Motor unit MTR-DCI. Description MTR-DCI-...IO. Description en 1209d [763197]

Transcription

1 Motor unit MTR-DCI Description MTR-DCI-...IO Description en 1209d [763197]

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

4 Contents and general instructions II

5 Contents and general instructions Contents Designated use... Safety instructions... Target group... Service... Scope of delivery... Important user instructions... Manuals on motor unit MTR-DCI... Information on the version... Product-specific terms and abbreviations... VII VIII IX IX IX X XII XIII XIV 1. System summary Positioning with electric drives Components Control and regulating functions Operational reliability Measuring reference system Basis points and work range Signs and directions Homing Mounting General instructions Dimensions of the motor unit Mounting electric axes Installation Overview of installation Earthing Power supply Serial interface Input for external reference switch Connecting the higher-order controller III

6 Contents and general instructions 4. Control panel (MTR-DCI-...-H2IO) Composition and function of the control panel The menu system Accessing the main menu Menu [Diagnostic] Menu [Settings] Menu [Positioning] Menu command [HMI control] Commissioning Procedure for commissioning Commissioning with the control panel (only MTR-DCI-...-H2) Selecting the axis type Setting the homing parameter Teach the axis zero point and the software end positions Positioning with position sets Teach position sets Test run Commissioning with FCT Installing the FCT Procedure for commissioning with the Festo Configuration Tool Communication with the higher-order controller I/O function check Description of the I/Os Function description (pulse-time diagram) Operating, maintenance and diagnosis Important user instructions Diagnosis and fault display General diagnostic possibilities LED status displays Fault messages on the display (only type MTR-DCI-...-H2) IV

7 Contents and general instructions A. Technical appendix... A-1 A.1 Technical specifications... A-3 A.2 Accessories... A-6 A.3 Motor characteristic curves... A-7 A.4 Converting measuring units... A-13 B. Supplementary information... B-1 B.1 The Command Interpreter (CI)... B-3 B.1.1 Procedure for data transfer... B-4 B.1.2 CI commands... B-8 B.1.3 CI Objects (overview)... B-12 B.1.4 Object description... B-16 C. Index... C-1 V

8 Contents and general instructions VI

9 Contents and general instructions Designated use The MTR-DCI motor unit is an intelligent servo motor consisting of DC motor, planetary gear, encoder and integrated control electronics (positioning control and position regulator). The mechanical layout and plug-in interface of the MTR-DCI have been optimized for use with electric linear drives (e.g. DMES) from Festo. The motor unit can also be used for customer-specific positioning applications with slow spindle drives. This manual deals with the basic functions of the MTR-DCI and the I/O interface of the MTR-DCI-...I0. Additional components as well as the field bus variants of the MTR-DCI are described in separate manuals. It is absolutely necessary to observe the Safety instructions as well as the designated use of the relevant components and modules. Observe also the safety instructions in the operating instructions for the electric components used. The MTR-DCI and the connectable modules and cables may only be used as follows: in accordance with designated use only in industrial applications without any modifications by the user. Only the conversions or modifications described in the documentation supplied with the product are permitted. in faultless technical condition. If additional commercially-available components such as sensors and actuators are connected, the specified limits for temperatures, electrical data, torques, etc. must not be exceeded. Please observe the standards specified in the relevant chapters and comply with technical regulations, as well as with national and local regulations. VII

10 Contents and general instructions Safety instructions When commissioning and programming positioning systems, you must observe the safety regulations in this manual as well as those in the operating instructions for the other components used. The user must make sure that nobody is in the operating range of the connected actuators or axis system. Access to thepossibledangerareamustbepreventedbysuitable measures such as protective screens and warning signs. Warning Electric axes can move suddenly with high force and at high speed. Collisions can lead to serious injury to human beings and damage to components. Make sure that nobody can gain access to the operating range of the axes or other connected actuators and that no objects lie in the positioning range while the system is still connected to a power supply. Warning Faults in parametrization can cause injury to people and damage to property. Enable the controller only if the axis system is correctly installed and parametrized. VIII

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

12 Contents and general instructions Important user instructions Danger categories This manual contains instructions on the possible dangers which may occur if the product is not used correctly. These instructions are marked (Warning, Caution, etc.), printed on a shaded background and marked additionally with a pictogram. A distinction is made between the following danger warnings: Warning This means that failure to observe this instruction may result in serious personal injury or damage to property. Caution This means that failure to observe this instruction may result in personal injury or damage to property. Note This means that failure to observe this instruction may result in damage to property. The following pictogram marks passages in the text which describe activities with electrostatically sensitive components. Electrostatically sensitive components may be damaged if they are not handled correctly. X

13 Contents and general instructions Marking special information The following pictograms mark passages in the text containing special information. Pictograms Information: Recommendations, tips and references to other sources of information. Accessories: Information on necessary or sensible accessories for the Festo product. Environment: Information on environment-friendly use of Festo products. Text markings The bullet indicates activities which may be carried out in any order. 1. Figures denote activities which must be carried out in the numerical order specified. Hyphens indicate general activities. XI

14 Contents and general instructions Manuals on motor unit MTR-DCI This manual contains information on the method of operation, as well as on mounting, installing and commissioning electric positioning drives with motor unit MTR-DCI-...IO (I/O interface). Information on components, e.g. the reference switch, can be found in the operating instructions supplied with the product. Type Designation Contents Operating package with brief description +descriptions (+ commissioning software) on CD ROM Description Help system for software Operating instructions Further manuals P.BE-MTR-DCI Motor unit MTR-DCI with I/O interface P.BE-MTR-DCI-IO-DE P.BE-MTR-DCI-IO-EN P.BE-MTR-DCI-IO-FR P.BE-MTR-DCI-IO-IT P.BE-MTR-DCI-IO-ES P.BE-MTR-DCI-IO-SV Festo Configuration Tool help (contained in FCT software) Positioning axis DMES-... Motor unit MTR-DCI with other communication interfaces e.g. P.BE-MTR-DCI-CO P.BE-MTR-DCI-PB Brief description: Important instructions on commissioning and preliminary information. Manuals on CD ROM: for motor unit MTR-DCI (contents as described below) Installation, commissioning and diagnosis of electric axes with motor unit MTR-DCI; communication via I/O interface. Function description of the Festo Configuration Tool (FCT) configuration software. Mounting and commissioning the linear axis with slide shaft as drive element. Installing, commissioning and diagnosing electric axes with motor unit MTR- DCI; communication via the relevant field bus. Tab. 0/1: Documentation on the MTR-DCI XII

15 Contents and general instructions Informationontheversion The hardware version specifies the version status of the mechanical parts and electronics of the MTR-DCI. The firmware version specifies the version status of the operating system of the MTR-DCI. You can find the specifications on the version status as follows: Hardware version and firmware version in the Festo Configuration Tool with active device connection to the MTR-DCI under Device data Firmware version on the control panel under [Diagnostic] [Software information] Firmware version V-DME1.19 What is new? Supports the motor sizes MTR-DCI-42 and 52 and the combination with the following positioning axes from Festo: Motor unit Axis MTR-DCI-42 DMES-25 MTR-DCI-52 DMES-40 Which FCT PlugIn? MTR-DCI V1.0.0 V1.20 Supports the motor sizes MTR-DCI-32 and 62 and the combination with the following positioning axes from Festo: Motor unit Axis MTR-DCI-32 DMES-18 MTR-DCI-42 DMES-25 MTR-DCI-52 DMES-40 MTR-DCI-62 DMES-63 MTR-DCI V1.1.0 Modifying the start-up reaction of all sizes V1.35 Function Save position when switching off removed. The CI-parameter 60FB h, subindex 20 h,contains the fixed value 240 (0x00F0) and cannot be overwritten, see appendix B.1.4. MTR-DCI V Tab. 0/2: Firmware versions XIII

16 Contents and general instructions Product-specific terms and abbreviations The following product-specific terms and abbreviations are used in this manual: Term/abbreviation 0-signal 1-signal Axis Axis zero point (AZ) Controller DMES Drive EMC Encoder Festo Configuration Tool (FCT) HMI Homing method Homing mode Meaning 0 V present at input or output (positive logic, corresponds to LOW). 24 V present at input or output (positive logic, corresponds to HIGH). Mechanical component of a drive which converts the motor revolutions into positioning movements of a work load. An axis (e.g. positioning axis DMES-...) enables: the work load to be fitted and guided a reference switch to be fitted. Measuring basis point for the project zero point and the software end positions. The basis point for the axis zero point is the reference point. Corresponds to the project zero point with the MTR-DCI (offset = 0). Control electronics which evaluate the control signals and provide the power supply for the motor via the power electronics (power electronics + controller + position controller). Type designation, electric linear axis Complete actuator, consisting of controller, motor, measuring system and, if applicable, gear and (linear) axis. Electromagnetic compatibility Optical pulse generator (rotor position transducer on the motor shaft of the MTR-DCI). The electric signals generated are sent to the controller, which then calculates the position and speed on the basis of the signals received. Commissioning software with uniform project and data management for all supported device types. The special requirements of a device type are supported by PlugIns with the necessary descriptions and dialogues. Human Machine Interface, with the MTR-DCI the control panel with LC display and 4 operating buttons. Methodfor determinationof the reference position: against a fixedstop (overload current/speed evaluation) or with reference switch. Operating mode inwhich a homing runiscarriedout. XIV

17 Contents and general instructions Term/abbreviation Homing run I O I/O Jog mode Motor unit Operating mode PLC Positioning mode (Profile position mode) Position set Project zero point (PZ) Reference point (REF) Reference switch Referencing Meaning The reference positionandtherefore the source of the basissystemof the axis are defined by a homing run. Input Output Input and/or output Manual positioning in positive or negative direction (only on field bus variants of the MTR-DCI via the field bus or only with FCT or control panel). Integratedunit consistingof the controller, motor, measuringsystemand, if applicable, gears (e.g. motor unit MTR-DCI). Type of controller or internal operating mode of the controller. Type of control: Record Select, Direct mode Operating mode of the controller: Position profile mode, homing mode, Demo mode,... Programmable logic controller; in brief: controller: (PLC: progammable logic controller) Operating mode for processing a position set or a direct positioning task. Positioning command defined in the position set table, consisting of: The number of the position set The absolute or relative basis of the nominal position The nominal position of the position set The positioning speed of the position set Basis point for all positions in positioning tasks (Project zero point). The project zero point forms the basis for all absolute position specifications (e.g. in the position set table or with direct control via the control or diagnostic interface). The basis point for the project zero point is the axis zero point. With the MTR-DCI the project zero point PZ and the axis zero point AZ are identical. Basispoint forthe incrementalmeasuringsystem. The reference point defines a known orientation or position within the positioning path of the drive. External sensor (e.g. SMT-8 or SIEN) which serves for ascertaining the reference position and is connected directly to the controller. Complete definition of the basis system of the axis with reference point and, if applicable, zero point. XV

