Motor controller. Description. Mounting and installationtyp CMMS-AS-... Description en 0708NH [ ]

Transcription

1 Beschneiden: Oben: 6,5 mm Unten: 6,5 mm Links: 43,5 mm Rechts: 43,5 mm Motor controller Description Mounting and installationtyp CMMS-AS-... Description en 78NH [ ]

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3 Edition en 78NH Description P.BE-CMMS-AS-HW-EN Order No (Festo AG & Co KG., D Esslingen, 28) Internet: Hhttp:// The copying, distribution and utilization of this document as well as the communication of its contents to others without expressed authorization is prohibited. Offenders will be held liable for the payment of damages. All rights reserved, in particular the right to register patents, utility models and designs. Festo P.BE-CMMS-AS-HW-EN en 78NH 3

4 Index of revisions Author: Name of manual: P.BE-CMMS-AS-HW-EN File name: File location: Consec. no. Description Index of revisions Date of change Creation 78NH Festo P.BE-CMMS-AS-HW-EN en 78NH

5 Table of contents Table of contents. General data Documentation Type code CMMS-AS-C4-3A Scope of delivery Safety instructions for electrical drives and controllers Symbols used General Information Hazards due to improper use Safety instructions General safety information Safety instructions for assembly and maintenance Protection aganst touching electric components Protection by low voltage (PELV) against electric shock Protection against dangerous movements Protection aganst touching hot components Protection during handling and installation Product description General data Performance characteristics Interfaces Overview of interfaces I/O functions and device control Analogue setpoint specification RS232 interface (diagnosis/ parameterization interface) Interfaces for direct synchronous operation Multi-firmware strategy Synchronisation interface Motor feedback Brake chopper (Brake control) Feedback from motor (angle encoder) Control interface X Incremental encoder interface [X] Serial parameterization interface RS232 and RS485 X SD cardholder X SD memory card Field bus interface FHPP Festo P.BE-CMMS-AS-HW-EN en 78NH 5

6 Table of contents CAN bus PROFIBUS DeviceNet Function overview Operating modes Timing diagram operation mode switchover Setpoint processing I²T function Positioning controller Homing run Timing diagrams for homing run Trajectory generator I/O sequence control Safety functions, error messages Behaviour when switching off enable Oscilloscope function Jog and teach function I/O Route program with position record linking with switchover positioning/torque control On-the-fly measurement Endless positioning Adjustment to the axis and motor construction set Functional safety engineering General information and intended use Integrated "Safe standstill" function General information / description of "Safe standstill" Secure stopping brake control Functional method / timing Application examples Mechanical installation Important instructions Assembly Electrical installation Device view Interfaces Entire CMMS-AS system Interfaces and plug assignments I/O interface [X] Encoder motor EnDat 2. and 2.2 (X2) Field bus CAN [X4] Festo P.BE-CMMS-AS-HW-EN en 78NH

7 Table of contents RS232/RS485 [X5] Motor connection [X6] Power supply [X9] Synchronisation control [X] SD card [X2] Plug assignments for Safe standstill [X3] Field bus settings and boot loader Instructions on safe and EMC-compliant installation Explanations and terms Connection instructions General information on EMC EMC areas: second environment EMC-compliant wiring Operation with long motor cables ESD protection Preparations for commissioning General connection instructions Tools / material Connecting the motor Connect the CMMS-AS motor controller to the power supply Connecting a PC Checking readiness for operation Timing diagram Switch-on sequence diagram Service functions and error messages Protective and service functions Overview Short-circuit monitoring of the end stage/overload current and shortcircuit monitoring Voltage monitoring for the intermediate circuit Temperature monitoring for motor and power section, Temperature monitoring for the heat sink Monitoring the encoder I²t monitoring Power monitoring for the brake chopper Operating mode and error messages Operating mode and error display Error messages... A. Technical specifications... 5 A. General information... 5 Festo P.BE-CMMS-AS-HW-EN en 78NH 7

8 Table of contents A.2 Operation and display components... 6 A.2. Status display... 6 A.2.2 Control elements... 6 A.3 Interfaces... 7 A.3. Power supply [X9]... 7 A.3.2 Motor connection [X6] CMMS-AS... 8 A.3.3 Brake output... 8 A.3.4 Incremental encoder input [X2]... 8 A.3.5 Incremental sensor interface [X]... 9 A.3.6 RS232/RS485 [X5]... 9 A.3.7 CAN bus [X4]... 9 A.3.8 I/O interface [X]... 9 B. Glossary Festo P.BE-CMMS-AS-HW-EN en 78NH

9 . General data. General data. Documentation This product manual is intended to help you safely work with the servo motor controller of the CMMS-ST series. It contains safety instructions that have to be observed. This document provides information on: - mechanical fitting - electrical installation and an - overview of the range of functions. See the following manuals on the CMMS product family for further information: - CANopen manual P.BE-CMMS-CO- : Description of the implemented CANopen protocol according to DSP42 - PROFIBUS manual P.BE-CMMS-FHPP-PB- : Description of the implemented PROFIBUS-DP protocol. - DeviceNet manual P.BE-CMMS-FHPP-DN- : Description of the implemented DeviceNet protocol. - FHPP manual P.BE-CMM-FHPP- : Description of the implemented Festo profiles for handling and positioning..2 Type code CMMS-AS-C4-3A Motor controller for servo motor controller for servo motors, 4 A nominal current, 23V AC CMM S AS C4 3A Series CMM Motor Controller Version S Standard Motor technology AS AC-Servo Rated motor current C4 4A Input voltage 3A 23 VAC Power section Festo P.BE-CMMS-AS-HW-EN en 78NH 9

10 . General data.3 Scope of delivery The delivery includes: Number Delivery Motor controller CMMS-AS-C4-3A Operating packet (configuration software, documentation, S7 module, GSD, EDS, firmware) NEKM-C-4 plug assortment Table. Scope of delivery Festo P.BE-CMMS-AS-HW-EN en 78NH

11 2. Safety instructions for electrical drives and controllers 2. Safety instructions for electrical drives and controllers 2. Symbols used Information Please note Important information and remarks. Caution Failure to comply can result in severe property damage. Warning Failure to comply can result in property damage and personal injury. Warning DANGER! Considerable damage to property and injury to human beings may occur if these instructions are not observed. Warning Dangerous voltage The safety instructions contain reference to dangerous voltages which may occur. Accessories Environment Festo P.BE-CMMS-AS-HW-EN en 78NH

12 2. Safety instructions for electrical drives and controllers 2.2 General Information Festo AG & Co.KG is not liable for damage caused by failure to observe the warning instructions in these operating instructions. Please note Before initial start-up, read through the 2HSafety instructions for electrical drives and controllers starting on page 22H and the chapter 23H6.5 42HInstructions on safe and EMC-compliant installation page 25H. If the documentation in the language in question cannot be understood fully, please contact your vendor and inform them. Proper and safe operation of the motor controller requires correct transport, storage, mounting and installation as well as project planning, taking into account the risks, protection and emergency measures, as well as careful operation and maintenance. Please note Only trained and qualified personnel should be allowed to handle the electric systems. Trained and qualified personnel For the purpose of this manual and the warning instructions on the product itself, technicians working with this product must be adequately familiar with the setting up, mounting, commissioning and operation of the product as well as with all warnings and precautionary measures in accordance with the operating instructions in this product manual, and must be sufficiently qualified for this task: - Training and instructions on or authorization to switch on and switch off devices/systems in accordance with technical safety standards, and to earth and mark them appropriately in accordance with the application requirements. - Training or instructions in using and maintaining suitable safety equipment in accordance with technical safety standards. - Training in first aid. The following instructions must be read before the first start-up of the sytem in order that bodily injuries and/or damage to property can be avoided. These safety instructions must be observed at all times. 2 Festo P.BE-CMMS-AS-HW-EN en 78NH

13 2. Safety instructions for electrical drives and controllers Do not try to install or commission the motor controller before you have carefully read through all safety instructions for electric drives and controllers in this documentation. You must read through these safety instructions and all other user instructions before working with the motor controller. If you do not have any user instructions for the motor controller, please contact your responsible sales representative. Request that the operating instructions be sent immediately to the responsible person so that the motor controller can be operated correctly and safely. These safety instructions must also be provided if the motor controller is sold, lent and/or passed on to third parties. For safety and guarantee reasons, the user is not permitted to open the motor controller. The prerequisite for faultless functioning of the motor controller is skilled project planning. Warning DANGER! Incorrect handling of the motor controller and failure to observe the specified warning instructions, as well as unskilled interference with the safety devices can lead to damage to property, bodily injury, electric shock or in extreme cases to death. 2.3 Hazards due to improper use Warning DANGER! High electric voltage and high working current! Danger of death or serious bodily injury due to electric shock! Festo P.BE-CMMS-AS-HW-EN en 78NH 3

14 2. Safety instructions for electrical drives and controllers Warning DANGER! High electric voltage due to incorrect connection! Danger of death or bodily injury due to electric shock! Warning DANGER! Surfaces of the device housing may be hot! Danger of injury Danger of burns! Warning DANGER! Dangerous movements! Danger of death, serious bodily injury or damage to property due to unintentional movement of the motors! 2.4 Safety instructions 2.4. General safety information Warning The motor controller corresponds to protection class IP2 as well as degree of contamination 2. Care must be taken that the surroundings correspond to this protection and contamination class (see chapter 5.) Warning Use only accessories and spare parts which are approved of by the manufacturer. Warning The motor controllers must be connected to the mains network in accordance with EN standards and VDE/appropriate national regulations, so that they can be disconnected with suitable uncoupling devices (e.g. main switch, fuse, circuit breaker). Warning For switching the control contacts, gold contacts or contacts with high contact pressure should be used. 4 Festo P.BE-CMMS-AS-HW-EN en 78NH

15 2. Safety instructions for electrical drives and controllers Precautionary measures must be taken for preventing interference to switching systems, e.g. switching protective switches and relays with RC elements or diodes. You must observe the safety regulations and directives of the country in which the device is to be used. Warning The environmental conditions specified in the product documentation must be observed. Safety-critical applications are not permitted if they are not explicitly approved by the manufacturer. For instructions on safe and EMC-compliant installation, see Chapter 26H6.5 27HInstructions on safe and EMC-compliant installation (page 28H).The instructions for EMC-compliant installation. The manufacturer of the system or machine is responsible for ensuring that the limit values required by the national regulations are observed. Warning The technical specifications as well as the connection and installation conditions for the motor controller can be found in this product manual. These specifications must be observed at all times. Warning DANGER! The general installation and safety regulations for working on high-current systems (e.g. DIN, VDE, EN, IEC or other national and international regulations) must be observed. Failure to observe these regulations can lead to bodily injury, death or considerable damage to property. The following precautionary measures also apply without claim to completeness: VDE EN 624- EN 578 Regulations for setting up high-voltage systems up to, volts Electrical equipment for machines. Equipping high-voltage systems with electronic Festo P.BE-CMMS-AS-HW-EN en 78NH 5

16 2. Safety instructions for electrical drives and controllers EN ISO 2 EN 5 EN 37 EN 954- operating media. Safety of machines basic concepts, general guidelines Safety of machines guidelines for risk evaluation Safety of machines avoiding unintentional starting Safety-relevant parts of controllers Safety instructions for assembly and maintenance For assembling and maintaining the system, the relevant DIN, VDE, EN and IEC regulations, as well as all national and local safety and accident prevention regulations must always be observed. The system manufacturer or the user is responsible for ensuring that these regulations are observed. Warning The operation, maintenance and/or commissioning of the motor controller may only be carried out by trained qualified personnel and with electrical appliances suited for this work. Avoiding accidents, bodily injury and/or material damage: Warning The series-supplied motor holding brake or an external motorholding brake controlled by the drive controller alone is not suitable for protecting human beings. Vertical axes must be additionally secured against falling or sliding down when the motor is switched off with e.g. - mechanical locking of the vertical axis, - external braking, safety catch or clamping devices or - sufficient weight compensation of the axis. Warning The internal brake resistance can cause dangerous intermediate circuit voltage during operation and up to several minutes after the motor controller is switched off. If touched, this can lead to fatal or serious injuries. Before carrying out maintenance work, make sure that the power supply is switched off and locked and that the intermediate circuit is discharged. Switch the electrical equipment free of voltage via the main switch and make sure that it cannot be switched on again. Wait until the intermediate circuit is discharged after - maintenance work and repairs - cleaning - long periods out of use 6 Festo P.BE-CMMS-AS-HW-EN en 78NH

17 2. Safety instructions for electrical drives and controllers Warning Proceed carefully with mounting. During mounting as well as later during drive operation, make sure that that no drill shavings, metal dust or mounting parts (screws, nuts, pieces of wire) can fall into the motor controller. Ensure that the external power supply of the controller (mains voltage 23 V) is switched off. The intermediate circuit or the 23 V mains voltage must always be switched off before the 24 V logic power supply is switched off. Warning Other work in the vicinity of the machine must only be carried out when the AC or DC supply is switched off and locked. Switched-off final stage or switched-off controller enable are not suitable locking conditions. In the event of a fault, this could lead to unintentional movement of the drive. Warning Carry out commissioning with a free-running motor, in order to avoid mechanical damage, e.g. due to incorrect direction of rotation. Warning Electronic devices are never fail-proof. The user is responsible for ensuring that his system is brought into a safe state if the electric device fails. Warning DANGER! The motor controller and, in particular, the brake resistance can take on high temperatures, which can cause severe bodily burns on contact Protection aganst touching electric components This section concerns only devices and drive components with voltages over 5 V. It is dangerous to touch components with voltages of more than 5 V, as this can cause an Festo P.BE-CMMS-AS-HW-EN en 78NH 7

