCI-CO-... P.BE-MTR-DCI-PB-... Brief description: important instructions on commissioning and preliminary information Descriptions on CD-ROM: contents as described below Installation, commissioning and diagnosis of electric drives with MTR-DCI motor unit; communication via the DeviceNet interface. Function description of the Festo Configuration Tool (FCT) configuration software Fitting and commissioning the drives Installing, commissioning and diagnosing electric axes with motor controller type MTR-DCI with communication via I/O interface or via the relevant Fieldbus. Table 0/1: Documentation on the MTR-DCI XIV

17 Contents and general safety instructions About the version The hardware version specifies the version status of the mechanical parts and electronics of the MTR-DCI. The firmware version indicates the version status of the MTR-DCI's operating system. You can find the version specifications as follows: Hardware version and firmware version under Device data in the Festo Configuration Tool with active device connection to the MTR-DCI Firmware version on the control panel under [Diagnostic] [Software information] Firmware version What is new? Which FCT plug-in? V1.00 Supports the listed sizes of the MTR-DCI-DN in combination with the following Festo axes: Motor unit Axes MTR-DCI DMES-18; DNCE-32 MTR-DCI DMES-25; DNCE-32/40 MTR-DCI DMES-40; DNCE-40/63 MTR-DCI DMES-63; DNCE-63 MTR-DCI-DN V2.1.0 Table 0/2: Firmware versions XV

18 Contents and general safety instructions Product-specific terms and abbreviations Abbreviation AZ BCD EMC FCT FHPP FPC I O I/O LSB MSB PZ REF PLC Meaning Axis zero point Binary Coded Decimal number Electromagnetic compatibility Festo Configuration Tool Festo Handling and Positioning Profile Festo Parameter Channel Input, Output Input and/or output Least significant bit Most significant bit Project zero point REFerence point Programmable logic controller; or in short: Controller Fieldbus specific abbreviations 0x1234 or 1234h Hexadecimal numbers are identified by a prefix of 0x or a suffix of h ATTR ATTRibute number (see Object, Table 0/4) CI Command Interface CLS CLaSS, Object class identifier (see Object, Table 0/4) COS ChangeOfState(see COS/Cyclic,Table0/4) EDS Electronic Data Sheet (see EDS file, Table 0/4) INST INSTance number (see Object, Table 0/4) XVI

19 Contents and general safety instructions Abbreviation MAC-ID PNU Meaning Media Access Control IDentifier, see Participant address Parameter number as per FHPP-FPC Table 0/3: List of abbreviations Term Axis Axis zero point (AZ) Drive Operation mode Controller Encoder Festo Configuration Tool (FCT) Festo Handling and Positioning Profile (FHPP) FHPP standard Meaning Mechanical component of a drive which converts the motor revolutions into positioning movements of a work load. An axis (e.g. positioning servo axis DMES-...) enables the work load to be mounted and guided and the reference switch to be mounted. Reference point of the software endpositions andthe project zero position PZ. The axis zero point AZ is defined by a preset offset to the reference point REF. Complete actuator, consisting of controller, motor, measuring system and, if applicable, gear and axis Is used in the following contexts: Type of access: Record selection, direct task Internal logical state of the controller: Position Profile Mode, Profile Toque Mode, Homing Mode,... Contains power electronics + controller + positioning control, analyses sensor signals, calculates movements and forces, and provides the motor power supply via the power electronics. Optical pulse generator (rotor position transducer on the motor shaft of the MTR-DCI). The electric signals generated are sent to the controller, which then calculates the position and speed on the basis of the signals received. Commissioning software with uniform project and data management for all supported device types. The special requirements of a device type are supported with the necessary descriptions and dialogues by means of plug-ins. Uniform field bus data profile for positioning controllers from Festo. Parameter values, control bytes, and status bytes required during operation can be directly read and written via the FHPP object directory. Defines the sequence control as per the Festo Handling und Positioning Profile XVII

20 Contents and general safety instructions Term Festo Parameter Channel (FPC) HMI Homing mode Load voltage, logic voltage Force mode (Profile Torque Mode) Motor unit Positioning mode (Profile Position mode) Project zero point (PZ) Homing Homing method Homing point (REF) Reference switch Homing run Meaning Parameter access as per the Festo Handling und Positioning Profile Human Machine Interface; on the MTR-DCI, this is the control panel with LCD display and 4 operating buttons. Operating mode inwhich homing iscarriedout. The load voltage supplies power to the power electronics of the controller and thus to the motor. The logic voltage supplies power to the evaluation and control logic of the controller. Operating mode for performing a direct positioning task with force control (open loop transmission control) by controlling the motor current. Integratedunit consistingof a controller, motor, measuringsystemand, if applicable, gears (e.g. motor unit type MTR-DCI) Operating mode for executing a traversing record or a direct positioning task with position control (closed loop position control) Reference point for all positions in positioning tasks. The project zero point PZ forms the basis for all absolute position specifications (e.g. in the position set table or with direct control via the controller interface or diagnostic interface). The PZ is defined by an adjustable offset to the axis zero point. Definition of the dimensional reference system of the axis Methodfor finding the homing pointref: via a reference switch inside the possible traversing path or by overcurrent analysis when traversing against a stop. The homing point (the reference point =REF) definesa knownposition/orientation within the positioning path of the drive. It is the basic point of reference for the dimensional reference system. External sensor used for ascertaining the homing point; is directly connected to the controller. A positioning processusedto definedthe homing point andtherefore the source of the dimensional reference system for the axis. XVIII

21 Contents and general safety instructions Term Software end position Teach mode (Teach mode) Jog mode Position set record Meaning Programmable stroke limitation (point of reference = axis zero point) Software end position, positive: Max. limit position of the stroke in the positive direction; must not be exceeded during positioning. Software end position, negative: Min. limit position in the negative direction; must not be exceeded during positioning. Operation mode for setting positions by moving to the target position e. g. when creating position set records. Moving manually in positive or negative direction. Positioning command defined in the position set table, consisting of: The number of the position set record The absolute or relative basis of the target position Target position Positioning speed Fieldbus specific terms Terminating resistor Bit Strobe COS/Cyclic Explicit Messaging Resistor for minimizing signal reflections. Terminating resistors must be installed or switched in at the end of bus segment cables. All slaves are queried by a command from the master. Used for transferring small quantities of data between a master and one or more slaves, e.g. for synchronisation of input or output data (not supported by MTR-DCI) The messages are sent from the master or slave cyclically (in a fixed time interval) or when a state change occurs. With COS messaging, a message is generated cyclically when not status change occurs within a given timeframe; for this reason, COS and Cyclic are often treated as the same message type. Direct connectionexplicit Messagingrepresentsan (acyclic) lowpriority, point-to-point communications connection between two devices and is typically used for configuration and diagnostic purposes. Explicit messages contain the address and value of an attribute and also an identifier (service code) describing how the data is to be handled. XIX

22 Contents and general safety instructions Term I/O Messaging (Implicit messaging) I/O Polling EDS file Object Object directory Participant address (node address) Meaning I/O data transfer I/O Messaging is used for exchanging time-critical data (e.g. process data). An I/O message contains only data. All information defining how the data is to be handled is stored in the Connection object the message is assigned to. The slaves are cyclically queried by the master. The master sends a polling command to a slave that also contains data for the slave. If the slave has data for the master then it sends this to the master. If a slave does not answer a polling request from the master then this leads to a timeout error. Contains the specific properties of the DeviceNet slave (e.g. number of I/Os, parameters, etc.). The DeviceNet configuration tool reads the EDS files of the devices in the network and uses these to calculate the configuration data that is subsequently loaded into the DeviceNet participants. An object is a collection of data (attributes). These attributes defined different properties of a DeviceNet device and can be read and written over the bus. For access, see: Object directory The object directory contains all device parameters and current process data that is directly accessible via FHPP, the Fieldbus, or directly via CI. The object directory is subdivided into an area containing general device information (device identification, manufacturer name, etc.) and communication parameters, and an area describing the specific device functionality. An entry (object) in the object directory is identified by FHPP FPC: Parameter number PNU CI: Index and Subindex DeviceNet: class, instance, attribute Each of the up to 64 participants in a DeviceNet network has its own MAC ID (Media Access Control Identifier); which is a component of the CAN identifier. Table 0/4: Terminology XX

23 System overview Chapter 1 System overview 1-1

24 1. System overview Contents 1. System overview Positioning with electric drives Fieldbus communication Data exchange using DeviceNet FHPP data profile Components Control and regulation functions Operational safety Dimensional reference system Reference points and positioning range Plus/minus signs and directions Homing

25 1. System overview 1.1 Positioning with electric drives 1 Process control and parameter access through the higher-order controller / Fieldbus master 2 Software level: Commissioning with the Festo Configuration Tool software 3 Drive level with Motorunit Coupling Coupling housing Axis 1 2 I/O CANopen Profibus DeviceNet 3 RS232 Fig. 1/1: Principle of positioning system with the MTR-DCI The MTR-DCI-...-DN motor unit with DeviceNet fieldbus interface allows positioning of the connected linear or rotational axis in accordance with the Festo Handling and Positioning Profile 1-3

26 1. System overview You can parameterise and commission the MTR-DCI as follows: Using the FCT software package and the RS232 interface of your PC. With the optional control panel with display and 4 operating buttons (MTR-DCI-...-H2 only). Over the Fieldbus. Functions HMI FCT Field bus Parameter assignment Selecting the axis type and the axis parameters Specifying a gear factor (for external gears) Uploading/downloading configuration data Saving different configurations in projects x x x x x x x x Position records Compiling a position set table with set record number, target position, positioning mode, positioning speed, acceleration x x x Commissioning Homing Jog mode Teaching positions Moving in individual steps Starting and stopping positioning procedures while commissioning Extended test functions e.g. status displays Testing or demonstrating the position records x x x x (x) x x x x x x x x x x x x x x x Diagnosis/Service Reading and displaying diagnostic data x x x 1-4

27 1. System overview All values are entered and displayed according to the configured units of measurement. Units of measurement Control panel FCT Field bus Linear axis Metric Metric units, e. g. mm, mm/s, mm/s 2 x x Inches 1) Increments Imperial units, x e. g. inch, inch/s, inch/s 2 Increment-based measuring x units, e. g. inc, inc/s, inc/s 2 Rotational axis Degrees Angular measurement 360 = 1 revolution e. g. deg, deg/s, deg/s 2 x x Revolutions 2) Increments Number of revolutions x e. g. rev, rev/min, rev/min 2 Increment-based measuring x units, e. g. inc, inc/s, inc/s 2 1) Only with FCT when setting up a project. 2) Setting only with the control panel [Settings] [Axis type] [Rotation axis] The setting for the units of measurement influences only the display. In the controller all parameters are always saved in increment specifications (inc, inc/s, inc/s 2...) and not converted until they are written or read. Measurements transmitted via Fieldbus or RS232 are based on increments (for conversion see appendix A.4). 1-5

28 1. System overview 1.2 Fieldbus communication Data exchange using DeviceNet DeviceNet was developed by Rockwell Automation and the ODVA (Open DeviceNet Vendor Association) as an open Fieldbus standard based on the CAN protocol. DeviceNet belongs to the class of CIP-based networks. CIP (Common Industrial Protocol) forms the application layer of DeviceNet and defines the exchange of the following data: Explicit messages with low priority, e.g. for configuration or diagnosis. I/O messages, e.g. time-critical process data The Open DeviceNet Vendor Association (ODVA) is the user organisation for DeviceNet. Publications on the DeviceNet/ CIP specifications are provided at ODVA (Open DeviceNet Vendor Association) CI (ControlNet International ) Explicit Messaging Explicit messages consists of a request and a response. This allows services to be requested or executed directly from a participant. Explicit messages contain (target) address, class, instance, attribute, and attribute value, as well as a service code for data usage. 1-6

29 1. System overview I/O Messaging I/O messages are sent by a participant and can be received and processed by one or more other participants. For I/O messages, the following dialogues between the participants are possible: The slaves can be cyclically queries by the master (polled I/O) or the messages are cyclically sent from the master or slave, or sent when a state change occurs (COS/Cyclic) or all slaves are queried by the master with a single command (bit-strobe, not supported by the MTR-DCI). The data field contains exclusively user data, protocol data is not specified. All information required for using the data is stored in the assigned Connection Object. Up to 64 fieldbus nodes can be operated via the serial CAN bus in a DeviceNet network. The expansion of the network depends on the selected bit rate (125 kbps, 250 kbps or 500 kbps). DeviceNet telegrams contain up to 8 bytes of user data. If it is necessary to exchange larger amounts of data, then before sending the data has to be broken down by means of fragmentation, transmitted sequentially, and then put together again in the recipient. In contrast to other Fieldbus systems, the messages are identified and not the bus participants. The participants may send messages when the bus is free. Every bus participant decides when they want to send data or request other bus participants to send data. Bus conflicts are resolved by assigning a particular priority (Connection ID) to the messages. The smaller the identifier, the higher the priority. Before DeviceNet devices can exchange messages using these IDs, they must first be appropriately configured. 1-7

30 1. System overview The configuration data contains the source and target addresses of the data for the sender and receiver of the messages. Object model Access to the data in DeviceNet occurs via objects. Every DeviceNet participant has one or more objects of different classes. An object is an instance of a class: Standard classes describe (e.g.) basic properties, communications behaviour, or the parameters of individual channels of a participant. Manufacturer-specific classes describe device-specific properties or parameters. Device profile Predefined connection Device profiles define the minimum available objects and communications functions for each device type. The MTR-DCI conforms to the DeviceNet specification of the device profile Communication Adapter (device type number 000Ch). For simple slave devices, predefined master-slave connections, so-called Predefined Master/Slave Connection Set, can be used to simplify the transfer of I/O data between the higher-level control system (master) and the decentralised peripherals (slaves). The MTR-DCI-DN operates according to the specification Predefined connection set, Group 2 slave only. 1-8

31 1. System overview As a Group 2 Slave the MTR-DCI-DN supports the following dialogues, services, and object classes: CAN ID 10zzzzzz001 10xxxxxx010 10yyyyyy011 10xxxxxx100 10xxxxxx101 10xxxxxx110 10xxxxxx111 Dialogue (Message Type) Master s I/O Multicast Poll Command Master s Change of State or Cyclic Acknowledge Slave s Explicit/ Unconnected Response Master s Explicit Request Master s I/O Poll Command/Change of State/Cyclic Unconnected Explicit Request Messages Duplicate MAC ID Check Messages CAN ID xxxxxx yyyyyy zzzzzz = Connection ID (DeviceNet) = MAC-ID (Destination) = MAC-ID (Source) = MAC ID (Multicast) Service-Code Service-name 14 (0x0E) Get Attribute Single 16 (0x10) Set Attribute Single 75 (0x4B) Allocate Group 2 Identifier Set 76 (0x4C) Release Group 2 Identifier Set DeviceNet Standard Classes Identity Objects E.g. Manufacturer ID, Device type... Message Router For forwarding Explicit Messages to other objects DeviceNet Objects E.g. MAC-ID, bit rate... Class

32 1. System overview DeviceNet Standard Classes Assembly Objects Collection of the attributes of several objects so that the data can be sent to or received from several objects over a single connection. Connection Objects Management of the resources for Explicit Messaging and I/O-Messaging. Acknowledge Handler Management and responses of receipt acknowledgments, acknowledgement timeouts, threshold values for repetition attempts, etc. Class Festo-specific Classes Class Diagnostic memory 101 Diagnostic memory (administration) 102 Process data 103 Record list 104 Project data 105 Factor group 106 Axis data electrical drives System errors 108 Fieldbus diagnosis

33 1. System overview FHPP data profile Festo has developed an optimised data profile, known as the Festo Handling and Positioning Profile (FHPP) tailored to handling and positioning tasks. The FHPP enables uniform control and programming for Festo's various Fieldbus systems and controllers. Parameter values, control bytes, and status bytes required during operation can be directly read and written via the object directory. Communication over the Fieldbus can be selected as cyclic (I/O messaging) or acyclic (Explicit messaging). A mixture of these is typical: Commissioning and application parameters are transferred using Explicit messaging Parameter access in normal operation is done as per FHPP FPC (I/O messaging, additional 8 byte I/O) or optionally using Explicit messaging Time-critical process control is done as per the FHPP standard ( I/O messaging, 8 byte I/O) FHPP standard The content and meaning of the cyclical I/O data and the functions that can be accessed in the MTR-DCI differ depending on the operating mode. Direct task: As a direct task, tasks can be performed in positioning or force mode. The positioning task is transferred directly in the I/O telegram. The key nominal values (position, speed, force/ torque) are transmitted with it. Supplementary parameters are defined via the parameterisation (FHPP FPC or Explicit messaging). Record selection With record positioning, tasks can be carried out in positioning mode. The positioning data are indirectly set using positioning records, which are taught via FCT, the control panel, or the Fieldbus and then stored in the controller. 1-11

34 1. System overview 31 position set records can be saved in the MTR-DCI. A record contains all the parameters which are specified for a positioning task. The record number is transferred to the cyclical I/O data (FHPP standard) as a nominal or actual value. FHPP-FPC Optionally, an additional 8 bytes of I/O data can be used as a parameterisation access via FPC (Festo Parameter Channel ). The additional bytes can be configured via the I/O data length (HMI, FCT software). Data profile Assembly Object Data 1) Input Output Byte FHPP standard FHPP standard + FPC ) Setting the data length, see CI object 2FF5 Tab. 1/5: Data profile If the FPC is not required in normal operation, the data length can be reduced to 8 bytes to optimise the PLC access for cyclic data transfer. Parameter changes can still be done using Explicit messaging. Detailed information on FHPP can be found in chapter 5.5 onwards. 1-12

35 1. System overview Param Group MTR-DCI-...-EDS Sequence control/process data Parameterisation/Service data I/O messaging (cyclic data channel) I/O messaging (cyclic data channel) Explicit messaging (acyclic data channel) 8 Byte Tx/Rx ( Assembly Instance 128/130) 16 Byte Tx/Rx ( Assembly Instance 129/131) 8ByteTx/Rx FHPP standard FHPP standard + FHPP-FPC DeviceNet S/C CON S/C POS...CON.B6/B7 PNU SI... Class Inst Attr x05 0x02 0x Record selection Direct Task n S/C DIR...DIR.B1/B2 Positioning mode Positioning mode Force mode Fig. 1/2: Festo Handling and Positioning Profile (FHPP) 1-13

36 1. System overview 1.3 Components To construct an electrical drive with the MTR-DCI, you need the following components: Motor unit MTR-DCI Axis Coupling with coupling housing Power supply cable Programming cable Fieldbus cable Reference switch Accessories Motor with controller, available in four sizes, optionally with control panel (type...-h2). By means of different gear reductions, different requirements can be fulfilled in respect of (gear) drive output torque and (gear) drive output speed (see appendix A.1). Positioning functions are characterised by high torques at low speeds. With the smaller gear reduction, the positioning speed of the axis can be increased with correspondingly reduced force. Linear or rotational axes as per catalogue In order to fit Festo axes, e.g. type DMES-... or type DNCE-..., couplings and coupling housings are available as accessories. The motor unit is connected to the axis by means of a clamping connector in the coupling housing. Additional motor flanges are not therefore necessary. Further information can be found in the operating instructions for the axis. Power supply to the MTR-DCI via a power unit. The power for the electronics (logic voltage) can also be supplied separately from the load voltage (see section 3.3). For parameterisation of the MTR-DCI during commissioning with the FCT For connection of the MTR-DCI to any higher-order controller (PLC/IPC). Sensor as described in appendix A.2. For positioning systems, Festo provides specially adapted accessories (see Festo product range or catalogue). 1-14

37 1. System overview 1.4 Control and regulation functions The controller essentially performs the following tasks: Controlling via FHPP Specifying the nominal values Regulation of the following variables: position, speed, acceleration, current. 1 Motor controller 3 2 Closed-loop controllers Nominal value generator P 4 PI P M 4 Position controller Speed regulator 1 6 Current regulator 7 Output stage 8 Signal converter Fig. 1/3: Simplified diagram of the cascade controller Profile position mode Position mode Operating mode for executing a positioning record or a direct positioning task with position control (closed loop position control) The target position defines the position that the drive controller should move to. The target position is interpreted as either an absolute or relative value. The set target position is passed to the nominal value generator. This then generates a nominal position value for the position controller. For position control, the current settings for speed, acceleration, braking delay, etc. are taken into account. 1-15

38 1. System overview Changes in position are detected by the internal increment generator (optical encoder). With a known starting point, the actual position is calculated from the gear reduction and/or the spindle pitch. Profile torque mode Homing Mode Force mode Force control (open loop transmission control) by controlling the motor current. This operating mode allows specification of an external nominal torque value (relative to the nominal motor current) for the controller. Force control occurs indirectly via the control of the motor current. All specification for forces/torques are defined in relation to the nominal motor torque or the nominal motor current. Homing Execution of a positioning task for determining the reference point and thus also the origin of the dimensional reference system for the axis, e.g. via a reference switch within the possible motion range or via overcurrent monitoring when moving against a stop. The following additional functions for commissioning, testing or demonstration are available from the control panel of the MTR-DCI-...-H2: Positioning travel for defining the target position of a positioning record (Teaching), [Settings] [Position set] Positioning run to test all position set records in the position set table [Demo posit tab]. Positioning run for testing a certain position set record in the position set table [Move posit set]. 1-16

39 1. System overview 1.5 Operational safety An extensive system of sensors and monitoring functions ensures operational safety: i 2 t-monitoring Temperature monitoring (measuring the motor temperature and the power output stage temperature) Current monitoring Voltage monitoring Detecting faults in the internal voltage supply. MTR-DCI-62...: Identification of overvoltage in the intermediate circuit; brake chopper integrated. Following error monitoring Software end position detection Please note the following: By the arrangement of the limit switches and, if necessary, additionally by means of mechanical stops, make sure that the axis always lies within the permitted positioning range. 1-17

40 1. System overview Warning For the purposes of your EMERGENCY STOP procedures, check what measures are necessary for switching your system into a safe state in the event of an EMERGENCY STOP. If an EMERGENCY STOP circuit is required for your application, use additional, separate safety limit switches (e.g. as normally closed series-connected switches) for cancelling the ENABLE signal at the control interface, or for switching off the load voltage. 1-18