18 Contents and general instructions Term/abbreviation Software end position Teach mode (Teach mode) Meaning Programmable stroke limitation (basis point = axis zero point) Software end position, positive: max. limit position of the stroke in the positive direction; must not be exceeded during positioning. Software end position, negative: min. limit position in the negative direction; must not be exceeded during positioning. Operating mode for setting positions by moving to the target position, e.g. when creating position sets. Tab. 0/3: Index of terms and abbreviations XVI

19 System summary Chapter 1 System summary 1-1

20 1. System summary Contents 1. System summary Positioning with electric drives Components Control and regulating functions Operational reliability Measuring reference system Basis points and work range Signs and directions Homing

21 1. System summary 1.1 Positioning with electric drives 1 Process control and parameter access through the higher-order controller 2 Software level: Commissioning with the Festo Configuration Tool software 3 Drive level with Motorunit Coupling Coupling housing Axis 1 2 I/O CANopen Profibus DeviceNet 3 RS232 Fig. 1/1: Principle of a positioning system with motor unit MTR-DCI and positioning axis DMES The motor unit MTR-DCI enables the connected linear or rotation axis to be placed in max. 15 positions (plus homing) with separate speed adjustment. The permitted positioning range can be limited by means of software end positions. 1-3

22 1. System summary You can parametrize and commission the MTR-DCI as follows: with the FCT software package via the RS232 interface of your PC with the optional control panel with display and 4 operating buttons (only MTR-DCI-...-H2) Coupling to a higher-order PLC/IPC is carried out in operation via digital inputs/outputs. Functions HMI FCT Parameterisation Selecting the axis type and the axis parameters Specifying a gear factor (with external gears) Uploading/downloading of configuration data Saving different configurations in projects x x x x x Positioning records Compiling a position set table with set number, target position, positioning mode, positioning speed, acceleration x x Commissioning Homing Jogmode Teaching of positions Travel in individual steps Starting and stopping positioning procedures during commissioning Extended test functions, e.g. status displays Testing or demonstrating the positioning records x x x x x x x x x x x x Diagnostics/ Service Reading and displaying diagnostic data x x Tab. 1/1: Functions 1-4

23 1. System summary All parameters are entered or displayed in the relevant set measuring units. Units of Measurement Control panel FCT Linear axis Metric Metric units of measurement, e.g. mm, mm/s, mm/s 2 x x Customs duties 1) Increments Imperial units of measurement, x e.g. inch, inch/s, inch/s 2 Increment-based units of measurement, e.g. inc, inc/s, inc/s 2 Rotation axis Degree Angle dimension 360 = 1 revolution e.g. deg, deg/s, deg/s 2 x x Revolutions 2) Increments Number of revolutions x e.g. rev, rev/min, rev/min 2 Increment-based units of measurement, e.g. inc, inc/s, inc/s 2 1) Only with FCT when creating a project. 2) Setting only with the control panel [Settings] [Axis type] [Rotation axis] Tab. 1/2: Units of Measurement Setting the units of measurement influences only the display. All the parameters in the controller are saved internally in increments (inc, inc/s, inc/s 2...) and are not converted until they are written or read. Measurements transmitted directly via RS232 are conducted on an increment basis (for conversion see appendix A.4). 1-5

24 1. System summary 1.2 Components For setting up an electric drive with the MTR-DCI you will require the following components: Motor unit MTR-DCI Axis Coupling with coupling housing Power supply cable Motor with controller, available in four sizes, optionally with control panel (type...-h2). By means of different gear reductions, different requirements can be fulfilled in respect of (gear unit) output torque and (gear unit) output speed (see appendix A.1). High drive output torques with low drive output speeds are characteristic for positioning functions. With the smaller gear reduction, the positioning speed of the axis can be increased with correspondingly reduced positioning force. Linear or rotation axes as per catalogue For the axial attachment of Festo axes, e.g. type DMES-... or type DNCE-..., couplings and coupling housings are available as accessories. The motor unit is connected to the axis by means of a clamping connection in the coupling housing. Additional motor flanges are not therefore necessary. Further information can be found in the operating instructions for the axis. for supplying the MTR-DCI with operating voltage via a power unit (DC 24 V / size 62: 48 V) Programming cable Homing Switch Accessories Parametrizing the MTR-DCI during commissioning with the FCT Sensor as per appendix A.2. For positioning systems Festo offers special matching accessories (see Festo delivery program or catalogue). 1-6

25 1. System summary 1.3 Controlandregulatingfunctions The controller takes over the following tasks: specification of the nominal values regulation of the following factors: Position, speed, acceleration, current. 1 Motor controller 3 2 Regulator 3 Setpoint value generator P PI P M 4 Position controller 5 Velocity control 6 Current control Output stage 8 Signal converter Fig. 1/2: Simplified diagram of the cascade regulator Profile position mode Positioning mode Operating mode for executing a position set or a direct positioning task with position control (closed loop position control). The target position defines the position to which the drive controller is to move. The target position is interpreted either as an absolute or relative specification. The set target position is transferred to the setpoint value generator. This generates a setpoint position value for the position controller. For position control the current settings for speed, acceleration, braking deceleration, etc. are taken into account. 1-7

26 1. System summary Changes in position are recognized by the internal incremental sensor (optical encoder). With a known starting point the actual position is calculated from the gear reduction and/or the spindle slope. Homing mode Homing. Execution of a positioning procedure in which the reference point and therefore the source of the measuring reference system of the axis are defined, e.g. via a reference switch within the possible positioning path or with overcurrent evaluation n the case of movement to a stop. For commissioning, for testing or for demonstration the following functions are also available via the control panel of the MTR-DCI-...-H2: Positioning travel for defining the target position of a positioning record [Settings][Position set]. Positioning travel for testing all positioning records in the positioning record table [Demo posit tab]. Positioning travel for testing a certain positioning record in the positioning record table [Move posit set]. 1-8

27 1. System summary 1.4 Operational reliability An extensive system of sensors and monitoring functions ensure operational safety: i 2 t-monitoring Temperature monitoring (measuring the motor temperature and the power end stage temperature) Current monitoring Voltage monitoring Recognizing faults in the internal voltage supply. MTR-DCI-62...: detection of overvoltages in the intermediate circuit; brake chopper integrated. Drag fault monitoring Software end position recognition. Observe the following: By the arrangement of the limit switches and, if necessary, additionally by means of mechanical stops, make sure that the axis always lies within the permitted positioning range. 1-9

28 1. System summary Warning Please note that the MTR-DCI- IO does not have a separate logic voltage supply. Check the measures which are necessary within the framework of your EMERGENCY STOP circuit for switching your machine/system into a safe state in the event of an EMERGENCY STOP. If corresponding EMERGENCY STOP circuitry is necessary for your application, use additional, separated safety limit switches (e.g. as normally closed limit switches wired in series connection) Cancelling the ENABLE signal at the controller interface Switch off the load voltage. 1.5 Measuring reference system For commissioning, a measuring reference system for referencing the reference coordinates must be defined. By means of the measuring system all (absolute) positions are defined and movement can be made to them Basis points and work range The basis system of the MTR-DCI is based on the axis zero point which is defined by the offset to the reference point. Homing run Homing method Homing point REF The position of the reference point REF is defined by a homing run. When a homing run is finished, the drive stands at the axis zero point AZ. The homing method defines the way in which the reference point is determined. forms the mechanical starting point of the measuring reference system and is defined for the homing run by a reference switch or a fixed stop, depending on the homing method. It is the reference point of the axis zero point. 1-10

29 1. System summary Axis zero point AZ Software end positions Project zero point PZ is shifted by a defined distance from the reference point REF (axis zero point offset) and is the basis point of the software end positions and the project zero point PZ. By defining the axis zero point AZ and the software end positions you can limit the work area of the linear axis to the permitted range (work stroke). limit the permitted positioning range (work stroke). If the target position of a positioning command lies outside the software end positions, the positioning command will not be processed and a fault status will be displayed. is a basis point which the user can freely select within the workstrokeandtowhichtheactualpositionaswellasthe target positions in the position set table refer. The axis zero point AZ is the basis point for the project zero point. The project zero point PZ is specified with the MTR-DCI and is identical to the axis zero point AZ (project zero point offset = 0). 1-11

30 1. System summary Measuring reference system: basis points and work range Linear axis with homing method: Fixed stop negative d e Rotation axis with homing method: Reference switch negative REF AZ A b, c d e Reference point: Point determined during homing run: reference switch or stop Axis zero point: reference point for the project zero point and the software end positions. Corresponds to the project zero point with the MTR-DCI (offset project zero point = 0). The basis point for the axis zero point is the reference point. Offset axis zero point: Defined distance of the axis zero point AZ from the reference point REF Software end positions: limit the permitted positioning range (work stroke). Work stroke: Permitted positioning range. Rated stroke of the axis used Tab. 1/3: Measuring reference system 1-12

31 1. System summary Signs and directions All offsets and position values are vectors (with a given algebraic sign, + or -). The active direction can be reversed on the control panel (see 5.2.1) or via FCT. This can be useful when using angular gear units or toothed belt drives. A homing run must be carried out again if the direction is reversed. The direction in which the work load moves depends on the gearing, the spindle type (left/right-rotating), the algebraic signs on the positioning specifications, and the set active direction Factory setting for active direction 2 Reversal of direction Fig. 1/3: Active direction (using the example of MTR-DCI + DMES, axial gearing) 1-13

32 1. System summary Homing In the case of drives with incremental measuring system, homing must always be carried out after the drive is switched on. The following homing modes are permitted: Search for stop in a negative direction Search for stop in a positive direction Search for reference switch in a positive direction Search for reference switch in a negative direction (default). In order to search for the reference point and for positioning the drive in the axis zero point, you can set two different speeds. Homing sequence: 1. Search for the reference point in accordance with the configured method. 2. Move from reference point to axis zero point AZ (offset axis zero point) After successful homing the drive stands at the axis zero point AZ. On initial commissioning or following a change of homing method the axis zero offset is = 0; after homing the drive is then positioned at the reference point (REF). 1-14

33 1. System summary Search for fixed stop With this reference travel method, at first the drive moves at search speed in a negative or positive direction until it reaches the fixed stop. A rise in the motor current signals that the stop has been reached. When the maximum motor current is reached at the same time as the motor is at a standstill, the MTR-DCI recognizes that the stop, and therefore the reference position, has been reached. As the axis should not stand still at the stop, the axis zero point offset must be 0 (min mm). + 1 REF (-) AZ 2 AZ REF (+) 1 Stop in a negative direction 2 Stop in a positive direction Fig. 1/4: Search for fixed stop reference travel method 1-15

34 1. System summary Search for reference switch With this reference travel method, at first the drive moves at search speed in a negative or positive direction until it reaches the limit switch. It then moves back at creep speed: The reference position lies at the point at which the reference switch becomes inactive again when the drive moves back. 1 + REF (-) AZ 2 AZ REF (+) 1 Reference switch in negative direction 2 Reference switch in positive direction Fig. 1/5: Search for reference switch reference travel method If the drive stands on the reference switch at the start of reference travel, it will move in the opposite direction to the reference switch. The drive then moves as usual to the axis zero point. Note If a reference signal is not found by the reference switch homing method before the drive reaches a fixed stop, the MTR-DCI will stop and an error will be displayed (HOMING ERROR). 1-16