18 2. Safety instructions for electrical drives and controllers electric shock. When electric devices are operated, certain components in these devices are always under dangerous tension. Warning Dangerous voltage High voltage! Danger of death or serious bodily injury due to electric shock! For operation the relevant DIN, VDE, EN und IEC regulations, as well as all national and local safety and accident prevention regulations must always be observed. The system manufacturer or the user is responsible for ensuring that these regulations are observed. Warning Before switching the device on, fit the covers and protective screens so that the device cannot be touched. For built-in devices, make sure that there is an external housing, such as a control cabinet, to ensure that the electric components cannot be touched. The standards EN 624- and EN 578 must be observed. Warning Ensure that the minimum copper cross section is used for the entire length of the protective earth conductor in accordance with standard EN 624. Warning Before commissioning, also for brief measuring and test purposes, always connect the protective conductor to all electric devices or connect to an earth cable in accordance with the connection diagram. Otherwise, high voltages may occur on the housing. These could cause an electric shock. Warning Do not touch the electrical connection points of the components when the device is switched on. Warning Before touching electric components with voltages over 5 V, disconnect the device from the mains or voltage source. Protect the device against being switched on again. 8 Festo P.BE-CMMS-AS-HW-EN en 78NH

19 2. Safety instructions for electrical drives and controllers Warning During installation note the amount of intermediate circuit voltage, especially with regard to insulation and protective measures. Make sure that the earthing, the cross section size of the conductor and the corresponding short-circuit protection are correct Protection by low voltage (PELV) against electric shock Voltages from 5 to 5 V on the connections and terminals of the motor controller are protective small voltages which can be touched without danger in accordance with the following standards: - international: IEC Normen (standards) - European: EN 578 Warning DANGER! High electric voltage due to incorrect connection! Mortal danger, danger of injury from electric shock. Devices, electrical components and cables may only be connected to connections and terminals from to 5 V, providing they have protective low voltage (PELV = Protective Extra Low Voltage). Connect only voltages and current circuits which have reliable separation of dangerous voltages. Such separation is achieved e.g. with isolating transformers, reliable optocouplers or battery operation separate from the mains network Protection against dangerous movements During initial start-up, the safety functions used, e.g. "Safe standstill", must be checked for proper functioning. The user shall establish a regular inspection of the safety function. Dangerous movements can be caused by incorrect control of connected motors. There are various causes: - Unsafe or faulty circuitry or cabling Causes - Faults in operating the components - Faults in the measured value and signal generators - Faults or non-emc-compliant components - Faults in the software in the higher-order control system These faults can occur immediately after the device is switched on or after an uncertain period of operation. Festo P.BE-CMMS-AS-HW-EN en 78NH 9

20 2. Safety instructions for electrical drives and controllers The monitoring functions in the drive components exclude to a large extent the possibility of incorrect operation of the connected drives. WIth regard to the protection of human beings, especially the danger of bodily injury and/or material damage, one must not rely on these circumstances alone. Until the fitted monitoring functions become effective, you must reckon with at least one incorrect drive movement, the extent of which depends on the type of control and on the operating state. Warning DANGER! Dangerous movements! Danger of injury or death, serious bodily injury or material damage. For the above-mentioned reasons, the protection of human beings must be ensured with the aid of monitoring systems or by measures which are of higher order than the system. These measures are foreseen depending on the specific features of a danger and fault analysis by the system manufacturer. The safety regulations applicable to the system must be observed here as well. Undesired movements of the machine or other incorrect functions can occur as a result of switching off, avoiding or failing to activate safety devices Protection aganst touching hot components Warning DANGER! Surfaces of the device housing may be hot! (up to approx. 85 C, see 8..4). Danger of injury Danger of burns! Warning Danger of burns! Do not touch the surface of the housing in the vicinity of heat sources. After switching devices off, leave them for minutes to cool down before touching them. If you touch hot parts of the device such as the housing, which contains the heat sink and resistors, you may burn yourself Protection during handling and installation Handling and assembling certain components in an unsuitable manner can under circumstances cause injury. 2 Festo P.BE-CMMS-AS-HW-EN en 78NH

21 2. Safety instructions for electrical drives and controllers Warning DANGER! Danger of injury as a result of incorrect handling Bodily injury caused by squeezing, cutting, impact! The following safety measures apply here: Warning Observe the general regulations on setting up and safety when handling and mounting. Use suitable mounting and transport devices. Take suitable measures to prevent clamping and squashing of fingers. Use only suitable tools. If specified, use special tools. Use lifting devices and tools in a correct manner. If necessary, use suitable protective equipment (e.g. protective glasses, safety shoes, safety gloves). Do not stand under hanging loads. Wipe up spilt liquids on the floor to avoid slipping. Festo P.BE-CMMS-AS-HW-EN en 78NH 2

22 3. Product description 3. Product description 3. General data The CMMS-AS series of servo positioning controllers are intelligent AC servo converters with extensive parameterisation possibilities and expansion options. This allows flexible use in a wide range of different applications. The servo positioning controller CMMS-AS is intended for operation of the servo motor series EMMS-AS with digital absolute value decoders in singleturn and multiturn design. Point-to-point positioning or master-slave applications are possible in both a single and multiple-axis synchronised contour drive. With a higher-level multiple axis controller, communication can take place via the integrated CAN interface. The parameterisation tool FCT (Festo Configuration tool) makes possible simple operation and start-up of the servo positioning controller. Graphic depictions and pictograms make intuitive parameterization possible. 3.2 Performance characteristics Compactness Smallest dimensions Can be arrayed directly next to each other Full integration of all components for controllers and power section, including RS232 and CANopen interface. Integrated brake chopper Integrated EMC filters Automatic triggering for a holding brake integrated into the motor. Conformance to the current CE and EN standards without additional external measures (up to 5m of motor cable length) Encoder interface High-resolution Heidenhain incremental encoder, absolute value encoder (multiturn and singleturn) with EnDat. Input / Output Freely programmable I/O`s High resolution 2 bit analogue input Jog/Teach mode Simple coupling to a higher-level controller via I/O Synchronous operation Master/slave operation Extension and field bus module PROFIBUS DP 22 Festo P.BE-CMMS-AS-HW-EN en 78NH

23 3. Product description DeviceNet Integrated CANopen interface Open interface in accordance with CANopen Festo Profile for Handling and Positioning (FHPP) Protocol in accordance with the CANopen standards DS 3 and DSP 42 Contains "Interpolated position mode" for multiple-axis applications Motion control Operation as torque, speed or position controller Integrated positioning control Time-optimised (trapezoidal shape) or jerk-free positioning (S shape) Absolute and relative movements Point-to-point positioning with and without smooth transitions Location synchronisation Electronic gear 64 Position sets 8 Driving profiles A wide range of homing methods Integrated sequence control Automatic sequence of position records without higher-level controller Linear and cyclical position sequences Adjustable delay times Branches and waiting positions Definable stop positions for uncritical standstill points Integrated safety functions Integrated "Safe standstill" in accordance with EN 954- safety category 3 in the basic unit Protection against unexpected starting up Two-channel switch-off of the final stage Certification of BG (in preparation) Reduction of the external wiring Shorter reaction times in case of error Faster restart, intermediate circuit stays charged Interpolating multi-axis movement With an appropriate controller, the CMMS-AS can perform contour runs with interpolation via CANopen. To do this, position setpoints are specified by the controller in a fixed time slot pattern. In between, the servo positioning controller independently interpolates the data values between two support points. Parameterization program "Festo Configuration Tool FCT" Simplest start-up and diagnosis Festo P.BE-CMMS-AS-HW-EN en 78NH 23

24 3. Product description Confiuration Configuration of Motor Controller, Motor and Axis Automatic adjustment of all controller parameters with use of Festo Mechanics 4-channel oscilloscope function English and German 3.3 Interfaces 3.3. Overview of interfaces Setpoint interface / Interface Setpoint specification via Function Operating mode Analogue inputs X (+ V) Analogue setpoing specification with 2-bit resolution Regulating torque Speed control Pulse direction of interface X (24 V) or X (5 V) CW/CCW (Cycle CW / Cycle CCW) CLK / DIR (Cycle / Direction) Synchronisation A/B tracking signals X (5 V RS422) Encoder Digital inputs/outputs X (24 VDC) Record selection Jog-teach mode - Input (slave) - Emulation (master) Linked position records Start and stop functions CANopen field bus X4 (CAN) Direct mode Reference run (homing) Jog mode Record selection Interpolated position mode Synchronisation Positioning controller Regulating torque Speed control Position control Positioning controller Table 3. Interfaces I/O functions and device control Digital inputs The digital inputs provide the elementary control functions. To allow positioning targets to be saved, the CMMS-AS motor controller has a target table, in which positioning targets can be saved and called up later. Six digital inputs allow you to select the targets, another input is used as the start input. Two inputs are used to enable the hardware-side output stage and the controller. 24 Festo P.BE-CMMS-AS-HW-EN en 78NH

25 3. Product description Limit switch The limit switches serve to limit the range of motion for safety reasons. During homing, one of the two limit switches can serve as reference points for positioning control. Sample input If a Field bus is used for activation, a high-speed sampling input is available for timecritical tasks for various applications (position sensing, special applications,...). Analogue input The motor controller CMMS-AS has an analogue input for input levels in the range of + V to - V. The input is designed as a difference input (2 bit) to ensure a high degree of protection against interference. The analogue signals are quantified and digitalised by the analogue-digital converter at a resolution of 2 bits. These analogue signals serve to specify setpoints (speed or torque) for the control. Basic functions The existing digital inputs are already allocated to the basic functions in standard applications. The analogue input AIN is also available as a digital input for use of further functions such as the jog function, route program and synchronisation. MODE switching allows you to switch between the following default settings: Mode Mode Mode Mode 2 Mode 3 Table 3.2 Mode switching Function Positioning Jog function Travel program Synchronisation Analogue setpoint specification The analogue setpoint specification +/- VDC can be configured as setpoint specification for - Speed setpoint value - Torque setpoint value Festo P.BE-CMMS-AS-HW-EN en 78NH 25

26 3. Product description Necessary triggering with analogue setpoint specification The connection plan shows the switch position in the active operating state. *) The limit switches are set by default to opener (configuration over FCT) RS232 interface (diagnosis/ parameterization interface) The RS232 interface is intended as a configuration interface. Parameter Signal level Baud rate ESD protection Connection Connection In accordance with RS232 specification or RS485 specification 96 baud to 5k baud ESD protected (6kV) driver Null modem standard, X5 over X5 / DSUB 9 pin / pin Table 3.3 Parameters of the RS232 interface 26 Festo P.BE-CMMS-AS-HW-EN en 78NH

27 3. Product description The RS485 interface is on the same plug connector as the RS232 interface. Communication must be activated separately by the user. RS232 messages can also be received when RS485 communication is activated, which means that the device can be accessed for configuration at all times. After reset, the serial interface always has the following basic settings. Parameters Baud rate Value 96 Baud Data bits 8 Parity None Stop bits Table 3.4 Default parameters To be able to operate an interface with a terminal program, such as for test purposes, the following settings are required (recommendations): Parameter Flow control Emulation ASCII configuration Value, None VT - Sent characters finish with line feed - Output entered characters locally (local echo) - During reception, attach line feed to the end of the line Table 3.5 Setting for terminal program Please note that, immediately after a reset, the motor controller independently issues a bootup message via the serial interface. A reception program on the controller must either process or reject these received characters. General commands Command Syntax Reply New initialisation of the servo positioning controller RESET! None (bootup message) Save the current parameter set and all position sets in the non-volatile flash memory. Setting the baud rate for serial communication SAVE! BAUD96 BAUD92 BAUD384 BAUD576 BAUD52 DONE Unknown command Any ERROR! Read the version number of the CM (Configuration Management) release of the firmware VERSION? 23:VERSION:MMMM.SSSS*) Festo P.BE-CMMS-AS-HW-EN en 78NH 27

28 3. Product description Command Syntax Reply *)MMMM: Main version of the CM release (hexadecimal format) SSSS: Subversion of the CM release (hexadecimal format) Table 3.6 General commands Parameter commands The exchange of parameters and data takes place over "communication objects" (CO). They are used in a fixed syntax. Special return values are defined for errors in a write or read access. Command Syntax Reply Reading a CO OR:nnnn nnnn:hhhhhhhh or OR:EEEEEEEE Writing a CO OW:nnnn:HHHHHHHH OK! or OW:EEEEEEEE Reading a lower limit of a CO ON:nnnn nnnn:hhhhhhhh or ON:EEEEEEEE Reading an upper limit of a CO OX:nnnn nnnn:hhhhhhhh or OX:EEEEEEEE Reading an actual value of a CO OI:nnnn nnnn:hhhhhhhh or OI:EEEEEEEE *)nnnn: Number of the communication object (CO), 6 bit (hexadecimal format) HHHHHHHH: 32 bit data / values (hexadecimal format) EEEEEEEE: Return value in case of an access fault Table 3.7 Parameter commands The meaning of the return values is the following. Return value Meaning x 2 x 3 x 4 x 5 x 8 x 9 Table 3.8 Return values Data are less than the lower limit, data were not written Data are greater than the upper limit, data were not written Data are less than the lower limit, the data were limited to the lower limit and then accepted Data are greater than the upper limit, the data were limited to the upper limit and then accepted Data are outside the valid value range and were not written Data are currently outside the valid value range and were not written Function commands Command Syntax Reply Activate controller enable. To do this, the controller enable logic must be set to "DIN5 and RS232". Deactivate controller enable. To do this, the controller enable logic must be set to "DIN5 and RS232". Deactivate end stage. To do this, the controller enable logic must be set to "DIN5 and RS232". Acknowledge fault OW:6: OK! or OW:EEEEEEEE ) OW:6:2 OK! or OW:EEEEEEEE ) OW:6:3 OK! or OW:EEEEEEEE ) OW:3: OK! 28 Festo P.BE-CMMS-AS-HW-EN en 78NH