41 1. System overview 1.6 Dimensional reference system For commissioning, a dimensional reference system for homing the reference coordinates must be defined. The dimensional reference system defines all the (absolute) positions, which can then be approached Reference points and positioning range The dimensional reference system is defined by: 1. Homing for determining the reference point 2. Setting the zero point (Offset between axis zero point and projectzeropoint) 3. Limiting of the travel range (software end positions) Homing point REF Axis zero point AZ Project zero point PZ Software end point anchors the dimensional reference system at a reference switch or fixed stop, depending on the homing method chosen. (see also section Homing ). is a point at a defined distance from the homing point REF (this distance is the axis zero point offset). is a point of reference within the effective stroke which the user can select, and to which both the actual position and the target positions in the position set table refer. Theprojectzeropointisapointatadefineddistancefrom the axis zero point AZ (this distance is the project zero point offset). The project zero point PZ can only be set via FCT, or by using the CI object 21F4 h, or FHPP PNU 500 (not at control panel). Setting the software end points limits the permissible travel range (effective stroke). The software end points are relative to the axis zero point. If a positioning command's target position lies outside the software end positions, the positioning command will not be executed and a fault status will be set. 1-19

42 1. System overview Dimensional reference system Linear axis with the homing method: Fixed stop e f Rotational axis with the homing method: Reference switch REF AZ PZ a b, c d e f Homing point (or reference point): point determined during the homing run: reference switch or stop. Axis zero point: point of reference for the project zero point and the software end positions. Project zero point: Reference point (= zero point) for actual position and absolute positions in the position set table. Axis zero point offset: distance between axis zero point AZ and homing point REF Software end position offsets: limits for the permitted positioning range (= effective stroke) Project zero point offset: distance from AZ Effective stroke: permitted positioning range Nominal stroke of the axis used Tab. 1/6: Dimensional reference system 1-20

43 1. System overview Point of reference Calculation rule Axis zero point AZ =REF+ a Project zero point PZ =AZ+ d =(REF+ a) + d Lower software end position LSE =AZ+ b =(REF+ a) + b USE =AZ+ c =(REF+ a) + c Tab. 1/7: Calculation regulations for a dimensional reference system with incremental measurement systems Plus/minus signs and directions Upper software end position Alloffsetsandpositionvaluesarevectors(withagivenalgebraic sign, + or -). The +/- operating direction of the vectors can be assigned to the rotation direction of the motor shaft (visual inspection of the motor shaft). The factory settings are + for clockwise rotation and - for anticlockwise rotation. The active direction can be reversed at the control panel (see chapter 4.5.2) or via FCT. This can be useful when using angular gear units or toothed belt drives. Homing must be carried out again if the direction is reversed. The direction in which the work load moves depends on the gearing, the spindle type (left/right-rotating), the algebraic signs on the positioning specifications (+/-), and the currently set active direction: 1-21

44 1. System overview Factory setting for active direction 2 Direction change by changing the active direction Fig. 1/4: Setting the active direction (using the example of MTR-DCI + DMES, axial gearing, spindle rotating to the right) 1-22

45 1. System overview Homing For drives with incremental measuring systems, homing must always be done after switching on. This is defined on a drive.specific basis using the parameter Homing required (PNU 1014, CI 23F6h). The following homing modes are permitted: Search for stop in negative direction Search for stop in positive direction Search for reference switch in positive direction Search for reference switch in negative direction (default). To locate the reference point and position the drive at the axis zero point, two different speeds can be set. Homing procedure: 1. Search for the reference point in accordance with the configured method 2. Move from the reference point to the axis zero point AZ (axis zero point offset) 3. Setataxiszeropoint: Current position = 0 project zero point offset PZ After a successful homing the drive stops at the axis zero point AZ. With first commissioning or when the homing method is changed, the offset of the axis zero point = 0; after homing the drive then stands at the homing point REF. 1-23

46 1. System overview Search for fixed stop In this homing method the drive initially moves at a search speed in a negative or positive direction until it reaches the fixed stop. A rise in the motor current signals that the stop has been reached. When the maximum motor current is reached at the same time as the motor is at a standstill, the MTR-DCI recognizes that the stop, and therefore the reference position, has been reached. As the axis should not stand still at the stop, the axis zero point offset must be 0 (min mm). + 1 REF (-) AZ 2 AZ REF (+) 1 Stop in negative direction 2 Stop in positive direction Fig. 1/5: Homing methods Search for fixed stop 1-24

47 1. System overview Search for reference switch In this homing method the drive initially moves at a search speed in a negative or positive direction until it reaches the limit switch. It then moves back at creep speed: The reference position lies at the point at which the reference switch becomes inactive again when the drive moves back. 1 + REF (-) AZ 2 AZ REF (+) 1 Reference switch in negative direction 2 Reference switch in positive direction Fig. 1/6: Homing methods Search for reference switch If the drive is already at the reference switch when started, it moves in the opposite direction to the reference switch. Then the drive runs as usual to the axis zero point. 1-25

48 1. System overview 1-26

49 Mounting Chapter 2 Mounting 2-1

50 2. Mounting Contents 2. Mounting General instructions Dimensions of the motor unit Mounting the electric axes

51 2. Mounting 2.1 General instructions Warning Danger of electric shock, short circuiting or unexpected drive motion! Always switch off all power supply before carrying out mounting, installation and maintenance work. Note Handle all modules and components with great care. Note especially the following: Screw connections must be fitted free of distortion and mechanical tension. Screws must be fitted accurately (otherwise threads will be damaged). The specified torques must be observed. The modules must not be offset from one another. Contact surfaces must be clean (avoid contact faults). 2-3

52 2. Mounting 2.2 Dimensions of the motor unit 13 T1 H1 D4 D2 D3 D1 H0 H2 5 L1 L5 L2 L4 L3 B1 B2 Sizes [mm] Gear reduction G7/G14 G7 G14 G7 G14 G7/G14/G22 Diameter of flange/shaft D D1 D2 D3 D h8 6 h7 42 g10 42 ± h8 8 h7 52 g10 52 ± h8 12 h7 62 g10 62 ± j7 14 h7 Height H H0 H1 H ± ± ± ± ± ± ± ± ± ± ± ±0.5 Length L L1 L2 L3 L ± ± ± ± ±1 25 ±1 2 ± ± ±1 25 ±1 2 ± ±1 39 ±1 33 ±1 3 ± ±1 53 ±1 33 ±1 3 ± ±1 47 ±1 39 ±1 5 ±0.3 Width B B1 B ± ± ± ± ± ± ± ±0.4 Depth T T1 6 M3: 7 / M4: Tab. 2/1: Dimensions of the motor unit 2-4

53 2. Mounting 2.3 Mounting the electric axes When mounting the electric axes, read and keep in mind the documentation for the axis used and the additional components. Warning If an axis is mounted in a sloping or vertical position, falling work loads could cause injuries. Use the motor unit preferably with self-locking or selfbraking spindle drives. This prevents the work load sliding down suddenly if there is a power failure. With DMES-...: check whether additional external safety measures against spindle nut fracture are necessary (e. g. toothed latches or moving bolts). Make sure that: The drive is mounted securely and is correctly aligned. The working space in which the axis moves is of sufficient size for operation with a work load. The work load does not collide with any component of the drive when the slide moves into the end position. Make sure that you observe the maximum safe values for the following variables. The point of reference for forces and torques is the centre of the shaft (L3 see Tab. 2/1). 2-5

54 2. Mounting L3 L3 x 0.5 F x F y Fig. 2/1: Forces and torques Forces and torques MTR-DCI-...-G7 1-stage Radial shaft load Axial shaft load Maximum permissible shaft output torque of the gear unit 1) F y [n] F x [n] Mx [Nm] MTR-DCI-...-G14/G22 2-stage Radial shaft load Axial shaft load Maximum permissible shaft output torque of the gear unit 1) F y F x M x [n] [n] [Nm] ) 1) With operating factor cb=1.0 (3 hours operation daily, no shocks, direction of rotation constant). The gear output torque or the motor unit is usually much lower, see Technical appendix A, Mechanical data. 2) MTR-DCI G22: In the start-up phase, torque peaks up to 37 Nm are possible at 20 A peak current. Tab. 2/2: Safe load for the gear shaft 2-6

55 2. Mounting Note Motor unit MTR-DCI G22 can generate torque peaks of up to 37 Nm at a peak current of 20 A in the start-up phase. Make sure by calculating the dynamic loading that the maximum safe shaft output torque for the gear is not exceeded even in the start-up phase (e.g. by reducing the load). Use the thread on the front of the gear (see Fig. 2/2) when mounting the MTR-DCI to a mechanical drive fixture (machine frame). In order to minimise the shaft offset: position the axis with the aid of the centring diameter (D1 or D3, see Tab. 2/1) relative to the rotary axis of the mechanism to be driven. Fasten the motor unit with 4 screws and tighten the 4 screws with the specified tightening torque. Motor unit type MTR-DCI-32 has a total of 6 threads for different mounting variants (axial, parallel). In each case only 4 screws should be used. Size Thread/thread depth Tightening torque MTR-DCI M3 6mm 1.2 Nm MTR-DCI M3 7mm 1.2 Nm M4 10 mm 2.9 Nm MTR-DCI M5 10 mm 5.9 Nm MTR-DCI M5 10 mm 5.9 Nm Tab. 2/3: Tightening torques 2-7

56 2. Mounting To fit Festo axes e. g. type DMES-... or type DGE-..., couplings and coupling housings are available as accessories. The motor unit is connected to the axis by means of a clamp in the coupling housing. Additional motor flanges are not therefore necessary. Further information can be found in appendix A.2 and in the operating instructions for the axis. MTR-DCI MTR-DCI Ø32 4x 90 4x 90 M3 x6 (6) M 4 x10(4x) M 3 x7 (4x) MTR-DCI MTR-DCI Ø40 4X 90 4x 90 Ø50 Ø36 Ø32 M 5 x10(4x) M 5 x10(4x) Fig. 2/2: Mounting the drive by means of front threads (direct fastening) 2-8

57 Installation Chapter 3 Installation 3-1

58 3. Installation Contents 3. Installation Overview of installation Earthing Power supply Power supply requirements Load and logic voltage Serial interface Input for external reference switch Field bus Connecting the higher-order controller Fieldbus cable Fieldbus bit rate and fieldbus length

59 3. Installation 3.1 Overview of installation Warning Danger of electric shock, short circuiting or unexpected drive motion! Always switch off all power supply before carrying out mounting, installation and maintenance work. Caution Faulty pre-assembled lines may destroy the electronics and trigger unexpected movements of the motor. When connecting the electric components of the system use the cables that are listed as accessories (see Tab. 3/2). This is the only way to ensure the system will work properly. Note Lay all moveable motor and sensor cables free of bends and free of mechanical stress, in a drag chain if necessary. 3-3

60 3. Installation 1 Serial interface 2 Connection Reference switch 3 Fieldbus interface (I/F) 4 Power supply (Power) Fig. 3/1: Connections on the MTR-DCI ConnectionontheMTR-DCI 1 Serial interface M8x1, 4-pin socket 2 Reference switch M8x1, 3-pin socket 3 Fieldbus interface Sub-D, 9-pin Plug 4 Power supply Sub-D, 2-pin Plug Description RS232 interface for parameterising, commissioning and diagnosing with FCT Sensor input for N.O. (normally open) switch type in PNP configuration Interface for connecting the higher-level control system via Fieldbus (DeviceNet) Connection with two high-current contacts Tab. 3/1: Description of the connections If non-assigned plug connectors are touched, there is a danger that damage may occur to the MTR-DCI or to other parts of the system as a result of ESD (electrostatic discharge). Place protective caps on unused terminals in order to prevent such discharges. 3-4

61 3. Installation The plug connectors of the following Festo cables have been designed so that, when inserted and screwed tight, or if fitted with protective covers, the connections on the MTR-DCI will comply with protection class IP54. Caution Long lines reduce immunity to interference (EMC). Do not exceed the specified maximum cable lengths. Connection Cable Designation Length [m] Serialinterface Programming cable KDI-MC-M8-SUB-9-2,5 2.5 (max. 2.5) Homing Switch Connecting cable KM8-M8-GSGD /1/2/5 Fieldbus interface Field bus plug for M12 adapter FBA-CO-SUB-9-M12 Voltage supply Power supply cable KPWR-MC-1-SUB-9HC /5/10 (max. 10) Tab. 3/2: Overview of cables (accessories) To maintain the IP protection class: Seal unused M8 connections with ISK-M8 protective caps (accessories). Hand-tighten the union nuts/locking screws of the plugs: Observe the permitted tightening torques specified in the documentation for the cables and connectors used. 3-5

62 3. Installation 3.2 Earthing Note Connect the earth terminal of the MTR-DCI with low impedance (short cable with large cross section) to the earth potential. This prevents interference from electromagnetic sources and ensures electromagnetic compatibility in accordance with EMC directives. To connect the MTR-DCI to the earth potential use only the following earthing connection: Earthing strap at the free end of the power supply cable; see assembly instructions for cable type KPWR-MC-1-SUB-9HC-... (see chapter 3.3.2) Caution Earth or mass loops can make EMC safety measures ineffective and allow high compensating currents to destroy the motor unit. Connect only thecablescreenofthepower supply cable to the functional earth FE. Do not connect the GND connection to the housing, screening or functional earth FE! Never connect one of the power supply connections (see chapter 3.2, A1, A2) to the FE or the housing. This will avoid damaging the device and impairing protection against electromagnetic interference (EMC). 3-6

63 3. Installation 3.3 Power supply Power supply requirements Warning In order to provide the electric power supply, use only PELV circuits as per IEC/DIN EN (Protective Extra-Low Voltage, PELV). Take into account also the general requirements for PELV circuits as per IEC/DIN EN Use only power sources providing reliable electrical isolation of the operating voltage as per IEC/DIN EN By the use of PELV power units, protection against electric shock (protection against direct and indirect contact) is guaranteed in accordance with IEC/DIN EN (electrical equipment of machines, general requirements). Caution Device damage from overvoltage The voltage inputs of the motor unit have no internal protection against overvoltage. Make sure that the permitted voltage tolerance is not exceeded. The tolerance must also be observed directly at the operating voltage connections on the MTR-DCI (see appendix A.1). Install external fuses (see Tab. 3/4). 3-7

64 3. Installation Load and logic voltage Load voltage The power electronics and thereby the motor are supplied with DC voltage via the power supply connection. Use the power supply cable KPWR-MC-1-SUB-9HC-... (max length of 10 m). For the load voltage supply, use a stabilised power supply unit with high reserve capacity and external fuses. Plug Pin Colour 1) Description A1 Black (1) MTR-DCI-32/42/52: MTR-DCI-62: POWER DC +24 V POWER DC +48 V A1 A2 A2 Black (2) MTR-DCI-32/42/52/62: POWER GND 2) 1) Cable colours with power supply cable KPWR-MC-1-SUB-9HC-... 2) Do not link the GND terminal to any housing, screen or functional earth (FE)! Tab. 3/3: Connecting the power supply to the motor unit Regulated DC motors consume many times their nominal operating current when switched on or when producing the startup torque. These consumers represent an overload or short-circuit to the power supply at these times. Power supplies with a U/I output characteristic curve still provide the full output current (at a lower output voltage) under heavy loads or short-circuits. Power supplies with additional power reserves (Power Boost) provide a constant output voltage, even under overload conditions. Power supplies with a U/I output characteristic curve and additional power reserves are therefore optimally suited for universal industrial use. 3-8

65 3. Installation Note the following selection criteria for the MTR-DCI power supply: The power supply nominal current should be at least the same as the motor startup current (peak current). The motor tolerances should be allowed for with 20% - 50% reserve power. voltage supply MTR- -32 MTR- -42 MTR- -52 MTR- -62 Motor nominal current A Motor peak current A Nominal current of power supply unit A ) External fuse secondary side A 5A slow-blowing 7A slow-blowing 10 A slow-blowing 25 A slow-blowing 1) Exception Tab. 3/4: Power supply and fuse requirements 1 external fuse 2 Earthing connection (see chapter 3.2) A1 A1 A2 A2 Fig. 3/2: Connection example Power supply 3-9

66 3. Installation Logic voltage In operation, the logic voltage is connected via the FBA-... Fieldbus adapter separately to the load voltage. For MTR-DCI-42, 52, 62: For commissioning purposes, the logic voltage can be optionally connected together with the load voltage via the power supply connection. In normal operation, the logic voltage must be connected separately to the load voltage via the FBA-... Fieldbus adapter. With separate supply, the load voltage can be switched off e.g. in the case of EMERGENCY-STOP, with logic voltage continuing to be applied and the controller remaining functional and retaining its reference position. Switch-on sequence Do not switch on the logic voltage after the load voltage, since this may cause the MTR-DCI to switch off and back on again (= reset). Logic voltage failure If the logic voltage fails, the controller will switch off. For MTR-DCI-42, 52, 62: if the load voltage is still active, the controller will switch back on but will lose its reference position. Logic voltage supply In operation: via Fieldbus adapter FBA-... For commissioning and parameterisation: optionally via the power supply connection x x x x x x x Tab. 3/5: Logic voltage supply Information on the connection specifications of the Fieldbus adapter is provided in chapter and also in the installation manual of the Fieldbus adapter. 3-10

67 3. Installation 3.4 Serial interface Serial interface for parameter assignment, commissioning and diagnosis Use the following cable exclusively for connecting a PC to the MTR-DCI: Programming cable KDI-MC-M8-SUB If necessary, remove the protective cap from the serial interface of the MTR-DCI. Connect the following terminals with the programming cable: The connection socket on the MTR-DCI. A serial interface COMx on the diagnostic PC. M8x1 socket Description 1 GND Ground 2 TXD RS232 transmitting cable 1) 3 RXD RS232 receiving cable 1) Reserved for service personnel do not connect! 1) The levels conform to the RS232 standard Data transfer rate: 9600 bit/s Tab. 3/6: Pin allocation for the serial interface on the MTR-DCI 3-11

68 3. Installation Information on commissioning and parameterising the MTR-DCI via the serial interface can be found in chapter 5.3 and in the help system for the FCT software package. Information on transmitting CI commands via the serial interface can be found in appendix C.1.2. Note The RS232 communications port is not electrically isolated. It is not suitable for permanent connection to PC systems, nor for use as a control interface. Use this terminal only for commissioning. Remove the programming cable in continuous operation. Seal the connection with the protective cap supplied (ISK-M8). 3-12

69 3. Installation 3.5 Input for external reference switch If you are not using a reference switch: Seal the connection with the protective cap supplied (ISK-M8). When selecting the reference switch: For the reference switch, use the correct N.O. (normally-open) switch type in PNP configuration. Use a reference switch with a screw-type lock (external thread M8x1) at the end of the cable, or use the connecting cable KM8-M8-... with a screw-type lock as an adapter. Use (e.g.) the following Festo proximity sensors: magnetic proximity sensor SMT-8M-... inductive proximity sensor SIEN-...-M8B-... When selecting the sensor, note that the accuracy of the switchover point of the sensor determines the accuracy of the homing (reference) point. M8x1 socket Description 1 DC +24 V DC + 24 V voltage output (only for reference switch) 4 REF Reference switch contact GND Ground Tab. 3/7: REF connection (reference switch) on the MTR-DCI The power supply for the reference switch (DC 24 V/Ground) is provided via pin 1/

70 3. Installation Caution Damage to the device The DC 24 V voltage on pin 1 does not have any special protection against overload; the voltage is taken from the main supply with protection against ESD and incorrect polarity. Use the terminal only for the reference switch (sensor supply). Use of this connection as a power supply for other devices is not safe. The input for REF sensor signal complies in its electrical properties with the input specifications in the appendix Technical data. 3-14

71 3. Installation 3.6 Field bus Connecting the higher-order controller Communication with the higher-order controller occurs via the Fieldbus interface (I/F) on the MTR-DCI-... To connect to the Fieldbus there is a 9-pin Sub-D plug on the MTR-DCI-...-DN. This connection is used for feed-in and continuation of the Fieldbus line. Note Only the FBA-CO-SUB-9-M12 Fieldbus adapter from Festo guarantees IP 54 protection. Note The shield connection at pin 5 of the Fieldbus interface is internally capacitively and high resistance connected to the housing. This prevents compensating currents from flowing via the shield of the Fieldbus cable (see Fig. 3/3). 1 Capacitive connection 2 Housing Fig. 3/3: Shield connection inside the MTR-DCI In normal operation, pins 6 and 9 must be supplied with 24 V (bus voltage and logic voltage supplies). The CAN bus (pins 2, 3, 7) potential is relative to the bus power supply (permits electrically isolated bus connection). 3-15

72 3. Installation For the logic voltage supply, please also follow the advice in chapter Information on the connection specifications of the Fieldbus adapter is provided in the installation manual of the Fieldbus adapter. Connection Pin Designation Function 1 1 n.c. Not connected 2 CAN_L CAN bus Low 3 CAN GND CAN bus reference potential 9 4 n.c. Not connected 5 CAN_SHLD Shield, capacitive connection to housing 6 CAN_V Bus supply 0V / Logic voltage GND 7 CAN_H CAN bus High 8 n.c. Not connected 9 CAN_V+ Bus supply 24 V / Logic voltage 24 V Shield/housing Connection to (FE) functional earth Tab. 3/8: Fieldbus interface I/F at the MTR-DCI-...-DN Note Always use a bus termination at both ends of the fieldbus. If the MTR-DCI is at the beginning or end of the fieldbus segment: Connect the terminating resistor (121 Ω, 0.25W) between the wires for CAN_H and CAN_L. 3-16

73 3. Installation Fieldbus cable Note Faulty installation and high transmission rates may cause data transmission errors as a result of signal reflections and attenuations. Transmission errors can be caused by: missing or incorrect terminating resistor incorrect screened connection branches transmission over long distances inappropriate cables Observe the cable specifications! For information on the cabletyperefertothemanualforyourcontrollerortothe DeviceNet specification. Note If the MTR-DCI is mounted onto a moving part of a machine, the Fieldbus cable on the moving part must be provided with strain relief. Please observe also the relevant regulations in EN part 1. Use a shielded, twisted pair 4-wire cable as a fieldbus cable. When using a Festo fieldbus a cable diameter of or mm is permitted. Bus length Exact specifications on the bus length can be found in the next section and in the manuals for your control system. 3-17