35 Mounting Chapter 2 Mounting 2-1

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

37 2. Mounting 2.1 General instructions Warning Electric shock Before carrying out mounting, installation and maintenance work, always switch off the power supply for the electronic components. Note Handle all modules and components with great care. Please note especially the following: Screw connections must be fitted free of offset and mechanical tension. Screws must be fitted accurately (otherwise threads will be damaged). The specified torques must be observed. The modules must not be offset. Contact surfaces must be clean (avoid contact faults). 2-3

38 2. Mounting 2.2 Dimensions of the motor unit 13 T1 H1 D4 D2 D3 D1 H0 H2 5 L1 L5 L2 L4 L3 B1 B2 Sizes [mm] Gear ratio G7/G14 G7 G14 G7 G14 G7/G14/G22 Diameter of flange/shaft D D1 D2 D3 D h8 6 h7 42 g10 42 ± h8 8 h7 52 g10 52 ± h8 12 h7 62 g10 62 ± j7 14 h7 Height H H0 H1 H ± ± ±0.3 70,8 ±0,4 26,5 ±0,6 54,5 ±0, ± ±0, ± ± ± ±0.5 Length L L1 L2 L3 L ± ± ± ± ±1 25 ±1 2 ± ±1 46,3 ±1 25 ±1 2 ± ±1 39 ±1 33 ±1 3 ± ±1 53 ±1 33 ±1 3 ±0,3 270 ±1 47 ±1 39 ±1 5 ±0.3 Width B B1 B ± ± ± ± ± ± ± ±0.4 Depth T T1 6 M3: 7 / M4: Tab. 2/1: Dimensions of the motor unit 2-4

39 2. Mounting 2.3 Mounting electric axes Refer to the following documentation when mounting the electric axis: Operating instructions for the axis used. Instructions for the components used. Warning If an axis is fitted in a sloping or vertical position, the work load may fall down and injure somebody. Use the motor unit preferably with self-locking or selfbraking spindle drives. You can then avoid the working mass sliding down if there is a sudden power failure. With DMES: Check whether additional external safety measures against spindle nut fracture are necessary (e.g. toothed latches or moving bolts). Make sure that: the drive is fitted securely and is free of distortion, the work space, in which the axis moves, is of sufficient size for operation with a work load, the work load does not collide with any component of the drive when the slide moves into the end position. Make sure that you observe the maximum permitted values of the following variables: the basis point for forces and torques is the centre of the shaft (L3 see Tab. 2/1). 2-5

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

41 2. Mounting Note Motor unit MTR-DCI G22 can generate up to 37 Nm at a peak current of 20 A in the start-up phase. Make sure by calculating the dynamic loading that the maximum permitted shaft output torque of the gear is not exceeded in the start-up phase (e.g. by reducing the load). Use the thread on the front of the gear (see Fig. 2/2) for mounting the MTR-DCI to a mechanical drive device (machine frame). In order to minimize the shaft offset: Position the axis with the aid of the centring diameter (D1 or D3 see Tab. 2/1) relative to the rotary axis of the mechanism to be driven. Fasten the motor unit with 4 screws and tighten the 4 screws with the specified tightening torque. Motor unit MTR-DCI-32 has 6 threads for different mounting variants (axial, parallel); 4 screws must be used here. Size Thread depth Tightening torque MTR-DCI-32 M3 6mm 1.2 Nm MTR-DCI-42 M3 7mm 1.2 Nm M4 10 mm 2.9 Nm MTR-DCI-52 M5 10 mm 5.9 Nm MTR-DCI-62 M5 10 mm 5.9 Nm Tab. 2/3: Tightening torques 2-7

42 2. Mounting In order to fit Festo axes e.g. DMES or DGE axially, you will require couplings and coupling housings as accessories. The motor unit is connected to the axis by means of a clamp in the coupling housing. Additional motor flanges are not therefore necessary. Fit the motor onto the permitted axis in accordance with the Øassembly instructions for the motor mounting kit recommended in the catalogue. MTR-DCI MTR-DCI Ø32 4x 90 4x 90 6xM3x xM4x10 4xM3x7 MTR-DCI MTR-DCI Ø40 4X 90 4x 90 Ø50 Ø36 Ø32 4xM5x10 4xM5x10 Fig. 2/2: Fastening the drive by means of the front threads (direct fastening) 2-8

43 Installation Chapter 3 Installation 3-1

44 3. Installation Contents 3. Installation Overview of installation Earthing Power supply Serial interface Input for external reference switch Connecting the higher-order controller

45 3. Installation 3.1 Overview of installation Warning Before carrying out installation and maintenance work always switch off the power supply for the electronic components. You can thereby avoid: unexpected movements of the connected actuators non-defined switching states of the electronic components. Caution Faulty pre-assembled lines may destroy the electronics and trigger unexpected movements of the motor. For cabling the electric components of the system, use only the cables listed as accessories (see Tab. 3/2). This is the only way to ensure the system will work properly. Caution Earth or ground loops can under circumstances cause EMC protective measures to become ineffective, resulting in high compensating currents which will damage the motor unit (e.g. with faulty power supply). Connect only one cable shield (control cable or supply cable) to functional earth (FE). The GND connection must not be connected to the housing, the shield or functional earth (FE)! 3-3

46 3. Installation 1 Power supply 2 I/O control 3 Reference switch 4 Serial interface Fig. 3/1: Connections on the MTR-DCI ConnectionontheMTR-DCI Manual Power supply Controller Reference switch Serial interface D-Sub, 2-pin Plug D-Sub, 9-pin Plug M8x1, 3-pin Socket M8x1, 4-pin Socket Operating voltage connection with 2 high-current contacts Interface for connection to any PLC controller Sensor input for switch type normally open contact in the design PNP, e.g. SMT-8F RS232 interface for parametrizing, commissioning and diagnosing Tab. 3/1: Overview of connections 3-4

47 3. Installation If non-assigned plug connectors are touched, there is a danger that damage may occur to the MTR-DCI or to other parts of the system as a result of ESD (electrostatic discharge). Place protective caps on unused connections in order to prevent such discharges. The plug connectors of the following Festo cables have been designed so that, when inserted and screwed tight, or if fitted with protective covers, the connections on the MTR-DCI will comply with protection class IP54. Connection Cable Designation Length [m] Voltage supply Power supply cable KPWR-MC-1-SUB-9HC 2.5/5/10 I/Ocontrol Pilot line KES-MC-1-SUB-9HC 2.5/5/10 Serialinterface Programming cable KDI-MC-M8-SUB Homing Switch If necessary, connecting cable with screw-type lock KM8-M8-GSGD 0.5/1/2/5 Tab. 3/2: Overview of cables (accessories) In order to guarantee compliance with the IP protection class: Seal unused M8 connections with ISK-M8 protective caps (accessories). Hand-tighten the union nuts/locking screws of the plugs. Observe the permissible tightening torques specified in the documentation for the lines and plugs used. Note Lay all moveable motor and sensor cables free of bends and free of mechanical stress, if necessary, in a drag chain. Observe the maximum specified cable lengths. 3-5

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

49 3. Installation 3.3 Power supply Warning In order to provide the electric power supply, use only PELV circuits as per IEC/DIN EN (Protective Extra-Low Voltage, PELV). Take into account also the general requirements for PELV circuits as per IEC/DIN EN Use only power packs which guarantee reliable electrical isolation of the operating voltage as per IEC/DIN EN By the use of PELV power units, protection against electric shock (protection against direct and indirect contact) is guaranteed in accordance with IEC/DIN EN (electrical equipment of machines, general requirements). Caution Damage to the device. The voltage input of the motor unit has no special protection against overvoltage. Make sure that the permitted voltage tolerance is not exceeded. The tolerance must also be observed directly at the operating voltage connection of the MTR-DCI (see Tab. 3/3). Install an external fuse in the DC supply in order to limit the available current (see Tab. 3/4). 3-7

50 3. Installation The internal power and controller electronics are supplied with DC voltage via the power supply connection. The power supply must fulfil the following requirements: Specifications MTR- -32 MTR- -42 MTR- -52 MTR- -62 Rated voltage DC 24 V ±10 % DC 48 V % Rated current 0.73 A ±20 % 2A±20% 5A±20% 6.19 A ±20 % Peak current 2.1A±20% 3.8A±20% 7.7A±20% 20 A ±20 % Tab. 3/3: Power supply Recommendation Use a closed-loop controlled power unit with high output reserve and external fuse: MTR- -32 MTR- -42 MTR- -52 MTR- -62 Power unit (closedloop controlled) External fuse secondary side DC 24 V /3 A DC 24 V/6 A DC 24 V/10 A DC 48 V/20 A 5 A slow-blowing 7 A slow-blowing 10 A slow-blowing 25 A slow-blowing Tab. 3/4: Selecting the power unit A1 A2 A1 A2 Fig. 3/2: Connection example power supply with external fuse 3-8

51 3. Installation Use the following cable from Festo's accessories: power supply cable KPWR-MC-1-SUB-9HC cable length max. 10 m. Only connect one cable screen (control cable or power supply cable) to the functional earth (FE). Plug Pin Colour 1) Manual A1 black (1) MTR-DCI-32/42/52: MTR-DCI-62: POWER DC +24 V POWER DC +48 V A1 A2 A2 black (2) MTR-DCI-32/42/52/62: POWER GND 2) 1) Cable colours with power supply cable KPWR-MC-1-SUB-9HC 2) Do not link the GND terminal to any housing, screen or functional earth (FE)! Tab. 3/5: Connecting the power supply to the motor unit 3-9

52 3. Installation 3.4 Serial interface Serial interface for parametrizing, commissioning and diagnosing Note To connect a PC to the MTR-DCI, use the following cable from Festo's accessories: Programming cable KDI-MC-M8-SUB-9 Cable length 2.5 m (maximum permitted signal cable length). If necessary, remove the protective cap from the serial interface of the MTR-DCI. Connect the following terminals with the programming cable: the connection socket on the MTR-DCI a serial interface COMx of the diagnostic PC. M8x1 socket Description 1 GND Ground 2 TXD RS232 transmitting cable 1) 3 RXD RS232 receiving cable 1) Reserved for service personal. Do not connect. 1) The levels correspond to the RS232 standard and enable a data transmission rate of 9600 bit/s Tab. 3/6: Connecting the serial interface on the MTR-DCI 3-10

53 3. Installation Information on commissioning and parametrizing the MTR-DCI via the serial interface can be found in chapter 5.3 and in the help system for the FCT software package. Information on transmitting CI commands via the serial interface can be found in appendix B.1.2. Note The RS232 interface is not electrically isolated. It is not suitable for permanent connection to PC systems, nor for use as a control interface. Use this terminal only for commissioning. Remove the programming cable in continuous operation. Seal the terminal with the supplied protective cap (ISK- M8). 3-11