29 3. Product description Command Syntax Reply ) Faulty return values can be called up due to an inappropriately set controller enable logic, an intermediate circuit that is not loaded, etc. Table 3.9 Function commands Setting the operating mode Due to a necessary synchronisation of internal processes, the change of operation mode can require some cycle times of the controller. We therefore recommend that you always verify and wait for reception of the desired operation mode. Operating mode Syntax Response Regulating torque Speed control Positioning Table 3. Operating mode OW:3:4 OW:3:8 OW:3:2 OK! or OW:EEEEEEEE Faulty return values can be called up due to invalid values that do not come from the above-named group. The current operation mode can be read by using the "OR" command. Control via RS485 Please note Before activating the RS485 interface, please make sure that you are using a completely wired null modem cable. All pins of the cable must be occupied according to the following specification (see chapter 6.4.4). Pin Brief description Designation Signal direction Description DCD Data carrier detect 2 RxD Receive (x) Data 3 TxD Transmit (x) Data 4 DTR Data terminal ready Transfer device --> end device Transfer device --> end device End device --> Transfer device End device --> Transfer device Data carrier signal was recorded by transfer device Line at the end device that receives a data bit from the transfer device. Line at the end device that sends a data bit to the transfer device. End device is ready for use 5 GND Ground (earth) None Reference potential at V 6 DSR Data set ready Transfer device --> end device Transfer device is ready for use 7 RTS Request to send 8 CTS Clear to send End device --> Transfer device Transfer device --> end device End device displays that the remote station should send (send request) Transfer device shows reception readiness (send permission) Festo P.BE-CMMS-AS-HW-EN en 78NH 29

30 3. Product description Pin Brief description Designation Signal direction Description 9 RI Ring indicator Table 3. Design of a null modem line Transfer device --> end device Transfer device receives a ring or call sign on the telephone line Configuration in the FCT For configuration, the following settings are required in the "Work station" window: - On the "Application data" page in the "Operating modes selection" tab, set the control interface to "RS485". - On the page "Controller, control interface", do not activate the mode selection Then, with the "Download" buttons, load the changed configurations into the motor controller and save them permanently with the "Save" button. With a "Reset" (or switching off and back on) of the motor controller, the new configuration is activated. Command syntax under RS485 The control of the step motor controller via RS485 takes place with the same objects as with RS232. Only the syntax of the commands to read/write the objects is expanded in comparison to the RS232. Syntax: XTnn:HH HH:CC Meanings: XT: HH HH: nn: Fixed constants Data (normal command syntax) Node number, identical to the CANopen node number (setting via DIP switch 3 Festo P.BE-CMMS-AS-HW-EN en 78NH

31 3. Product description Note The reply sends the following characters to the first five characters: "XRnn:" with nn = node number of the device All devices react to the node number as "Broadcast". In this way, each device can be addressed without knowing the node number. The commands of type "OW", "OR" etc. support an optional check sum. This check sum is formed without the first five characters. The bootup message of the boot loader as well as the bootup message of the firmware are sent in the RS232 mode. Example "Profile position mode" via RS232 With the CAN access simulated via RS232, the motor controller can also be operated in the CAN "Profile position mode". The following describes the sequence in principle.. Changing of the controller enable logic The controller enable logic can be changed via the COB 65_. Since the simulation of the CAN interface over RS232 can be completely taken over, the enable logic can also be changed to DINs + CAN. Command: =65:2 As a result, the release can be granted via the CAN control word (COB 64_). Command: =64:6 Command "Shutdown" Command: =64:7 Command "Switch On / Disable Operation" Command: =64:F Commando "Enable Operation" 2. Activation of the "Profile position mode" The positioning mode is activated via the COB 66_ (Mode of Operation). This must be written once, since all internal sectors must be set correctly thereby. Command: =66: Profile Position Mode 3. Write position parameters The target position can be written over the COB 67A_ (target position). The target position is thereby written in "position units". That means, it depends on the set CAN factor group. The default setting here is / 2 6 revolutions. (6 bit portion before the point, 6 bit portion after the point. Command: =67:58 Target position 5.5 revolutions The speed of travel can be written via the COB 68_ (profile velocity), the final speed via the COB 682_ (end velocity). The speeds are thereby written in "speed units". That means, they depend on the set CAN factor group. The default setting here is / 2 2 revolutions/min. (2 bit portion before the point, 2 bit portion after the point. Command: =68:3E8 Speed of travel RPM The acceleration can be written via the COB 683_ (profile acceleration), the deceleration via the COB 684_ (profile deceleration) and the quick stop ramp via the COB 685 (quick stop deceleration). The acceleration is thereby written in "acceleration units". That means, they depend on the set CAN factor group. The default setting here is / 2 8 revolutions/min/s. (24 bit portion before the point, 8 bit portion after the point. Command: =684:388 Acceleration 5 RPM/s Festo P.BE-CMMS-AS-HW-EN en 78NH 3

32 3. Product description 4. Start positioning Positioning is started via the CAN control word (COB 64_): - Controller enable is controlled via bit..3 (see above). - The positioning is started over a rising edge at bit 4. The following settings are taken over thereby - Bit 5 establishes whether an ongoing positioning is ended first before the new positioning task is taken over (), or whether the ongoing positioning should be cancelled () - Bit 6 establishes whether the positioning should be carried out absolutely () or relatively (). Command: =64:F Start absolute positioning or Command: =64:5F Start relative positioning 5. Operation over RS485 If the CMMS-ST is operated over RS485, control can take place just as with operation over RS232. If required, the node number is simply written in front of the command. The node number is set via the DIP switches. Command: XT7:=67:A Target position revolutions send to node Interfaces for direct synchronous operation The motor controller permits a master-slave mode, which hereafter is designated synchronisation. The controller can function either as a master or slave. If the motor controller works as master, it can provide (RS422) A/B signals to the incremental encoder output (X). When the motor controller is to operate as a slave, various inputs and signal forms are available for synchronisation. X [5V RS422] X [24V]: A/B, CW/CCW, CLK/DIR CW/CCW, CLK/DIR). Using software, the incremental encoder interface can be configured as both output and input (master or slave). Additionally, two inputs for the connection of 5V pulse-direction signals (CLK / DIR), (CW / CCW) are planned on the plug connector. 24 VDC pulse-direction signals are carried out via X Din2 and Din3. Note 5V DC 24V DC Pulse-direction signals over X Pulse-direction signals over X Output: Generation of incremental encoder signals (X) Based on the encoder data, the motor controller generates the tracking signals A, B as well as the zero pulse of an incremental encoder. The number of lines can be set in the FCT with values between Festo P.BE-CMMS-AS-HW-EN en 78NH

33 3. Product description Please note To avoid rounding errors, the number of lines per revolutionshould contain the factor 2 n. (32,64.248) Changes to this interface only become effective after a "Reset"(download, secure, reset). An RS422 power driver provides the signals to X differentially. Input: Processing of incremental encoder or pulse-direction signals (X) The signals are evaluated optionally as A / B tracking signals of an incremental encoder or as pulse / direction signals (CW/CCW or CLK/DIR) of a stepping motor control. The signal form is selected in the FCT. The number of steps per revolution can be parameterized. Beyond that, an additional electronic gear can be parameterized. The following signals can be evaluated: A/B tracking signals CLK/DIR pulse/direction CW/CCW pulse Input: Processing of pulse-direction signals 24V DC (X) CLK/DIR pulse/direction CW/CCW pulse 24V DC pulse-direction signals are carried out via X DIN2 and DIN3. Cycle rate pulse-direction signals Voltage Input Cycle rate 5 V X 5 khz 24V X up to 2 khz Table 3.2 Maximum input frequency Activation of synchronization Synchronization can be set in various ways. With the FCT parameterization software, through selection of the control interface "Synchronization" on the "Application data" page in the "Operating modes selection" tab Via X (digital I/O interface) through selection of mode 3 Please note With setting of synchronization via FCT, the controller only reacts via the synchronisation interface. All other functions of the positioning operating mode are no longer available. Festo P.BE-CMMS-AS-HW-EN en 78NH 33

34 3. Product description Please note After the change of configuration with FCT with the "Download" buttons, load the changed configurations into the motor controller and save them permanently with the "Save" button. With a "Reset" (or switching off and back on) of the motor controller, the new configuration is activated. To ensure flexibility of the controller, synchronization should be switched on over the I/O interface. 34 Festo P.BE-CMMS-AS-HW-EN en 78NH

35 3. Product description Necessary I/O triggering during synchronisation via I/O mode 3 The connection plan shows the switch position in the active operating state. *) The limit switches are set by default to opener (configuration over FCT) Festo P.BE-CMMS-AS-HW-EN en 78NH 35

36 3. Product description The connection plan shows the switch position in the active operating state. *) The limit switches are set by default to opener (configuration over FCT) 36 Festo P.BE-CMMS-AS-HW-EN en 78NH

37 3. Product description I/O timing diagrams ENABLE START STOP DOUT: READY DOUT: MC DOUT2: Speed reached DOUT3: ERROR Drive is moving t t mc tx t tx t tx tmc =.6 ms = x ms (dependent on ramps) = x ms (dependent on MC window) Fig. 3.Signal sequence with Synchronisation selection operation mode / during activation of synchronisation through START (DIN8) The signal MC is set as long as the drive is at a standstill during active synchronisation (DIN8:START set). That is, the MC signal is set as long as the window for "DZ = " has not been left. Festo P.BE-CMMS-AS-HW-EN en 78NH 37

38 3. Product description For the feedback message "Speed reached", the comparison speed is set to zero and only a message range is placed in the message window. General Information The general limitations and settings via FCT are also valid during synchronisation. Axle limitations, speeds, accelerations, message windows, etc. During resynchronisation on a forward-running master, the message "Setpoint achieved" comes as soon as the speed within the set message window is reached. If overshooting occurs during the catch-up phase or the message window is set too low, the message may come several times or flicker Multi-firmware strategy A firmware update can be achieved using any desired customer firmware through the builtin SD card reader. Automatic Boadloader Synchronisation interface The following synchronisation signals can be processed: - Pulse / direction signals (CLK / DIR) via interfaces X and X - CW / CCW signals via interfaces X and X - A / B signals via interface X Signals with a level of 5 V can be processed via the X interface. Interface X is intended for a signal level of 24 V. MODE3 synchronisation must be activated via DIN9= and DIN2= Motor feedback Position return takes place purely digitally via EnDat. EnDat interface V2.x for single and multiturn encoders Parameter Value Communication protocol Heidenhain EnDat 2. (without analogue track) and 2.2 Signal level DATA, SCLK Angle resolution / number of lines incr. encoder 5 V differential / RS422 / RS485 controller-internal up to 6 bit / revolution Cable length L 25 m Cable design in accordance with Heidenhain specification Limit frequency SCLK MHz Generator supply from the controller, 5 V % / +5% I A = 2 ma max. 38 Festo P.BE-CMMS-AS-HW-EN en 78NH

39 3. Product description Parameter Sense lines for power supply Value not supported Table 3.3 Signal description of encoder motor EnDat 2. and 2.2 (X2) Brake chopper (Brake control) A brake chopper with a braking resistor is integrated in the power output stage. If the permitted load capacity of the intermediate circuit is exceeded during the energy recovery, the braking energy may be converted to heat by the internal braking resistor. The brake chopper is actuated with software control. The internal braking resistor is protected against overloading via software and hardware Feedback from motor (angle encoder) The CMMS-AS has a connection for an angle encoder mounted on the motor shaft. This encoder is used for commutation of a 3-phase synchronous motor and as an actual-value recorder for the built-in speed and position controller. The controller supports the following encoders: ENDAT 2. encoder exclusively digital angle information ENDAT 2.2 encoder digital angle information and service parameters (temperature) 3.3. Control interface X The control interface X is planned as D-Sub 25-pin. The following signals are available: Signal: AMON AIN / #AIN DOUT...DOUT3 Description Analogue output for monitor purposes Differential analogue input with 2-bit resolution. Alternatively, the differential analogue input can be parameterized with the function Mode and Stop. (DIN2 and DIN3) (dependent on the parameterized control interface). Digital outputs with 24 V level, DOUT is permanently occupied with the function "Ready for operation". Additional outputs can be configured (Target reached, Axis in motion, Target speed achieved...) Festo P.BE-CMMS-AS-HW-EN en 78NH 39

40 3. Product description Signal: DIN...DIN3 Description Digital inputs for 24 V level, following functions: (The inputs are occupied in their function, dependent on the mode selection) Mode : x End stage enable (DIN4) x Controller enable / Acknowledge error (DIN5) 2 x Limit switches (DIN6 + DIN7) 6 x Position selection (DIN-3, DIN, ) x Start positioning (DIN8) 2 x MODE switchover (DIN9, 2) x Stop (DIN3) Mode : 2 x Jog mode. (DIN, ) x Teach (DIN8) Mode 2: x Stop route program (DIN3) x Start route program (DIN8) 2x Next for route program, step criterion (DIN, ) Mode 3: 2x Pulse/direction (CLK/DIR or CW/CCW on DIN2, 3) x Start sync (DIN8) Table 3.4 Control interface X The digital inputs are designed to be configurable: Mode : Mode : Mode 2: Mode 3: Standard assignment Special assignment for jog and teach mode Special assignment for the route program Special assignment for synchronisation To be able to switch between different I/O configurations, DIN2 and DIN9 can also be configured as als selector signals. As a result, a maximum of four different I/O assignments can be selected. These are described in the tables Table 6.2 Pin allocation: I/O interface [X] Mode, Table 6.3 Pin allocation: I/O interface [X] Mode, Table 6.4 Pin allocation: I/O interface [X] Mode 2and Table 6.5 Pin allocation: I/O interface [X] Mode 3. 4 Festo P.BE-CMMS-AS-HW-EN en 78NH