74 3. Installation Fieldbus bit rate and fieldbus length Note The maximum permitted length for fieldbus segments depends on the bit rate used. You will find detailed information in the manuals for your control system or bus interface or DeviceNet specification. Note the maximum permitted segment length (cable length without repeater) if you are connecting the MTR- DCI to a fieldbus segment. Avoid branch lines. Note Refer to the manuals for your control system or bus interface in order to ascertain which T-adapter and maximum branch line length are permitted for your controller. Also take into account the sum of the branch line lengths when calculating the maximum permitted length of the fieldbus cable. Bit rate Maximum segment length 500 kbps 100 m 250 kbit/s 250 m 125 kbit/s 500 m Tab. 3/9: Maximum length of fieldbus segments as a function of the bit rate Information on setting the bit rate and further bus parametersonthecontrolpanelcanbefoundinsection

75 The control panel (type MTR-DCI-...-H2 only) Chapter 4 The control panel (type MTR-DCI-...-H2 only) 4-1

76 4. The control panel (type MTR-DCI-...-H2 only) Contents 4. The control panel (type MTR-DCI-...-H2 only) Composition and function of the control panel The menu system Accessing the main menu Selecting a menu command [Diagnostic] menu [Positioning] menu [Positioning] [Move position set] [Positioning] [Demo position table] [Positioning] [Homing] [Settings] menu [Settings] [Axis type] [Settings] [Axis parameter] [Settings] [Homing paramet.] [Settings] [Position set] [Settings] [Password edit] [Settings] [BUS parameter] Menu command [HMI control]

77 4. The control panel (type MTR-DCI-...-H2 only) Thecontrolpanelof motor unit MTR-DCI-...-H2 enables commissioning directly on the MTR-DCI. An overview of the key and menu functions can be found in this chapter. Commissioning with the control panel is described from chapter 5.2. Withthe MTR-DCI-...-R2 (without control panel) you can commission the MTR-DCI via the RS232 interface (with FCT software). Instructions on this can be found in chapter 5.3. Caution Simultaneous access of control functions and operating functions by the FCT and the control panel can cause faults. Make sure that FCT and the control panel are not in use at the same time. If necessary, utilise the facility to disable parameterisation and positioning functions from the control panel (HMI Access, see section 5.5.2). Note Remove the protective film from the display, if still fitted, before using it for the first time. 4-3

78 4. The control panel (type MTR-DCI-...-H2 only) 4.1 Composition and function of the control panel 1 LC display 2 Operating buttons LEDs Power (green) I/F (green/red) Error (red) Fig. 4/1: LC display Control panel of the MTR-DCI-...-H2-... The graphical LCD (128 x 64 pixels) shows all text in English. The display can be rotated if required; see the menu commands [LCD adjustment]. Membrane keyboard The 4 buttons on the membrane keyboard are used to perform menu-driven settings and commissioning functions: Parameter assignment and referencing the axis Teaching of standard applications and editing of positioning sets Execution/Testing of individual positioning sets. LEDs The operating statuses are indicated visually by 3 LEDs (see also chapter 6.2): Power: Power supply I/F: Bus status (Network, Module) Error: Faults 4-4

79 4. The control panel (type MTR-DCI-...-H2 only) Function MENU ESC EMERG.STOP OK SAVE START/STOP Activates the main menu from the status display. Rejects the current entry and switches back in stages to the higher menu level or status display. Interrupts the current positioning procedure (> Error mode; confirm with <Enter>, then automatic return to the status display). Only when HMI =on! Confirms the current selection or entry. Saves parameter settings permanently in the EEPROM. Starts or stops a positioning procedure (only in Demo mode). After stop: display of current position; use <Menu> to return to the higher menu level. Button Menu Enter <- -> Scrolls within a menu level in order to select a menu command. v EDIT Sets parameters. V Tab. 4/1: Button function (overview) 4-5

80 4. The control panel (type MTR-DCI-...-H2 only) 4.2 The menu system Accessing the main menu MTR-DCI... X a = 0.00 mm HMI:off <Menu> When the power supply is switched on, the MTR-DCI automatically carries out an internal check. At first the display briefly shows the Festo logo, then changes to the status display. The status display shows the following information: The type designation of your MTR-DCI The current position of the drive x a =... The current setting for device control (HMI = Human Machine Interface) The current button function is indicated in the lines at the bottom of the display: <Menu> The main menu is accessed from the status display using the <Menu> button Selecting a menu command } Diagnostic Positioning Settings * S ESC <Menu> <--> OK <Enter> } HMI control LCD adjustment s ESC <Menu> <--> OK <Enter> <- -> You can use the arrow buttons on the control panel to select a menu item from the list. The current selection is marked with an arrow (} Diagnostic). Select S todisplay further menu commands. ESC OK You can use the <Menu> to cancel your current input and return to the status display, or to return from a submenu to the menu above. The <Enter> button is used to confirm the current selection or entry. 4-6

81 4. The control panel (type MTR-DCI-...-H2 only) Menu command Description } Diagnostic Displays the system data and the currently effective settings (see section 4.3) } Pos. set table Displays the position set table } Axis parameter Displays axis parameters and data } System paramet. Displays system parameters and system data } DeviceNet Diag Displays DeviceNet diagnosis data } SW information Displays the operating system version (firmware) } Positioning 1) 2) Homing and positioning runs for testing the position set records (see section 4.4) } Move posit set Starts the positioning run for position set record } Demo posit tab Starts the positioning run for position set table } Homing Starts the homing run } Settings 1) 2) Selection of the drive, parameter assignment, programming the position set records... (see section 4.5) } Axis type } Type DMES-... Valve actuator DMES-... } Type DNCE-... Electric cylinder DNCE-... } Rotation drive Rotational axis with stop } User config Any linear drive } Axis parameter } Zero point 3) Offset of axis zero point } Abs.min. pos 3) Stroke limitation: software end position, negative } Abs.max. pos 3) Stroke limitation: software end position, positive } SAVE... Saves parameters in EEPROM } Homing paramet. } Homing method Selectsreferencing (homing) method (stop, software limit switch...) } Velocity v_sw Positioning speed for searching for the homing point } Velocity v_s0 Positioning speed for moving to the axis zero point } SAVE... Saves parameters in EEPROM } Position set } Position nr. Number of the position set record (0...14) } Pos set mode Absolute or relative positioning } Position 3) Target position of the position set record } Velocity Positioning speed of the position set record } SAVE... Saves parameters in EEPROM } Password edit Sets up a local password with 3 digits for the control panel (see chapter 4.5) } BUS parameter Setting Fieldbus parameters. } HMI control 1) Presetting for device control via the control panel (see chapter 4.6) } LCD adjustment Rotates the display in steps of 90 1) May be password-protected 3) Teach mode 2) Control interface must be deactivated; see [HMI control] :HMI = on Tab. 4/2: Menu commands (overview) 4-7

82 4. The control panel (type MTR-DCI-...-H2 only) 4.3 [Diagnostic] menu For displaying the currently active settings of the position set table, axis and system parameters, status and diagnostic information on bus communication, and the firmware version: } Diagnostic Pos.set table Axis parameter System paramet.. DeviceNet Diag SW information 1. From the main menu, select the [Diagnostic] menu. 2. Select a menu command (see Tab. 4/4). <- -> You can page through the data using the arrow buttons. ESC Pressing the <Menu> button returns you to the higher menu level. 4-8

83 4. The control panel (type MTR-DCI-...-H2 only) Menu command Description [Pos. set table] Nr The number of the position set record a/r Pos Vel a = absolute positioning, r = relative positioning Target position Positioning speed [Axis parameter] 1) v max Maximum positioning speed x min x max x 0 feed 2) Stroke limitation: Software end position, negative Stroke limitation: Software end position, positive Offset of the axis zero point Feed constant [System param] V power Supply voltage [V] Imax Iact Temp Cycle Ref.switch Mode Maximum current [A] Current current [A] Operating temperature [ C] Number of positioning movements Reference switch (ON/OFF) Units of measurement e.g. mm Hom.meth. bl.pos Fixed stop in positive direction bl.neg Fixed stop in negative direction sw.pos Reference switch in positive direction sw.neg Reference switch in negative direction Gear Gear reduction ratio of the drive (e.g. 6.75) 1) Unit of measurement depends on the measuring system set 2) Not for axis type Rotation drive Tab. 4/3: [Diagnostic] menu (1) 4-9

84 4. The control panel (type MTR-DCI-...-H2 only) Menu command [DeviceNet-Diag] Description Bus diagnosis No Power / BUS-Off Device Operational Device in Standby Bus supply is not connected or the Fieldbus is not correctly parameterised. Connection to the master is not possible. DeviceNet is in the Data exchange state and is connected to a master. No connection to the DeviceNet master exists, device is ready for operation. Minor Fault A recoverable faulthasoccurred (e.g. Timeout) Unrecoverable Fault Bit rate I/O data length MAC ID A severe, unrecoverable fault has occurred (e.g. duplicate MAC ID), a reset is required to bring the device back into operation. Set bit rate of the MTR-DCI: Values: 125 k, 250k, 500 k(bit/s) I/O data length setting. 8 bytes: only for the FHPP standard (control of the MTR-DCIisdoneaspertheFestoHandlingandPositioning Profile) 16 bytes: FHPP standard and FPC (additional use of the FPC for parameterising the MTR-DCI) DeviceNet address of the MTR-DCI (hexadecimal/decimal). [SW information] MTR-DCIfirmwareversion,e.g.V1.20 Tab. 4/4: [Diagnostic] menu (2) 4-10

85 4. The control panel (type MTR-DCI-...-H2 only) 4.4 [Positioning] menu Warning Injuries or damage to mechanical components. With all positioning procedures, the motor turns and the connected axis starts to move. Make sure that: Nobody can place their hands into the positioning range. There are no objects within the positioning range. Note Beforestartingahomingrun,makesurethat: The positioning system is set up and wired completely, and is supplied with power. Parameterising is completed. Do not start a positioning run until the reference system has been defined by homing (see chapter 4.4.3). Note Note that position set records with speed v=0 or an invalid target position (-> fault TARGET POSITION OUT OF LIMIT) will not be executed. 4-11

86 4. The control panel (type MTR-DCI-...-H2 only) For selecting a positioning run or a homing run: } Positioning Move position set Demo posit tab Homing 1. From the main menu, select the [Positioning] menu. 2. Select the menu command: [Move position set] to test a particular positioning set in the positioning set table (see chapter 4.4.1). [Demo posit tab] to run all position set records in the position set table one after the other. [Homing] Homing run to determine the dimensional reference system (see chapter 4.4.3) [Positioning] [Move position set] Note Do not start a position set record until the reference system has been defined by homing. To test a particular position set record in the position set table: 1. Select the position set number. Move position set Position no.: [1...31] = _? EDIT <--> ESC <Menu> OK <Enter> Move position set Attention! Motor moves ESC <Menu> START <Enter> <- -> Select the desired number using the arrow buttons. OK Confirm the selection using the <Enter> button. ESC Pressing the <Menu> button cancels the action and returns you to the higher menu level. 2. Start positioning with START <Enter>. During the positioning run, the following information is displayed: The active positioning set, e.g. Pos

87 4. The control panel (type MTR-DCI-...-H2 only) Move position set Pos 2 x t = 220 mm v = 22 mm/s x a = 200 mm EMERG.STOP<Menu> The target position x t The positioning speed, v The current position x a EMERG. STOP Pressing the <Menu> button cancels the current positioning run (> Fault MOTOR STOP). Move posit set Pos 2 x t = 220 mm/s v = 22 mm/s x a = 220 mm/s ESC<Menu> After the positioning run is finished: ESC Pressing the <Menu> button returns you to the selection of the positioning set [Positioning] [Demo position table] There must be at least two positioning sets in the memory. If the position set table contains a position set record with speed v = 0, this position set record and all the following records will not be executed; the positioning run will continue with the first position set record. To run all positioning sets in the position set table one after another: Demo position table Attention! Motor moves ESC <Menu> START <Enter> Demo position table Pos 2 x t = 220 mm v = 22 mm/s x a = 220 mm DEMO STOP<Enter> EMERG.STOP<Menu> Start positioning with START <Enter>. During the positioning run, the following information is displayed: The active positioning set, e.g. Pos 2 The target position x t The positioning speed, v The current position x a 4-13

88 4. The control panel (type MTR-DCI-...-H2 only) DEMO. STOP EMERG. STOP Pressing <Enter> cancels the positioning run. The current positioning set is executed before the axis stops. On restart, the process begins with the first positioning set. Pressing the <Menu> button cancels the current positioning run (> Fault MOTOR STOP) [Positioning] [Homing] Note When performing a homing run, please also note the explanation in chapter 5.2. First set the parameters in the menu [Settings] [Homing paramet.]. (see chapter ). Factory setting: Homing to stop in negative direction. Homing Attention! Motor moves. ESC <Menu> START <Enter> To define the reference point through a homing run: Start homing with START <Enter>. The following information is displayed: The search speed v_sw for moving to the reference point The positioning speed v_s0 to the axis zero point v_0. Homing V_sw = 20 mm/s v_s0 = 10 mm/s During the homing run, the axis slowly moves with reduced search speed to the stop or reference switch and then accepts this position as the reference point. EMERG.STOP<Menu> 4-14

89 4. The control panel (type MTR-DCI-...-H2 only) EMERG. STOP Pressing the <Menu> button cancels the homing run (> Fault HOMING ERROR). Acknowledge the error message with <Enter>. Repeat the homing run. After a successful homing run, the [Positioning] menu is displayed. 4-15

90 4. The control panel (type MTR-DCI-...-H2 only) 4.5 [Settings] menu The [Settings] menu contains all functions for parameterising the axis system and the positioning sets. Further information on the individual menu commands is provided in the specified chapters (see Tab. 4/5). } Settings Axis type Axis parameter Homing paramet. Position set Password edit BUS parameter 1. From the main menu, select the [Settings] menu 2. Select a menu command. [Settings] Description Chapter [Axis type] Selection of the axis driven by the MTR-DCI [Axis parameter] Teach mode for setting the axis parameters [Homing paramet.] Setting of the homing run method and the homing speed [Position set] Teach mode for programming the position set table [Password edit] Set up a local3-character passwordfor the controlpanel [BUS parameter] Setting Fieldbus parameters Tab. 4/5: [Settings] menu Note The pre-set parameters take immediate effect when you press OK <ENTER>. Choose [SAVE...] to save the settings permanently to the EEPROM: Choose [SAVE...] tosavethe parameter settings. Only then will the settings be retained even if the power supply is switched off or if there is a power failure. 4-16

91 4. The control panel (type MTR-DCI-...-H2 only) [Settings] [Axis type] Selection of the axis driven by the MTR-DCI [Axis type] [Type DMES-...] [Type DNCE-...] [Rotation drive] [User config] Description Festo servo axis Festo electrical drive Specific rotation axis Specific linear axis Tab. 4/6: [Settings] [Axis type] menu <- -> You use the arrow buttons to set the axis-specific properties in accordance with the display prompts, e.g. feed constants, units of measurement, or counting direction. (for details, see chapter 5.2.1) SAVE Pressing the <Enter> button permanently saves the settings in an EEPROM. ESC Pressing the <Menu> button cancels the action and returns you to the higher menu level. Press SAVE <Enter> to save your settings. 4-17

92 4. The control panel (type MTR-DCI-...-H2 only) [Settings] [Axis parameter] Teach mode for setting the axis parameters. Select the following parameters to set the dimensional reference system. Follow the instructions in chapter [Axis parameter] [Zero point] [Abs.min.pos] [Abs.max.pos] [SAVE...] Description Offset of the axis zero point Stroke limitation: Software end position, negative Stroke limitation: Software end position, positive Save parameters in EEPROM Tab. 4/7: [Settings] [Axis parameter] menu <- -> Use the arrow buttons to move the axis to the desired position. OK ESC Confirm the selection using the <Enter> button. Pressing the <Menu> button cancels the action and returns you to the higher menu level. Choose [SAVE...] tosavethe parameter settings. Only then will the settings be retained even if the power supply is switched off or if there is a power failure. 4-18

93 4. The control panel (type MTR-DCI-...-H2 only) [Settings] [Homing paramet.] Setting of the homing run method and the homing speed. Follow the instructions in chapter The maximum speed during homing is limited to half the maximum positioning speed v_max (for v_max see [Diagnostic] [Axis param] ). [Hom. paramet.] Param. Description [Homing method] sw.neg (switch negative) sw.pos (switch positive) bl.neg (block negative) bl.pos (block positive) Homing to reference switch, negative = factory setting Homing to reference switch, positive Homing to fixed stop, negative Homing to fixed stop, positive [Velocity v_sw] v_sw Speed for searching for the homing point [Velocity v_s0] v_s0 Speed for moving to the axis zero point [SAVE...] Save parameters in EEPROM Tab. 4/8: [Settings] [Homing paramet.] menu Choose [SAVE...] to save the parameter settings. 4-19

94 4. The control panel (type MTR-DCI-...-H2 only) [Settings] [Position set] Programming the position set table First select the desired position set number. The following settings related to the currently selected positioning set. When performing a homing run, please also note the explanation in chapter [Position set] Param. Description [Position nr.] Nr The number of the position set record [Pos set mode] [absolute/ relative] Positioning mode absolute = absolute position specification, related to the project zero point relative = relative position specification, related to the current position [Position] xt Teach mode for setting the target position in the selected units of measurement, e.g. [mm]. Do not teach the positions until the reference system has been defined by homing. (see chapter 4.4.3). [Velocity] v Positioning speed in the selected system of measurement e.g. [mm/s] [SAVE...] Save parameters in EEPROM Tab. 4/9: [Settings] [Position set] menu <- -> Use the arrow buttons to move the axis to the desired position or select the parameter setting. OK ESC Confirm the selection using the <Enter> button. Pressing the <Menu> button cancels the action and returns you to the higher menu level. Choose [SAVE...] tosavethe parameter settings. Only then will the settings be retained even if the power supply is switched off or if there is a power failure. 4-20

95 4. The control panel (type MTR-DCI-...-H2 only) [Settings] [Password edit] In order to prevent unauthorised or unintentional overwriting or modification of parameters in the device, access via the control panel can be protected by a local password. No password has been preset at the factory (presetting = 000). KeepthepasswordfortheMTR-DCIinasuitablelocation, such as in the internal documentation pack for your system. If the active password in the MTR-DCI is lost in spite of care being taken: If needed, the password can be deleted by entering a master password. In this case please contact your Festo Service partner. Activating the password Select [Settings] [Password edit] in the menu. New Password: [?xx] = ESC <Menu> EDIT <--> OK <Enter> Enter a password with 3 digits (0..9). The current entry position is marked with a question mark. 1. Use the arrow keys to select a digit. 2. Confirm your entry with <Enter>. 3. Set a number for the next input position?. 4. After selecting the third digit, save the password with SAVE <Enter>. After saving the password, access to all parameterisation and control functions in the control panel is locked by a password query. 4-21

96 4. The control panel (type MTR-DCI-...-H2 only) Enter Password: [?xx] = EDIT <--> ESC <Menu> OK <Enter> Entering a password As soon as a password is active, it will be scanned automatically when the menu commands [Positioning], [Settings] or [HMI control] are accessed. The current entry position is marked with a question mark. 1. Use the arrow buttons to select a digit Confirm your entry with <Enter>. The next entry position will be displayed. 3. Repeat the entry for the remaining entry positions. When the correct password is entered, all parameterising and control functions of the control panel are enabled until the power supply is switched off. Modifying/deactivating the password Select [Settings] [Password edit] in the menu: Enter Password: [?xx] = EDIT <--> ESC <Menu> OK <Enter> Enter the current password with 3 digits (0..9). The current entry position is marked with a question mark. 1. Set the first digit of the password using the arrow buttons. 2. Confirm the digit with OK <Enter>. 3. Set the digit for the next input position?. After entering the third digit of the current password you can change or deactivate the password. New Password: [?xx] = EDIT <--> ESC <Menu> OK <Enter> Enter 3 digits for the new password or enter 000 to deactivate the password: 4. Use the arrow keys to select the first digit. 4-22

97 4. The control panel (type MTR-DCI-...-H2 only) 5. Confirm the digit with OK <Enter>. 6. Set the digit for the next input position?. 7. After entering the third digit, save your setting with SAVE <Enter> [Settings] [BUS parameter] Setting Fieldbus parameters. [BUS parameter] Param. [MAC ID] (0...3fh) Description Fieldbus address of the MTR-DCI. Representation: 0 dec, 0 hex dec, 3f hex [Bit rate] [I/O DATA] 500 kbit/s, 250 kbit/s, 125 kbit/s 8bytes 16 bytes Fieldbus bit rate corresponding to the settings on the master. I/O data length setting 8 bytes: only for the FHPP standard (control of the MTR-DCI is done as per the Festo Handling and Positioning Profile) 16 bytes: FHPP standard and FPC (additional use of the Festo Parameter Channel for parameterising the MTR-DCI) Tab. 4/10: [Settings] [BUS Parameter] menu <- -> Select the parameter setting using the arrow buttons. OK Confirm the selection using the <Enter> button. ESC Pressing the <Menu> button cancels the action and returns you to the higher menu level. The settings made in the [BUS Parameter] menu are saved directly and permanently (including in the event of a power failure) to the EEPROM when you confirm them with OK<Enter>. 4-23

98 4. The control panel (type MTR-DCI-...-H2 only) 4.6 Menu command [HMI control] HMI control [on/off] = on? HMI Access free ESC <Menu> <--> OK <Enter> To select the [Positioning] and [Settings] menu commands the HMI: on setting is required. Only then is the MTR-DCI ready to process user entries on the control panel. When selecting the menu commands, you will be prompted to modify the HMI setting. You can also change the setting directly by selecting the [HMI control] menu item. HMI 1) on off Description Device control is carried out manually via the control panel. The control interface of the MTR-DCI is deactivated and control enable is set. The actual status of the FHPP control bytes or the transmitted DS402 control word then has no effect. When control panel control is active the drive cannot be stopped with the STOP bit. Device control is carried out via the control interface of the MTR-DCI. 1) Human Machine Interface Tab. 4/11: States [HMI control] <- -> Select the parameter setting using the arrow buttons. OK ESC Confirm the selection using the <Enter> button. Pressing the <Menu> button cancels the action and returns you to the higher menu level. Access to the MTR-DCI via HMI and FCT can be blocked via the Fieldbus in the following manner: FHPP: Bit CCON.B5, HMI Access locked. 4-24