54 3. Installation 3.5 Input for external reference switch If you are not using a reference switch: Seal the connection with the protective cap supplied (ISK-M8). Connecting the reference switch: Use the correct switch type normally-open contact in the PNP variant for the reference switch. When connecting the reference switch use a sensor with a screw-type lock (external thread M8x1) at the end of the cableorusetheconnectingcablekm8-m8withascrewtype lock as an adapter. Use e.g. the following proximity switches from Festo: magnetic proximity switch SMT-8F inductive proximity switch SIEN-...-M8B When selecting the sensor, note that the accuracy of the switchover point of the sensor determines the accuracy of the reference point. M8x1 socket Description 1 DC+24 V DC +24 V voltage output (only for reference switch) 4 REF Contact reference switch GND Ground Tab. 3/7: Connection Ref (reference switch) on the MTR-DCI The power supply for the reference switch (DC 24 V / Ground) is provided via pin 1/

55 3. Installation Caution Damage to the device The DC 24 V voltage at pin 1 does not have any special protection against overload; the voltage is taken from the main supply with protection against ESD and incorrect polarity. Use this connection only for the reference switch (sensor supply). Use of this connection as a power supply for other devices is not permitted. The input for sensor signal REF complies in its electrical features with the input specification in the appendix Technical specifications. 3-13

56 3. Installation 3.6 Connecting the higher-order controller Communication with the higher-order controller is made via the control connection on the MTR-DCI Use the control cable KES-MC-1-SUB-9 to connect the MTR-DCI to a higher-level controller (PLC). Caution Long I/O signal cables reduce the immunity to interference. Do not, therefore, exceed the maximum permitted I/O signal cable length of 30 m. Sub-D plug Colour 1) Description 1 1 white I1 Position set code Bit0 2 brown I2 Position set code Bit1 3 green I3 Position set code Bit2 9 4 yellow I4 Position set code Bit3 5 grey I5 START 6 pink I6 ENABLE 7 blue O1 READY 8 red O2 MOTION COMPLETE (MC) 9 black GND GROUND (basis potential) 1) Cable colours of pilot line KES-MC-1-SUB-9 Tab. 3/8: Controller connection on the MTR-DCI 3-14

57 3. Installation Warning If a voltage is applied and the output pins are used incorrectly, the device may be seriously damaged, therefore: Do not connect voltage to the outputs. Note the current limit at the outputs. 3-15

58 3. Installation 3-16

59 Control panel (MTR-DCI-...-H2IO) Chapter 4 Control panel (MTR-DCI-...-H2IO) 4-1

60 4. Control panel (MTR-DCI-...-H2IO) Contents 4. Control panel (MTR-DCI-...-H2IO) Composition and function of the control panel The menu system Accessing the main menu Menu [Diagnostic] Menu [Settings] Menu [Positioning] Menu command [HMI control]

61 4. Control panel (MTR-DCI-...-H2IO) Onthecontrolpanel, motor unit typemtr-dci-...-h2 offers all the functions necessary for commissioning, programming and diagnosis. An overview of the button and menu functions for the MTR-DCI-...IO can be found in this chapter. Commissioning with the control panel is described as from chapter 5.2. Withthe MTR-DCI-...-R2 (without control panel) you can commission the MTR-DCI via the RS232 interface (with FCT software). Instructions on this can be found in chapter 5.3. Caution Faults may occur if you attempt to access control and operating functions at the same time via the FCT and the control panel. Make sure that the FCT, the control panel and the control interface of the MTR-DCI are not used at the same time. Note If necessary, remove the protective foil from the display before commissioning. 4-3

62 4. Control panel (MTR-DCI-...-H2IO) 4.1 Composition and function of the control panel The control panel enables commissioning directly on the MTR-DCI with the following functions: Parametrizing and referencing the axis Entering position sets Test functions e.g. for moving to individual position sets. 1 LC display 2 Operating buttons LEDs Power (green) I/F (green/red) Error (red) Fig. 4/1: Control panel of the MTR-DCI-...-H2 With the 4 buttons on the control panel you can carry out all operating functions and settings as indicated in the menu. The graphic LCD display shows all texts in English. The display can be turned in 90 steps, see menu command [LCD adjustment]. The visual display of the operating states is shown via 3 LEDs (see also chapter 6.2.2). Power: display of power supply I/F: ready to operate, positioning status Error: fault 4-4

63 4. Control panel (MTR-DCI-...-H2IO) Function MENU ESC EMERG.STOP OK SAVE START/STOP Activated by the status display from the main menu Rejects the current entry and switches back in stages to the higher-order menu level or status display Interrupts the current positioning procedure (> Error mode; confirm with <Enter>, then automatic return to the status display) Only when HMI = on. Confirms the current selection or entry Saves parameter settings permanently in the EEPROM Starts or stops a positioning procedure (only in Demo mode). After stop: Display the current position, return to the higher-order menu level with <Menu>. Button Menu Enter <- -> Scrolls within a menu level in order to select a menu command. v EDIT Sets the parameter V Tab. 4/1: Button function (overview) 4-5

64 4. Control panel (MTR-DCI-...-H2IO) 4.2 The menu system Accessing the main menu MTR-DCI... X a = 0.00 mm HMI:off <Menu> When the power supply is switched on, the MTR-DCI automatically carries out an internal check. At first the display briefly shows the Festo Logo then changes to the status display. The status display shows the following information: the type designation of your MTR-DCI the current position of the drive x a =... the current setting of the device control (HMI = Human Machine Interface) } Diagnostic positioning Settings S ESC <Menu> <--> OK <Enter> } HMI control LCD adjustment v ESC <Menu> <--> OK <Enter> The main menu is accessed from the status display with the button <Menu>. The current button function will be displayed in the lower lines of the LCD display. Function <- -> With the arrow buttons on the control panel you can select a menu item from the list. The current selection is marked with an arrow (} Diagnostic). Select the menu item S in order to display further menu items (HMI control...). Button v V ESC OK With <Menu> you can interrupt the current entry and return in stages to the higher-order menu level or status display. With <Enter> you can confirm the current selection or entry. Menu Enter Tab. 4/2: Button function (menu selection) 4-6

65 4. Control panel (MTR-DCI-...-H2IO) Menu command Description } Diagnostic Display the system data and the currently effective settings (see chapter 4.2.2) } Posset table Display the position set table } Axis param Display axis parameters and data } System param Display system parameters and system data } SW information Display the operating system version (firmware) } Positioning 1) 2) Homing and positioning run for testing the position sets (see chapter 4.2.4) } Move posit set Start positioning run Position set } Demo posit tab Start positioning run Position set table } Homing Start homing run } Settings 1) 2) Select the drive, parametrizing, programming the position sets... (see chapter 4.2.3) } Axis type } Type DMES Positioning axis DMES } Rotation drive Rotation axis with stop } User config Any lineardrive } Axis param } Zero point 3) Offset of axis zero point } Abs.min.pos 3) Stroke limitation: Software end position, negative } Abs.max.pos 3) Stroke limitation: Software end position, positive } Save... Save parameters in EEPROM } Homing param } Homing method Select referencing (homing) method (stop, software limit switch...) } Velocity v_sw Positioning speed for searching for the reference point } Velocity v_s0 Positioning speed for moving to the axis zero point } Save... Save parameters in EEPROM } Position set } Position no. Number of the position set (0...14) } Pos set mode Set status: absolute or relative positioning } Position 3) Target position of the position set } Velocity Positioning speed of the position set } Save... Save parameters in EEPROM } Password Set up a local password with 3 figures for the control panel (see chapter 4.2.3). } HMI control 1) Preset the device control via the control panel (see chapter 4.2.5) } LCD adjustment Rotate the display in steps of 90 1) If necessary password protection 2) Control interface must be deactivated, see [HMI control] :HMI = on 3) Teach mode Tab. 4/3: Menu commands (overview) 4-7

66 4. Control panel (MTR-DCI-...-H2IO) For selecting the menu commands [Positioning] and [Settings] you will require the setting HMI: on. Only then is the MTR-DCI ready to process user entries on the control panel. When selecting the menu commands, you will be requested to modify the HMI setting. You can also modify the setting directly in the main menu with the menu command [HMI control] Menu [Diagnostic] Inordertodisplaythesystemdataandthecurrentlyeffective settings: } Diagnostic } Pos.set table Axis param System param SW information 1. Select [Diagnostic] in the main menu with the arrow buttons and press the <Enter> button. 2. Select one of the following menu commands: Position set table [Pos. set table] Axis parameter [Axis param] System parameter [System param] Version of firmware of the MTR-DCI [SW information] Function <- -> You can scroll through the diagnostic data with the arrow buttons. Button v V ESC With <Menu> you can return to the higher-order menu level. Menu 4-8

67 4. Control panel (MTR-DCI-...-H2IO) [Pos. set table] Menu command for displaying the following entries in the position set table: [Pos. set table] Description Nr Number of the position set (0...14) a/r Pos Vel absolute (a) or relative (r) positioning Target position Positioning speed [Axis param] Menu command for displaying the following axis parameters and data: [Axis param] 1) vmax xmin xmax x0 feed 2) Description Maximum positioning speed Stroke limitation: Software end position, negative Stroke limitation: Software end position, positive Offset axis zero point Feed constant 1) Measuring unit depends on measuring system set 2) Not for axis type Rotation drive 4-9

68 4. Control panel (MTR-DCI-...-H2IO) [System param] Menu command for displaying the following system parameters and data: [System param] Description Vpower [V] Supply voltage Vdd [V] Voltage of display Imax [A] Maximum current Iact [A] Current current Temp [ C] Operating temperature Cycle In signal Out signal Number of positioning movements Hexadecimal representation of the inputs Bit 0: I0 Bit 1: I1 Bit 2: I2 Bit 3: I3 Bit 4: START Bit 5: ENABLE Hexadecimal representation of the outputs Bit 0: READY Bit 1: MOTION COMPLETE Ref. switch on/off Signal at reference switch input Mode e.g. mm Measuring system Hom.meth. bl.pos bl.neg sw.pos sw.neg Fixed stop in positive direction Fixed stop in negative direction Reference switch in positive direction Reference switch in negative direction Gear e.g Gear ratio of the MTR-DCI 4-10

69 4. Control panel (MTR-DCI-...-H2IO) Menu [Settings] Warning Damage to or impairment of the mechanical components With all teach procedures the motor turns or the connected axis starts to move. Make sure that: nobody can place his/her hand in the positioning range there are no objects in the positioning range. Parametrizing the axis system and programming the position sets: } Settings } Axis type Axis param Homing param Position set Password 1. Select [Settings] in the main menu with the arrow buttons and press the <Enter> button. 2. Select: the axis type [Axis type] the axis parameters [Axis param] the reference run parameters [Homing param] the position set table [Position set] the password setting [Password]. [Axis type] Design of the axis driven by the MTR-DCI (parameters see chapter 5.2.1) [Axis type] [Type DMES-...] [Rotation drive] [User config] [Save...] Description Festo positioning axis Specific rotation axis Specific linear axis Save parameter in EEPROM 4-11