41 3. Product description Incremental encoder interface [X] Using software, the incremental encoder interface can be configured both as input and as output. Additionally, two inputs for the connection of 5V pulse-direction signals (CLK / DIR), (CW / CCW) are planned on the plug connector. Encoder emulation of the incremental encoder [X] is output: From the rotational angle determined via the encoder at the motor, the controller generates the tracking signals A, B as well as the zero pulse of an incremental encoder. The signals A, B, and N equal those of an incremental encoder. Angle resolution / Number of lines Output The number of lines is continuously switchable. The following numbers of lines are supported: lines per revolution. The switchover only becomes effective after a RESET of the controller. An RS422 line driver provides the signals to X differentially. Synchronization [X] is input: Using software, the X interface can be configured as an input for processing of incremental encoder or pulse-direction signals. The signals are evaluated optionally as A / B tracking signals of an incremental encoder or as pulse / direction signals (CW/CCW or CLK/DIR) of a stepping motor control. The signal form is selected via software. The number of steps per revolution can be parameterized. Beyond that, an additional electronic gear can be parameterized Serial parameterization interface RS232 and RS485 X5 It permits parameterization of the controller as well as downloading of the parameter set and firmware through an RS232 zero modem interface with up to 5 KBit/s. The interface can be used either as an RS232 interface or alternatively as an RS 485 interface. Simultaneous use is not possible, since both interfaces use the same UART in the DSP SD cardholder X2 To permit saving of control parameters as well as the complete controller firmware, a connection possibility for an SD memory card (popular storage medium for digital cameras) has been incorporated. The connection has been designed as a "push-push" holder for reasons of quality perception SD memory card Via the SD memory card, parameter records can be loaded or firmware can be downloaded. A menu in the configuration software allows you to specify a set of parameters on the memory card, and load it or save it. Festo P.BE-CMMS-AS-HW-EN en 78NH 4

42 3. Product description Also, a configuration word in the parameter record can be used to specify whether firmware and/or a parameter record is to be loaded from the memory card automatically on activation. If automatic firmware download (DIP switch 8 = ) is activated or there is no valid firmware in the controller, a check is performed on initialisation whether an SD memory card is inserted, and if so, initialises it. If there is a firmware file on the card, it is checked first (checksum test). If no fault is found, the firmware is transferred from the card to the controller and saved in the FLASH program. If the Load automatic parameter record is activated via the commissioning software, the system checks whether a card is inserted when the firmware is started and it is initialised if applicable. Depending on the setting, a certain or the latest parameter record file is loaded and saved in the data flash. 3.4 Field bus interface With CMMS-AS, different field busses can be used. By default, the CAN bus is permanently integrated in the controller with the CMMS-AS. Optionally, the PROFIBUS or DeviceNet can be used via plug-in modules. But only one field bus can be active at any given time. For all field busses, the Festo Profile for Handling and Positioning (FHPP) has been implemented as the communication protocol. Additionally, for the CAN bus, the communication protocol based on the CANopen profile in accordance with the CiA Draft Standard DS-3 and the drive profile in accordance with the CiA Draft Standard DSP-42 have been implemented. Independent of the field bus, a factor group can be used so that application data can be transferred into user-specific units. 42 Festo P.BE-CMMS-AS-HW-EN en 78NH

43 3. Product description Required I/O connection for field bus control The connection plan shows the switch position in the active operating state. *) The limit switches are set by default to opener (configuration over FCT) 3.4. FHPP FHPP makes it possible to achieve a uniform control concept regardless of the field bus used. The user therefore no longer be concerned with the specific characteristics of the respective busses or controllers (PLC), but receives a preparameterized profile in order to place his drive into operation in the shortest possible time and control it. Among the operation types, FHPP distinguishes between record selection and direct operation. With record selection, the position records stored in the controller are used. In direct operation, the positioning mode, speed control or force control can be employed. These can be dynamically switched over in direct operation as needed. Additional information can be found in the FHPP manual P.BE CMM FHPP SW EN. Festo P.BE-CMMS-AS-HW-EN en 78NH 43

44 3. Product description CAN bus The CAN bus is permanently integrated in the controller and can be parameterized and activated/deactivated via the DIP switches on the front side. With the DIP switches, the node address and baud rate can be set visibly from the outside. In addition, a termination resistor can be switched on and the CAN bus switched on or off. The controller supports baud rates up to Mbit/s. If the communication protocol FHPP is used, the above-mentioned operating modes are available. Alternatively, if the CANopen protocol in accordance with DS3 with application profile DSP42 is activated, the positioning mode (CiA: profile position mode), homing mode (CiA: homing mode), interpolated position mode (CiA: interpolated position mode) speed control (CiA: profile velocity mode) and force mode (CiA: torque profile mode) can be used. Communication can take place optionally over SDOs (service data objects) and/or PDOs (process data objects). Two PDOs are available for each sending direction (transmit/receive). Contour control with linear interpolation With the "interpolated position mode", a contour control can be implemented in a multiaxis application of the controller. For this, position setpoints are specified by a higherorder control system in a fixed time slot pattern. If the time slot pattern of the position setpoints is greater than the internal position controller cycle time of the controller, the controller automatically interpolates the data values between two prescribed position setpoints. The controller also calculates a corresponding speed pilot control. 44 Festo P.BE-CMMS-AS-HW-EN en 78NH

45 3. Product description Position setpoint time slot pattern 2 Position control cycle time 3 Interpolated sequence of the position 4 Interpolated sequence of the position 3 4 Fig. 3.2Interpolated position mode PROFIBUS The controller is connected to the PROFIBUS with a corresponding expansion module (CAMC-PB), which can be plugged into the expansion slot X7. If the module is plugged in, it automatically becomes active the next time the controller is switched on. The slave address is configured over the DIP switches on the front side of the controller. Baud rates up to 2 MBaud are supported. FHPP with the above-described control and operating modes is used as communication protocol DeviceNet The controller is connected to the DeviceNet network with a corresponding expansion module (CAMC-PB), which can be plugged into the expansion slot X7. If the module is plugged in, it automatically becomes active the next time the controller is switched on. The MAC-ID and baud rate are configured over the DIP switches on the front side of the controller. Baud rates up to 5 kbaud are supported. FHPP with the above-described control and operating modes is used as communication protocol. Festo P.BE-CMMS-AS-HW-EN en 78NH 45

46 3. Product description 3.5 Function overview 3.5. Operating modes - Setpoint specification via incremental encoder signals, suitable for frequencies up to 5 khz - Analogue speed specification with 2-bit resolution - Reference point - Simple connection via digital I/Os to a higher-order control system, e.g. a PLC. - Jolt-limited or time-optimised positioning absolutely or relative to a reference point via the integrated trajectory generator. - Position specification via the integrated fieldbus CANopen with automatic interpolation between the setpoints Operating mode Function Setpoint interface / Interface Setpoint specification via Regulating torque Analogue setpoint X Field bus Direct mode Speed control Analogue X CW/CCW signals CLK/DIR Pulse/direction signals Field bus Master/Slave A/B signals + I/O (start synchronisation) X (24V / Mode3) X (5 V) X (24V / Mode3) X (5 V) Direct mode X X (Mode3) Position control Field bus Interpolated position mode Field bus Direct mode Positioning controller I/O Record selection Field bus Field bus Direct mode Record selection Homing run I/O Record selection Field bus Field bus Direct mode Record selection Jog mode I/O Field bus Direct mode Teach-in function via I/O Table 3.5 Operating modes 46 Festo P.BE-CMMS-AS-HW-EN en 78NH

47 3. Product description Timing diagram operation mode switchover ENABLE STOP DIN9 DIN2 DOUT: READY DOUT: MC DOUT2: ACK DOUT3: ERROR t =.6 ms ) Positioning 2) Sequences / Route program 3) Jog / Teach t t t t t 4) Synchronisation Fig. 3.3 Timing for activation of the individual operating modes Setpoint processing Setpoint selectors allow you to switch setpoints from a range of sources to the corresponding controllers. The following setpoint selectors are implemented in the firmware: - Selector for the speed setpoint - Auxiliary value selector, whose setpoint is added to the speed setpoint. The position of the setpoint selectors is saved in non-volatile parameters. Depending on the prefix, the speed setpoint is disabled via the signal of the corresponding limit switch input. The limit switch inputs also affect the ramp generator for the speed setpoint. The speed setpoint (without the auxiliary setpoint) is reached via a setpoint ramp. Four acceleration ramps can be parameterized in the range of up to approx. s. The setpoint ramp can be deactivated. Festo P.BE-CMMS-AS-HW-EN en 78NH 47

48 3. Product description I²T function An integrator monitors the current² time integral of the CMMS-AS controller. As soon as the configured time expires, a warning is sent and the maximum current is limited to the nominal current Positioning controller A positioning control system is set above the current controller. Up to 64 positions (homing + 63 positions) can be selected and run via a trajectory generator. There are also volatile position data records for positioning via the field bus. The position records are made up of a position value and a motion profile. The following parameters can be set for the eight motion profiles: - Positioning speed - Acceleration - Delay - Smoothing - Time - Start delay - Final speed - Wait for current positioning, reject or ignore initial instruction. From every position record, any other position record can be started directly. You can transition to a new position record without first coming to a standstill. The parameter records can be called up via: - Digital inputs (position record... 63) - RS232 interface (for test purposes only) or a - field bus interface 48 Festo P.BE-CMMS-AS-HW-EN en 78NH

49 3. Product description Required I/O connection for positioning (mode ) The connection plan shows the switch position in the active operating state. *) The limit switches are set by default to opener (configuration over FCT) Festo P.BE-CMMS-AS-HW-EN en 78NH 49

50 3. Product description Homing run You can choose either of the following methods, which are based on DS42. Run to Positive method Negative method Graphical representation Limit switch with zero pulse evaluation Dec. Hex Dec. Hex 2 2 Index Impuls Negativer Endschalter Fixed stop with zero pulse evaluation -2 FE - FF - Index Impuls Limit switch Fixed stop -8 EE -7 EF -7 Zero pulse Save current position Table 3.6 Homing run methods 5 Festo P.BE-CMMS-AS-HW-EN en 78NH

51 3. Product description Homing - method Negative limit switch with index pulse. If negative limit switch inactive: Run at search speed in negative direction to the negative limit switch. Run at crawl speed in positive direction until the limit switch becomes inactive, then on to first index pulse. This position is saved as a reference point. If configured: Run at travel speed to axis zero point. 2 Positive limit switch with index pulse. If positive limit switch inactive: Run at search speed in positive direction to the positive limit switch. Run at crawl speed in negative direction until the limit switch becomes inactive, then on to first index pulse. This position is saved as a reference point. If configured: Run at travel speed to axis zero point. - Negative stop with index pulse ) Run at search speed in negative direction to stop. Run at crawl speed in positive direction to next index pulse. This position is saved as a reference point. If configured: Run at travel speed to axis zero point. -2 Positive stop with index pulse ) Run at search speed in positive direction to stop. Run at crawl speed in negative direction to next index pulse. This position is saved as a reference point. If configured: Run at travel speed to axis zero point. 7 Negative limit switch If negative limit switch inactive: Run at search speed in negative direction to the negative limit switch. Run at crawl speed in positive direction until limit switch becomes inactive. This position is saved as a reference point. If configured: Run at travel speed to axis zero point. 8 Positive limit switch If positive limit switch inactive: Run at search speed in positive direction to the positive limit switch. Run at crawl speed in negative direction until limit switch becomes inactive. This position is saved as a reference point. If configured: Run at travel speed to axis zero point. -7 Negative stop )2) -8 Positive stop )2) Run at search speed in negative direction to stop. This position is saved as a reference point. If configured: Run at travel speed to axis zero point. Run at search speed in positive direction to stop. This position is saved as a reference point. If configured: Run at travel speed to axis zero point. 33 Index pulse in a negative direction Run at crawl speed in negative direction to index pulse. This position is saved as a reference point. If configured: Run at travel speed to axis zero point. Festo P.BE-CMMS-AS-HW-EN en 78NH 5

52 3. Product description Homing - method 34 Index pulse in a negative direction Run at crawl speed in positive direction to index pulse. This position is saved as a reference point. If configured: Run at travel speed to axis zero point. 35 Current position The current position is saved as the reference point. If configured: Run at travel speed to axis zero point. Note: If the reference system is shifted, runs to the limit switch or fixed stop are possible. The are therefore generally used for rotating axes. Table 3.7 Explanation of the homing methods Timing diagrams for homing run Controller release Statusword: referenced START Limit switch E Limit switch E DOUT: READY DOUT: MC DOUT2: ACK DOUT3: ERROR + t tx =.6 ms = x ms (dependent on ramps) t t tx tx tx tx Fig. 3.4Signal sequence with start of the homing run and with positive design 52 Festo P.BE-CMMS-AS-HW-EN en 78NH

53 3. Product description Controller release Statusword: referenced START Limit switch E Limit switch E DOUT: READY DOUT: MC DOUT2: ACK DOUT3: ERROR Drive is moving neg t tx t tx tx pos tx t =.6 ms tx = x ms (dependent on ramps) Fig. 3.5Signal sequence with faulty interruption (contour error,...) Festo P.BE-CMMS-AS-HW-EN en 78NH 53