99 Commissioning Chapter 5 Commissioning 5-1

100 5. Commissioning Contents 5. Commissioning Commissioning procedure Commissioning with the control panel (MTR-DCI-...-H2 only) Setting the axis type Setting the homing parameters Starting homing Teaching the axis zero point AZ and the software end positions Teaching position set records Test run Setting bus parameters Commissioning with FCT Installing the FCT Procedure Further information on FCT Commissioning a DeviceNet master Overview of commissioning on the Fieldbus Configuration of the DeviceNet master ( I/O configuration ) Festo profile for handling and positioning (FHPP) Supported operating modes Structure of the cyclic I/O data (FHPP standard) Description of the I/O data (record selection) Description of the I/O data (direct task) Description of the control bytes CCON, CPOS, CDIR Description of the status bytes SCON, SPOS, SDIR (RSB) Examples of I/O data Sequence control according to the FHPP standard Homing Jog mode Teaching via Fieldbus Record selection (Positioning mode)

101 5. Commissioning Direct task (Positioning mode, Force mode) Standstill monitoring The Festo Parameter Channel (FPC) Structure of the cyclic I/O data (FHPP-FPC) Request identifiers, response identifiers and error numbers Rules for request-response processing Parameterisation example FHPP finite state machine Establish ready to operate status Positioning Notes on operation

102 5. Commissioning 5.1 Commissioning procedure Before commissioning Warning Danger of injury. Electric axes can move suddenly with high force and at high speed. Collisions can lead to serious injury to human beings and damage to components. Make sure no one is able to intervene in the action range of the axes or of any other connected actuators, and that there are no objects in the movement range as long as the system is connected to a power source. Note In the following cases the MTR-DCI must not be accessed with the FCT for writing (e. g. downloading parameters) or controlling (e. g. with Move manually or to start homing): When the MTR-DCI is currently performing a positioning movement or when a movement is started during access (e.g. via the control interface or via the control panel) When parameter assignment or operation is being carried out with the control panel of the MTR-DCI. Please note the following: The device link in the Festo Configuration Tool (FCT ) must not be active when control panel control ( HMI control = on ) is activated. Control panel control ( HMI control = on ) must not be active when the device link in the Festo Configuration Tool is activated. Control by the FCT must not be activated while the drive is in motion or when control is being carried out via Fieldbus. 5-4

103 5. Commissioning Beforecommissioningthedrivemakesurethat: The work space is of sufficient size for operation with a work load. The work load does not collide with the motor or the gear of the axis when the slide moves into the end position. Pleaseobservethenotesintheoperatinginstructionsfor your axis. Switching on Note Note that the tolerance for the supply voltage must be observed. The tolerance must also be observed directly at the operating voltage connection of the MTR-DCI (see chapter 3.3). Note When the power supply is switched off, wait for approx. 5 seconds before switching the device on again. When the logic voltage is connected via the Fieldbus adapter: Switch-on sequence Logic voltage failure Do not switch on the logic voltage after the load voltage, since this may cause the MTR-DCI to switch off and back on again (= reset). If the logic voltage fails, the controller will switch off. MTR-DCI 42, 52, 62: if the load voltage is still active, the controller will switch back on but will lose its reference position. 5-5

104 5. Commissioning 1. Switch on the power supply for the MTR-DCI. When the power supply is switched on, the MTR-DCI automatically carries out an internal check. Preset operating mode after switch-on: record selection. 2. Carry out parameterising and commissioning with the control panel or the FCT, as described in the following chapters or in the FCT/plug-in help. 3. In order to complete commissioning note the instructions for operation in the FCT/plug-in help and in section 5.9. Note To restore the default settings the EEPROM can be deleted if necessary with CI object 20F1 (Data memory control) directlyviatheserialinterface(seesectionc.1).userspecific settings will then be lost. Use CI commands only if you already have experience of using Service Data Objects. If necessary consult Festo. Warning Danger of injury. Faults in parameterisation can cause injury to human beings and damage to property. To ensure correct setting of the reference coordinates and the operating range it is essential to perform a homing run in the following cases: On initial commissioning, After a change of homing method, Every time the logic voltage supply is connected! 5-6

105 5. Commissioning 5.2 Commissioning with the control panel (MTR-DCI-...-H2 only) The control panel provides all the necessary functions for commissioning, parameterisation, diagnosis and operator control directly at the MTR-DCI. Positioning records and parameters can be edited using the menu system. You can use the Teach functions to easily move to positions and load these into the position set table. Note TheprojectzeropointPZcanonlybesetviaFCTorby using the CI object 21F4 h (FHHP PNU 500). Informationonthebuttonfunctionsandonthemenucomposition of the control panel can be found in Chapter 4. Diagnostic Positioning Settings } HMI control LCD adjustment Device control In order that the control panel can control the connected MTR-DCI, the control interface of the MTR-DCI must be deactivated and control panel enable must be set [HMI = on]. The actual status of the FHPP control bit has no effect after this. You will find information on the control enable in section 4.6. Overview of parameter assignment and commissioning Information on the current parameter assignment of the motor unit can be found in the menu [Diagnostic] on the control panel. Carry out the following steps in order to commission the MTR-DCI the first time with the control panel. Refer to the detailed description in the chapters specified. 5-7

106 5. Commissioning Commissioning (overview) 1. Select the drive type and adapt the parameters to your axis as necessary. 2. Set the following parameters for homing: Homing method, search speed to reference point, positioning speed to axis zero point, 3. Carry out homing. In the fixed stop... homing method: teach an axis zero point To define the axis zero point and the operating range teach-in the following axis parameters: Axis zero offset to reference point Positive and negative software end positions. 5. Enter multiple positioning sets (target position, positioning mode, travel speed and accelerations). 6. Perform a test run to test the positioning response of the axis, the reference coordinates and the operating range. 7. Optimise the positioning set configuration and the reference coordinate and operating range settings as necessary. 8. Switch on the Fieldbus interface of the MTR-DCI. This step may optionally be carried out first. 9. To complete the commissioning process refer to the information relating to operation of the unit. Chap and Tab. 5/1: Commissioning steps 5-8

107 5. Commissioning Setting the axis type } Settings Axis type Type DMES... Type DNCE... Rotation drive User config 1. Select your axis type in the [Settings] [Axis type] menu 2. Set axis-specific parameters as prompted using the arrow buttons, e.g. feed constant, system of measurement, or counting direction. Axis type Description Parameter Type DMES Festo servo axis A DMES size can be selected, according to the size of the MTR-DCI. The feed constant is already configured. Type DNCE Festo electrical drive FeedCon: feed constant in [mm/rev] (see the operating instructions for DNCE-...). Count direction: direction of motor rotation left or right (see chapter 1.6). Rotation drive 1) Any rotational axis Any rotary/semi-rotary drive: [Degrees] (360 /rev) or [Revolutions] User config Any linear axis Any linear drive: feed constant in [mm/rev] as per the documentation of your linear axis. 1) If an external gear is used, the gear factor can be set with FCT. Tab. 5/2: Assigning parameters to the axis 3. Press SAVE <Enter> to save your axis type setting. Note After changing the axis type it is essential to perform a reset in order to adapt internal controller settings. After changing the axis type/size, switch the power supply off and back on again (Power off/on). 5-9

108 5. Commissioning Setting the homing parameters Information on homing to a reference switch Note Damage to components. The slide may only move directly against a fixed stop if the maximum permitted impact energy is not exceeded (impact energy = 0.5 x mass x speed 2 ). The permitted value can be found in the description for your positioning axis. If necessary, reduce the speed at which movement to the stop is made. The speed can amount to 0 % to 50 % of the rated speed. When referencing to a stop, set the offset of the axis zero point 0 (see chapter 5.2.4). Protect sensitive stops by limiting the motor current. The positioning axis DMES-... can conduct a homing run with the preset current limitation (150 %). The current limitation need not be modified. Current limitation When the max. motor current is reached and the motor is stationary, the MTR-DCI will detect a stop. The maximum motor current during homing can be specified as % of the rated motor current (see FCT help or CI object h ). Note If the drive is arranged vertically, an increase in the motor current may be necessary. If the motor current is too low, homing cannot be carried out or the unit may detect a stop incorrectly. The set required speed cannot be reached if current limitation is too great. 5-10

109 5. Commissioning Current limitation 1) % Z 1 x nominal motor current Motor current Motor torque A mnm % (default) Z 1.5 x nominal motor current Motor current Motor torque A mnm % Z 2 x nominal motor current Motor current Motor torque A mnm ) ) ) Parameter specification in FCT: relative motor current in % of nominal current. Setting range %. 2) Due to maximum current limiting the value does not rise further. Tab. 5/3: Current limitation } Settings Homing parameter Homing method Velocity v_sw Velocity v_s0 SAVE Setting parameters 1. Select the homing parameters in the [Settings][Homing parameter] menu (see Tab. 5/5). 2. Accept each setting with OK <Enter>. The setting will then take effect in the drive. 3. Save the parameter settings with the [SAVE] menu command. 5-11

110 5. Commissioning Factory settings Speeds v_sw, v_s0 % 1) inc/s ~41 % ~22 % ~17 % ~15 % Rated motor speed rot/s inc/s Homing method Reference switch, negative (near motor) 1) % of the nominal motor speed; max. = 50 % Tab. 5/4: Factory pre-setting for homing parameters [Hom. paramet.] Param. Description [Homing method] 1) sw.neg (switch negative) sw.pos (switch positive) bl.neg (block negative) bl.pos (block positive) Homing to reference switch, positive, negative Homing to reference switch, positive Homing to fixed stop, negative Homing to fixed stop, positive [Velocity v_sw] v_sw Speed for searching for the homing point [Velocityv_s0] v_s0 Speed for moving to the axis zero point [SAVE...] Save parameters in EEPROM 1) Further information on homing methods is provided in chapter Tab. 5/5: Homing parameters 5-12

111 5. Commissioning Caution When the homing method is changed the axis zero offset is reset to zero. Any existing settings of the software end positions and target positions in the positioning set table are retained. Note that these values move together with the axis zero point AZ. After changing the homing method always perform a homing run. Then teach-in the axis zero offset. If the axis zero point is modified: Teach-in the new software end positions and target positions Starting homing Note Note that at the start the drive must be in front of the stop or reference switch in terms of the search direction (see chapter 1.6.3). 1. If necessary, position the drive in Teach mode so that, when viewed in terms of the search direction, it is in front of the stop or reference switch at the start. Select e.g. [Settings] [Position set] [Position] (see also section 5.2.5). Move the drive to the desired position manually with the arrow buttons. End the procedure with ESC <Menu> so that the position is not included in the position set table. } Positioning Demo posit tab Move posit set Homing 2. Select [Positioning] [Homing]. 3. Start homing with START <Enter>. 5-13

112 5. Commissioning After a successful homing the drive stops at the axis zero point AZ. With first commissioning or when the homing method is changed, the offset of the axis zero point = 0; after homing the drive then stands at the homing point REF. Discontinuing homing If necessary, homing can be discontinued with the <Menu> button (EMERG STOP). If correct homing has already been carried out, the previous homing point will retain its validity. Error in the homing run If the axis does not find a reference switch during homing, it keeps moving until it encounters a stop. Then it comes to rest at the stop and HOMING ERROR is displayed. Homing must be repeated after resetting the error message: Reasons for this may be: Axis already positioned behind reference switch at start of homing, Reference switch defective, Axis defective or incorrectly mounted, e.g. clutch attachment slipping. 5-14

113 5. Commissioning If a fault occurs during homing: Acknowledge the error message with <Enter>. If necessary, check the function of the reference switch. Check the settings of the parameters. If necessary, position the drive in Teach mode so that, when viewed in terms of the search direction, it is in front of the stop or reference switch at the start. Repeat the homing run Teaching the axis zero point AZ and the software end positions Caution Damage to components. Movement to the mechanical end positions is not permitted during operation. During movement to the end positions with a high load, the mechanical axis components (e.g. the lead screw) can block in the end positions. Set the offset of the axis zero point 0, e.g mm when referencing to a negative fixed stop or mm when referencing to a positive fixed stop. Limit the positioning range by defining valid software end positions during commissioning (see section 1.6). Specify target positions within the permitted positioning range only. 5-15

114 5. Commissioning Teach the axis zero point AZ: } Settings Axis parameter Zero point Abs.min.pos Abs.max.pos SAVE 1. Select [Settings] [Axis parameter] [Zero point]. 2. Move the drive to the desired axis zero point manually with the arrow buttons. 3. Accept the position reached with OK <Enter>. The setting will then take effect in the drive. The current position x a becomes the axis zero point (x a =0). Note If the axis zero point is modified: Check existing settings of the software end positions and (if applicable) the project zero point and the target positions in the position set table. Note that these values move together with the axis zero point AZ. Teach the software end positions, project zero point and the target positions again if needed. Teach the software end positions: 1. Select [Settings] [Axis parameter] [Abs.min.pos] or [Abs.max.pos]. 2. Move the drive with the arrow keys. 3. Accept the position reached with OK <Enter>. The setting will then take effect in the drive. 4. Choose [SAVE] to save the parameter settings. Only then will the settings be retained even if the power supply is switched off or if there is a power failure. 5-16

115 5. Commissioning Teaching position set records Enter the position set records as follows: } Settings Position set Position nr Pos set mode Position Velocity SAVE 1. Activate the desired position record (1...31) with [Settings] [Position set] [Position nr]. 2. Select the positioning mode of the position set: Select [Pos set mode]. Set the positioning mode with the arrow keys: absolute= absolute position specification, in relation to the project zero point relative = relative position specification, in relation to the current position. Accept the value with OK <Enter>. 3. Teach the target position of the position record: Select [Position]. Move the drive manually to the desired target position with the arrow keys. Accept the position reached with OK <Enter>. The setting of the target position and the positioning mode will then take effect in the drive. 4. Set the speed: Select [Velocity]. Set the nominal speed with the arrow keys. Accept the setting with OK <Enter>. The setting will then take effect in the drive. Position records with speed v = 0 or invalid target positions (-> error TARGET POSITION OUT OF LIMIT) cannot be executed. 5-17

116 5. Commissioning 5. Select [SAVE] to save the positioning set. Only then will the settings be retained even if the power supply is switched off or if there is a power failure. 6. Enter the next position record. Digitalisation errors of the analogue-digital converter can accumulate in the case of relative position movements which occur frequently one after the other, leading to deviations of the position values. If necessary, insert an absolute position set or a homing run into the positioning cycle, in order to correct deviations Test run Warning Injury to persons and damage to property With all positioning procedures, the motor turns and the connected axis moves. Make sure that: Nobody can place their hands into the positioning range, There are no objects within the positioning range. Caution Damage to components The unit must not move onto mechanical end positions (stops) during operation. When the unit moves to the end positions with a heavy load, blockage may occur in the end positions Limit the positioning range by defining valid software end positions during commissioning (see section 5.2.4). 5-18

117 5. Commissioning 1. Enter several position set records: Set target positions at the limits of the positioning range in order to check the software end positions. Set different speeds. } Positioning Demo posit tab Move posit set Homing 2. Select [Positioning] [Move posit. set] in order to execute a certain position set record or 3. Select [Positioning] [Demo posit tab] in order to process all position set records. At least two position set records must be entered in the position set table in order to use this function. In the [Demo posit tab] positioning cycle, all position set records in the position set table will be executed one after the other. If the position set table contains a position set with speed v = 0, neither this position set record nor the following records will be executed; the positioning cycle will continue from the first position set record. 4. Start the test run. Note With EMERG.STOP <Menu> you can interrupt the current positioning procedure. With DEMO STOP <Enter> you can interrupt the positioning cycle [Demo posit tab]. The current position set will be executed before the drive stops. Check the positioning behaviour. Check the position details displayed. 5. If necessary, optimise the settings for position sets, and also (if needed) for the points of reference and the working range. 5-19

118 5. Commissioning Setting bus parameters Before commissioning on DeviceNet, valid bus parameters must be set. Station number (MAC-ID) Valid station numbers: The invalid station number 255 is preset (control panel display:???). This is to make sure that a correct address is set during commissioning or when replacing. Recommendation: Assign the station numbers in ascending order. Adapt the station numbering to the machinery infrastructure of your plant. Note Station numbers can only be assigned once per Fieldbus line. Set the station numbers as follows: } Settings Bus parameter MAC ID EDIT -- Baud rate 500 kbd ESC Menu OK Enter 1. Select [Settings] [Bus parameter] [MAC ID] (see also section 4.5). 2. Press <Enter> to display the current setting. 3. Use the arrow keys to set the desired bit rate. 4. Accept the setting with OK Enter. The set bit rate is saved permanently and protected against network failure. Note The set bit rate will not take effect until after a power off/ on process! 5-20

119 5. Commissioning Bitrate(bitrate) Possible bit rates: 500 kbit, 250 kbit, 125 kbit An invalid bit rate is preset (display on the control panel:??? ). This ensures that a correct bit rate must be set during commissioning or replacement. Note All of the participants on a fieldbus line must use the same bit rate. Otherwise no communication will be possible. Set the bit rate as follows: } Settings Bus parameter Baudrate EDIT <--> Baudrate 500 kbd ESC <Menu> OK <Enter> 1. Choose [Settings] [Bus parameter] [Baudrate] (see also section 4.5). 2. Press <Enter> to display the current setting. 3. Use the arrow keys to set the desired baud rate. 4. Accept the setting with OK <Enter>. The defined baud rate is permanently saved. Note The defined baud rate only takes effect after a power off/on cycle! 5-21

120 5. Commissioning I/O data length Possibledatalengths: 8 bytes (for sequence control as per the FHPP standard) 16 bytes (8 bytes for sequence control as per the FHPP standard + an additional 8 bytes for parameterising via FHPP FPC) The default setting is an invalid data length (displayed on the control panel as??? ) This ensures that the correct data length has to be entered during commissioning or when replacing the unit. Set the data length as follows: } Settings Bus parameter I/O Datalength EDIT <--> I/O Datalength 8 Byte I/O Data ESC <Menu> OK <Enter> 1. Select [Settings] [Bus parameter] [I/O Datalength] (see also section 4.5). 2. Press <Enter> to display the current setting. 3. Set the desired length with the arrow buttons. The setting must agree with the configuration of the DeviceNet master (see chapter 5.4.2). 4. Accept the setting with OK <Enter>. The set data length becomes effective immediately and is saved against power failure. 5-22

121 5. Commissioning 5.3 Commissioning with FCT The Festo Configuration Tool (FCT) is the software platform for configuring and commissioning different components and devices from Festo. The FCT consists of the following components: A framework as program start and entry point with uniform project and data management for all supported typesofdevices, A plug-in for the special demands of each device type (e.g. MTR-DCI) with the necessary descriptions and dialogues. The plug-ins are managed and started from the framework. The MTR-DCI plug-in for the Festo Configuration Tool supports all the steps necessary to commission an MTR-DCI. With the MTR-DCI plug-in for the Festo Configuration Tool the necessary parameter settings can be performed offline - that is, without connecting the MTR-DCI to the PC. This enables the actual commissioning procedure to be prepared in advance, such as in the design office when planning a plant setup Installing the FCT The FCT is installed on your PC with an installation program. The MTR-DCI plug-in is installed on your PC together with the FCT's installation program. Note Administrator rights are required for installing the FCT. 5-23

122 5. Commissioning Note As of version V2.1.0, the plug-in MTR-DCI supports the following motor units: MTR-DCI-...-DN: firmware version V1.00 and higher Check with later versions of the MTR-DCI to ascertain whether an updated plug-in is provided. If necessary consult Festo. 1. Close all programs. 2. Place the Festo Configuration Tool CD in your CD ROM drive. If Auto Run is activated on your system, the installation will start automatically and you can omit steps 3 and Select [Run] in the Start menu. 4. Enter D:\setup (if necessary replace D by the letter of your CD ROM drive). 5. Follow the instructions on the screen Procedure Starting the FCT 1. Connect the MTR-DCI to your PC via the RS232 port. Follow the instructions in section Start the FCT: Double-click the FCT icon on the desktop or Select the entry [Festo Software] [Festo Configuration Tool] in the Windows [Start] menu. 3. Create a project in the FCT or open an existing project. Add a device to the project with the MTR-DCI plug-in. 5-24

123 5. Commissioning 4. Create the device connection (online connection) between the PC and the MTR-DCI via the FCT tool bar. You may need to synchronise the device names. Device control In order that the FCT can control the connected MTR-DCI, the control interface of the MTR-DCI must be deactivated and control enable must be set for the FCT (FCT/HMI = On). The actual status of the ENABLE control bit then has no effect. Access the Project output window, Operate tab, then under Device control activate first the box FCT/HMI and then the box Enable. The control interface of the MTR-DCI will then be deactivated and control will be enabled for the FCT. Access to the MTR-DCI by means of the Festo Configuration Tool can be blocked via the DeviceNet interface (see section 5.5.2, FHPP control bit CCON.B5, CiA 402 control word bit14). In this case the boxes FCT control and Enable are blocked (inactive) Further information on FCT Further information is provided in the Festo Configuration Tool help: FCT Help via the menu command [Help] [General FCT contents] e.g. for working with projects and on including a device in a project, for defining the dimensional reference system (homing and reference coordinates), on setting the Fieldbus address. 5-25

124 5. Commissioning Plug-in help With the menu command [Help] [Contents of installed plugins] [Festo (manufacturer name)] [MTR-DCI (Plug-In-Name)], e.g.: For describing the dialogues of the Device MTR-DCI, For describing the work steps for commissioning, For the basic functions: Device connection, Device names and Device control, and for password protection. Printed information In order to use the complete Help or parts of it without a PC, you can use one of the following options: With the button Print in the Help window, print individual Help pages or all the pages of a book directly from the Help index. Print a prepared printed version of the Help in Adobe PDF format or Rich Text Format (RTF): Printed version Directory File FCT help...(fct installation directory)\help\ FCT_de.pdf FCT_de.rtf Plug-in help (MTR-DCI)...(FCT installation directory)\hardwarefamilies\ Festo\MTR-DCI\V...\Help\ MTR-DCI_de.pdf MTR-DCI_de.rtf To print in Adobe PDF format, you will require Adobe Reader. 5-26