70 4. Control panel (MTR-DCI-...-H2IO) [Axis param] Teach mode for setting the axis parameters [Axis param] [Zero point] [Abs.min.pos] [Abs.max.pos] [Save...] Description Offset of axis zero point Stroke limitation: Software limit switch, negative Stroke limitation: Software limit switch, positive Save parameter in EEPROM Note The set parameters become effective immediately after confirmation with OK <Enter>. The settings are saved permanently in EEPROM with the menu command [Save...]: Save the parameter settings with the menu command [Save]. Only then will the settings be retained even if the power supply is switched off or if there is a power failure. 4-12

71 4. Control panel (MTR-DCI-...-H2IO) [Homing param] Setting the reference travel method and the speed during reference travel. The maximum speed during homing is limited to half the maximum positioning speed v_max (v_max see [Diagnostic] [Axis param]). [Hom. param] Param. Description [Homing method] sw.neg (switch negative) sw.pos (switch positive) bl.neg (block negative) bl.pos (block positive) Homing to reference switch, negative = factory setting Homing to reference switch, positive Homing to fixed stop, negative Homing to fixed stop, positive [Velocity v_sw] v_sw Speed for searching for the reference point [Velocity v_s0] v_s0 Speed for moving to the axis zero point [Save...] Save parameter in EEPROM. Note The set parameters become effective immediately after confirmation with OK <Enter>. The settings are saved permanently in EEPROM with the menu command [Save...]: Save the parameter settings with the menu command [Save]. Only then will the settings be retained even if the power supply is switched off or if there is a power failure. 4-13

72 4. Control panel (MTR-DCI-...-H2IO) [Position set] Teach mode for programming the position set table. [Position set] Param. Description [Position nr] Nr Number of the position set [0...14] [Pos set mode] [absolute/ relative] Positioning mode absolute = absolute position specification, related to the project zero point relative = relative position specification, related to the current position [Position] x t Target position in the selected measuring system e.g. [mm] [Velocity] v Positioning speed in the selected measuring system e.g. [mm/s] [Save...] Save parameter in EEPROM Note The set parameters become effective immediately after confirmation with OK <Enter>. The settings are saved permanently in EEPROM with the menu command [Save...]: Save the parameter settings with [Save]. Only then will the settings be retained even if the power supply is switched off or if there is a power failure. 4-14

73 4. Control panel (MTR-DCI-...-H2IO) Set up a password In order to prevent unauthorized or unintentional overwriting or modification of parameters in the device, access via the control panel can be protected by a (local) password. No password is specified at the factory (presetting 000). [Password] New Password: [?xx] = EDIT <--> ESC <menu> OK <Enter> Select [Settings] [Password] in the menu: Enter a password with 3 figures. The current entry position is marked with a question mark. 1. Use the arrow buttons to select a figure Confirm your entry with <Enter>. The next entry position will be displayed. 3. After entering the third figure, save your setting with SAVE <Enter>. Enter password: [?xx] = EDIT <--> ESC <menu> OK <Enter> Enter password As soon as a password is active, it will be scanned automatically when the menu commands [Positioning], [Settings] or [HMI control] are accessed. When the correct password is entered, all parametrizing and control functions of the control panel are enabled until the power supply is switched off. The current entry position is marked with a question mark. 1. Use the arrow buttons to select a figure Confirm your entry with <Enter>. The next entry position will be displayed. 3. Repeat the entry for the further entry positions. When the third figure has been entered, access via the control panel is enabled. 4-15

74 4. Control panel (MTR-DCI-...-H2IO) [Password] Enter password: [?xx] = EDIT <--> ESC <menu> OK <Enter> Modify/deactivate password Select [Settings] [Password] in the menu: Enter the existing password with 3 figures. The current entry position is marked with a question mark. 1. Use the arrow buttons to select a figure Confirm your entry with OK <Enter>. The next entry position will be displayed. 3. Repeat the entry for the further entry positions. New Password: [?xx] = EDIT <--> ESC <menu> OK <Enter> 4. Enter the new password with 3 figures. If you wish to deactivate the password, enter After entering the third figure, save your setting with SAVE <Enter>. KeepthepasswordfortheMTR-DCIinasafeplace,e.g. with the internal documentation for your system. If the active password in the MTR-DCI should be lost in spite of care being taken: you can delete the password by entering a master password. In this case please contact your Festo Service partner. 4-16

75 4. Control panel (MTR-DCI-...-H2IO) Menu [Positioning] Start reference run or positioning run for testing the position sets. Warning Damage to or impairment of the mechanical components With all positioning procedures the motor turns or the connected axis starts to move. Make sure that: nobody can place his/her hand in the positioning range there are no objects in the positioning range. Note Before starting the reference run, make sure that: the positioning system is set up completely, wired and supplied with power, the parametrizing is completed. Do not start a positioning run until the reference system has been defined by means of a reference run. Note Please note that position sets with speed v = 0 or invalid target positions (-> Fault TARGET POSITION OUT OF LIMIT) cannot be processed. 4-17

76 4. Control panel (MTR-DCI-...-H2IO) } Positioning Move posit set Demo posit tab } Homing Carry out homing 1. Select [Positioning] in the main menu with the arrow buttons and press the <Enter> button. 2. Select the menu command: [Homing] [Positioning] Description Note [Homing] Homing for determining the mechanical reference system First set the parameter in the menu [Settings] [Homing parameter]. Factory setting: Homing to reference switch in negative direction.... Warning Motor moves ESC <menu> START <Enter> HOMING V_ 0 = 20 mm/s v_sw = 10 mm/s EMERG.STOP<Menu> 3. Make sure that nobody can place his/her hand in the positioning range of the moveable mass and that there are no objects in its path. Start homing run with START <Enter>. The following information is displayed: the search speed v_sw the positioning speed to the axis zero point v_0. Function EMERG. STOP With <Menu> you can interrupt the positioning procedure (> Errormode EMERG.STOP; confirm with <Enter>, then automatic return to the status display). Menu 4-18

77 4. Control panel (MTR-DCI-...-H2IO) Process position sets } Positioning } Move posit set Demo posit tab Homing 1. Select [Positioning] in the main menu with the arrow buttons and press the <Enter> button. 2. Select the menu command: Positioning run Position set [Move posit set] or Positioning run Position set table [Demo posit tab] [Positioning] Description Note [Move posit set] Positioning run for testing a certain position set in the position set table. Parametrizing and referencing must be completed. [Demo posit tab] Positioning run (continuous loop) for testing all position sets (0...14) in the position set table. Parametrizing and referencing must be completed. There must be at least two position sets in the memory.... Warning Motor moves ESC <menu> START <Enter> With positioning run [Demo posit tab] all position sets in the position set table will be processed one after the other. If the position set table contains a position set with speed v = 0, this position set and all the following sets will not be processed; positioning run will be continued with position set Make sure that nobody can place his/her hand in the positioning range of the moveable mass and that no objects lie in its path. Start the positioning procedure with START <Enter>. Move posit set Pos 1 X t = mm v = 20 mm/s X a = mm EMERG.STOP<Menu> During the positioning run the following information is displayed: the active position set Pos... the target position x t the positioning speed v the current position x a. 4-19

78 4. Control panel (MTR-DCI-...-H2IO) Function EMERG. STOP DEMO STOP With <Menu> you can interrupt the positioning procedure (> Errormode EMERG.STOP; confirm with <Enter>, then automatic return to the status display). With <Enter> you can interrupt the positioning run Pos set table [Demo pos tab]. The current positioning set will be processed before the axis stops. A new start will be made with position set 0. Menu Enter Menu command [HMI control] For selecting the menu commands [Positioning] and [Settings] you will require the setting HMI: on. Only then is the MTR-DCI ready to process user entries on the control panel. When selecting the menu commands, you will be requested to modify the HMI setting. [HMI control] You can also modify the setting directly with the menu command [HMI control]. HMI 1) on off Device control The device control is carried out manually via the control panel. The control interface of the MTR-DCI is deactivated and the control enable is set. The actual status of the ENABLE input then has no effect. The device control is carried out via the control interface of the MTR-DCI. 1) Human Machine Interface 4-20

79 Commissioning Chapter 5 Commissioning 5-1

80 5. Commissioning Contents 5. Commissioning Procedure for commissioning Commissioning with the control panel (only MTR-DCI-...-H2) Selecting the axis type Setting the homing parameter Teach the axis zero point and the software end positions Positioning with position sets Teach position sets Test run Commissioning with FCT Installing the FCT Procedure for commissioning with the Festo Configuration Tool Communication with the higher-order controller I/O function check Description of the I/Os Function description (pulse-time diagram)

81 5. Commissioning 5.1 Procedure for commissioning Warning Danger of injury. Electric axes can move suddenly with high force and at high speed. Collisions can lead to serious injury to human beings and damage to components. Make sure that nobody can gain access to the operating range of the axis or of other connected actuators and that no objects lie in the path of the axes while the system is still connected to a power supply (voltage). Note In the following cases it is not permitted to access the MTR-DCI with the FCT writing (e.g. downloading parameters) or controlling (e.g. with Move manually or when starting homing run): When the MTR-DCI is currently performing a positioning movement or when a movement is started during access (e.g. via the control interface or via the control panel). When parametrizing or operation is carried out with the control panel of the MTR-DCI. Pleasenotethefollowing: The device connection in the FCT must not be activated when the control panel is being used for control ( HMI control = on ). Control with the control panel ( HMI control = on ) must not be activated when the device connection in the FCT is activated. Control by the FCT must not be activated while the drive is in motion or when control is being carried out via I/Os. 5-3

82 5. Commissioning Before commissioning Before commissioning the servo drive make sure that: the work space is of sufficient size for operation with a work load, the work load does not collide with the motor or the gear of the axis when the axis moves into the end position. Pleaseobservethenotesintheoperatinginstructionsfor the positioning drive. First commissioning Switch-on reaction Relative positioning movements can be carried out as soon as the device is switched on, e.g. in order to position the axis in the permitted positioning range. If an absolute positioning process is started, the following error will be displayed: LAST ACTUAL POSITION IS NOT SAVED! PLEASE ENFORCE HOMING RUN. Absolute positioning movements can only be carried out after a homing run. Execute a homing run every time thedeviceisswitched on. For the homing method refer to chapter

83 5. Commissioning Switching on Note Note that the tolerance for the supply voltage must be observed. The tolerance must also be observed directly at the operating voltage connection of the MTR-DCI (see chapter 3.3). Note Make sure that the axis is within the permitted positioning range when it is switched on. Instructions on this can be found in chapter When the power supply is switched off, wait for approx. 5 seconds before switching the device on again. Switch on the power supply for the MTR-DCI. When the power supply is switched on, the MTR-DCI automatically carries out an internal check. Carry out parametrizing and commissioning with the control panel or the FCT, as described in the following chapters or in the FCT/PlugIn help. In order to complete commissioning note the instructions for operation in the FCT/PlugIn help and in chapter