54 3. Product description Controller release Statusword: referenced START STOP Limit switch E Limit switch E DOUT: READY DOUT: MC DOUT2: ACK DOUT3: ERROR + t tx t tx tx t tx t =.6 ms tx = x ms (dependent on ramps) Fig. 3.6Signal sequence with interruption through STOP input Trajectory generator With a start signal for a positioning set via DIN8, field bus or RS232 interface, the selected positioning set is loaded into the trajectory generator. Based on the data record loaded, the necessary internal pre-calculations are made. The pre-calculations can take up to 5 ms. The following programmable possibilities are available for processing the start signal: - A start signal detected during an ongoing positioning run is ignored (ignoring). - After a start signal is detected during an ongoing positioning run, the run continues to the end (waiting). - After a start signal is detected, positioning is cancelled and the drive runs at a constant speed. After pre-calculation is completed, the drive runs to the new target position (interrupting). The trajectory generator sends the following messages: - Target reached, (Default: digital output DOUT - MC) - Remaining distance reached. 54 Festo P.BE-CMMS-AS-HW-EN en 78NH

55 3. Product description I/O sequence control RESET Power ON T Boot program Firmware download From all except RESET / Power ON T2 T23 Initialization Fault status Initialise SD card T9 T3 Operational T25 T24 Acknowledge error T8 Load save SD card parameters T2 T2 T4 T7 Activate end stage T5 Torque control T6 Deactivate end stage Speed control T6 T5 Positioning controller T8 T3 T9 T T T2 Jog mode Homing - run T Conditions Actions of the user T T2 T3 RESET / Power ON Time out has expired or the firmware download is complete. The initialisation has been carried out successfully. T4 DIN4= and DIN5= Festo P.BE-CMMS-AS-HW-EN en 78NH 55

56 3. Product description T Conditions Actions of the user T5 T6 T8 T9 T T T2 T3 T5 T6 T7 T8 T9 T2 T2 T22 T23 T24 T25 "Torque control" was selected in the commissioning software. "Speed control" was selected in the commissioning software. "Positioning" was selected in the commissioning software. All parameters for the jog mode were set in the commissioning software (e.g. max. speed, acceleration...). Selection of the homing method and configuration of the speeds and accelerations in the commissioning software. The drive is referenced. The SD card was initialised successfully. "Load from SD after restart" was selected in the commissioning software. Parameter record was loaded A fault has occurred which causes the end stage to be switched off The error was acknowledged and no other errors are pending. Setpoint specification via AIN/AGND Setpoint specification via AIN/AGND Set selection via DIN DIN3, DIN, DIN Start for the positioning process: DIN8= Selection I/O mode: DIN9=, DIN2= Jog +: DIN= Jog -: DIN= Selection I/O mode: DIN9=, DIN2= Selection of positioning record Start for positioning process: DIN8= DIN5= DIN5= DIN5= DIN4= Write or read request to SD card such as: - Load parameters - Save parameters - Download firmware. Edge controlled fault acknowledgement DIN5: - Table 3.8 I/O sequence control 56 Festo P.BE-CMMS-AS-HW-EN en 78NH

57 3. Product description 3.5. Safety functions, error messages The following conditions are monitored for safe operation of the CMMS-AS: - Safe standstill, EN 954/Cat 3 and IEC End stage temperature, - Motor temperature, - Intermediate circuit voltage to minimum and maximum value, - Initialisation errors, - Check-sum error on parameter transfer, - Communication error, - Contour error - Homing run, - Overload current / short circuit in the power end stage, - Encoder system, - Watchdog (processor monitoring) Behaviour when switching off enable Controller enable Output stage release START Holding brake current-carrying Output stage switched on DOUT: READY DOUT: MC DOUT2: ACK DOUT3: ERROR Drive is moving t t tx t tx =.6 ms = x ms (dependent on brake ramps) Fig. 3.7 Behaviour when switching off controller enable Festo P.BE-CMMS-AS-HW-EN en 78NH 57

58 3. Product description Controller released Output stage release START Holding brake current-carrying Output stage switched on DOUT: READY DOUT: MC DOUT2: ACK DOUT3: ERROR Drive is moving t t t tx t =.6 ms tx = x ms (dependent on brake ramps) Fig. 3.8Behaviour when switching off end-stage enable 58 Festo P.BE-CMMS-AS-HW-EN en 78NH

59 3. Product description Controller release Output stage release START Holding brake currentcarrying Output stage switched on DOUT: READY DOUT: MC DOUT2: ACK DOUT3: ERROR Intermediate circuit Drive is moving t t tx t t tx =.6 ms = x ms (ZK discharges) Fig. 3.9Behaviour during interruption of the intermediate circuit supply (error: end stage off immediately) Oscilloscope function The oscilloscope function implemented in the controller is an important aid for optimising the controller settings by the person placing it into operation, without using a separate measuring device. The function permits recording of important signal sequences over time. It consists of three blocks: The initialisation part, which runs at low priority and performs pre-calculations for the actual measurement process. The data transfer section also has low priority. It is integrated into the time slice of serial communication. The measuring section runs at a high priority in the rule interrupt and records the measuring channels. If the trigger condition occurs, the measurement process is cancelled after a defined number of scan steps. Two channels with bit values each can be recorded. Capable of parameterization are: - Trigger source (current, speed, position, rotor location, end stage voltage, contouring error, controller enable, limit switch, positioning started, motion com- Festo P.BE-CMMS-AS-HW-EN en 78NH 59

60 3. Product description plete, contouring error (message), general error, end stage active, homing run active) - Trigger level - Trigger option (auto, normal, force, rising / falling edge) - Measurement frequency Jog and teach function I/O The jog / teach mode is parameterized via the parameterization surface (FCT) or via the CANopen object. It can then be activated via the digital inputs for MODE. If the jog / teach mode is activated, two additional digital inputs are used to control the motor. The jog control overrides the current control system in this mode. With position control, the motor is run continuously with the parameterized profile (jog mode) (positive / negative) if there is a positive signal to the digital input. The digital input DIN8 serves to take over the set target position. The condition of the digital inputs DIN to DIN3 is thereby evaluated and the target position saved at the corresponding location. General Information The first 5 positions of the position record table can be taught. (Pos.-5) With Din8, the current position is taken over into the position record, which is selected with Din-Din3. Final saving of the taught positions in permanent memory takes place with falling edge from Din5 controller enable. Please note The positions are saved on the SD card only through FCT. And so when jog/teach (without FCT) is used, an SD card may not be plugged in or "Read from SD after restart" must be inactive, otherwise, when the controller is restarted, the old values will be read off the SD card again. Activating jog/teach function The jog/teach function is started in I/O operation through selection of mode. 6 Festo P.BE-CMMS-AS-HW-EN en 78NH

61 3. Product description Necessary I/O triggering with jog/teach (mode ) The connection plan shows the switch position in the active operating state. *) The limit switches are set by default to opener (configuration over FCT) Festo P.BE-CMMS-AS-HW-EN en 78NH 6

62 3. Product description Settings in the FCT The parameters set here are valid for jogging via I/O interface and jogging via FCT. The acceleration also applies with "single step" over FCT. 62 Festo P.BE-CMMS-AS-HW-EN en 78NH

63 3. Product description I/O timing diagrams ENABLE START/TEACH STOP DIN: Jog - DIN: Jog + DOUT: READY DOUT: MC DOUT2: ACK-TEACH DOUT3: ERROR Drive is moving neg pos t tx t tx t tx =.6 ms = x ms (dependent on brake ramps) Fig. 3. Signal sequence with jogging positive and negative Festo P.BE-CMMS-AS-HW-EN en 78NH 63

64 3. Product description ENABLE START/TEACH STOP DIN: Jog - DIN: Jog + DOUT: READY DOUT: MC DOUT2: ACK-TEACH DOUT3: ERROR Drive is moving + + t tx t tx t tx t tx t tx t tx =.6 ms = x ms (dependent on brake ramps) Fig. 3.Signal sequence when both signals are activated simultaneously / briefly staggered 64 Festo P.BE-CMMS-AS-HW-EN en 78NH

65 3. Product description ENABLE START / TEACH STOP DIN: Jog - () DIN: Jog + () DIN - DIN3 () DOUT: READY DOUT: MC DOUT2: ACK-TEACH DOUT3: ERROR + t tx t tx t t t t tx =.6 ms = x ms (dependent on brake ramps) () Setting of the target position to be programmed Fig. 3.2 Behaviour with teach input Route program with position record linking with switchover positioning/torque control The route program allows multiple positioning jobs to be linked in a sequence. These positions are travelled to one after another. The characteristics of the route program are: All 63 position records of the position record table can be set in the route program. Besides linear sequences, ring-shaped linkages are also allowed. (endless linkage) For each route program step, a free following position can be set. As step criterion, 2 digital inputs are available as Next and Next 2. There are 7 possibilities to jump into the route program with I/O control, that is, 7 different sequences are possible. Under FHPP, the entry is freely selectable and the number limited only by the maximum number of position sets. The program lines of the route program are worked off every,6 ms. This ensures that an output set by the route program remains set for at least.6 ms. The route program can be controlled via digital inputs. Digital inputs in which the levels (high/low) are evaluated must remain stable for at least.6 ms (cycle time of the sequence control for the route program). Festo P.BE-CMMS-AS-HW-EN en 78NH 65

66 3. Product description From every position record, any other position record can be started directly. You can transition to a new position record without first reaching end speed =. Step criteria Value Condition Abb. Description - End No automatic continuation. Motion complete MC Continues when the motion complete condition is fulfilled (tolerance window). Thus the axis is at a standstill for a moment during positioning. 4 Standstill STS Continues when the drive reaches a standstill and the programmed time has expired. Standstill here does not just meajn the end of the position record (MC), but also running to the block at any desired location. 5 Time TIM Continues when the programmed time has expired. Time measurement begins with the start of the position record. 6 NEXT (positive edge) 7 NEXT (negative edge) 9 NEXT (positive edge) waiting NEXT (negative edge) waiting NRI NFI NRS NFS Continues immediately after a positive edge at DIN (NEXT) or DIN (NEXT2). Continues immediately after a negative edge at DIN (NEXT) or DIN (NEXT2). Continues after the motion complete message and a positive edge on DIN (NEXT) or DIN (NEXT2). Continues after the motion complete message and a negative edge on DIN (NEXT) or DIN (NEXT2). Table 3.9 Step criteria for the route program Please note The time specification for STS and TIM is the time entered in the motion profile. The time begins with execution of the position record. 66 Festo P.BE-CMMS-AS-HW-EN en 78NH

67 3. Product description Speed profiles with end speed <> Please note Position records containing an end speed <> must NOT be used for individual records, since the end speed condition can only be reached in linkages. Activation of set linkage Set linkage is started in I/O operation through selection of mode 2. Festo P.BE-CMMS-AS-HW-EN en 78NH 67

68 3. Product description Required I/O connection for set linkage (mode 2) The connection plan shows the switch position in the active operating state. *) The limit switches are set by default to opener (configuration over FCT) With removal of Din3 "Stop route program", the ongoing route program is stopped at the current position. If Din3 returns, the route program is automatically continued from this position. With removal of Din9 "Mode switchover", the ongoing route program is ended. The ongoing position record is still run to the end. With removal of Din3 "Stop", the route program is interrupted. The route program must be restarted. 68 Festo P.BE-CMMS-AS-HW-EN en 78NH

69 3. Product description I/O timing diagrams ENABLE START STOP Positioning record DOUT: READY DOUT: MC DOUT2: ACK DOUT3: ERROR Drive is moving t tx =.6 ms = x ms (dependent on positioning) t t t t t tx () Applies for positioning records with end speed = Fig. 3.3 Signal sequence at the start of a sequence () ENABLE START STOP Positioning record DOUT: READY DOUT: MC DOUT2: ACK DOUT3: ERROR Drive is moving t t t t t t tx t tx =.6 ms = x ms (dependent on brake ramps) Festo P.BE-CMMS-AS-HW-EN en 78NH 69

70 3. Product description Fig. 3.4 Signal sequence with interruption through Stop input ENABLE START STOP HALT Positioning record DOUT: READY DOUT: MC DOUT2: ACK DOUT3: ERROR Drive is moving t tx =.6 ms = x ms (dependent on brake ramps) t t t t tx tx t tx tx Fig. 3.5 Signal sequence with interruption and continuation through HALT input On-the-fly measurement The actual position can be recorded at any given time via high-speed input DIN9. The rising or falling edge is evaluated for this (can be parameterized). The maximum delay time in position recording is in the range of a few microseconds. A field bus connection can be used to access the saved position data Endless positioning Endless positioning in one direction (rotary axis applications) can be implemented without a problem (in the range +/ revolutions). The limit switch input can be used as a reference switch input Adjustment to the axis and motor construction set Preset parameter records are provided to the user. For optimal operation of the motor-axis combination, optimization of the control parameters must always be carried out. All drive components and sizes of the entire mechanical construction set are available for the motor series EMMS-AS. 7 Festo P.BE-CMMS-AS-HW-EN en 78NH

71 3. Product description EMMS-AS servo motors to be operated at the CMMS-AS: EMMS-AS -4-M, -55-S -TS / -TM / -TSB / -TMB EMMS-AS -7-S, -7-M, --S -RS / -RM / -RSB / -RMB Festo P.BE-CMMS-AS-HW-EN en 78NH 7