125 5. Commissioning 5.4 Commissioning a DeviceNet master The following sections describe the configuration and addressing of the MTR-DCI on a DeviceNet interface or a DeviceNet master. In order to understand this section you should be familiar with DeviceNet and know the specification Overview of commissioning on the Fieldbus The following steps are required for commissioning the MTR-DCI as a Fieldbus station: 1. Configure the MTR-DCI: on the control panel (MTR-DCI-...-H2 only, see section 5.2.7), or with the Festo Configuration Tool (see Festo Configuration Tool Help). Settings MAC-ID Bit rate I/O datalength Description Permissible participant address (station number) Permissible bit rates: 500, 250, 125 kbit/s I/O data length 8 bytes (FHPP standard) 16 bytes (FHPP standard + FHPP-FPC) Tab. 5/6: Fieldbus-specific parameters of the MTR-DCI 2. Configure master (see section 5.4.2): Install EDS file, or manually configure. 3. Test the Fieldbus connection in online mode. 5-27

126 5. Commissioning Configuration of the DeviceNet master ( I/O configuration ) Configuration with EDS file EDS files are provided for configuration of the master. These files are installed using the configuration software of the master. For the detailed procedure refer to the manuals for the configuration software used. Sources: The accompanying CD contains EDS files for the MTR-DCI in the DeviceNet folder. You will also find the latest EDS files on the Festo website at: EDS file: For the MTR-DCI you will need one of the following EDS files (in English): MTR-DCI-aa-DN-bb1_0.eds aa: Sizes 32, 42, 52, 62 bb: I/O data length (bytes) 08, 16 Graphic file: MTR-DCI.ico. The configuration of the DeviceNet master must agree with the parameterisation of the device, otherwise no connection for cyclic data exchange is possible. If necessary, the I/O data length can be manually configured in the software for the master. Manual configuration Vendor Code 26 (=1Ah) Product Type 12 (=0Ch) Product Code 90x0(decimal) x: size (1st character) 3, 4, 5, 6 You can also find the appropriate device information under [Device] in the EDS file. 5-28

127 5. Commissioning Allen-Bradley Omron Supporting Auto Device Replacement (ADR) from Allen- Bradley. The master controllers from Rockwell Automation offer a special function, which supports automatic parameter setting of slave participants when a device is swapped for servicing. All writable parameters addressed in the EDS file are uploaded by the master after commissioning and stored in the controller scanner. When the network is started, Explicit Messaging is used to automatically download the parameter values into the slave(s). This allows plant devices to be swapped without an FCT project. Supporting the Auto-config mode of Omron controllers. With Omron controllers, the DeviceNet participants are configured using an Auto-config mode. Configuration of nominal values using the DeviceNet configuration software is not required. The current network configuration automatically becomes the nominal configuration. The scanner also independently performs an I/O mapping. 5-29

128 5. Commissioning 5.5 Festo profile for handling and positioning (FHPP) Supported operating modes The operating modes differ in the contents and meaning of the cyclical I/O data and in the functions which can be accessed in the MTR-DCI. Operating mode Record selection (default) Direct Task Description 31 position set records canbe saved in the MTR-DCI. A record contains all the parameters which are specified for a positioning task. The record number is transferred to the cyclical I/O data (FHPP standard) as a nominal or actual value. The positioning task is transferred directly in the I/O telegram (FHPP standard). The key nominal values (position, speed, force/torque) are transmitted with it. Supplementary parameters are defined via the parameterisation (FHPP FPC). Tab. 5/7: Overview of operation modes The mode is switched by the control byte CCON (see below) and the mode status is indicated in the status byte SCON. Definition by means of parameterisation is not possible. Switching between modes is only permissible in the drive disabled or drive enabled state. Positioning drive Record selection The MTR-DCI has 31 records ( ) containing all the information necessary for a positioning task (+ set 0 = homing). The record number which the MTR-DCI is to execute at the next startup is transferred in the output data of the master. Its input data contains the last executed record number. The positioning task itself does not need to be still active. 5-30

129 5. Commissioning The MTR-DCI cannot work in a stand-alone manner, i. e. it does not support any user program of its own. Records cannot be processed automatically using programmable logic. The drive cannot accomplish any practical tasks in stand-alone mode; close coupling to the PLC is always necessary. There are also three records with special functions (which cannot be executed in record selection mode): Record 32 contains the parameters for jog mode. Record 33 contains the parameters for direct mode. Record 34 is the direct record for the FCT software. Direct task In direct task mode positioning tasks are formulated directly in the master's output data. Positioning mode Force mode A typical application dynamically calculates the nominal target values for each task, or just for some tasks. Adaptation to different workpiece sizes is therefore possible. In this case, it is not practical to assign parameters to the record list every time. The positioning data are managed completely in the PLC and sent directly to the MTR-DCI. Here also, close coupling between the PLC and the MTR-DCI is necessary. Alternatively, nominal values can be specified in Direct mode relative to the nominal motor current. This gives a torque and, in the case of linear drives, a force (= force control). 5-31

130 5. Commissioning Structure of the cyclic I/O data (FHPP standard) The FHPP protocol stipulates 8 bytes of input data and 8 bytes of output data. Further 8 byte I/O according to FHPP-FPC In the cyclic data a further 8 bytes of input data and 8 bytes of output data are permissible for transmitting parameters according to the FPC protocol (Festo Parameter Channel). A description of the I/O data and the parameters is provided in section 5.7. Data Byte 1 Byte 2 Byte 3 Byte 4 Byte 5 Byte 6 Byte 7 Byte 8 Odata Idata Bytes 1 and 2 (fix) are retained in every operating mode and transfer control and status bytes (e.g. CCon, SCON...) for enabling the MTR- DCI and setting the operating modes Bytes 3 to 8 depend on the selected operating mode (direct task, record selection) and transfer further control and/or status bytes (e.g. CDir, SDir...), as well as nominal and actual values: Record number or nominal position in the output data Feedback of actual position and record number in the input data Additional mode-dependent nominal and actual values. I/O data: Record selection Data Byte 1 Byte 2 Byte 3 Byte 4 Byte 5 Byte 6 Byte 7 Byte 8 Odata CCON CPOS Record no. Reserved Reserved Idata SCON SPOS Record no. RSB Actual position I/O data: Direct Task Data Byte 1 Byte 2 Byte 3 Byte 4 Byte 5 Byte 6 Byte 7 Byte 8 Odata CCON CPOS CDIR Nominal value 1 (Velocity) Idata SCON SPOS SDIR Actual value 1 (position, force/ torque,...) Nominal value 2 (position, force/torque,...) Actual value 2 (Actual position) 5-32

131 5. Commissioning Allocation of the control bytes (overview) 1) CCON B7 OPM2 B6 OPM1 B5 LOCK B4 B3 RESET B2 BRAKE B1 STOP B0 ENABLE Operating mode selection MMI access Blocked Acknowledge fault Stop Enable drive CPOS B7 B6 CLEAR B5 TEACH B4 JOGN B3 JOGP B2 HOM B1 START B0 HALT CDIR (direct task only) 1) :Reserved Delete remaining position B7 FUNC B6 FAST Teach value B5 XLIM Deactivate stroke limit Jog negative B4 VLIM Jog positive B3 CONT Start homing B2 COM2 Start positioning task B1 COM1 Control mode (position, force/ torque,...) Halt B0 ABS Absolute/ Relative Allocation of the status bytes (overview) 1) SCON B7 OPM2 B6 OPM1 B5 LOCK B4 24VL B3 FAULT B2 WARN B1 OPEN B0 ENABLED Operating mode acknowledgement FCT/HMI device control Load voltage applied Fault Warning Operation enabled Drive enabled SPOS B7 REF B6 STILL B5 DEV B4 MOV B3 TEACH B2 MC B1 ACK B0 HALT Drive homed Following error Axis is moving Standstill monitoring Acknowledge teaching Motion complete Acknowledge start Halt SDIR (direct task only) B7 FUNC B6 FAST B5 XLIM Stroke limit reached B4 VLIM Speed limit reached B3 CONT B2 COM2 B1 COM1 Control mode feedback (position, force/ torque,...) B0 ABS Absolute/ Relative 1) :reserved. 5-33

132 5. Commissioning Description of the I/O data (record selection) Description of the O data: Record selection Byte Bit EN Description 1 B0... B7 CCON Control bytes, see chapter B0... B7 CPOS 3 B0... B7 Record number Pre-selection of record number for record selection (0...31) 4 B0... B7 Reserved (= 0) B0...B31 Reserved (= 0) Description of the I data: Record selection Byte Bit EN Description 1 B0... B7 SCON Status bytes, see chapter B0... B7 SPOS 3 B0... B7 Record number 4 B0... B7 Record status byte (RSB) Acknowledgement of record number for record selection (0...31) see SDIR for direct task, chapter B0... B31 Position,... Acknowledgement of position for record selection: Position in increments (32-bit number, Low byte first) 5-34

133 5. Commissioning Description of the I/O data (direct task) O data Direct task Byte Bit EN Description 1 B0... B7 CCON Control bytes, see chapter B0... B7 CPOS 3 B0... B7 CDIR 4 B0... B7 Velocity Nominal value 1: preselection of velocity in % of the maximum velocity B0...B31 Position Force,... Nominal value 2: preselection depending on the controller mode of operation (see control byte 3 CDIR) Positioning mode: position in increments Force mode: force/torque in % of the rated current O data Direct task Byte Bit EN Description 1 B0... B7 SCON Status bytes, see chapter B0... B7 SPOS 3 B0... B7 SDIR 4 B0... B7 Velocity Force/Torque Actual value 1: acknowledgement depending on the controller mode of operation (see control byte 3 CDIR) Positioning mode: preselection of speed in % of the maximum speed Force mode: force/torque in % of the rated current B0...B31 Position Actual value 2: acknowledgement of position in increments 5-35

134 5. Commissioning Description of the control bytes CCON, CPOS, CDIR CCON Control byte 1 (CCON) is used to control all states that must be available in all operating modes. The cooperation of the control bits can be found under the description of the drive functions in section 5.6. Control byte 1 (CCON) Bit EN Description B0 ENABLE B1 STOP Drive Enable Stop 1 = 1: Drive (controller) enabled = 0: Drive (controller) blocked = 1: Operation enabled. Any existing faults will be deleted. = 0: Stop 1 active (emergency ramp + cancel positioning task). The axis stops with maximum braking ramp; the positioning task is reset. B2 BRAKE Reserved :=0 B3 RESET Reset Error With a rising edge a fault is acknowledged (reset) and the fault value cleared. B4 Reserved :=0 B5 LOCK B6 OPM1 B7 OPM2 HMI access locked Select Operating Mode Controls access to the diagnostic interface of the drive. = 1: HMI and FCT may only observe the drive, the device control (HMI control) cannot be taken over by HMI and FCT. = 0: HMI or FCT may take control of the device (in order to modify parameters or to control inputs) = 00: Record selection = 01: Direct task = 10: Reserved = 11: Reserved 1) Switching between record selection and direct task is additionally permitted in the Ready state. 5-36

135 5. Commissioning CPOS Control byte 2 (CPOS) controls the positioning sequences as soon as the drive is enabled. Control byte 2 (CPOS) Record selection and direct task Bit EN Description B0 HALT B1 START B2 HOM B3 JOGP B4 JOGN B5 TEACH B6 CLEAR Halt Start Positioning Task Start Homing Jog positive Jog negative Teach actual value Clear remaining positioning path =1: Halt isnotactive. = 0: Halt activated (braking ramp + do not cancel positioning task). The axis stops with a defined braking ramp; the positioning task remains active (the remaining positioning can be deleted with B6). The current nominal values will be transferred and positioning started (record 0 = homing) by means of a rising edge. Homing with the defined parameters is started by means of a rising edge. The drive moves at the specified speed or rotational speed towards larger actual values, while the bit is set. The movement begins with the rising edge and ends with the falling edge. The drive moves at the pre-set speed (rotation) towards lower actual values; see bit 3. At a falling edge the current actual position is imported into the setpoint register of the current addressed positioning set; see section The Teach target is defined with PNU 520. Inthe Halt state a rising edge causes the positioning task to be cleared and a transition to the Ready state B7 Reserved :=0 5-37

136 5. Commissioning CDIR Control byte CDIR is a special control byte for operating mode Direct task. Control byte 3 (CDIR) Direct task only Bit EN Description B0 ABS Absolute/ Relative = 0: Nominal value is absolute = 1: Nominal value is relative to last nominal value B1 COM1 B2 COM2 B3 CONT B4 VLIM B5 XLIM B6 FAST B7 FUNC Control Mode = 00: Positioning operation (see also point 6) = 01: Force operation (see also point 7) = 10: Reserved = 11: Reserved Reserved :=0 Reserved :=0 Stroke (X-) limit not active Reserved :=0 Reserved :=0 Force control: = 0: Stroke monitoring active = 1: Stroke monitoring not active 5-38

137 5. Commissioning Description of the status bytes SCON, SPOS, SDIR (RSB) Status byte 1 (SCON) Bit EN Description B0 ENABLED Drive enabled = 0: Drive blocked, controller not active = 1: Drive (controller) enabled B1 OPEN B2 WARN B3 FAULT B4 24VL B5 LOCK B6 OPM1 B7 OPM2 Operation enabled Warning Fault Supply Voltage is Applied Drive Control by FCT/MMI Display operating mode =0: Stopactive = 1: Operation enabled, positioning possible = 0: Warning not present = 1: Warning present =0: Nofault = 1: Fault present / fault response active. Fault code in fault buffer = 0: No load voltage = 1: Load voltage applied = 0: Device control by PLC/Fieldbus = 1: Device control by FCT/HMI (PLC control is locked) = 00: Record selection (Standard) = 01: Direct task = 10: Reserved = 11: Reserved 5-39

138 5. Commissioning Status byte 2 (SPOS) Bit EN Description B0 HALT B1 ACK B2 MC B3 TEACH B4 MOV B5 DEV B6 STILL B7 REF Halt Acknowledge start Motion Complete Acknowledge Teaching Axis is moving Drag Error Standstill control Axis is referenced =0: Haltisactive = 1: Halt is not active, axis can be moved = 0: Ready for start (homing, jog) = 1: Start carried out (homing, jog) = 0: Positioning task active = 1: Positioning task completed, possibly with fault Note: MC is first set after switching on (status Drive blocked ). = 0: Ready for teaching = 1: Teaching carried out, actual value transferred = 0: Speed of the axis < limit value = 1: Speed of the axis >= limit value = 0: No following error = 1: Following error active = 0: After MC, axis remains in tolerance window = 1: After MC, axis is outside tolerance window = 0: Homing must be carried out = 1: Home information exist, homing does not need to be carried out 5-40

139 5. Commissioning Status byte 3 (SDIR) Direct task Bit EN Description B0 ABS B1 COM1 B2 COM2 Absolute/ Relative COntrol Mode feed back = 0: Nominal value is absolute = 1: Nominal value is relative to last nominal value = 00: Positioning mode = 01: Force mode = 10: Reserved = 11: Reserved B3 CONT Reserved B4 VLIM B5 XLIM Speed (V-) LIMit reached Stroke (X-) LIMit reached Force mode: = 1: Speed limit reached = 0: Speed limit not reached Force mode: = 1: Stroke limit value reached = 0: Stroke limit value not reached B6 FAST B7 FUNC Reserved Reserved 5-41

140 5. Commissioning Examples of I/O data The following pages provide typical examples of the I/O data according to the FHPP standard: 1. Record selection: establish ready to operate status 2. Direct task: establish ready to operate status 3. Fault handling 4. Homing 5. Record selection: Positioning mode 6. Direct task: Positioning mode 7. Direct task: Force mode A description of the MTR-DCI's finite state machine can be found in section 5.8. Ensuring device control Step/ Description 0.1 HMI device control = on Odata Idata Byte B7 B6 B5 B4 B3 B2 B1 B0 Byte B7 B6 B5 B4 B3 B2 B1 B0 Byte 1 OPM2 OPM1 LOCK RESET BRAKE STOP ENABL Byte 1 OPM2 OPM1 LOCK 24VL FAULT WARN OPEN ENABL CCON x 0 0 SCON Byte 2 CLEAR TEACH JOGN JOGP HOM START HALT Byte 2 REF STILL DEV MOV TEACH MC ACK HALT CPOS SPOS : 0 signal 1: 1 signal; x: not relevant (any); F: Edge positive Tab. 5/8: I/O data: Device control active Device control via the control panel or the Festo Configuration Tool has been activated. To control the MTR-DCI via the DeviceNet interface, device control by FCT/HMI must first be deactivated. 5-42

141 5. Commissioning 1. Record selection: establish ready to operate status 1.1 Basic status of the drive when the supply voltage is switched on. } Step 1.2 or Disable device control by FCT/HMI. Optionally, the takeover of device control by FCT/HMI canbeblockedwithccon.b5=1(lock). } Step Enable drive (record selection) } Homing: example 4, Tab. 5/12. Step/ Description 1.1 Basic status (HMI device control = off) 1.2 Disable device control by FCT/HMI Odata Idata Byte B7 B6 B5 B4 B3 B2 B1 B0 Byte B7 B6 B5 B4 B3 B2 B1 B0 Byte 1 OPM2 OPM1 LOCK RESET BRAKE STOP ENABL Byte 1 OPM2 OPM1 LOCK 24VL FAULT WARN OPEN ENABL CCON x 0 0 SCON Byte 2 CLEAR TEACH JOGN JOGP HOM START HALT Byte 2 REF STILL DEV MOV TEACH MC ACK HALT CPOS SPOS Byte 1 OPM2 OPM1 LOCK RESET BRAKE STOP ENABL Byte 1 OPM2 OPM1 LOCK 24VL FAULT WARN OPEN ENABL CCON x x 1 0 x x x x SCON x x 0 x x x x x Byte 2 CLEAR TEACH JOGN JOGP HOM START HALT Byte 2 REF STILL DEV MOV TEACH MC ACK HALT CPOS 0 x x x x x x x SPOS x x x x x x x x 1.3 Enable drive, enable operation Byte 1 OPM2 OPM1 LOCK RESET BRAKE STOP ENABL Byte 1 OPM2 OPM1 LOCK 24VL FAULT WARN OPEN ENABL CCON 0 0 x 0 0 x 1 1 SCON (Record Select) CPOS SPOS : 0 signal 1: 1 signal; x: not relevant (any); F: Edge positive Byte 2 CLEAR TEACH JOGN JOGP HOM START HALT Byte 2 REF STILL DEV MOV TEACH MC ACK HALT Tab. 5/9: I/O data Record selection: establish ready to operate status If there are faults after switching on or after setting CCON.B0 (ENABLE): } Fault handling: see example 3, Tab. 5/

142 5. Commissioning 2. Direct task: establish ready to operate status 2.1 Basic status of the drive when the supply voltage is switched on. } Step 2.2 or Disable device control by FCT/HMI. Optionally, the takeover of device control by FCT/HMI canbeblockedwithccon.b5=1(lock). } Step Enable drive. (Direct Task) } Homing: example 4, Tab. 5/12. Step/ Description 2.1 Basic status (HMI device control = off) 2.2 Disable device control by FCT/HMI Odata Idata Byte B7 B6 B5 B4 B3 B2 B1 B0 Byte B7 B6 B5 B4 B3 B2 B1 B0 Byte 1 OPM2 OPM1 LOCK RESET BRAKE STOP ENABL Byte 1 OPM2 OPM1 LOCK 24VL FAULT WARN OPEN ENABL CCON x 0 0 SCON Byte 2 CLEAR TEACH JOGN JOGP HOM START HALT Byte 2 REF STILL DEV MOV TEACH MC ACK HALT CPOS SPOS Byte 1 OPM2 OPM1 LOCK RESET BRAKE STOP ENABL Byte 1 OPM2 OPM1 LOCK 24VL FAULT WARN OPEN ENABL CCON x x 1 0 x x x x SCON x x 0 x x x x x Byte 2 CLEAR TEACH JOGN JOGP HOM START HALT Byte 2 REF STILL DEV MOV TEACH MC ACK HALT CPOS 0 x x x x x x x SPOS x x x x x x x x 2.3 Enable drive, enable operation Byte 1 OPM2 OPM1 LOCK RESET BRAKE STOP ENABL Byte 1 OPM2 OPM1 LOCK 24VL FAULT WARN OPEN ENABL CCON 0 1 x 0 0 x 1 1 SCON (Direct Task) CPOS SPOS : 0 signal 1: 1 signal; x: not relevant (any); F: Edge positive Byte 2 CLEAR TEACH JOGN JOGP HOM START HALT Byte 2 REF STILL DEV MOV TEACH MC ACK HALT Tab. 5/10: Control and status bytes for Establish 'ready to operate' status Direct task If there are faults after switching on or after setting CCON.B0 (ENABLE): } Fault handling: see example 3, Tab. 5/

143 5. Commissioning 3. Fault handling For description of faults and warnings, see section A fault is shown with SCON.B3 (FAULT). } Positioning can no longer be undertaken. 3.2 A warning is shown with SCON.B2 (WARN). } Positioning is still possible. 3.3 Reset fault with positive edge on CCON.B3 (RESET). } Fault bit SCON.B3 (FAULT) or SCON.B2 (WARN) is reset. } SPOS.B2 (MC) is set } Drive is ready for operation 3.4 Reset fault with negative edge on CCON.B0 (ENABLE). } Fault bit SCON.B3 (FAULT) or SCON.B2 (WARN) is reset. } SPOS.B2 (MC) is set } Establish ready to operate status again (see examples 1, Tab. 5/9 and 2, Tab. 5/10) 5-45