84 5. Commissioning 5.2 Commissioning with the control panel (only MTR-DCI-...-H2) Informationonthebuttonfunctionsandonthemenucomposition of the control panel can be found in chapter 4. Diagnostic positioning Settings } HMI control LCD adjustment Device control In order that the control panel can control the connected MTR-DCI, the control interface of the MTR-DCI must be deactivated and controller enable must be set [HMI = on]. The actual status of the ENABLE input then has no effect. Instructions on parametrizing and commissioning Information on the current parametrizing of the motor unit can be found in the menu [Diagnostic] on the control panel. Carry out the following steps in order to commission the MTR-DCI the first time with the control panel: Note the detailed description in the chapters specified. Commissioning (overview) 1. Select the axis type and, if necessary, adapt the parametrizing to suit your axis. 2. Set the following parameters for reference travel: Homing method Search speed to reference point Positioning speed to axis zero point Chapter Carry out homing run Teach the following axis parameters for defining the axis zero point and the working area: Offset of the axis zero point to the reference point Positive and negative software end positions

85 5. Commissioning Commissioning (overview) 5. Enter several position sets (target position, positioning mode and positioning speed). 6. Carry out a test run to check the positioning reaction of the axis, as well as the basis coordinates and the working area. 7. If necessary, optimize the settings for position sets as well as for the basis coordinates and the working area. 8. Check the function of the control interface of the MTR-DCI (function test). 9. Before completing commissioning, note the instructions on operation. Chapter Tab. 5/1: Commissioning (overview) In order to restore the default settings, the EEPROM can be deleted, if required, with the CI command 20F1 (Data memory control) directly via the serial interface (see chapter B.1.2) Selecting the axis type } Settings Axis type Type DMES... Rotation drive User config 1. Select the axis type which matches your positioning system. Festo positioning axis [Type DMES] Rotation axis [Rotation drive] Linear axis [User config]. 2. Depending on the entry requested, set axis-specific parameters by means of the arrow buttons: feed constant (Feedcon) or measuring system (degree/revolutions). 3. Save the setting with SAVE <Enter>. 5-7

86 5. Commissioning Axis type Feed constant [mm/revolution] Measuring system Festo positioning DMES Metric 3) axis 1) 2) DMES DMES-40 4 DMES-63 6 Rotation axis Degree or revolutions Linear axis 2) According to the type plate or technical specifications of the axis Metric 3) 1) Values defined at factory Z spindle pitch of the axis [mm] 2) If an external gear is used, the gear factor can be set with FCT. 3) Pre-setting metric; inches can only be set with FCT Tab. 5/2: Parametrizing the axis 5-8

87 5. Commissioning Setting the homing parameter Caution Damage to components The slide may only move against the fixed stop if the permitted impact energy is not exceeded. The permitted value can be found in the manual for your positioning axis. Impact energy = 0.5 x mass x speed 2 For the protection of the mechanical components: Reduce the speed at which homing run is carried out. The speed can be specified at 0 % to 50 % of the rated speed depending on the specific application. If necessary, limit the motor current during homing run with the FCT software. The motor current can be specified with 1 to 200 % of the rated motor current depending on the specific application (see FCT/PlugIn help MTR-DCI). Caution If the homing method is changed, the axis zero point offset is reset to zero. Any settings implemented for the software end positions and the target positions in the positioning record table are retained. Note that these values refer to the previous axis zero point. Always carry out a homing run after changing the referencing method. Then teach the offset of the axis zero point. If the axis zero point is modified: Teach the software end positions and the target positions again. 5-9

88 5. Commissioning Current limiting The motor current can be specified with 1 to 200 % of the rated motor current depending on the specific application (see FCT/PlugIn help MTR-DCI). Positioning axis DMES can carry out homing run with the factory-set current limitation (150 % of the rated motor current). The current limitation need not be modified. Current limitation 1) % Z 1 x rated motor current motor current motor torque A mnm % (default) Z 1.5 x rated motor current motor current motor torque A mnm % Z 2 x rated motor current motor current motor torque A mnm ) ) ) Parameter specification in FCT: relative motor current in % of rated current, setting range ) Due to maximum current limitation the value does not rise further. Tab. 5/3: Current limitation Note Please note the following when adapting the current limitation: By means of a current limitation, the maximum possible speed of homing run will also be reduced. The set rated speed will therefore, in some cases, no longer be achieved. If the drive is arranged vertically, an increase in the motor current may be necessary. If the motor current is too low, homing run cannot be carried out. 5-10

89 5. Commissioning Set parameters The reference point is defined by means of a reference switch or fixed stop depending on the set homing method. If a homing run to a mechanical end position is not possible in the application, an external sensor (reference switch) can be used as reference signal (see also chapter 1.5.1). Reference run parameters (factory setting) Homing method Reference switch, negative (near motor) Velocities v_sw, v_s0 % 1) inc/s ~41 % ~22 % ~17% ~15% Rated speed of the motor rot/s inc/s , ) % of the rated speed of the motor; max. 50 % } Settings Homing parameter Homing method Velocity v_ B+W Velocity v_ s0 Save Set the following homing parameters one after the other: the [Homing method] the search speed for ascertaining the reference point [Velocity v_sw] the positioning speed to the axis zero point [Velocity v_s0]. Accept each setting with OK <Enter>. The setting will then become effective in the drive. Save the parameter settings with the menu command [Save]. Only then will the settings be retained even if the power supply is switched off or if there is a power failure. Finally, carry out a homing run, otherwise the previous reference system of the MTR-DCI will remain unmodified. 5-11

90 5. Commissioning Start homing run Note When carrying out a homing run note that the drive must be in the permitted positioning range. the drive moves in the search direction according to the selected homing method and, at the start, must be positioned in front of the fixed stop or reference switch. 1. If necessary, position the drive in the Teach mode so that, at the start, it is positioned in front of the fixed stop or reference switch in the search direction. Select e.g. [Settings] [Position set] [Position] (see also chapter 5.2.5). Move the drive to the desired position manually with the arrow buttons. Interrupt the procedure with ESC <menu>, in order that the position is not included in the position set table. } Positioning Demo posit tab Move posit set Homing 2. Select [Positioning] [Homing]. 3. Start homing run with START <Enter>. After successful reference travel the drive stands at the axis zero point. During the initial commissioning procedure or after changing the homing method, the offset of the axis zero point = 0; after a homing run the drive then stands at the reference point (= axis zero point). 5-12

91 5. Commissioning Discontinue homing run If necessary, homing run can be discontinued with the <Menu> button (EMERG STOP). If homing run is interrupted, the display will show the fault message HOMING ERROR. If a correct homing run has already been carried out, the previous reference point will retain its validity. Quit the fault message with <Enter>. Repeat homing run. Fault during homing run If a fault occurs during homing run: quit the fault message with <Enter> if necessary, check the function of the reference switch check the settings of the parameters. If necessary, position the drive in Teach mode so that at the start it stands in the search direction in front of the stop or reference switch. Repeat homing run Teach the axis zero point and the software end positions Prerequisites for teaching the axis zero point and the software end positions: Homing run was successful. Note When homing run to a stop, set the offset of the axis zero point to 0. You will then prevent movement to the mechanical end positions during operation. 5-13

92 5. Commissioning Teach the axis zero point: } Settings Axis parameter Zero point Abs.min.pos Abs.max.pos Save 1. Select [Settings] [Axis parameter] [Zero point]. 2. Move the drive to the desired axis zero point manually with the arrow buttons. 3. Accept the position reached with OK <Enter>. The setting will then become effective in the drive. The current position x a becomes the axis zero point (x a =0). Note If the axis zero point is modified: Check existing settings of the software end positions and of target positions in the position table. Note that these values refer to the previous axis zero point. Teach the software end positions and the target positions again. Teach the negative software end position and the positive software end position: 1. Select [Settings] [Axis parameter] [Abs. min. pos] or [Abs.max.pos]. 2. Move the drive manually with the arrow buttons. 3. Accept the position reached with OK <Enter>. The setting will then become effective in the drive. 4. Save the parameter settings with [Save]. Only then will the settings be retained even if the power supply is switched off or if there is a power failure. 5-14

93 5. Commissioning Positioning with position sets Warning Damage to or impairment of the mechanical components. With all positioning procedures the motor turns or the connected axis starts to move. Make sure that: nobody can place his/her hand in the positioning range there are no objects in the positioning range. The following conditions must be fulfilled: Homing run was successful. The axis zero point and the software end positions are set correctly. Note Please note that position sets with speed v = 0 or invalid target positions (-> Fault TARGET POSITION OUT OF LIMIT) cannot be carried out. After successful homing run, teach several position sets (see chapter 5.2.5). First carry out a test run, if necessary, without a work load (see chapter 5.2.6). If necessary, optimize the settings for position sets as well as for the basis coordinates and the working area (see chapter 5.2). After a successful test run you can teach the positions in the position set table to which movement must be made. 5-15

94 5. Commissioning Teach position sets Enter the position sets as follows: } Settings Position set Position no Pos. set mode Position Velocity Save 1. Activate the desired position set (0...14) with [Settings] [Position set] [Position no]. 2. Complete or correct the positioning mode of the position set: Select [Pos. set mode]. Set the positioning mode with the arrow buttons: absolute = absolute position specification, related to the project zero point relative = relative position specification, related to the current position. Accept the value with OK <Enter>. Note After each change of the positioning mode, teach the target position of the position set, otherwise the change of positioning mode will not be accepted. 3. Teach the target position of the position set: Select [Position]. Move the drive to the desired target position manually with the arrow buttons. Accept the position reached with OK <Enter>. The setting of the target position and the positioning mode will then become effective in the drive. 4. Complete or correct the speed. Select [Velocity]. 5-16

95 5. Commissioning Set the nominal speed with the arrow buttons. Accept the setting with OK <Enter>. The setting will then become effective in the drive. 5. Save the position set with [Save]. Only then will the settings be retained even if the power supply is switched off or if there is a power failure. 6. Enter the next position set. Digitalization faults of the analogue-digital convertor can accumulate in the case of relative position movements which occur frequently one after the other and lead to deviations of the position values. If necessary, insert an absolute position set or homing run into the positioning cycle, in order to correct deviations Test run Caution Damage to components During operation it is not permitted to move to the mechanical end positions (stops). If movement is made to the end positions with a heavy load, jamming may occur in the end positions. Set the offset of the axis zero point 0. Limit the positioning range by defining valid software end positions during commissioning (see chapter 1.5.1). Specify target positions only within the permitted positioning range. 5-17