72 4. Functional safety engineering 4. Functional safety engineering 4. General information and intended use The CMMS-AS family of servo positioning controllers supports the "Safe standstill" safety function, providing protection against unexpected motion as per the requirements of the EN 954-, Category 3 standard. Bringing the machine to a standstill must be carried out and ensured by the machine control system. This especially applies to vertical axes without self-limiting mechanics or counterbalancing. Based on a danger / risk analysis, as per the machine directives EN ISO 2, EN 954- and EN 5, the machine manufacturer must plan a safety system for the entire machine, including all integrated components. This also included the electric drives. The EN 954- standard defines the controller requirements in five different categories based on the level of risk (see Table 4.). Category ) Summary of requirements System behaviour 2) Principles for achieving safety B The safety-relevant components The occurrence of a fault Primarily characterised and/or protection mechanisms, and can lead to a loss of the by the selection of com- your own components, must be safety function. ponents. designed, built, selected, assembled and combined in such a way as to conform with the relevant standards so that they can withstand the expected influences. The requirements of category B must be satisfied. Proven components and safety principles must be used. 2 The category B requirements have to be fulfilled and proven safety principles must be used. The safety function must be checked by the machine controller at suitable intervals. The occurrence of a fault can lead to a loss of the safety function, but the probability of a fault occurring is less than for category B. The occurrence of a fault between such checks can lead to a loss of the safety function. The loss of the safety function will be detected by the next check. Primarily characterised by the structure 72 Festo P.BE-CMMS-AS-HW-EN en 78NH

73 4. Functional safety engineering Category ) Summary of requirements System behaviour 2) Principles for achieving safety 3 The category B requirements have to be fulfilled and proven safety principles must be used. Safetyrelevant parts must be equipped as follows: - A single fault in any component must not lead to a loss of the safety function. - Single faults must be recognised as soon as this is reasonable possible. 4 The category B requirements have to be fulfilled and proven safety principles must be used. Safetyrelated components must be constructed as two-channel systems with constant self-monitoring and full error recognition! When this one fault occurs, the safety function is still preserved. Some, but not all faults will be detected. The occurrence of a number of undetected faults together can lead to a loss of the safety function. When faults occur, the safety function must always be preserved. The faults must be detected early enough to prevent a loss of the safety function. Primarily characterised by the structure ) The category is not intended to define any sort sequence or hierarchical arrangement of safetyrelated requirements. 2) Risk analysis is used to determine whether a complete or partial loss of safety function(s) due to faults is acceptable. Table 4. Description of the category requirements as per EN 954- Among other issues, the EN 624- standard deals with the handling of emergencies and defines the terms EMERGENCY-OFF and EMERGENCY--STOP (see Table 4.2). Handling Definition (EN 624-) Danger case EMERGENCY- STOP EMERGENCY- STOP Electrical safety in case of emergency by switching off the electrical energy to all or part of the installation. Functional safety in case of emergency by bringing a machine or movable parts to a standstill. EMERGENCY-OFF is to be used where a risk of electric shock or other electrical risk exists. EMERGENCY-STOP is used to stop a process or a motion if this represents a danger. Table 4.2 EMERGENCY-OFF and EMERGENCY-STOP as per EN 624- Electrical isolation does not occur with the "Safe standstill" function. This does not provide protection from an electric shock. In the sense of the standards, an EMERGENCY-OFF system cannot be implemented via "Safe standstill" because this requires the complete system to be switched off via a mains power isolator of some kind (main power switch or mains circuit breaker). The EN 624- standard describes three Stop categories that can be used for shutdowns, depending on the results of a risk analysis (see Table 4.3). Festo P.BE-CMMS-AS-HW-EN en 78NH 73

74 4. Functional safety engineering Stop category Type Handling Uncontrolled shutdown through immediate switching off of the energy. Controlled shutdown through switching off of the energy when a standstill has been reached. 2 Controlled standstill without switching off of the energy. EMERGENCY-OFF or EMERGENCY-STOP EMERGENCY-STOP Not suitable for EMERGENCY-OFF or EMERGENCY-STOP Table 4.3 Stop categories 4.2 Integrated "Safe standstill" function Warning The "Safe standstill" function does not provide protection against electric shock but rather only against dangerous motion! 4.2. General information / description of "Safe standstill" With "Safe standstill" the energy supply to the device is reliably interrupted. The drive may not generate torque and thus cannot make any dangerous movements. With suspended loads, additional measures must be taken to ensure that the load does not fall (e.g. mechanical holding brake). Monitoring of the standstill position is not required in the "Safe standstill" state. There are 3 suitable measures for implementing "Safe standstill": Measure - Circuit breaker between the mains grid and the drive system (mains breaker) - Circuit breaker between the power unit and the drive motor (motor breaker) - Secure pulse blocker (blocking of impulses to the power semiconductors, integrated into the CMMS-AS) The use of the integrated solution (secure pulse blocker) offers several advantages: Advantages - Fewer external components, e.g. circuit breakers - Less cabling effort and less space required in the switching cabinet - and thus lower cost Another advantage is the availability of the system. The integrated solution allows the intermediate circuit of the servo controller to remain charged. This means no waiting time when the system is restarted. 74 Festo P.BE-CMMS-AS-HW-EN en 78NH

75 4. Functional safety engineering Fig. 4. "Safe standstill" block schematic as per EN 954- Category 3 Caution If the "Safe standstill" function is not required, then pins and 2 of [X3] must be bridged. For "Safe standstill" as per EN 954- Category 3, a second channel is required, i.e. motion must be reliably prevented via two separate, completely independent paths. These two paths for interrupting the energy supply supply to the drive with the reliable impulse block, are called switch-off paths:. Switch-off path: End stage enable via [X] (blocking of the PWM signals; the IGBT drivers no longer receive pulse patterns). Festo P.BE-CMMS-AS-HW-EN en 78NH 75

76 4. Functional safety engineering 2. Switch-off path: Interruption of the supply for the six end stage IGBTs via[x3] using a relay (the IGBT optocoupler drivers are removed from the power supply via a relay, thus preventing the PWM signals from reaching the IGBTs). Potential-free feedback contact: A plausibility check between the relay control for the end stage driver supply and the monitoring of the driver supply is performed by the microprocessor. This is used for error detection of the pulse blocker and also for suppressing error messages occurring in normal operation E 5-2 ("Driver supply undervoltage"). The integrated "Safe standstill" circuitry also has a potential-free feedback contact ([X3] Pins 5 and 6) for the existence of the driver supply. This is a normally closed contact. It must be connected to (e.g.) the higher level control system. At suitable intervals (e.g. PLC cycle time or at every "Safe standstill" request), the PLC must perform a plausibility check between the relay control for the driver supply and the feedback contact (contact open = driver supply present). If an error occurs in the plausibility check, the control system must prevent further operation by (e.g.) removing the controller enable or switching off the mains circuit breaker Secure stopping brake control When "Safe standstill" is activated, power is removed from the holding brake via two channels (brake engaged); (see block schematic).. Channel The holding brake is controlled by DIN5 (controller enable) in normal operation (see following timing diagram). The st "end stage enable" switch-off path affects the brake driver via the microprocessor and removes power from the holding brake (brake applied). 2. Channel The 2nd "Relay control for driver supply" switch-off path directly controls a MOSFET that activates the holding brake (brake applied). Caution The user is responsible for the dimensioning and the reliable functioning of the holding brake. The functioning of the brake must be ensured via a suitable braking test. 76 Festo P.BE-CMMS-AS-HW-EN en 78NH

77 4. Functional safety engineering Functional method / timing The following timing diagram illustrates the functional method of "Safe standstill" together with controller enabling and the stopping brake: "safe stop" X3.2 (24V) X3.2 (V) ON (5V) Triggering of pulse amplifier supply relay (optocoupler driver) 2. shut-down path Supply of pulse amplifiers (optocoupler driver) "safe stop" Timing of "safe stop" activation variable. To be determined by user, e.g. by means of safety switching devices, depending on application. Discharge curve of electrolytic capacitors for the supply of the pulse amplifiers t OFF open Floating feedback contact for driver supply (X3.5/6) t closed ON Output stage enabling (X, DIN4) t Timing of output stage enabling variable. shut-down path OFF Controller enabling (X, DIN5) t ON Internal output stage enabling (controlled by µp) t OFF Released (24V) Holding brake control (X6./2) Delay until brake is released! Delay until brake is applied! t Fixed (V) n Set speed "n" Can be set via FCT t Both ramps ca be set separately via FCT n= H Seven-segment display H t H t t 2 t 3 t 4 t 5 t 6 Fig. 4.2 "Safe standstill" timing as per EN 954- Category 3 t 7 t 8 t 9 t t t 2 t 3 t Festo P.BE-CMMS-AS-HW-EN en 78NH 77

78 4. Functional safety engineering Description of the timing diagram: This timing diagram is based on the example of speed regulation using the controller enable DIN 5 at [X]. For field bus applications, the controller enable is additionally controlled via the respective field bus. Depending on the application, the operating mode is also parameterizable via the parameterizing software. Please note The "Safe standstill" state is shown in GREY compared to the functional operation! Starting state: - The 24V supply is switched on and the intermediate circuit is charged. - The servo controlled is in the "Safe standstill" state. This state is indicated by a flashing "H" on the 7- segment display. Restart after activated "Safe standstill" In order to switch the servo controller end stage active once more, and thus operate the connected motor, the following steps must occur:. The relay control for switching the end stage driver power supply (2nd switch-off path) must be supplied with 24V between pin 2 and pin 3 of [X3] at time t. 2. The driver supply is then charged. 3. The potential-free feedback contact ([X3] Pins 5 and 6) for plausibility checking of the driver supply relay control opens a maximum of 2 ms after t (t2-t) and the driver supply is switched off. 4. Approx. ms after the feedback contact opens, the "H" on the display goes out at time t3. 5. The time for the end stage enable ([X], DIN4) is largely freely selectable (t4-t). The enable may occur at the same time as the relay is controlled, but it must occur approx. µs (t5-t4) before the rising edge of the controller enable ([X], DIN5), depending on the application. 6. The rising edge of the controller enable at time t5 releases the motor holding brake (if present) and the end stage enable occurs. The brake can only be released when the relay for switching the driver supply is engaged, since this controls a MOSFET in the holding brake circuit. Using the parameterizing software, a travel start delay time (t6- t5) can be set that regulates the drive at a speed of "" for the specified time before moving, after this delay, at the defined speed at time t6. The travel start delay time is set to ensure that the brake has actually released before motion begins. For motors without a holding brake, this time can be set to. 7. At time t7 the drive has reached the set speed. The requires ramp settings can be parameterized using the FCT parameterizing software. 78 Festo P.BE-CMMS-AS-HW-EN en 78NH

79 4. Functional safety engineering Activation of "safe standstill" The following steps show how you can bring a rotating drive into the "Safe standstill" state:. Before "Safe standstill" is activated (i.e. the driver supply relay "OFF" and the end stage enable "OFF"; both switch-off paths block the PWM signals), the drive should be brought to a standstill by removing the controller enable. Depending on the application, the braking ramp (t9-t8) is parameterizable using the parameterizing software ("Emergency stop braking"). Warning DANGER! Activating "Safe standstill" during operation causes the drive to slowly come to a stop. For drives with a holding brake, this is applied. It is therefore essential to ensure that the brake system can stop the drive motion. 2. After reaching a speed of, the drive is controlled at this setpoint for a parameterizable switch-off delay time (t-t9). This adjustable time is the delay required to apply the motor holding brake. This time depends on the holding brake used and must be parameterized by the user. For applications without a holding brake, this time can be set to. 3. After this time, the internal end stage enable is switched off by the microprocessor (t). The holding brake is always applied when the "braking ramp time + set switch-off delay" has expired, even when the drive has not come to a stop within this time! 4. From time t the "Safe standstill" can be activated (driver supply relay and end stage enable switched off at the same time). Time (t-t) depends on the application and must be defined by the user. 5. When the driver supply relay control signal is removed (t), the capacitors in this circuit area discharge. Approx. 8 ms (t2-t) after removal of the driver supply relay control, signal the feedback contact closes ([X3], Pin 5 and 6). 6. At time t3, an "H" is displayed on the 7-segment display of the servo controller to indicate a "Safe standstill". This occurs at least 3 ms after the the potential-free feedback contact closes (t3-t2). Festo P.BE-CMMS-AS-HW-EN en 78NH 79

80 Feedback driver supply Output stage driver supply Output stage enabling Controller enabling 4. Functional safety engineering Application examples Emergency stop circuit PLC Inputs Outputs EMERGENCY STOP requested EMERGENCY STOP request Power contactor L N K [X9.] Power supply Mains input 2 EMERGENCY STOP switching device EN954- KAT3 with delay +24V Drawn contact position: EMERGENCY STOP requested or supply voltage switched off +24V V V Input CMMS-AS [X] I/O communication +24V 9 2 DIN5: Controller enabling DIN4: Output stage enabling +24V [X3] SAFE STANDSTILL / SUPPLY 24V 2 24V-Input Triggering of relay Driver supply of output stage V 3 V µp n.c. NC NC2 Fig. 4.3 Emergency stop circuit as per EN 954- Category 3 and Stop Category as per EN 624- Mode of operation: The EMERGENCY-STOP request causes the EMERGENCY-STOP switching device to block the end stage enable and the relay control for the IGBT end stage driver supply. The drive runs to a standstill and, if present, the motor holding brake is engaged. The drive is in the "Safe standstill" state. The EMERGENCY-STOP switching device is approved for safety category 3 as per EN Festo P.BE-CMMS-AS-HW-EN en 78NH