144 5. Commissioning Step/ Description Odata Idata Byte B7 B6 B5 B4 B3 B2 B1 B0 Byte B7 B6 B5 B4 B3 B2 B1 B0 Byte 1 OPM2 OPM1 LOCK RESET BRAKE STOP ENABL Byte 1 OPM2 OPM1 LOCK 24VL FAULT WARN OPEN ENABL 3.1 Fault CCON x x x 0 x x x x SCON x x x x 1 x x x Byte 2 CLEAR TEACH JOGN JOGP HOM START HALT Byte 2 REF STILL DEV MOV TEACH MC ACK HALT CPOS 0 x x x x x x x SPOS x x x x x 0 x x Byte 1 OPM2 OPM1 LOCK RESET BRAKE STOP ENABL Byte 1 OPM2 OPM1 LOCK 24VL FAULT WARN OPEN ENABL 3.2 Warning CCON x x x 0 x x x x SCON x x x x x 1 x x Byte 2 CLEAR TEACH JOGN JOGP HOM START HALT Byte 2 REF STILL DEV MOV TEACH MC ACK HALT CPOS 0 x x x x x x x SPOS x x x x x 0 x x 3.3 Reset fault with CCON.B3 (RESET) 3.4 Reset fault with CCON.B0 (ENABLE) Byte 1 OPM2 OPM1 LOCK RESET BRAKE STOP ENABL Byte 1 OPM2 OPM1 LOCK 24VL FAULT WARN OPEN ENABL CCON 0 x x 0 F x x 1 SCON 0 x Byte 2 CLEAR TEACH JOGN JOGP HOM START HALT Byte 2 REF STILL DEV MOV TEACH MC ACK HALT CPOS x x SPOS x Byte 1 OPM2 OPM1 LOCK RESET BRAKE STOP ENABL Byte 1 OPM2 OPM1 LOCK 24VL FAULT WARN OPEN ENABL CCON 0 x x 0 0 x x N SCON 0 x x 0 Byte 2 CLEAR TEACH JOGN JOGP HOM START HALT Byte 2 REF STILL DEV MOV TEACH MC ACK HALT CPOS x x SPOS x x x 0: 0 signal 1: 1 signal; x: not relevant (any); F: Edge positive Tab. 5/11: I/O data Fault handling 5-46

145 5. Commissioning 4. Homing (requires status 1.4 or 1.5) 4.1 A positive edge at CPOS.B2 (HOM, Start homing) starts the homing run. The start is confirmed with SPOS.B1 (Acknowledge start) as long as CPOS.B2 (HOM) is set. 4.2 Movement of the axis is shown with SPOS.B4 (MOV, Axis is moving). 4.3 After successful homing, SPOS.B2 (MC, Motion Complete) and SPOS.B7 (REF) are set. Step/ Description Odata Idata Byte B7 B6 B5 B4 B3 B2 B1 B0 Byte B7 B6 B5 B4 B3 B2 B1 B0 Byte 1 OPM2 OPM1 LOCK RESET BRAKE STOP ENABL Byte 1 OPM2 OPM1 LOCK 24VL FAULT WARN OPEN ENABL 4.1 Start homing CCON 0 x x 0 0 x 1 1 SCON 0 x Byte 2 CLEAR TEACH JOGN JOGP HOM START HALT Byte 2 REF STILL DEV MOV TEACH MC ACK HALT CPOS F 0 1 SPOS Homing is in progress Byte 1 OPM2 OPM1 LOCK RESET BRAKE STOP ENABL Byte 1 OPM2 OPM1 LOCK 24VL FAULT WARN OPEN ENABL CCON 0 x x 0 0 x 1 1 SCON 0 x Byte 2 CLEAR TEACH JOGN JOGP HOM START HALT Byte 2 REF STILL DEV MOV TEACH MC ACK HALT CPOS SPOS Homing concluded Byte 1 OPM2 OPM1 LOCK RESET BRAKE STOP ENABL Byte 1 OPM2 OPM1 LOCK 24VL FAULT WARN OPEN ENABL CCON 0 x x 0 0 x 1 1 SCON 0 x Byte 2 CLEAR TEACH JOGN JOGP HOM START HALT Byte 2 REF STILL DEV MOV TEACH MC ACK HALT CPOS SPOS : 0 signal 1: 1 signal; x: not relevant (any); F: Edge positive Tab. 5/12: I/O data Homing If there are faults during homing: } Fault handling: see example 3, Tab. 5/

146 5. Commissioning 5. Record selection: Positioning mode (requires status 1.3/2.3 and 4.) Once ready to operate is established and homing has been carried out, a positioning task can be started (sequence depends on steps ): 5.1 Preselect record number: Byte 3 of the output data 0 =Homingrun = Programmable position set records 5.2 With CPOS.B1 (START, Start task) the preselected positioning task is started. The start is confirmed with SPOS.B1 (Acknowledge start) as long as CPOS.B1 (START) is set. 5.3 Movement of the axis is shown with SPOS.B4 (MOV, Axis is moving). 5.4 On completion of the positioning task SPOS.B2 (MC, Motion Complete) is set. If there are faults during positioning: } Fault handling: see example 3, Tab. 5/

147 5. Commissioning Step/ Description 5.1 Preselect record number (Byte 3) Odata Idata Byte B7 B6 B5 B4 B3 B2 B1 B0 Byte B7 B6 B5 B4 B3 B2 B1 B0 Byte 3 Record number Byte 3 Record number Record no. Record no. (0...31) Record no. Previous record no. (0...31) 5.2 Start task Byte 1 OPM2 OPM1 LOCK RESET BRAKE STOP ENABL Byte 1 OPM2 OPM1 LOCK 24VL FAULT WARN OPEN ENABL CCON 0 0 x 0 0 x 1 1 SCON Byte 2 CLEAR TEACH JOGN JOGP HOM START HALT Byte 2 REF STILL DEV MOV TEACH MC ACK HALT CPOS F 1 SPOS Positioning task in progress Byte 1 OPM2 OPM1 LOCK RESET BRAKE STOP ENABL Byte 1 OPM2 OPM1 LOCK 24VL FAULT WARN OPEN ENABL CCON 0 0 x 0 0 x 1 1 SCON Byte 2 CLEAR TEACH JOGN JOGP HOM START HALT Byte 2 REF STILL DEV MOV TEACH MC ACK HALT CPOS SPOS Byte 3 Record number Byte 3 Record number Record no. Record no. (0...31) Record no. Current record no. (0...31) 5.4 Positioning task concluded Byte 1 OPM2 OPM1 LOCK RESET BRAKE STOP ENABL Byte 1 OPM2 OPM1 LOCK 24VL FAULT WARN OPEN ENABL CCON 0 0 x 0 0 x 1 1 SCON Byte 2 CLEAR TEACH JOGN JOGP HOM START HALT Byte 2 REF STILL DEV MOV TEACH MC ACK HALT CPOS SPOS Byte Reserved Byte Position Reserved Actual position Actual position (increments) 0: 0 signal 1: 1 signal; x: not relevant (any); F: Edge positive Tab. 5/13: I/O data Record selection: Positioning mode 5-49

148 5. Commissioning 6. Direct task: Positioning mode (requires status 1.3/2.3 and 4.) Once ready to operate is established and homing has been carried out, a nominal position must be preselected (sequence depends on steps ) 6.1 The nominal position is transferred in increments in bytes of the output word. The nominal speed is transferred in % in byte 3 (0 = no speed; 100 = max. speed). 6.2 With CPOS.B1 (START, Start positioning task) the preselected positioning task is started. The start is confirmed with SPOS.B1 (Acknowledge start) as long as CPOS.B1 (START) is set. 6.3 Movement of the axis is shown with SPOS.B4 (MOV, Axis is moving). 6.4 At the end of the positioning task, SPOS.B2 (MC, Motion Complete) is set. If there are faults during positioning: } Fault handling: see example 3, Tab. 5/

149 5. Commissioning Step/ Description 6.1 Preselect position and speed (bytes 4 and 5...8) Odata Idata Byte B7 B6 B5 B4 B3 B2 B1 B0 Byte B7 B6 B5 B4 B3 B2 B1 B0 Byte 4 Velocity Byte 4 Velocity Speed Speed preselection ( %) Speed Speed response message ( %) Byte Position Byte Position Nominal position Nominal position (increments), see section Actual position Actual position (increments), see section Byte 1 OPM2 OPM1 LOCK RESET BRAKE STOP ENABL Byte 1 OPM2 OPM1 LOCK 24VL FAULT WARN OPEN ENABL 6.2 Start task CCON 0 1 x 0 0 x 1 1 SCON Byte 2 CLEAR TEACH JOGN JOGP HOM START HALT Byte 2 REF STILL DEV MOV TEACH MC ACK HALT CPOS F 1 SPOS Byte 3 FUNC FAST XLIM VLIM CONT COM2 COM1 ABS Byte 3 FUNC FAST XLIM VLIM CONT COM2 COM1 ABS CDIR S SDIR S 6.3. Positioning task in progress Byte 1 OPM2 OPM1 LOCK RESET BRAKE STOP ENABL Byte 1 OPM2 OPM1 LOCK 24VL FAULT WARN OPEN ENABL CCON 0 1 x 0 0 x 1 1 SCON Byte 2 CLEAR TEACH JOGN JOGP HOM START HALT Byte 2 REF STILL DEV MOV TEACH MC ACK HALT CPOS SPOS Positioning task concluded Byte 1 OPM2 OPM1 LOCK RESET BRAKE STOP ENABL Byte 1 OPM2 OPM1 LOCK 24VL FAULT WARN OPEN ENABL CCON 0 1 x 0 0 x 1 1 SCON Byte 2 CLEAR TEACH JOGN JOGP HOM START HALT Byte 2 REF STILL DEV MOV TEACH MC ACK HALT CPOS SPOS : 0 signal 1: 1 signal; x: not relevant (any); F: Edge positive S: Positioning condition: 0= absolute; 1 = relative Tab. 5/14: I/O data Direct task: Positioning mode 5-51

150 5. Commissioning 7. Direct task: Force mode (requires status 1.3/2.3 and 4) Once ready to operate is established and homing has been carried out, a nominal value must be specified and the system must be prepared for operation in Force mode. 7.1 Specify the nominal value in % of nominal motor current. (Take account of friction influences of the connected axis). 7.2 Prepare Force mode: set bit CDIR.B1 COM1, and set bit CDIR.B5 XLIM depending on the desired level of stroke limitation. 7.3 Start the positioning task with CPOS.B1 START. The start is confirmed with SPOS.B1 (Acknowledge start) as long as CPOS.B1 (START) is set. 7.4 or 7.5 The corresponding status bits are set depending on whether or not the nominal value is reached. 7.6 The positioning task is ended automatically when the stroke limit or software end position is reached. The system switches back to position control. 7.7 The positioning task can be stopped from the controller, e. g. by means of STOP. Note In Force mode, the nominal value can only be changed after the last specification is reached (MC), by means of a new start pulse edge. 5-52

151 5. Commissioning Step/ Description 7.1 Specify nominal value Odata Idata Byte B7 B6 B5 B4 B3 B2 B1 B0 Byte B7 B6 B5 B4 B3 B2 B1 B0 4 Not relevant 4 Actual value in % of the nominal current Nominal value in % of the nominal current Actual positions in increments 7.2 Preparing for Force mode Byte 1 OPM2 OPM1 LOCK RESET BRAKE STOP ENABL Byte 1 OPM2 OPM1 LOCK 24VL FAULT WARN OPEN ENABL CCON 0 1 x x 0 x 1 1 SCON Byte 2 CLEAR TEACH JOGN JOGP HOM START HALT Byte 2 REF STILL DEV MOV TEACH MC ACK HALT CPOS x SPOS Byte 3 FUNC FAST XUM CONT COM2 COM1 ABS Byte 3 FUNC FAST XUM VUM CONT COM2 COM1 ABS CDIR 0 0 S x SDIR x Byte 1 OPM2 OPM1 LOCK RESET BRAKE STOP ENABL Byte 1 OPM2 OPM1 LOCK 24VL FAULT WARN OPEN ENABL 7.3 Start task CCON 0 1 x x 0 x 1 1 SCON Byte 2 CLEAR TEACH JOGN JOGP HOM START HALT Byte 2 REF STILL DEV MOV TEACH MC ACK HALT CPOS x F 1 SPOS Byte 3 FUNC FAST XUM CONT COM2 COM1 ABS Byte 3 FUNC FAST XUM VUM CONT COM2 COM1 ABS CDIR 0 0 S x SDIR Positioning task in progress (nominal value not reached) Byte 1 OPM2 OPM1 LOCK RESET BRAKE STOP ENABL Byte 1 OPM2 OPM1 LOCK 24VL FAULT WARN OPEN ENABL CCON 0 1 x x 0 x 1 1 SCON Byte 2 CLEAR TEACH JOGN JOGP HOM START HALT Byte 2 REF STILL DEV MOV TEACH MC ACK HALT CPOS x x 1 SPOS x 1 Byte 3 FUNC FAST XUM CONT COM2 COM1 ABS Byte 3 FUNC FAST XUM VUM CONT COM2 COM1 ABS CDIR 0 0 S x SDIR Positioning task in progress (nominal value reached) Byte 1 OPM2 OPM1 LOCK RESET BRAKE STOP ENABL Byte 1 OPM2 OPM1 LOCK 24VL FAULT WARN OPEN ENABL CCON 0 1 x x 0 x 1 1 SCON Byte 2 CLEAR TEACH JOGN JOGP HOM START HALT Byte 2 REF STILL DEV MOV TEACH MC ACK HALT CPOS x x 1 SPOS x 1 Byte 3 FUNC FAST XUM CONT COM2 COM1 ABS Byte 3 FUNC FAST XUM VUM CONT COM2 COM1 ABS CDIR 0 0 S x SDIR

152 5. Commissioning Step/ Description 7.6 Positioning task interrupted (stroke limit or software end position reached) Odata Idata Byte B7 B6 B5 B4 B3 B2 B1 B0 Byte B7 B6 B5 B4 B3 B2 B1 B0 Byte 1 OPM2 OPM1 LOCK RESET BRAKE STOP ENABL Byte 1 OPM2 OPM1 LOCK 24VL FAULT WARN OPEN ENABL CCON 0 1 x x 0 x 1 1 SCON Byte 2 CLEAR TEACH JOGN JOGP HOM START HALT Byte 2 REF STILL DEV MOV TEACH MC ACK HALT CPOS x x 1 SPOS x 1 Byte 3 FUNC FAST XUM CONT COM2 COM1 ABS Byte 3 FUNC FAST XUM VUM CONT COM2 COM1 ABS CDIR 0 0 S x SDIR End positioning task (e. g. with STOP) Byte 1 OPM2 OPM1 LOCK RESET BRAKE STOP ENABL Byte 1 OPM2 OPM1 LOCK 24VL FAULT WARN OPEN ENABL CCON 0 1 x x 0 x 0 1 SCON Byte 2 CLEAR TEACH JOGN JOGP HOM START HALT Byte 2 REF STILL DEV MOV TEACH MC ACK HALT CPOS x x 1 SPOS x 1 Byte 3 FUNC FAST XUM CONT COM2 COM1 ABS Byte 3 FUNC FAST XUM VUM CONT COM2 COM1 ABS CDIR 0 0 S x SDIR : 0 signal 1: 1 signal; x: not relevant (any); F: Edge positive S: Path limitation (stroke limit): 0 = stroke limit active, 1 = stroke limit not active Tab. 5/15: I/O data Direct task: Force mode If there are faults during Force mode: see example 3, table 5/13 Fault handling. 5-54

153 5. Commissioning 5.6 Sequence control according to the FHPP standard Homing Information on homing, reference coordinates, working area, and calculation rules for the reference system are provided in chapter 1.6 After switching on, homing must be carried out before a positioning task can be executed (see parameter Homing Required : FHPP PNU 1014 /CI 23F6h) The drive homes to a stop or a reference switch. An increase in the motor current with the drive shaft motionless indicates that a stop has been reached. Since the drive must not permanently rest at the stop, it must move a minimum of 0.25 mm back into the stroke range (axis zero point offset). Sequence: 1. Searching for the reference point in accordance with the configured method. 2. Moving from the reference point to the axis zero point (according to axis zero point offset AZ) 3. Setting at axis zero point: Current position = 0 project zero point offset PZ 5-55

154 5. Commissioning Overview of parameters involved (see also section B.2.15) Parameters involved Description FCT PNU CI Axis zero point offset x Ch Homing method x h Homing speeds x h Homing required F6h Maximum homing torque x F7h Start (FHPP) Feedback (FHPP) Requirement CPOS.B2 = positive edge: Start homing SPOS.B1 = positive edge: Acknowledge start SPOS.B7 = drive homed to reference point Device control by PLC/Fieldbus Controller must be in status Operation enabled No active command for jogging Tab. 5/16: Parameters involved in homing Homing methods 1) hex dec Description 17h 23 Search for reference switch in positive direction. 1Bh 27 Search for reference switch in negative direction. EFh -17 Search for negative stop. The point found is the reference position. As the axis must not stand still at the stop, the axis zero point offset must be 0. EEh -18 Search for positive stop. The point found is the reference position. As the axis must not stand still at the stop, the axis zero point offset must be 0. 1) For a detailed description of homing methods see section Tab. 5/17: Overview of homing methods 5-56

155 5. Commissioning Jog mode In the Operation enabled state the drive can be moved by left/right jogging. This function is usually used for Approaching teach positions. Moving the drive out of the way (e.g. after a plant malfunction). Manual positioning as normal mode (manual feed). Sequence 1. When one of the signals Jog left / Jog right is set, the drive starts to move slowly. Due to the slow speed, a position can be defined very accurately. 2. If the signal remains set for longer than the configured Phase 1 duration, the speed is increased until the configured maximum speed is reached. This enables large strokes to be covered rapidly. 3. If the signal changes to 0, the drive is braked with the pre-set maximum deceleration. 4. If the drive reaches a software end position, it will stop automatically. The software end position is not exceeded; the distance for stopping is accounted for according to the defined ramp. Here too, the system does not leave Jogging mode until Jogging =

156 5. Commissioning 1 Low speed phase 1 (slow travel) 2 Maximum speed for phase 2 3 Acceleration / deceleration Speed v (t) t[s] 4 Duration of phase 1 CPOS.B3 or CPOS.B4 (jogging positive/ negative) Fig. 5/2: Flow diagram for jogging mode Overview of parameters involved (see section B.2.9) Parameters involved Description FCT PNU CI Speed of phase 2 in (inc/s) x ED/21 Acceleration or deceleration (Inc/s 2 ) x EE/21 Duration of phase 1 in ms x E9/21 Start (FHPP) Feedback (FHPP) Requirement CPOS.B3 = positive edge: jogging positive (forwards) CPOS.B4 = positive edge: jogging negative (backwards) SPOS.B4 = 1: Drive is moving SPOS.B2 = 0: (Motion Complete) Device control by PLC/Fieldbus Controller must be in status Operation enabled Tab. 5/18: Parameters involved in jogging mode 5-58

157 5. Commissioning Teaching via Fieldbus Position values can be taught via the Fieldbus. Previously taught position values will then be overwritten. Sequence 1. The drive is brought to the desired position either by jog mode or manually. 2. The user must make sure that the desired parameter is selected. To do this, the Teach target parameter and, where appropriate, the correct record address must be written. Teach target (PNU 520) For teaching = 1 (default) Nominal position in the position set record. Record selection: Position set record after control byte 3 Direct task: Position set record after PNU=400 = 2 Axis zero point =3 Project zero point = 4 Lower software end position = 5 Upper software end position Tab. 5/19: Overview of teach targets 3. Teaching takes place via the handshake of the bits in the control and status bytes CPOS/SPOS: 5-59

158 5. Commissioning 1 Ready for teaching 2 Value transferred Teach value CPOS.B5 1 0 Reset SPOS.B Fig. 5/3: Handshake when teaching Note: The drive does not need to stop moving for teaching. However, a speed of 1 m/s means that the actual position changes by 1 mm every millisecond. With the usual cycle times of PLC + Fieldbus + motor controller, there will still be inaccuracies of several millimetres even at a speed of only 100 mm/s. Overview of parameters involved (see sections B.2.8 and B.2.9) Parameters involved Description FCT PNU CI Teach target 1) FEh Record number 1) h Start (FHPP) Acknowledgement (FHPP) Requirement CPOS.B5 = Falling edge: Teach value SPOS.B3 = 1: Value transferred Device control by PLC/Fieldbus Controller must be in status Operation enabled 1) Teaching is made possible in the Festo Configuration Tool by special functions. Tab. 5/20: Parameters involved in teaching 5-60

159 5. Commissioning Record selection (Positioning mode) A positioning task in record selection mode is described by a record of nominal values. In the operation enabled state, a record can be started via the record number. This function is usually used for: Moving to any position in the record list by the PLC Processing a positioning profile by linking records Known target positions that seldom change (change of formula). Sequence 1. Set the desired set number in the master's output data. Up till the start, the controller continues to respond with the number of the record last executed. 2. With a rising edge at START (CPOS.B1) the controller accepts the record number and starts the positioning task. 3. The controller signals with the rising edge on Acknowledge Start that the PLC output data have been accepted and that the positioning task is now active. The positioning command is executed regardless of whether Start (CPOS.B1) has been reset to zero or not. 4. When the record is concluded, MC (SPOS.B2) is set. 5-61

160 5. Commissioning Possible causes of faults: No homing performed. The target position and/or the preselect position cannot be reached. Invalid record number. Uninitialised record. 5-62

161 5. Commissioning Start/stop record Nominal record number in output data 1 0 N 1 N N+1 Stop CCON.B1 (STOP) 1 0 Start CPOS.B1 (START) Acknowledge Start SPOS.B1 (ACK) Motion Complete SPOS.B2 (MC) 1 0 Axis is moving SPOS.B4 (MOV) 1 0 Actual record number input data 1 0 N 1 N N+1 1 Precondition: Acknowledge Start = 0 2 Rising edge at Start results in application of the new record number N and setting of Acknowledge start 3 As soon as Acknowledge start is detected by the PLC, it can reset Start to 0 4 The controller responds with a falling edge at Acknowledge start 5 As soon as Acknowledge start is detected by the PLC, it can create the next record number 6 An ongoing positioning operation can be stopped with Stop Fig. 5/4: Flow diagram for start/stop record 5-63