96 5. Commissioning 1. Enter several position sets in order to check the positioning reaction (see chapter 5.2.5). Set the target positions at the limits of the positioning range in order to check the software end positions. Set different speeds. } Positioning Demo posit tab Move posit set Homing 2. Select [Positioning] [Move posit set] in order to process a certain position set - or - 3. Select [Positioning] [Demo posit tab] in order to process all position sets. At least two position sets must be entered in the position set table. With positioning run [Demo posit tab] all position sets in the position set table will be processed one after the other. If the position set table contains a position set with speed v = 0, neither this position set nor the following sets will be processed; positioning run will be continued with position set 0. With DEMO STOP <Enter> you can interrupt the positioning cycle [Demo posit tab]. The current position set will be processed before the drive stops. 4. Start the test run. Check the positioning reaction. Check the displayed coordinates of the axis. With EMERG.STOP <Menu> you can interrupt the current positioning procedure. 5. If necessary, optimize the settings for position sets as well as for the basis coordinates and the working area. 5-18

97 5. Commissioning 5.3 Commissioning with FCT Installing the FCT Note The PlugIn MTR-DCI version V1.1.0 supports the following motor units of MTR-DCI-...IO: MTR-DCI-32: Firmware version V-DME 1.20 MTR-DCI-42: Firmware version V-DME 1.19 / 1.20 MTR-DCI-52: Firmware version V-DME 1.19 / 1.20 MTR-DCI-62: Firmware version V-DME 1.20 Check with later versions of the MTR-DCI to ascertain whether an updated PlugIn is provided. If necessary consult Festo. Note Administrator rights are required for installing the FCT. The FCT is installed on your PC with an installation program. The PlugIn MTR-DCI is installed on your PC together with the installation program of the FCT. 1. Close all programs. 2. Place the Festo Configuration Tool CD in your CD ROM drive. If Auto Run is activated on your system, installation will start automatically and you can omit steps 3 and Select [Execute] in the starting menu. 4. Enter D:\setup (if necessary replace D by the letter of your CD ROM drive). 5. Follow the instructions on the display screen. 5-19

98 5. Commissioning Procedure for commissioning with the Festo Configuration Tool Starting the FCT Carry out the following steps in order to commission the MTR-DCI with the FCT: 1. Connect the MTR-DCI to your PC via the RS232 interface. Note here the instructions in chapter Starting the FCT: Double-click on the Festo Configuration Tool icon on the desktop. or switch to Windows and select the entry [Festo Software] [Festo Configuration Tool] in the menu [Start]. 3. Create a project in the FCT or open an existing project. Add a device to the project with the PlugIn MTR-DCI. 4. Create the device connection (online connection) between thepcandthemtr-dciviathefcttoolbar. It may be necessary here to have the same device names. Device control In order that the FCT can control the connected MTR-DCI, the control interface of the MTR-DCI must be deactivated and Controller enable must be set. The actual status of the ENABLE input then has no effect. Switch to the window Project output, then select the register Operate and activate under Device control first the control box FCT/HMI and then the control box Enable. The control interface of the MTR-DCI will then be deactivated and Control Enable will be set by the FCT. 5-20

99 5. Commissioning Instructions on parametrizing and commissioning Further information can be found in the help for the FCT with the command [Help] [Contents FCT general] e.g. Help on working with projects and on inserting a device into a project. Help on defining the measuring reference system (referencing and basis coordinates). The PlugIn MTR-DCI for the FCT supports all the steps necessary for commissioning an MTR-DCI. With the PlugIn MTR-DCI for the FCT the necessary parametrizing can be carried out offline, i.e. without the MTR-DCI being connected to the PC. This enables the actual commissioning to be prepared, e.g. in the design office when a new system is being planned. Further information can be found in the PlugIn help: Command [Help] [Contents of installed PlugIns] [Festo (manufacturer name)] [MTR-DCI (PlugIn name)] e.g.: for describing the dialogues of the Device MTR-DCI for describing the work steps for commissioning for the basic functions: Device connection, Device names, Device control and for password protection. 5-21

100 5. Commissioning 5.4 Communication with the higher-order controller I/O function check Warning Danger of injury. Faults in parametrizing can cause injury to people and damage to property. Enable the controller only if the drive system is correctly installed and parametrized. In order that the MTR-DCI can be controlled via the control interface, the manual device control via the control panel / FCT software must be deactivated: automatically when the operating voltage is switched on (HMI = off) via the control panel of the MTR-DCI with the menu command [HMI control] (HMI = off) with FCT under Device control in the window General output, (FCT = off). In order to check the configuration and the axis set-up, enter a simple test program or simulate control by directly setting the inputs. Please refer here to the function description of the control interface in chapter Provide the necessary system inputs on the MTR-DCI. There must be a 1-signal at the ENABLE input (controller and power end stage enabled). Take into account also the output signals. There will be a 1-signal at the READY output (readiness to operate) if the controller and the power end stage are enabled and if no fault has been recognized. Program or start homing run as well as some positioning movements. Check the positioning reaction. 5-22

101 5. Commissioning Description of the I/Os Position sets I1... I4 Selection of the position sets is carried out via the binary coding of inputs I1 (Bit 0)... I4 (Bit 3). Positioning set I1 (2 0 ) I2 (2 1 ) I3 (2 2 ) I4 (2 3 ) (Homing run) Tab. 5/4: Binary code of the position set 5-23

102 5. Commissioning START I5 The position set sequence is started with a rising edge at the START input. Prerequisite: a 1-signal must be active at READY (no fault, ENABLE = 1), a 1-signal must be active at MC, the desired position set must be at I1... I4. Pin Signal START (input) I5 0 > 1 Start of the position set Processing of the position set can be discontinued with a falling edge at the ENABLE input (> 0). If started again, the position set will be processed further as from the current position. ENABLE I6 Controller and power end stage enable Prerequisite: there must be an 0-signal at START nofault. A rising edge (> 1) at the ENABLE input causes the controller andthepowerendstageofthedrivetobeswitchedon. A falling edge (> 0) at the ENABLE input causes the controllerandthepowerendstageofthedrivetobeswitched off. Current run will be discontinued. When the power end stage is switched off, the drive becomes torque-free and goes into a spin. The motor no longer receives current and the drive can be shifted. As long as the power supply is not switched off, the actual position is registered even after the power end stage is switched off. When enabled again the drive will stand controlled be at the current position. 5-24

103 5. Commissioning If there is a 1-signal at the ENABLE input, the controller and the power end stage will be switched on. The current position set will be processed at the next START signal. Pin Status ENABLE I6 1-signal Controller and power end stage are switched on 0-signal Controller and power end stage are switched off 1 > 0 Quit faults READY O1 Ready to operate. All prerequisites for starting a positioning procedure are fulfilled. Pin Level READY O1 0 System is not ready to operate. ENABLEisnotsetor there is a fault 1 System is ready to operate. ENABLEissetand nofault MC O2 Motion complete Shows that a positioning order has been completed and that the START input has been reset. Pin Status MOTION COMPLETE O2 0-signal Positioning procedure is being carried out or there is still a START signal at 1. 1-signal Positioning task is completed 5-25

104 5. Commissioning Function description (pulse-time diagram) Start-up reaction Start homing run Disable Fault Switch-on and homing run In order to guarantee that the system starts correctly, all input signals must be stable when the power supply is switched on (min. 1 s). After this the input signals are scanned: If a fault occurs when the device is switched on, the START signal > 1 will not be observed until the FAULT signal is cancelled. If there are no faults and the enable is active (ENABLE signal = 1), the controller reports readiness for operation, i.e. (READY signal > 1 and MC signal =1 (Motion Complete). If there are no faults and enable is active (ENABLE = 1), homing run (input word I1... I4 = 1, positive edge at START input) can be carried out. When the START signal is set (> 1), the MC signal is reset (> 0) and the drive carries out homing run. Homing run can be discontinued like any position set with a falling edge at the ENABLE input (> 0). If homing run is discontinued by a cancelled ENABLE signal or a fault, the controller will set internally the FAULT signal (> 1, HOMING ERROR). The MC signal and the READY signal will be reset >

105 5. Commissioning Note If a fault occurs during homing run, you must do the following before starting a new position set: if necessary, reset the START input (= 0), delete the fault with a falling edge at ENABLE (> 0), repeat homing run. Note With non self-locking axes new homing run must always be carried out. With self-locking axes the existing reference point remains valid until new homing run is carried out. When homing run has been successfully completed, the MC signal is set again (> 1). After that, any number of positioning procedures can be carried out. 5-27

106 5. Commissioning (POWER) 1 0 min. 1 s (FAULT) (TR) Position set 15 I1...I HOMING ERROR t TR ENABLE START I6 I ms READY O1 1 0 MC O2 1 0 Drive in motion Initialization Start homing run Discontinue > Fault Delete faults Enable New homing run Homing run completed Fig. 5/2: Pulse-time diagram (switch-on homing run fault) To explain the function, the following internal states are also represented in the pulse-time diagrams: (POWER) Power supply (FAULT) Fault (TR) Target position reached (TARGET REACHED) 5-28

107 5. Commissioning Positioning procedures Start positioning procedure Disable Position reached Fault Iftherearenofaultsandenableisactive(ENABLE=1),the positioning procedure (input word I1... I4 = 1, positive edge at START input) can be carried out. When the START signal is set (> 1), the MC signal (Motion Complete) is reset (> 0) and the drive moves to the specified target position. As long as the drive is in motion, the MC signal remains reset, and no other position set can be started with the START signal. With a falling edge at the ENABLE input (> 0), the outputs READY and the MC are reset (> 0). A current positioning procedure is discontinued. The starting signal will then be ignored. When the ENABLE signal is enabled again > 1, READY and MC will still not be set until the START signal is reset (> 0). The next position set can then be started with a rising edge at the START input (> 1). The TR signal will be set with position sets when the nominal position is reached (after approx. 20 ms). If the TR signal is set while the START signal is still at 1, the MC signal will remain at 0 until the START signal is reset. This coupling of the START/ MC signal enables signal confirmation for the PLC Z(handshake function, see Fig. 5/3: Start 1). If the START signal is reset after the MC signal has confirmed the start (MC > 0) and before the TR signal is set, the MC signal will be set simultaneously with the TR signal when it has reached the nominal value (MC, TR > 1, see Fig. 5/3: Start 2). During operation the outputs READY and MC will be reset if there is a fault. A fault is clearly indicated during operation by the following I/O status: Operating voltage applied Inputs: ENABLE = 1 and START = 0 Outputs: MC = 0 and READY =

108 5. Commissioning Note If a fault occurs during operation, you must do the following before starting a new position set: if necessary, reset the START input (= 0). delete the fault with a falling edge at ENABLE (> 0), When the fault has been eliminated and there is a rising edge at ENABLE (> 1) the READY output signalizes (> 1) that a new positioning task can be started. If the fault cannot be eliminated, this may be caused by a cable fracture. (FAULT) (TR) Position set I1...I t TR ENABLE I6 1 0 START I5 1 0 t t TR t t TR READY O1 1 0 MC O2 1 0 Drive in motion Ready for operation Nominal position reached Start 1 Nominal position reached Start 2 Cancel Enable Fig. 5/3: Pulse-time diagram (positioning procedure start nominal position reached cancel) 5-30