81 4. Functional safety engineering A higher-level control system monitors the "EMERGENCY-STOP request" and "Driver supply feedback" signals and checks them for plausibility. If an error occurs the mains circuit breaker is switched off. The intermediate circuit voltage is maintained and is immediately available for the drive after the EMERGENCY-STOP switching device is deactivated and the controller is enabled once more. Connection of the motor and the optional holding brake is not shown here and can be found in chapter 6 Electrical installation. Warning DANGER! The brakes of the system must be designed to be capable of stopping the drive motion. Festo P.BE-CMMS-AS-HW-EN en 78NH 8

82 Feedback driver supply Output stage driver supply Output stage enabling Controller enabling 4. Functional safety engineering Protective door monitoring Request for standstill as per EN 624- (stop category ) PLC Inputs Outputs Safety door open Power contactor K Safety door monitor open L N [X9.] Power supply Mains input 2 closed Safety door switch EN954- KAT3 with delay +24V Drawn contact position: Safety door open or supply voltage switched off +24V V V Input CMMS-AS [X] I/O communication +24V 9 2 DIN5: Controller enabling DIN4: Output stage enabling [X3] SAFE STANDSTILL / SUPPLY 24V 2 24V-Input Triggering of relay Driver supply of output stage V 3 V µp 4 n.c. 5 NC 6 NC2 Fig. 4.4 Protective door monitoring as per EN 954- Category 3 and Stop Category as per EN 624- Mode of operation: The request to bring the motor to standstill sets the controller enable to low. The drive slows to a speed of using the defined braking ramp (parameterizable using the Festo Configuration Tool ). After the ramp time has expired (including the switch-off de- 82 Festo P.BE-CMMS-AS-HW-EN en 78NH

83 4. Functional safety engineering lay for the holding brake if present), the control signal for the driver supply relay and the end stage enable are removed by the higher-level control system. The higher-level control system monitors the "Protective door open", "End stage drive supply output" and "Driver supply feedback" signals and checks them for plausibility. If an error occurs the mains circuit breaker is switched off. Opening the protective door also interrupts the end stage enable and the control signal for the driver supply relay. The drive is in the "Safe standstill" state and is protected against restarting. The protective door switching device is approved for safety category 3 as per EN954-. The intermediate circuit voltage is maintained and is immediately available for the drive after the protective door is closed. If the protective door is opened without s standstill request, the drive runs to a stop as per EN 624- stop category and, if present, the motor holding brake is engaged. The drive is then in the "Safe standstill" state and is protected against restarting. A door position switch can also be used that keeps the protective door closed until the drive has stopped or the "Driver supply feedback" signal indicates a safe state and the plausibility check is successful. However, the "Safe standstill" state, providing protection from restarting, is only reached when the protective door is actually opened (not shown). Another possibility is to use a protective door switching device with delayed contacts. Opening the protective door directly affects the controller enable, whose falling edge causes a controlled standstill using a defined braking ramp. The "End stage enable" and "End stage driver supply" signals are then switched off after a delay by the safety component. The switch-off delay must match the braking ramp time (not shown) Warning DANGER! The brakes of the system must be designed to be capable of stopping the drive motion. Festo P.BE-CMMS-AS-HW-EN en 78NH 83

84 5. Mechanical installation 5. Mechanical installation 5. Important instructions Please note Using the CMMS-AS motor controller only as a device to be mounted in a control cabinet The mounting position is vertical with the power supply lines [X9] leading upwards Mount with the clip to the control cabinet plate Mounting clearance: For sufficient ventilation, mm of clearance to other assemblies is required above and below the device. The motor controllers of the CMMx series are designed such that they can be mounted on a heat-dissipating mounting panel if used as intended and installed correctly. We wish to point out that excessive heating can lead to premature aging and/or damage to the device. If the CMMS-AS motor controller is subject to high thermal loads, a mounting clearance (hole interval) - of 7 mm is required! 84 Festo P.BE-CMMS-AS-HW-EN en 78NH

85 5. Mechanical installation Fig. 5. Motor controller CMMS-AS: Installation clearance 5.2 Assembly There are mounting clips at the top and bottom of the CMMS-AS servo positioning controller. They are used to attach the motor controller vertically to a control cabinet mounting plate. The clips are part of the radiator profile, ensuring an optimal heat transfer to the control cabinet plate. Festo P.BE-CMMS-AS-HW-EN en 78NH 85

86 5. Mechanical installation Please use size M5 screws to attach the CMMS-AS motor controller. Fig. 5.2 Motor controller CMMS-AS: Assembly 86 Festo P.BE-CMMS-AS-HW-EN en 78NH

87 6. Electrical installation 6. Electrical installation 6. Device view Status display 2 S: Field bus settings and boot loader 3 Technology module (optional) 4 M: SD memory card 5 X4: CAN bus 6 X5: RS232/ Fig. 6. View CMMS-AS Front Festo P.BE-CMMS-AS-HW-EN en 78NH 87

88 6. Electrical installation Earthing screw 2 X9 power supply 3 X increment generator output 4 X I/O interface Fig. 6.2Top view CMMS-AS X3 safe standstill 2 X2 increment generator input 3 X6 motor connection 4 Screened connection Fig. 6.3Bottom view CMMS-AS 88 Festo P.BE-CMMS-AS-HW-EN en 78NH

89 6. Electrical installation 6.2 Interfaces X9: For operation of the motor controller CMMS-AS, the input voltage supply is connected to the plug X9 at L (pin ) and N (pin 2). The PE is connected to Pin 5. In the CMMS-AS plugin, the low-voltage monitoring must be adapted to the input voltage supply. For the control section, a 24 V- voltage source is needed, which is attached to the +24 V and V terminals of the X9 plug. An external brake resistance is connected to the contacts ZK+ and BR-CH. X6: The motor is connected to terminals U, V and W. The motor temperature sensor (PTC, SI sensor or N/C contact) is connected to the +MTdig and -MTdig terminals. (KTY8... KTY84 can be used as analogue temperature sensors. Not in the FCT and not with EMMS-AS motors). The motor brake is connected to the terminals Br+ and Br-. The motors' protective conductor is connected to PE of the X6 plug. The motor shield is conncected to the housing of the CMMS-AS using the shield connector. X2: The connection of the shaft encoder via the 5-pin D-sub plug to [X2] is roughly shown schematically in the illustration Fig H The motor controller must first be wired completely. Only then can the operating voltages be activated for the input voltage supply and the control section. If the polarity of the operating voltage connections is reversed, or if the operating voltage is too high or the operating voltage and motor connections are reversed, the CMMP-AS servo positioning controller will be damaged. Festo P.BE-CMMS-AS-HW-EN en 78NH 89

90 6. Electrical installation 6.3 Entire CMMS-AS system A complete CMMS-AS motor controller system is shown in 2HFehler! Verweisquelle konnte nicht gefunden werden.. To operate the motor controller, the following components are needed: Components - 24V power pack for control voltage supply (see Chapter A.3.) - Power supply (see Chapter A.3.) - Motor controller CMMS-AS - Motor EMMS-AS - Cable set consisting of motor and encoder line NEBM- A PC with a serial connection cable is required for parameterizing. 9 Festo P.BE-CMMS-AS-HW-EN en 78NH

91 6. Electrical installation Main switch 2 Fuse 3 Power pack for control voltage 4 CMMS-AS 5 PC 6 EMMS-AS Fig. 6.4 Complete structure of CMMS-AS with motor and PC Festo P.BE-CMMS-AS-HW-EN en 78NH 9

92 6. Electrical installation 6.4 Interfaces and plug assignments 6.4. I/O interface [X] Mode switching allows allows assignment of the X interface more than once. As a result, a maximum of four different I/O assignments can be selected. These are described in the tables Table 6.2 Pin allocation: I/O interface [X] Mode, Table 6.3 Pin allocation: I/O interface [X] Mode, Table 6.4 Pin allocation: I/O interface [X] Mode 2and Table 6.5 Pin allocation: I/O interface [X] Mode 3. Mode DIN9 DIN2 Mode Positioning Mode Jog mode Mode 2 Route program Mode 3 Synchronisation Table 6. Mode switching Pin Designation Value Mode = - Positioning AGND V Screen for analogue signals 2 AIN / DIN2 ± V Digital I/O control interface: DIN 2 mode selection (high active) Analogue input control interface: Setpoint input, differential, maximum 3 V input voltage 3 DIN Record selection 4 (high active) 4 +VREF + V ±4 % Reference output for setpoint potentiometer 5 free 6 GND24 Ass.GND Reference potential for digital inputs and outputs 7 DIN Record selection (high active) 8 DIN3 Record selection 3 (high active) 9 DIN5 Controller release EN (high active) DIN7 Limit switch DIN9 Digital I/O control interface: Mode selection (high active) Control interface field bus: Sample input (high speed input) 2 DOUT 24 V ma Output freely programmable default: Motion complete (high active) 3 DOUT3 24 V ma Output freely programmable default: Error (low active) 4 AGND V Reference potential for the analogue signals 92 Festo P.BE-CMMS-AS-HW-EN en 78NH

93 6. Electrical installation Pin Designation Value Mode = - Positioning 5 #AIN / DIN3 Ri = 2 k Control interface digital I/O:stop input (low active) Analogue input control interface: Reference potention setpoint input, differential 6 DIN Record selection 5 (high active) 7 AMON ± V ±4 % Analogue monitor output V 24 V ma 24 V feed-in feed-out 9 DIN Record selection (high active) 2 DIN2 Record selection 2 (high active) 2 DIN4 End stage enable (high active) 22 DIN6 Limit switch 23 DIN8 Start for the positioning process (high active) 24 DOUT 24 V ma Ready for operation output (high active) 25 DOUT2 24 V ma Output freely programmable default: Start ack (low active) Table 6.2 Pin allocation: I/O interface [X] Mode Pin Designation Value Mode = - Jog mode AGND V Screen for analogue signals 2 DIN2 24 V Mode switch "" = Jog mode 3 DIN Jog + (high active) 4 +VREF + V ±4 % Reference output for setpoint potentiometer 5 Free 6 GND24 Reference potential for digital inputs and outputs 7 DIN Record selection (high active) 8 DIN3 Record selection 3 (high active) 9 DIN5 Controller release/en (high active) (Taught positions are saved with neg. edge) DIN7 Limit switch DIN9 SAMP Digital I/O control interface: Mode selection "" = jog mode (high active) Control interface field bus: Sample input (high speed input) 2 DOUT 24 V ma Output freely programmable - default motion complete (high active) 3 DOUT3 24 V ma Output freely programmable - default error (low active) 4 AGND V Reference potential for the analogue signals 5 DIN3 Stop input (low active) 6 DIN Jog (high active) Festo P.BE-CMMS-AS-HW-EN en 78NH 93

94 6. Electrical installation Pin Designation Value Mode = - Jog mode 7 AMON ± V ±4 % Analogue monitor output V 24 V ma 24 V feed-in feed-out 9 DIN Record selection (high active) 2 DIN2 Record selection 2 (high active) 2 DIN4 End stage enable (high active) 22 DIN6 Limit switch 23 DIN8 Teach (high active) 24 DOUT 24 V ma Ready for operation output (high active) 25 DOUT2 24 V ma Teach ack Table 6.3 Pin allocation: I/O interface [X] Mode Pin Designation Value Mode = 2 - Route program AGND V Screen for analogue signals 2 DIN2 Mode switch "" = route program 3 DIN Next 4 +VREF + V ±4 % Reference output for setpoint potentiometer 5 Free 6 GND24 Reference potential for digital inputs and outputs 7 DIN Record selection (high active) 8 DIN3 Stop route program 9 DIN5 Controller release (high active) DIN7 Limit switch DIN9 Mode switch "" = route program 2 DOUT 24 V ma Output freely programmable default motion complete (high active) 3 DOUT3 24 V ma Output freely programmable - default error (low active) 4 AGND V Reference potential for the analogue signals 5 DIN3 Stop input (low active) 6 DIN Next 2 7 AMON ± V ±4 % Analogue monitor output V 24 V ma 24 V feed-in feed-out 9 DIN Record selection (high active) 2 DIN2 Record selection 2 (high active) 2 DIN4 End stage enable (high active) 22 DIN6 Limit switch 23 DIN8 Start route program 94 Festo P.BE-CMMS-AS-HW-EN en 78NH

95 6. Electrical installation Pin Designation Value Mode = 2 - Route program 24 DOUT 24 V ma Ready for operation output (high active) 25 DOUT2 24 V ma Output freely programmable - default start ack (high active) Table 6.4 Pin allocation: I/O interface [X] Mode 2 Pin Designation Value Mode = 3 - Synchronisation AGND V Screen for analogue signals 2 DIN2 Mode switch slave synchronisation "" = synchronisation 3 DIN 4 +VREF + V ±4 % Reference output for setpoint potentiometer 5 Free 6 GND24 Reference potential for digital inputs and outputs 7 DIN Record selection (high active) 8 DIN3 24 V Direction_24 /CCW 9 DIN5 Controller release (high active) DIN7 Limit switch DIN9 Mode switch slave synchronisation "" = synchronisation 2 DOUT 24 V ma Output freely programmable - default motion complete (high active) 3 DOUT3 24 V ma Output freely programmable - default error (low active) 4 AGND V Reference potential for the analogue signals 5 DIN3 Stop input (low active) 6 DIN 7 AMON ± V ±4 % Analogue monitor output V 24 V ma 24 V feed-in feed-out 9 DIN Record selection (high active) 2 DIN2 24 V Pulse_24 / CW 2 DIN4 End stage enable (high active) 22 DIN6 Limit switch 23 DIN8 Start synchronisation 24 DOUT 24 V ma Ready for operation output (high active) 25 DOUT2 24 V ma Setpoint reached output (high active) Table 6.5 Pin allocation: I/O interface [X] Mode Encoder motor EnDat 2. and 2.2 (X2) Only encoders with digital EnDat 2. or 2.2 interface with a maximum power consumption of 2 ma are supported. Festo P.BE-CMMS-AS-HW-EN en 78NH 95