162 5. Commissioning Stop record with Halt and continue Nominal record number in output data 1 0 N 1 N N+1 Halt CPOS.B0 (HALT) Start CPOS.B1 (START) Confirm Halt SPOS.B0 (HALT) 1 0 Acknowledge Start SPOS.B1 (ACK) 1 0 Motion Complete SPOS.B2 (MC) 1 0 Axis is moving SPOS.B4 (MC) 1 0 Actual record number input data 1 0 N 1 N 1 Record is stopped with Halt, actual record number N is retained, Motion Complete remains reset 2 Rising edge on Start starts record N again, Confirm Halt is set Fig. 5/5: Flow diagram for stop record with Hold and continue 5-64

163 5. Commissioning Nominal record number output data 1 0 Stop record with Hold and clear remaining positioning path N 1 N N+1 Halt CPOS.B0 (HALT) Start CPOS.B1 (START) 1 0 Delete remaining position CPOS.B6 (CLEAR) Confirm Halt SPOS.B0 (HALT) 1 0 Acknowledge Start SPOS.B1 (ACK) 1 0 Motion Complete SPOS.B2 (MC) 1 0 Axis is moving SPOS.B4 (MOV) 1 0 Actual record number input data 1 0 N 1 N 1 Stop record 2 Delete remaining position Fig. 5/6: Flow diagram for stop record with Halt and clear remaining positioning path N

164 5. Commissioning Parameters involved (Record structure) The entries in the position set table can be written via the Fieldbus (see Tab. 5/21). Each individual nominal value is addressed via a dedicated PNU. A record consists of the nominal values with the same subindex. The composition of the position set table as per FHPP is described in appendix B.2.8. Overview of parameters involved (see section B.2.8) Record structure Description FCT PNU CI Absolute/relative positioning x E0/01h Target position x E0/02h Speed x E0/03h Acceleration x E0/04h Start Feedback Requirements CPOS.B1 = positive edge: Start Jogging and homing have priority. SPOS.B2 = 0: Motion complete SPOS.B1 = positive edge: Acknowledge start SPOS.B4 = 1: Drive is moving Device control by PLC/Fieldbus. Controller must be in Operation enabled status. A valid record number is active Tab. 5/21: Parameters involved in record selection 5-66

165 5. Commissioning Direct task (Positioning mode, Force mode) In the operation enabled state (direct mode) a positioning task is formulated directly in the I/O data transmitted over the Fieldbus. The position nominal values for positioning or forcemodearestoredintheplc. A positioning profile based on sequencing of records can be implemented by means of external control by the master. Positioning mode The positioning mode is used in the following situations: Moving to any position within the effective stroke. The target positions are unknown during planning or change frequently (several different workpiece positions). Sequence 1. The user configures the desired nominal value (position) and the positioning condition (absolute/relative) in his/her output data. 2. With a rising edge on START (CPOS.B1), the controller accepts the nominal position and starts the positioning task. 3. After the start you must wait for MC before a new start can be made. 4. When the nominal position is reached, MC (SPOS.B2) is set. 5-67

166 5. Commissioning Starting the positioning task Nominal position output data 1 0 N-1 N N+1 N+2 Start CPOS.B1 1 0 Acknowledge Start SPOS.B1 1 0 Motion Complete SPOS.B2 1 0 Fig. 5/7: Starting the positioning task Thesequenceoftheremainingcontrolandstatusbitsaswell as the functions Halt and Stop react in the same way as the Record Select function; see Fig. 5/4, Fig. 5/5 and Fig. 5/6. Possible causes of faults: Homing not carried out. Target position cannot be reached or lies outside the software end positions. 5-68

167 5. Commissioning Overview of parameters involved (see section B.2.9) Parameters involved Description FCT PNU CI Nominal value for positioning mode Start (FHPP control byte) Feedback (FHPP status byte) Requirement Max. permissible speed 1) x F6/00h Direct mode acceleration in acceleration unit (inc/s 2 ) CPOS.B1 = positive edge: Start (CDIR.B0 = nominal position absolute/relative) SPOS.B2 = 0: Motion complete SPOS.B1 = positive edge: Acknowledge start SPOS.B4 = 1: Drive is moving Device control by PLC/Fieldbus Controller must be in status Operation enabled x EE/22h 1) The master transmits a percentage value in the output data, which is multiplied by the maximum permissible speed in order to obtain the final nominal speed. Tab. 5/22: Parameters involved in a direct task (positioning mode) Force mode The force mode is used in the following situations: For clamping and holding workpieces, as well as for processes where workpieces must be aligned (e.g. to a fixed stop). Pressing and joining processes. Special functions where (e.g.) workpieces must be probed in order to obtain position values. 5-69

168 5. Commissioning Note on Force mode The motor torque is controlled indirectly via the regulation of the current. All specification for forces/torques are defined in relation to the nominal motor torque (relative to the nominal motor current). The actual force on the axis should be determined/checked during commissioning using external measuring devices and adjusted. Note The following settings are necessary for parameterising the forcemode(seetab.5/23) Force window (permissible deviation from the nominal value obtained via Fieldbus). Speed limiting (the maximum speed that the drive should reach. Without this specification, the drive would accelerate unbraked if it encounters no opposing force (e.g. missing workpiece). Damping time (the time that the nominal force must be applied before the Motion complete message is generated). Extend the damping time if the nominal force is already reached on startup (before reaching the workpiece) due to the increased startup toque. Force mode is prepared by switching the control mode. The drive remains stationary in a controlled position. 5-70

169 5. Commissioning Sequence 1. The user specifies the desired nominal value (in % of the rated motor torque) and the speed limit in his/her output data. 2. With a rising edge on Start (CPOS.B1) the controller accepts the nominal torque and begins applying force/ torque in the direction indicated by the nominal value's sign. Once this speed has been reached, the Speed limit reached bit is set in the (status byte SDIR). Once the nominal value has been reached, taking into account the target window and the time window, the MC signal is set. The motor current continues to be controlled. In the case of resistance, e.g. from a workpiece in the traversing range, the drive pushes against the obstruction with a defined force (see Fig. 5/8). If the distance set in path/stroke monitoring (relative to the start position) is exceeded, the bit Stroke limit reached is set in the status byte SDIR. The drive is braked with the emergency-stop ramp, is then held in a controlled position (the current position), and the MC signal is set. Possible causes of faults: Homing not carried out. Axis is at the SW end position when the positioning task starts. 5-71

170 5. Commissioning Overview of parameters involved (see section B.2.9) Parameter Description FCT PNU CI Force mode 1) Stroke limitation x F6/01h Minimum torque x F6/05h Maximum torque x h Force target window (tolerance) x F6/03h Damping time in [ms] x F6/04h Max. permitted speed x F6/02h Start Feedback Requirement CPOS.B1 = positive edge (CDIR.B0 = nominal position absolute/relative) SPOS.B2 = 0: Motion complete SPOS.B1 = positive edge: Acknowledge start SPOS.B4 = 1: Drive is moving Device control by PLC/Fieldbus Controller must be in status Operation enabled 1) Other parameters: 6071h Target torque 6077h Actual torque 6088h Torque profile type 6076h Rated torque (nominal torque) 6087h Torque slope (torque ramp) CDIR.B5 Stroke limitation active/inactive Tab. 5/23: Parameters involved in a direct task (force mode) 5-72

171 5. Commissioning Nominal torque speed limiting output data 1 0 Starting the positioning task / Force mode N 1 N N+1 Start CPOS.B1 1 0 Acknowledge Start SPOS.B1 (ACK) Axis is moving SPOS.B4 (MOV) Motion Complete SPOS.B2 (MC) Nominal torque / force reached 2 Axis is pressing against resistance 3 Resistance removed / overcome 4 SW end position / stroke limit reached Fig. 5/8: Starting the positioning task / Force mode The signal MC (Motion Complete) is used in this control mode to mean nominal value/stroke limit reached. The sequenceoftheremainingcontrolandstatusbitsaswellas the functions Halt and Stop react in the same way as the Record Select function; see Fig. 5/4, Fig. 5/5 and Fig. 5/

172 5. Commissioning Standstill monitoring With standstill monitoring, the system can detect when the drive leaves the target position window when in standstill status. When the target position has been reached and MC has been signalled in the status word, the drive switches to standstill status; bit SPOS.B6 (standstill monitoring) is reset. If the drive is moved out of the standstill position window by external forces or other influences for a minimum defined time, bit SPOS.B6 is set. As soon as the drive is back in the standstill position window for the standstill monitoring time, bit SPOS.B6 is reset. 1 Target position 2 Actual position 3 Standstill monitoring (SPOS.B6) 4 Motion Complete (SPOS.B2) Standstill position window 6 Target position window 7 Settling / Adjustment time (position window time) Standstill monitoring time Fig. 5/9: Standstill monitoring Standstill monitoring cannot be explicitly switched on or off. It becomes inactive when the standstill position window is set to the value

173 5. Commissioning Overview of parameters involved (see section B.2.15) Parameters involved Description FCT PNU CI Nominal position h Current position h Standstill position window h Standstill monitoring time h Start (FHPP) Feedback (FHPP) Requirement SPOS.B2 = positive edge: Motion complete SPOS.B6 = 1: Drive has moved out of standstill position window Device control by PLC/Fieldbus Controller in Operation enabled state Tab. 5/24: Parameters involved in standstill monitoring 5-75

174 5. Commissioning 5.7 The Festo Parameter Channel (FPC) Structure of the cyclic I/O data (FHPP-FPC) The parameter channel serves for the transmission of parameters. The parameter channel comprises the following: Components Parameter identifier (PKE) Subindex (IND) Parameter value (PWE) Description Parameter channel component which contains the request and response identifiers (AK) and the parameter number (PNU). The parameter number serves for identifying or addressing the individual parameter. The request or response identifier (AK) describes the request or response as appropriate in the form of an identifier number. Addresses an element of an array parameter (sub-parameter number). Value of the parameter. If a task of the parameter processing cannot be carried out, an error number is shown instead of the value in the response telegram. The fault number describes the cause of the fault. Tab. 5/1: Components of the parameter channel (FPC) The parameter channel consists of 8 octets. The structure of the parameter channel as a factor of the size or type of the parameter value is shown in the following table: FPC Byte 1 Byte 2 Byte 3 Byte 4 Byte 5 Byte 6 Byte 7 Byte 8 Odata 0 IND ParID (PKE) Value (PWE) I data 0 IND ParID (PKE) Value (PWE) IND ParID (PKE) Value (PWE) Subindex for addressing an array element Parameter Identifier consists of ReqID or ResID and PNU Parameter Value, parameter value: With double word: Bytes Withword:Bytes7,8 Withbyte:Byte8 Tab. 5/2: Structure of parameter channel 5-76

175 5. Commissioning Parameter identifier (PKE) The parameter identifier contains the request or response identifier (AK) and the parameter number (PNU). ParID Octet 1 (byte 3) Octet 2 (byte 4) Bit Task ReqID (AK) Reserved Parameter number (PNU) Response ResID (AK) Reserved Parameter number (PNU) ReqID (AK) Request identifier task identifier (read, write,...) ResID (AK) Response identifier response identifier (transferred value, fault,...) Value (PNU) Parameter Number identifies and/or addresses the respective parameters (see section 5.7). The task or response identifier indicates the type of task or response (see section 5.7.2). Tab. 5/3: Structure of parameter identifier (PKE) 5-77

176 5. Commissioning Request identifiers, response identifiers and error numbers The request identifiers are shown in the following table: ReqID Description Response identifier Positive Negative 0 No request 0 1 Request parameter 1) 1, Modify parameter value (word) 1) Modify parameter value (double word) 1) 2 7 (4) (Reserved request description element) 2) (5) (Reserved modify description element) 2) 6 Request parameter (array) 4, Modify parameter value (array, word) Modify parameter value (array, double word) 5 7 (9) (Reserved request array elements) 2) (10) (Reserved) 2) 11 Modify parameter value (byte) 1) Modify parameter value (array, byte) 12 7 (13) (Reserved request lower limit value) 2) (14) (Reserved request upper limit value) 2) (15) reserved 2) 1) When access is made with request identifiers for simple variables to parameters which are implemented as arrays, the subindex is ignored or set to 0. This means that it is always the first element of an array which is addressed. 2) Requests with non-supported request numbers (ReqID) will be answered with response identifier 7 and fault number 22. Tab. 5/4: Request identifiers 5-78

177 5. Commissioning If the request cannot be carried out, response identifier 7 will be transmitted together with the corresponding fault number (negative response). The following table shows the response identifiers: ResID Description 0 No response 1 Parameter transferred (word) 2 Parameter transferred (double word) (3) (Reserved description element transferred) 1) 4 Parameter value transferred (array, word) 5 Parameter value transferred (array, double word) 6 Number of array elements transferred 7 Request cannot be carried out (with fault number) 2) (8) (reserved no higher order for PKW interface) 1) (9) (Reserved spontaneous message word) 1) (10) (Reserved spontaneous message double word) 1) 11 Parameter value transferred (byte) 12 Parameter value transferred (array, byte) (13) (Reserved lower limit value transferred) 1) (14) (Reserved upper limit value transferred) 1) (15) (Reserved) 1) 1) Not used for MTR-DCI 2) For fault numbers, see following table Tab. 5/5: Response identifiers If the parameter processing request cannot be carried out, a corresponding fault number will be transmitted in the response telegram (octets 7 and 8 of the FPC range). The following table shows the possible fault numbers: 5-79

178 5. Commissioning Fault numbers Description 0 0x00 Invalid PNU. The parameter does not exist. 1 0x01 Parameter value cannot be modified (read only) (2) 0x02 (Reserved lower or upper limit value exceeded) 1) 3 0x03 Faulty subindex 4 0x04 No array 5 0x05 Incorrect data type (6) 0x06 (Reserved setting not permitted can only be reset) 1) (7) 0x07 (Reserved description element cannot be modified) 1) (8) 0x08 (Reserved PPO-Write requested in IR does not exist) 1) 9 0x09 Description data does not exist (10) 0x10 (Reserved access group incorrect) 1) 11 0x0A No higher-order (12) 0x0B (Reserved password incorrect) 1) 13 0x0C Text cannot be read in cyclical exchange (14) 0x0D (Reserved name cannot be read in cyclical exchange) 1) (15) 0x0E (Reserved text array does not exist) 1) (16) 0x10 (Reserved PPO-Write missing) 1) (17) 0x11 (Reserved request cannot be processed because of operating status) 1) (18) 0x12 (Reserved otherfaults) 1) (19) 0x13 (Reserved data cannot be read in cyclical exchange) 1) (20) 0x14 (Reserved invalid value) 1) (21) 0x15 (Reserved response too long) 1) 22 0x16 Invalid: attributes, number of elements, PNU or IND (23) 0x17 (Reserved write request: invalid format) 1) 24 0x18 Write request: number of values is invalid (...99) 0x64 (Reserved PROFIBUS) 100 0x65 (Reserved Festo: ReqID is not supported) 1) (...255) 0xFF (Reserved Festo) 1) These error numbers are not used 5-80

179 5. Commissioning Rules for request-response processing Rules Description 1 If the master sends the identifier for No request, the MTR-DCI replies with the response identifier for No response. 2 A request or response telegram always refers to a single parameter. 3 The master must continue to send a request until it receives the appropriate response from the MTR-DCI. 4 The master recognizes the response to the request placed: by evaluating the response identifier, by evaluating the parameter number (PNU), if applicable, by evaluating the subindex (IND), If applicable, by evaluating the parameter value. 5 The MTR-DCI keeps providing the response until the master sends a new request. 6 a) A write request will only be carried out once by the MTR-DCI, even with cyclical repetition of the same request. b) Between two consecutive requests with the same request identifier (AK), parameter number (PNU) and subindex (IND), the request identifier 0 (no request) must be sent and the master must wait for the response identifier 0 (no response). This is to ensure that an old response is not interpreted as a new response. Tab. 5/6: Rules for request-response processing 5-81

180 5. Commissioning Sequence of parameter processing Caution Observe the following when modifying parameters: An FHPP control signal, which is to refer to a modified parameter, may only follow when the response identifier Parameter value transferred is received for the relevant parameter and if applicable for the index. If, e.g. a position value in a position register is to be modified and if movement is then to be made to this position, the positioning command must not be given until the MTR-DCI has completed and confirmed the modification of the position register. Caution In order to be sure that an old response cannot be interpreted as a new response, the request identifier 0 (no request) must be sent and the response identifier 0 (no response) must then be received between two consecutive requests with the same request identifier (AK), parameter number (PNU) and subindex (IND). Fault evaluation Inthecaseofrequestswhichcannotbecarriedout,theslave responds as follows: Output of response identifier = 7 Output of a fault number in bytes 7 and 8 of the parameter channel (FPC). 5-82

181 5. Commissioning Parameterisation example The following tables show an example of parameterising a positioning task in the position set table via FPC (Festo Parameter Channel). Step 1 Output status of the 8 bytes of FPC data: Byte 1 Byte 2 Byte 3 Byte 4 Byte 5 Byte 6 Byte 7 Byte 8 Reserved Subindex ReqID/ResID + PNU Parameter value Odata 0x00 0x00 0x00 0x00 0x00 0x00 0x00 0x00 Idata 0x00 0x00 0x00 0x00 0x00 0x00 0x00 0x00 Step 2 Write record number 1 with absolute positioning: PNU 401, subindex 2 modify parameter value, array, byte: ReqID 12 (0xC) with value 0x00. Byte 1 Byte 2 Byte 3 Byte 4 Byte 5 Byte 6 Byte 7 Byte 8 Reserved Subindex ReqID/ResID + PNU Parameter value Odata 0x00 0x02 0xC1 0x91 Unused Unused Unused 0x00 Idata 0x00 0x02 0xC1 0x91 0x00 0x00 0x00 0x00 Step 3 After receiving the I-data with ResID 0xC send O-data with ReqID = 0x0 and wait for I-data with ResID = 0x0: Byte 1 Byte 2 Byte 3 Byte 4 Byte 5 Byte 6 Byte 7 Byte 8 Reserved Subindex ReqID/ResID + PNU Parameter value Odata 0x00 0x02 0x01 0x91 Unused Unused Unused 0x00 Idata 0x00 0x02 0x01 0x91 0x00 0x00 0x00 0x

182 5. Commissioning Step 4 Write record number 1 with target position 0x1234 (decimal 4660 increments): PNU 404, subindex 2 modify parameter value, array, double word: ReqID 8 (0x8) with value 0x Byte 1 Byte 2 Byte 3 Byte 4 Byte 5 Byte 6 Byte 7 Byte 8 Reserved Subindex ReqID/ResID + PNU Parameter value Odata 0x00 0x02 0x81 0x94 0x00 0x00 0x12 0x34 Idata 0x00 0x02 0x81 0x94 0x00 0x00 0x12 0x34 Step 5 After receiving the I-data with ResID 0x8 send O-data with ReqID = 0x0 and wait for I-data with ResID = 0x0: Byte 1 Byte 2 Byte 3 Byte 4 Byte 5 Byte 6 Byte 7 Byte 8 Reserved Subindex ReqID/ResID + PNU Parameter value Odata 0x00 0x02 0x01 0x94 0x00 0x00 0x12 0x34 Idata 0x00 0x02 0x01 0x94 0x00 0x00 0x12 0x34 Step 6 Write record number 1 with speed 0x7743 (decimal increments/s): PNU 406, subindex 2 modify parameter value, array, double word: ReqID 8 (0x8) with value 0x Byte 1 Byte 2 Byte 3 Byte 4 Byte 5 Byte 6 Byte 7 Byte 8 Reserved Subindex ReqID/ResID + PNU Parameter value Odata 0x00 0x02 0x81 0x96 0x00 0x00 0x77 0x43 Idata 0x00 0x02 0x81 0x96 0x00 0x00 0x77 0x43 Step 7 After receiving the I-data with ResID 0x8 send O-data with ReqID = 0x0 and wait for I-data with ResID = 0x0: Byte 1 Byte 2 Byte 3 Byte 4 Byte 5 Byte 6 Byte 7 Byte 8 Reserved Subindex ReqID/ResID + PNU Parameter value Odata 0x00 0x02 0x01 0x94 0x00 0x00 0x77 0x43 Idata 0x00 0x02 0x01 0x94 0x00 0x00 0x77 0x

183 5. Commissioning 5.8 FHPP finite state machine Notes on the operation enabled state The transition T3 leads to state S4, which itself contains its own sub-state machine, the states of which are marked with SAx and the transitions of which are marked with TAx ; see Fig. 5/11. This enables a equivalent circuit diagram (Fig. 5/10) to be used, in which the internal states SAx are omitted. Switched off From all statuses T7* S1 Controller switched on S5 S5 Reaction to fault S2 T1 Drive blocked T9 S6 T8 Malfunction T11 T2 T5 S3 Drive enabled T10 T6 T4 T3 S4 Operation enabled Fig. 5/10: Equivalent circuit diagram for finite state machine Transitions T4, T6 and T7* are executed from every sub-state SAx and automatically have a higher priority than any transition TAx. Reaction to faults T7 ( fault detected ) has the highest priority (and therefore receives the asterisk * ). T7 is then executed from S5 + S6 when an fault with higher priority occurs. This means that a serious fault can suppress asimplefault. 5-85

184 5. Commissioning T7* always has the highest priority. Switched off From all states T7* S1 Controller switched on S5 Reaction to faults T1 T8 T11 S2 Drive Blocked T9 S6 Fault T6 S4 T5 T2 Drive enabled T10 T4 T3 SA5 SA6 Jog positive Jog negative TA9 TA10 TA11 TA12 SA1 Ready TA7 TA8 SA4 Homing is running TA2 TA1 SA2 Positioning task active TA5 TA6 TA4 TA3 S4 Operation enabled SA3 Intermediate stop Fig. 5/11: Finite state machine 5-86

185 5. Commissioning Establish ready to operate status T Internal conditions Actions of the user T1 T2 Drive has been switched on. No faults are ascertained. Load voltage applied. Fieldbus master is accepted as the higher-order controller. Enable drive = 1 CCON = xxx0.xxx1 T3 Stop = 1 CCON = xxx0.xx11 T4 Stop = 0 CCON = xxx0.xx01 T5 Enable drive = 0 CCON = xxx0.xxx0 T6 Enable drive = 0 CCON = xxx0.xxx0 T7* Fault detected. T8 T9 T10 Reaction to fault is complete, drive is stationary. There is no longer a fault. Itwasaseriousfault. There is no longer a fault. It was a minor fault. Acknowledge fault = 0 1 CCON = xxx0.pxxx Acknowledge fault = 0 1 CCON = xxx0.pxx1 T11 Fault still exists. Acknowledge fault = 0 1 CCON = xxx0.pxx1 Key: P = positive edge, N = negative edge, x = any 5-87

186 5. Commissioning Positioning The following always applies: Transitions T4, T6 and T7* always have priority. TA Internal conditions Actions of the user TA1 Homing has been carried out. Start positioning task = 0 1 Halt = 1 CCON = xxx0.xx11 CPOS = 0xx0.00P1 TA2 Motion Complete = 1 The current record has been completed. The next record is not to be executed automatically Halt state is any CCON = xxx0.xx11 CPOS = 0xxx.xxx0 TA3 Motion Complete = 0 Halt = 1 0 CCON = xxx0.xx11 CPOS = 0xxx.xxx0 TA4 Halt = 1 Start positioning task = 0 1 Clear remaining positioning = 0 CCON = xxx0.xx11 CPOS = 00xx.xxP1 TA5 Record selection: An individual record has been completed. The next record is to be executed automatically. Direct task: A new positioning task has arrived. CCON = xxx0.xx11 CPOS = 0xxx.xxx1 CCON = xxx0.xx11 CPOS = 0xxx.xx11 TA6 Clear remaining positioning = 0 1 CCON = xxx0.xx11 CPOS = 01xx.xxxx TA7 Start homing = 0 1 Halt = 1 CCON = xxx0.xx11 CPOS = 0xx0.0Px1 Key: P = positive edge, N = negative edge, x = any 5-88

187 5. Commissioning TA Internal conditions Actions of the user TA8 Homing completed or stopped ( Halt ). For Halt only: Halt = 1 0 CCON = xxx0.xx11 CPOS = 0xxx.xxxN TA9 Jog positive = 0 1 Halt = 1 CCON = xxx0.xx11 CPOS = 0xx0.Pxx1 TA10 Either Jogging, positive = 1 0 CCON = xxx0.xx11 CPOS = 0xxx.0xx1 or Halt = 1 0 CCON = xxx0.xx11 CPOS = 0xxx.xxxN TA11 Jog negative= 0 1 Halt = 1 CCON = xxx0.xx11 CPOS = 0xxP.xxx1 TA12 Key: P = positive edge, N = negative edge, x = any Either Jogging, negative= 1 0 CCON = xxx0.xx11 CPOS = 0xxN.xxx1 or Halt = 1 0 CCON = xxx0.xx11 CPOS = 0xxx.xxxN Features specific to different operation modes: Operating mode Recordselection Direct Task Notes on specific features No restrictions. TA2: The condition that no new record may be executed does not apply. TA5: A new record can be started at any time. 5-89

188 5. Commissioning 5.9 Notes on operation When programming positioning systems with electrical axes follow these instructions and recommendations: Start-up behaviour and homing Warning Incorrect parameterisation can cause injury to people and damage to property. In the following cases homing is absolutely essential in order that the points of reference and the working range can be set correctly: Every time the logic voltage is switched on. When the dimensional reference system (homing method, axis zero point, direction of rotation) has been modified (see object 607E h ). After a failed/cancelled homing run Before starting homing, make sure that the axis is in front of the reference switch or stop, in relation to the direction of travel. Note When the coupling or clamping element in the coupling housing is loosened, the motor can be turned on its longitudinal axis. The reference position will then be lost. Carry out homing again. Note When the power supply is switched off, wait for approx. 5 seconds before switching the device on again. 5-90

189 5. Commissioning Device connection Caution The RS232 interface is not electrically isolated. It is not intended for permanent connection to PC systems or as a controller interface. Use the connection only for parameterising and diagnosis. Controlling during operation Warning Danger of injury. Faults in parameter assignment can cause injury to people and damage to property when the controller is enabled. Only enable the controller once the axis system has been installed and parameterised by technically qualified staff. Caution Note the manufacturer's specifications for the permitted operating conditions of the motors and drives used, such as the permitted positioning speeds, for example. Caution Damage to components with DMES-... Movement onto the mechanical end positions is not permitted during operation. When movement is made to the end positions with a heavy load, blockage may occur in the end positions. Note Any functions implemented for the purposes of EMERGENCY-STOP procedures must also be taken into account in the control programs. 5-91

190 5. Commissioning Password protection In the factory settings, password protection is not active. In order to prevent unauthorised or unintentional overwriting or modification of parameters in the device, all download and control functions can be blocked. Recommendation: Protect the settings of your axis against undesired modifications with a password: FCT password protection (8 characters, see MTR-DCI plug-in help). HMI password protection for MTR-DCI-...-H2-... (3 characters; see chapter 4.5). Care and maintenance The motor units do not require maintenance during their specified service life. Follow the maintenance instructions for the accessory components. 5-92

191 Diagnosis and error display Chapter 6 Diagnosis and error display 6-1

192 6. Diagnosis and error display Contents 6. Diagnosis and error display Overview of diagnostic options LED status displays Fault messages Overview Description of the messages, warnings, and faults Diagnosis using Fieldbus Overview Diagnostic memory

193 6. Diagnosis and error display 6.1 Overview of diagnostic options Type of diagnostic information Access via... See... General status displays LED status displays on the MTR-DCI Section 6.2 FCT: virtual LEDs in the Device status window Plug-in help Status bytes SCON and SPOS Section5.5.2 / 6.4 Bus Status LED I/F on the MTR-DCI Section 6.2 DeviceNet class 109 Section 6.4 Current fault message (Text display) Display of the MTR-DCI (type...h2 only) Section 6.3 FCT: text field in the Device status window Plug-in help DeviceNet class 108 Section 6.4 Diagnostic messages FCTin Diagnosis window (whenconnected to device) DeviceNet classes 101/102 (diagnostic memory) Display of the MTR-DCI (type...h2 only) in the [Diagnose] menu Plug-in help Section / Section 4.3 Tab. 6/1: Diagnostic information by type 6-3

194 6. Diagnosis and error display Access Brief description Advantages / properties See... LEDs The LEDs indicate ready to operate status, positioning status, faults and bus status. Fast on-the-spot recognition of faults Section 6.2 Control panel on the MTR- DCI-...-H2 On the LCD display: messages, warnings and faults Fast on-the-spot diagnosis Section 6.3 In the [Diagnostic] menu: Diagnostic data, operation mode, current positioning set, target and actual positions, speed, and information on communication via Fieldbus Detailed on-the-spot diagnosis Section 4.3 Festo Configuration Tool With active device connection: Display of the current position set, target and actual positions, and speed. Display of the operation mode, special outputs and operating states, and fault messages from the connected MTR-DCI. Virtual LEDs in the Device status window Display of the bus status Display of the diagnostic memory Detailed diagnosis during commissioning MTR-DCI plug-in help FHPP/DeviceNet Diagnosis via FHPP status bytes SCON and SPOS Simple diagnosis via Fieldbus Section 6.4 Expanded access to diagnostic data, e.g. diagnostic memory Detailed diagnosis via Fieldbus Section Tab. 6/2: Diagnostic information by access 6-4

195 6. Diagnosis and error display 6.2 LED status displays 1 Power LED 2 I/F LED Error LED Fig. 6/1: LEDs on the control panel of the MTR-DCI-... POWER GREEN Power supply ON Load and logic voltages applied. FLASH- ING OUT Logic voltage is applied. Load voltage is not applied. No voltage is applied. Tab. 6/3: Power LED ERROR RED Fault display ON FLASH- ING OUT Fault. Device not ready for operation. Check cause and rectify if necessary; see section 6.3. Warning. Check cause and rectify if necessary; see section 6.3. No internal fault reported. Tab. 6/4: Error LED 6-5

196 6. Diagnosis and error display I/F Bus Status 1) GREEN Network ON OFF ON OFF ON FLASH- ING Operational System in operational state. Device in Standby MTR-DCI not yet place in the Operational state by the master. RED Modules ON OFF ON OFF ON OFF OUT FLASH- ING ON No Power / BUS-Off No bus connection or bus voltage not present. Warning Minor fault A recoverable fault has occurred, e.g. timeout when establishing a connection. Fault Unrecoverable fault A irrecoverable fault has occurred, e.g. a duplicate MAC ID was recognised. 1) Combined network and module status display as per the DeviceNet specification Tab. 6/5: I/F LED 6-6

197 6. Diagnosis and error display 6.3 Fault messages Overview Category Name, display Description Device Error 1) Fault number Fault LED Status bytes 2) Fault POSITIONERROR Following error 0x ON FAULT, DEV Fault MOTOR STOP Motorstop 0x ON FAULT Fault HOMING-ERROR Reference run fault Fault OVERHEATING Overtemperature (ActTemp > 80 C) 0x ON FAULT 0x ON FAULT Fault LOAD-POWER- DOWN Load voltage monitoring 0x ON FAULT Fault I2t-ERROR Current monitoring (i 2 t) 0x ON FAULT Fault HARDWARE-ERROR Device fault 0x ON FAULT Fault TARGET POSITION OUT OF LIMIT! Nominal position not reachable 0x ON FAULT Warning ILLEGAL RECORD Invalid record number 0x FLASH- ING WARN Fault PLEASE ENFORCE HOMING RUN! Homing required 0x ON FAULT Warning STANDSTILL- WARNING Standstill monitoring 0x FLASH- ING WARN, STILL Fault INIT NO PARA- METER ERROR Fault: Bus parameters not set. 0x ON FAULT 1) See PNU 205 / CI 2FF1/00 2) For FHPP status bytes, see section

198 6. Diagnosis and error display Category Name, display Description Device Error 1) Fault number Fault LED Status bytes 2) Warning HOT TEMPERATURE Temperature too high FLASHING WARN Warning COLD TEMPERA- TURE Temperature too low FLASHING WARN 1) See PNU 205 / CI 2FF1/00 2) For FHPP status bytes, see section Tab. 6/6: Faults and warnings with fault numbers and fault bits Description of the messages, warnings, and faults Messages Messages give information regarding operating states Notification Attention! Motor moves... Profile velocity = 0. Please set v. Cause Message before the start of a positioning movement. After confirmation with the <ENTER> button, the drive starts moving. The menu command [Move position set] is not being executed because the positioning speed of the position set record is v = 0. Modify the parameter assignment or select a different position set record. 6-8

199 6. Diagnosis and error display Warnings Warnings have no effect on the behaviour of the drive. The cause of the warning should however be eliminated so that it does not lead to a fault. When a warning occurs, the fault LED flashes and the output WARNING is set (FHPP status bits, SCON.B2). Warning HOT TEMPERATURE COLD TEMPERATURE STANDSTILL- WARNING ILLEGAL RECORD WARNING Cause Operating temperature 70 C < T < 80 C, may need to check whether drive is overloaded, check the mechanical parts (e.g. for stiffness), reduce ambient temperature. Operating temperature < -10 C, increase ambient temperature as appropriate. The axis has moved outside the standstill position window. Invalid record number. Fault If there is a fault, the drive will be stopped. The fault LED will flash. 1. Eliminate the cause of the fault. 2. Acknowledge the fault message: With <Enter> on the control panel, Via Fieldbus with a falling edge on the ENABLE signal, Via Fieldbus with a rising edge on the RESET signal CCON.B3, With the Acknowledge error button in the Festo Configuration Tool. 6-9

200 6. Diagnosis and error display Fault Possible cause Remedy DEVICENET INIT NO PARAMETER ERROR HARDWARE ERROR Essential bus parameters not set. MTR-DCI not on the bus. Device fault (EEPROM defective, or user data damaged) Set bus parameters (see section 5.2.7): MAC-ID Bitrate I/O Data length Contact Festo Service. I2t-ERROR Current monitoring i 2 t. The drive is blocked Check the drive mechanism. HOMING ERROR LOAD-POWER-DOWN MOTOR STOP OVERHEATING PLEASE ENFORCE HOMING RUN Error during homing Homing run interrupted Homing switch defective Voltage monitoring Load voltage too low MTR-DCI 32/42/52: U < 18 V MTR-DCI 62: U < 34 V Voltage drops under load Error during the positioning procedure A positioning procedure has been aborted on the control panel with EMERG.STOP (button Menu ). Overheating (Operating temperature > 80 C). Temperature of power stage too high. Ambient temperature too high When starting a position set: A valid homing process has not yet been conducted. Due to a logic voltage failure the reference position has been lost. If necessary, check the function of the homing switch. It is essential that you repeat homing. Check the power supply: Power supply unit too weak? Supply line too long? Acknowledge the error on the control panel with Enter Check: That the limits are complied with (motor characteristic curves), the mechanical parts e.g. for stiffness. If necessary, reduce the ambient temperature. Carry out homing. 6-10

201 6. Diagnosis and error display Fault POSITION ERROR TARGET POSITION OUT OF LIMIT Possible cause Position error (following error). The drive is blocked. The parametrized speed cannot be reached. The work load is too heavy. Target position error. The specified target position is outside the permitted positioning range. Remedy Check: The mechanics of the drive, The speed of the positioning record. Thesoftwareendpositions The target position The basis of the target position (absolute or relative). Tab. 6/7: Fault messages 6-11

202 6. Diagnosis and error display 6.4 Diagnosis using Fieldbus Overview The MTR-DCI supports the following diagnostic options over DeviceNet: Status bytes (access via FHPP, see section 5.5.2) SCON.B2:WARN Warning SCON.B3:FAULT Fault SPOS.B5: DEV Following error SPOS.B6: STILL Standstill monitoring. DeviceNet classes 101, 102, 108, 109. DeviceNet class INST 1) ATTR PNU 2) See (65h) Diagnostic memory Diagnosis event 01h...10h 01h 200 Section Malfunction number 01h...10h 02h 201 B.2.6 Timestamp 01h...10h 03h (66h) Diagnostic memory administration Record fault Resolution Delete buffer Number of entries 01h 01h 01h 01h 01h 02h 03h 04h 204 Section B (6Ch) Current fault, warnings 01h 01h 205 Section 6.3 / B (6Dh) Fieldbus diagnostics Bus status Current bit rate Current MAC ID Current I/O data length 01h 01h 01h 01h 01h 02h 04h 05h 206 Section B.2.6 1) Access via Explicit Messaging 2) Access via I/O Messaging (FHPP-FPC) Tab. 6/8: Diagnosis via Fieldbus: DeviceNet classes 6-12

203 6. Diagnosis and error display Diagnostic memory The diagnostic memory contains the last 16 diagnostic messages. It is secured if possible in the event of power failure. If it is full, the oldest element will be overwritten (circular buffer). Structure of the diagnostic memory Parameter 1) PNU 200 PNU 201 PNU 202 Format uint8 uint16 uint32 Meaning Diagnosis event Fault number Time Subindex 1 Subindex 2 Current diagnostic message Previous diagnostic message Subindex 16 Oldest diagnostic message 1) Access via Explicit Messaging see Tab. 6/8 Tab. 6/9: Diagnostic memory: Structure Configuration of the diagnostic memory (PNU 204) SI Description Specification Min. Max. 1 = 1: Record incoming and outgoing 2) faults = 2: Record only incoming faults 2 = 1: Time stamp resolution 10 ms = 2: Time stamp resolution 1 ms 3 Deleting the diagnostic memory. Writing with value = 1 deletes the diagnostic memory Read will always be answered with value = Number of valid entries in the diagnostic memory ) Access via Explicit Messaging see Tab. 6/8 2) Outgoing fault = time when the fault was acknowledged. Tab. 6/10: Diagnostic memory: configuration 6-13

204 6. Diagnosis and error display Group Name Comment The faults are divided into logical groups according to the fault numbers. 0 No fault active Execution fault Examples: no homing, nominal position outside software end positions, nominal value calculation not possible. Although the system is OK, a user command cannot be executed. In most cases there is a fault in operation. Source: sequence control, controller Parameter fault Example: software endpositionsoutside the effective stroke. A parameter lies within the limit values, allowing it to be written by the user. During the recalculation by the controller, it was found to be invalid in the context of the other parameters. Note: invalid parameters are rejected by the parameter protocol and do not generate a fault in the controller Closed-loop controllers Examples: Positioning timeout, homing not successful, following error too large,... The task could not be executed correctly. No hardware fault could be detected. Source: closed-loop controllers Initialisation Fault when initialising the controller Controller runtime Controller runtime fault: Undervoltage, checksum Reserved Reserved Motor runtime Motor runtime: undervoltage, overtemperature, Reserved Tab. 6/11: Overview of fault numbers A detailed description of the warnings and faults can be found in section

205 Technical appendix Appendix A Technical appendix A-1

206 A. Technical appendix Contents A. Technical appendix... A-1 A.1 Technical data... A-3 A.2 Accessories... A-6 A.3 Motor characteristic curves... A-8 A.4 Conversion of units of measurement... A-14 A-2

207 A. Technical appendix A.1 Technical data General information Protection class to EN Relative humidity IP54 (plug connectors plugged in or fitted with protective cap) 0to95%,non-condensing Temperature range Operation: C Storage/transport: C Vibration and shock Vibration tested in accordance with DIN/IEC 68/EN parts 2-6; 0.15 mm path at Hz; 2 g acceleration at Hz Shock tested in accordance with DIN/IEC 68/EN parts 2-27; ±15 g at 11 ms duration; 5 shocks in each direction Shock resistance Tested in accordance with DIN/IEC 68/EN parts 2-29, ±15 g at 6 ms duration; 1000 shocks in each direction Protection against electric shock 1) Electromagnetic compatibility (EMC) 2) Protection by a PELV power unit against direct and indirect contact as per IEC/DIN EN (Protected Extra-Low Voltage) See declaration of conformity ( Gearing type Encoder (with 4x evaluation) Planetary gearing MTR-DCI-32: 300 x4 > 1200 Increments/Revolution MTR-DCI-42, 52, 62: 500 x4 > 2000 Increments/Revolution Temperature monitoring Warning message at 70 C < T < 80 C Shut-down at temperature 80 C Display resolution 128 x 64 pixels 1) The device is intended for industrial use. 2) The maximum permitted I/O signal cable length is 30 metres. A-3

208 A. Technical appendix Motor data Rated torque (Motor without gearbox) [mnm] MTR-DCI-...-G7: Gear reduction 6.75:1; 1-stage Gear units 1) Drive output speed Torsional backlash Drive output torque Efficiency [rpm] [ ] [Nm] Mass moment of inertia Rotor Gearing [kg cm 2 ] [kg cm 2 ] MTR-DCI-...-G14: Gear reduction 13.73:1; 2-stage Gear units 1) Drive output speed Torsional backlash Drive output torque Efficiency [rpm] [ ] [Nm] Mass moment of inertia Rotor Gearing [kg cm 2 ] MTR-DCI-...-G22: Gear reduction ratio 22.21:1 Gear units 1) Drive output speed Torsional backlash Drive output torque Efficiency Mass moment of inertia Rotor Gearing [rpm] [ ] [Nm] [kg cm 2 ] [kg cm 2 ] ) For permitted loading of gear shaft, see chapter 2, Tab. 2/2 A-4

209 A. Technical appendix Electrical data Specifications for serial interface Specifications for reference switch input see section 3.4 see section 3.5 Load voltage supply Connection Power (Pin A1, A2) see section 3.3 Rated voltage DC 24 V ±10 % DC 48 V % Nominal current 0.73 A ±20 % 2A ±20% 5A ±20% 6.19 A ±20 % Peak current 2.1A±20% 3.8 A ±20 % 7.7A±20% 20 A ±20 % Fieldbus / Logic power supply *) Connection For connections see chapter Rated voltage DC 24 V ± 10% Nominal current Peak current 0.15 A 0.8 A *) Only relevant with separated voltage supply. Product weight MTR-DCI-...-G7 [kg] MTR-DCI-...-G14 [kg] MTR-DCI-...-G22 [kg] 8.0 A-5

210 A. Technical appendix Fieldbus Data Design Physical layer Data link layer DeviceNet Specification DeviceNet device type Manufacturer ID as per ISO (corresponding to DS 102) as per CAN specification 2.0 as per IEC62026 and EN50325 Predefined connection set: Group 2 slave only CommunicationAdapter (0x12) Festo Corporation26 (0x1A) Address area (MAC ID) Bus termination resistor Transmission rate Interface Plug Electrical isolation Integrated bus termination Cable type 121 Ω, 0.25W, external 125, 250, 500 kbit/s D-Sub, 9-pin yes no dependent on cable length and fieldbus bit rate, see controller manual A.2 Accessories Connection Accessories Designation Length [m] Voltage supply Power supply cable KPWR-MC-1-SUB-9HC /5/10 Serialinterface Programming cable KDI-MC-M8-SUB Homing Switch Switch, magnetic Switch, inductive SMT-8M-...-M8D SIEN-...-M8B-... Connecting cable with screw-type lock KM8-M8-GSGD /1/2/5 Fieldbus connection including logic voltage power supply Fieldbus adapter (IP54) FBA-CO-SUB-9-M12 A-6

211 A. Technical appendix Userdocumentationinpaperform German English French Italian Spanish Swedish P.BE-MTR-DCI-DN-DE P.BE-MTR-DCI-DN-EN P.BE-MTR-DCI-DN-FR P.BE-MTR-DCI-DN-IT P.BE-MTR-DCI-DN-ES P.BE-MTR-DCI-DN-SV A-7

212 A. Technical appendix A.3 Motor characteristic curves 1 Gear shaft driving torque M [Nm] 2 Current I [A] 3 Recommended operation 4 Impermissible range 5 Overload range A-8

213 A. Technical appendix MTR-DCI G7 n [1/min] 1 2 I[A] M[Nm] n [1/min] MTR-DCI G I[A] M[Nm] Fig. A/1: Motor characteristic curves MTR-DCI A-9

214 A. Technical appendix n [1/min] MTR-DCI G I[A] M[Nm] n [1/min] MTR-DCI G I[A] M[Nm] Fig. A/2: Motor characteristic curves MTR-DCI A-10

215 A. Technical appendix MTR-DCI G7 n [1/min] 1 2 I[A] n [1/min] MTR-DCI G M[Nm] I[A] M[Nm] Fig. A/3: Motor characteristic curves MTR-DCI A-11

216 A. Technical appendix MTR-DCI G7 n [1/min] 1 2 I[A] M[Nm] n [1/min] MTR-DCI G I[A] M[Nm] Fig. A/4: Motor characteristic curves MTR-DCI A-12