96 6. Electrical installation Operating voltage for the encoders is taken from the internal +5 V logic supply. An adjustment to maximum power of the voltage drops on the encoder connection cable is not planned (and for EnDat 2.2/22 encoder also not necessary). The tolerance of the encoder supply voltage is limited downward in order to operate older Heidenhain encoders with EnDat 2.2/ interface. But depending on power consumption and cable length, it may be necessary to double the wiring of the supply lines. Example: Encoder wiring with the cross section of.5 mm² Cable length of 25 m, (= 5 m line to and from) Double wiring Voltage drop with single wiring U diff.8 V Pin Designation Value Specification MT V / 3 ma Motor temperature sensor, NC, PTC, KTY... Not occupied with NEBM lines 2 U_SENS- 5V % / +5% I max = 2mA Connected internally with pin 3 4 n.c. 3 GND V Reference potential for encoder supply and motor temperature sensor 5 #DATA 5V ss R I 2 6 #SCLK 5V ss R I 2 Bidirectional RS485 data cable (differential) Zero impulse transmission with HYPERFACE Cycle output RS485 (differential) for data transfer via the EnDat interface 7 n.c. 8 n.c. 9 U_SENS+ 5V % / +5% I max = 2mA US 5V % / +5% I max = 2mA Connected internally with pin Operating voltage for EnDat encoder n.c. 2 DATA 5V ss R I 2 3 SCLK 5V ss R I 2 Bidirectional RS485 data cable (differential) Zero impulse transmission with HYPERFACE Cycle output RS485 (differential) for data transfer via the EnDat interface 4 n.c. 5 n.c. Table 6.6 Pin occupancy encoder motor-endat 2. and 2.2 (X2) 96 Festo P.BE-CMMS-AS-HW-EN en 78NH

97 6. Electrical installation Field bus CAN [X4] Pin Designation Value Specification - 2 CANL 5 V, Ri = 6 Ohm CAN-low signal line 3 GND V CAN-GND, electrically connected to GND in the controller Screened - Connection for the cable screen 6 GND V CAN-GND, electrically connected to GND in the controller 7 CANH 5 V, Ri = 6 Ohm CAN-high signal line Table 6.7 Pin allocation: Field bus CAN [X4] RS232/RS485 [X5] Pin Designation Value Specification - 2 RS232_RxD V, Ri > 2 kohm Reception line 3 RS232_ TxD V, Ra < 2 kohm Transmission line 4 RS485_A GND V RS232/485 GND, galvanically connected to GND in the controller V_Fuse 5 V Via PTC on plug 9 RS485_B - - Table 6.8 Pin allocation: RS232/RS485 [X5] Motor connection [X6] Type on controller Counterplug Plugged/optional plug set Material number Combicon 8-pin socket MSTB 2.5/8-ST-5.8 BK Blanking plug kit Table 6.9 Plug version: Motor connection [X6] Festo P.BE-CMMS-AS-HW-EN en 78NH 97

98 6. Electrical installation Pin no. Designation Value Specification BR- V brake Motor holding brake, signal level dependent on switch condition 2 BR+ 24V brake 3 -MTdig V Temp. Motor temperature sensor, NC, NO, PTC, KTY. 4 +MTdig +3.3V / 5mA 5 PE PE motor connection 6 W See technical specifications 7 V For EMMS-AS motors PTC PE connection in the motor cable Connection for the three motor phases * 8 U *The motor cable screen is fitted to the controller housing (The fastening flange is specially shaped for this) Table 6. Pin allocation: Motor connection [X6] Power supply [X9] Type on controller Counterplug Plugged/optional plug set Material number Combicon 7-pin socket MSTB 2.5/7-G-ST-5.8 BK Plugged Table 6. Plug version: Power supply [X9] Pin no. Designation Value Specification L 23 V AC compare with 2 N A.3. Mains voltage connection for ZK 3 ZK+ max. 4 V DC compare with A.3. 4 BR-CH V / 4 V, max. 4 A R BR > ZK+ connection for external brake resistance, not short-circuit-proof against L, N and PE! Connection for external brake resistance against ZK+ 5 PE PE PE connection of the mains power supply 6 24V +24V / A Supply for the control portion with DCDC converter, DOUT to DOUT3 and holding brake, max. A 7 V GND Common reference potential for the logic power supply and the control section 98 Festo P.BE-CMMS-AS-HW-EN en 78NH

99 6. Electrical installation Table 6.2 Pin allocation: Power supply [X9] Synchronisation control [X] The interface is bidirectional. It allows A/B tracking signals to be output in the "master axis" mode, or alternatively processing of A/B, CLK/DIR or CW/CCW control signals in the "slave axis" mode. Pin Designation Value Specification A/CLK/CW 5 V, Ri = 2 Ohm Incremental encoder signal A Pulse CLK Cycles clockwisecw Positive polarity in accordance with RS422 2 B/DIR/CCW 5 V, Ri = 2 Ohm Incremental encoder signal B Direction DIR, Cycles counterclockwise CCW Positive polarity in accordance with RS422 3 N 5 V, Ri = 2 Ohm Incremental encoder zero pulse N, positive polarity acc. to RS422 4 GND - Reference GND for the encoder 5 VCC +5 V +-5%, ma Auxiliary supply, max. load ma, short-circuit proof 6 A-/CLK-/CW- 5 V, Ri = 2 Ohm Incremental encoder signal A Pulse CLK Cycles clockwise CW Negative polarity in accordance with RS422 7 B-/DIR-/CCW- 5 V, Ri = 2 Ohm Incremental encoder signal B Direction DIR, Cycles counterclockwise CCW Negative polarity in accordance with RS422 8 N- 5 V, Ri = 2 Ohm Incremental encoder zero pulse N, negative polarity acc. to RS422 9 GND - Screen for the connecting cable Table 6.3 Pin allocation: Incremental encoder output / pulse, direction input [X] Festo P.BE-CMMS-AS-HW-EN en 78NH 99

100 6. Electrical installation SD card [X2] The optional SC card is intended for downloading firmware or saving parameters. The interface is allocated in accordance with the SD card specifications. Alternatively, an MMC card can be used. Type on device x2-pin SD card slot Plug assignments for Safe standstill [X3] Pin no. Designation Value Specification 24V 24V DC 24V DC feed-in feed-out 2 REL V / 24V DC Setting and resetting the relay for interrupting the driver supply 3 V V [GND 24V DC *)] Reference potential for PLC [Reference potential for the 24V DC power supply and for the PLC *)] 4 NOT CONNECT ED NC Max. 6V AC 6 NC2 3V DC 2 A Potential-free feedback contact for driver supply, normally closed contact. Table 6.4 Plug assignments for Safe standstill [X3] 6.4. Field bus settings and boot loader DIP switches Meaning Node number Bootloader (If the switch is set to ON, the system searches for new firmware on the SD card) 9 Baud rate Festo P.BE-CMMS-AS-HW-EN en 78NH

101 6. Electrical installation DIP switches Meaning Activation of the CAN interface 2 Terminating resistor Table 6.5 Assignment of the DIP switches DIP switches ON/OFF Meaning ON DIP switch is the lowest bit. =9 2 ON 3 OFF 4 ON 5 ON 6 OFF 7 ON Table 6.6 Sample node number DIP switches ON/OFF Meaning 9 ON Dip switch 9 is the low-value bit. OFF =25 kbaud =25 kbaud (example) =5 kbaud = kbaud Table 6.7 Sample baud rate 6.5 Instructions on safe and EMC-compliant installation 6.5. Explanations and terms Electromagnetic compatibility (EMC) comprises the following requirements: Interference immunity Sufficient interference immunity of an electrical system or electrical device against external electrical, magnetic or electromagnetic noise via lines or space. Festo P.BE-CMMS-AS-HW-EN en 78NH

102 6. Electrical installation Interference emission Sufficiently low interference emission of electrical, magnetic or electromagnetic interference of an electrical system or an electrical device on other devices in the environment via lines and space Connection instructions The motor cable shield and the internal PE conductor of the motor cable are both connected to the central PE connection of the CMMP-AS. The PE connection on the mains side and the screen of the encoder cable are also carried on this star point. This star point must be connected to the central mass of the entire switching cabinet (short cable to mounting panel) using a cable with a large conductive area (copper strap). With greater lengths, special EMC protective measures must be taken. Warning For reasons of safety, all PE cables must always be connected before commissioning. The mains PE connection is connected to the central PE connection point of the CMMS-AS. Make sure that the earth connections between devices and the mounting plate are of sufficiently large dimensions to conduct away HF interference General information on EMC Interference emission and resistance to interference of a motor controller always depend on the complete design of the drive, which consists of the following components: Components - Voltage supply - Motor controller - Motor - Motor cables - Electromechanics - Design and type of wiring - Higher-order control system In order to increase the interference immunity and decrease the interference emission, the CMMS-AS motor controller already has integrated motor chokes and mains filters, which means that it can be operated without additional shielding and filters in most applications. (Up to a max. motor line length of 5m) 2 Festo P.BE-CMMS-AS-HW-EN en 78NH

103 6. Electrical installation The CMMS-AS motor controllers have been approved in accordance with the product standard EN 68-3 applicable to electrical drives In the majority of cases, no external filter measures are required (Chapter 5.5.3). The EMC guidelines Declaration of Conformity is available from the manufacturer EMC areas: second environment When suitably installed, and with suitable cabling for all connections, the CMMS-AS motor controller conforms to the requirements of the corresponding EN 68-3 product standard. This standard no longer refers to "limit value classes" but rather to so-called "environments". The "first" environment includes electricity grids connected to residential housing. The "second" environment includes grids connected only to industrial plants. For the CMMS-AS motor controller without external filtering measures, the following applies: EMC class Range Compliance with EMC requirements Interference emission Second environment (industrial) Motor cable length up to 5m Interference immunity Second environment (industrial) Regardless of motor cable length Table 6.8 EMC requirements: Second environment Note When used in the first environment measures for interference suppression may be necessary EMC-compliant wiring The following must be observed for EMC-compliant installation of the drive system (see also Chapter 2H6 2HElectrical installation, Seite 23H87): Warning For reasons of safety, all PE cables must always be connected before commissioning. The protective earth regulations in EN 578 and EN 624- must always be observed in the installation!. To keep leaked current and losses in the motor connection cable as low as possible, the motor controller CMMS-AS should be placed as close to the motor as possible. 2. The motor and angle encoder cables must be screened. Festo P.BE-CMMS-AS-HW-EN en 78NH 3

104 6. Electrical installation 3. The screen of the motor cable is fitted to the housing of the CMMS-AS motor controller (screen connection terminals). The cable screen is also always fitted to the corresponding motor controller to prevent leaked current flowing back to the controller which caused it. 4. The mains grid PE connection is connected to the PE connection point of the power connection [X9]. 5. The internal PE conductor of the motor cable is connected to the PE connection point of the motor connection [X6]. 6. Signal lines must be separated as far as possible from the power cables. They should not be routed parallel to one another. If crossovers cannot be avoided, they should be made as close to vertical (i.e. at a 9 angle) as possible. 7. Unscreened signal and control lines should not be used. If they must be used, they should at least be twisted. 8. Even screened lines always have short unscreened parts at either end (unless a screened plug housing is used). In general: - Connect the inner screens to the pins of the plug connector provided for the purpose; length max. 4 mm. - Max. length of unscreened wires: 35 mm. - Connect total shield flat at the motor to the plug or motor housing; length max. 4 mm Operation with long motor cables For applications with long motor cables and/or if the wrong motor cables are selected with excessive cable capacity, the filters may be subjected to thermal overload. In order to avoid such problems, we recommend the following procedure for applications in which long motor cables are required: - From a cable length of over 5m, only cables with a capacitance between the motor phase and screen of less than 2 pf/m, or, if possible less than 5 pf/m! (Please contact your motor cable vendor if necessary) - Use of a du/dt filter on the motor output, - Filter on the voltage supply connection, - Mains filter ESD protection Caution If non-assigned plug connectors are used, there is a danger that damage may occur to the device or to other parts of the system as a result of ESD (electrostatic discharge). 4 Festo P.BE-CMMS-AS-HW-EN en 78NH

105 6. Electrical installation Protective caps are available from specialised retailers to prevent such discharges. Festo P.BE-CMMS-AS-HW-EN en 78NH 5

106 7. Preparations for commissioning 7. Preparations for commissioning 7. General connection instructions As the routing of the connecting cables is critical for EMC, it is essential that you follow the previous Chapter 27H HEMC-compliant wiring (Seite 29H3)! Warning DANGER! Failure to follow the instructions in Chapter 23H2 23HSafety instructions for electrical drives and controllers (page 232H) can result in property damage, bodily injury, electrical shock or, in extreme cases, death. 7.2 Tools / material Tool - Screwdriver size - Serial interface cable - Incremental encoder cable - Motor cable - Power supply cable - Control cable 7.3 Connecting the motor Connecting the motor. Insert the motor cable plug in the corresponding socket on the motor and secure it. 2. Insert the PHOENIX plug into the socket [X6] on the device. 3. Clamp the cable shields to the shield terminals (not suitable as strain-relief). 4. Insert the motor cable plug in the corresponding socket on the motor and secure it. 5. Insert the D-sub plug in socket [X2] of the device and secure the locking screws. 6. Check all plug connectors once again. 6 Festo P.BE-CMMS-AS-HW-EN en 78NH