109 Operating, maintenance and diagnosis Chapter 6 Operating, maintenance and diagnosis 6-1

110 6. Operating, maintenance and diagnosis Contents 6. Operating, maintenance and diagnosis Important user instructions Diagnosis and fault display General diagnostic possibilities LED status displays Fault messages on the display (only type MTR-DCI-...-H2)

111 6. Operating, maintenance and diagnosis 6.1 Important user instructions Take the following instructions and recommendations into account when programming positioning systems with electric axes: Start-up behaviour and referencing Note Make sure that the axis is within the permitted positioning range when it is switched on. When the power supply is switched off, wait for approx. 10 seconds before switching the device on again. Warning Risk of injury. Parameterisation errors can cause injury to people and damage to property. In the following cases reference travel is absolutely essential in order that the basis coordinates and the working range can be set correctly: when commissioning the first time, after the homing method is changed with the fault LAST ACTUAL POSITION NOT SAVED PLEASE ENFORCE HOMING RUN, with a non self-locking axis each time it is switched on. Make sure that the axis is within the permitted positioning range when it is switched on. 6-3

112 6. Operating, maintenance and diagnosis Note When the coupling or clamping element in the coupling housing is loosened, the motor can be turned on its longitudinal axis. The reference position will then be lost. homing run must then be carried out at all costs even with self-locking axes. Device connection Caution The RS232 interface is not electrically isolated. It is not intended for permanent connection to PC systems, nor as a control interface. Use the connection only for parametrizing and diagnosis. Password protection Protection by means of a password is not set when the product is supplied from the factory. In order to prevent unauthorized or unintentional overwriting or modification of parameters in the device, all download and control functions can be blocked. Recommendation: Protect the settings of your axis against undesired modifications with a password: FCT password protection (8 characters, see PlugIn help MTR-DCI) HMI password protection with the MTR-DCI-...-H2 (3 characters, see chapter 4.2.3) 6-4

113 6. Operating, maintenance and diagnosis Control in operation Warning Danger of injury Faults in parametrizing can cause injury to human beings and damage to property if the controller is enabled with a 1-signal at the ENABLE input. Enable the controller only if the axis system is correctly installed and parametrized. Caution Note the manufacturer s specifications for the permitted operating conditions of the motors and drives used, e.g. in respect of the permitted positioning speeds. Caution Damage to components Movement to the mechanical end positions is not permitted during operation. If movement is made to the end positions with a heavy load, jamming may occur in the end positions. Note Take into account any functions implemented within the framework of the EMERGENCY STOP concept correspondingly in the control programs. Care and maintenance The motor units do not require maintenance during their specified service life. Follow the maintenance instructions for the components used. 6-5

114 6. Operating, maintenance and diagnosis 6.2 Diagnosis and fault display General diagnostic possibilities The MTR-DCI offers the following possibilities of diagnosis and fault treatment: Diagnostic possibility Brief description Advantages / Properties Detailed description LED display LEDsindicatethereadinessto operate, positioning status, faults and bus status. Fast on-the-spot recognition of faults Section Control panel with LC display with MTR-DCI-...-H2 Warnings, messages and faults are displayed directly on the LC display Diagnostic data, operating mode, the current positioning set, target and actual positions, speed as well as information on I/O communication can be accessed on the control panel. Fast on-the-spot fault diagnosis Detailed diagnostic possibility on-the-spot Section Section Control interface The output READY indicates the readiness to operate. The output MOTION COMPLETE indicates whether a positioning task is completed. Simple diagnosis via the I/O interface Section 5.4 Festo Configuration Tool With active device connection: Display of the current position set, target and actual positions as well as speed. Display the operating mode, special outputs and operating states as swell as fault messages of the connected MTR-DCI. Detailed diagnosis during commissioning Help for PlugIn MTR-DCI Tab. 6/1: Overview of diagnostic possibilities 6-6

115 6. Operating, maintenance and diagnosis LED status displays The operating states are shown with 3 LEDs: (POWER) I/F (e.g. positioning status, controller enable) ERROR POWER Status Operating voltage applied. green off Tab. 6/2: Operating voltage not applied. Check the operating voltage connection if necessary. Power LED ERROR Status Internal fault. The motor unit is not ready to operate (deactivated). red off Tab. 6/3: No internal fault registered. The motor unit is operational. Error LED 6-7

116 6. Operating, maintenance and diagnosis I/F 1) Status 2) green red green/red off Ready for operation Positioning procedure is completed (Motion Complete) Controller and power end stage enabled. Not ready to operate and enable missing Nominal position not reached; positioning procedure stopped Controllerandpowerendstagenot enabled Ready to operate, is not enabled Positioning procedure is completed (Motion Complete) Controllerandpowerendstagenot enabled. Positioning mode Nominal position not reached (positioning procedure runs) Controller and power end stage enabled orfault 1) Two -colour LED 2) If there is no fault, i.e. LED ERROR = out Tab. 6/4: LED I/F (interface/field bus) 6-8

117 6. Operating, maintenance and diagnosis Fault messages on the display (only type MTR-DCI-...-H2) Messages Messages inform about operating states. Message Attention! Motor moves... Profile velocity =0. Please teach v. Temperature OK Cause Message at the start of a Teach procedure. After confirmation with the <ENTER> button the drive moves in the Teach mode. The menu command [Move posit set] is not processed because the positioning speed of the positioning set v = 0. Modify the parametrizing or select a different positioning set. Operating temperature lies in permitted range again after exceeding/not reaching limit. Warning In the event of non-permitted operating temperatures, the motor unit displays an appropriate warning. If a positioning task is running, it will not be interrupted. Warning HOT TEMPERATURE COLD TEMPERATURE Cause Operating temperature 70 C < T < 80 C, Check whether drive is overloaded, check the mechanical parts, e.g. for stiffness, reduce ambient temperature. Operating temperature < -10 C, if necessary, increase ambient temperature. Fault If there is a fault, the drive will be stopped. The fault LED will flash. Eliminate the cause of the fault. Acknowledge the fault message. on the control panel with <Enter>, via I/O with a falling edge at the ENABLE signal, with the Quit fault button in the Festo Configuration Tool. 6-9

118 6. Operating, maintenance and diagnosis Fault HARDWARE ERROR HOMING ERROR Possible cause Device fault e.g. EEPROM defective. Please contact your Festo Service. Fault during homing run Possible causes: homing run interrupted Reference switch defective If necessary, check the function of the reference switch It is essential that you repeat the homing run. i 2 t-error Current monitoring i 2 t. Possible cause The drive is blocked. Check the mechanical parts of the drive. LAST ACTUAL POSITION NOT SAVED PLEASE ENFORCE HOMING RUN MOTOR STOP OVERHEATING When starting a positioning set: Possible causes: Valid homing run has not yet been carried out. You must carry out homing run. The following applies up to firmware version V1.35: If the CI-parameter 60FBh, subindex 20h, does not contain the value 240 (0x00F0), overwrite this with value 240 (0x00F0), see appendix B.1.4. Fault during the positioning procedure Possible cause The positioning procedure is discontinued on the control panel with EMERG.STOP (<Menu> button). Quit the fault on the control panel with <Enter> Overheating (operating temperature > 80 C) Possible cause Motor overloaded Ambient temperature too high Check... that the limits are observed (motor characteristic curves) the mechanical parts e.g. for stiffness. If necessary, reduce the ambient temperature. 6-10

119 6. Operating, maintenance and diagnosis Fault POSITION ERROR POWER DOWN TARGET POSITION OUT OF LIMIT Possible cause Position fault (drag fault) Possible causes: The drive is blocked The positioning speed is too high The work load is too heavy Check... the mechanical parts of the drive the speed of the positioning set. Voltage monitoring Possible causes: Voltage supply too low MTR-DCI 32/42/52: U < 18 V MTR-DCI 62: U < 34 V Voltage dips under load Check the voltage supply. Power unit too weak? Supply line too long? The specified nominal position is outside the permitted positioning range. Check the... software end positions the set/nominal position the reference of the nominal position (absolute or relative). 6-11

120 6. Operating, maintenance and diagnosis 6-12

121 Technical appendix Appendix A Technical appendix A-1

122 A. Technical appendix Contents A. Technical appendix... A-1 A.1 Technical specifications... A-3 A.2 Accessories... A-6 A.3 Motor characteristic curves... A-7 A.4 Converting measuring units... A-13 A-2

123 A. Technical appendix A.1 Technical specifications General Protection class as per EN Relative humidity Temperature range Operation Storage/transport IP54 (Plug connector inserted or fitted with protective cap) 0to95%,non-condensing C C Vibration As per DIN/IEC 68/EN part 2-6: Severity level 2: 0.35 mm path at Hz; 5 g acceleration at Hz Shock As per DIN/IEC 68/EN part 2-27 Severity level 2: ±30 g at 11 ms duration; 5 shocks in each direction Protection against electric shock 1) (protection against direct and indirect contact as per IEC/DIN EN ) Electromagnetic compatibility (EMC) 2) Gear type Encoder (with 4-fold evaluation) By connection to a PELV power unit (Protected Extra-Low Voltage) See conformity declaration ( Planetary gear 500 x4 >2000 inc/revolution MTR-DCI-32: 300 x4 > 1200 inc/revolution Temperature monitoring Switching off at temperature > 70 C Display resolution Serial interface 128 x 64 pixels RS232, 9600 baud 1) The device is intended for industrial use. 2) The maximum permitted I/O signal cable length is 30 m. A-3

124 A. Technical appendix Mechanical data MTR-DCI-...-G7: Gear reduction 6.75:1; 1-stage Gear 1) Drive output speed Torsional backlash Drive output torque Degree of efficiency [1/min] [ ] [Nm] Mass moment of inertia Rotor Gear unit [kg cm 2 ] [kg cm 2 ] Product weight [kg] MTR-DCI-...-G14: Gear reduction 13.73:1; 2-stage Gear 1) Drive output speed Torsional backlash Drive output torque Degree of efficiency [1/min] [ ] [Nm] Mass moment of inertia Rotor Gear unit [kg cm 2 ] Product weight [kg] MTR-DCI-...-G22: Gear reduction ratio 22.21:1 Gear 1) Drive output speed Torsional backlash Drive output torque Degree of efficiency Mass moment of inertia Rotor Gear unit [1/min] [ ] [Nm] [kg cm 2 ] [kg cm 2 ] Product weight [kg] 8.0 1) Permitted loading of gear shaft see chapter 2, Tab. 2/2 A-4

125 A. Technical appendix Electrical specifications Rated voltage 24 V DC ±10 % 48 V DC % Rated current 0.73 A ±20 % 2A±20% 5A±20% 6.19 A ±20 % Nominal torque (motor without gears) 30 mnm 110 mnm 300 mnm 700 mnm Peak current 2.1A±20% 3.8 A ±20 % 7.7A±20% 20 A ±20 % I/O specification 32/42 52/62 Signal level Specified as per DIN EN part 2 (IEC ) LOW<5V HIGH>15V Positive switching Inputs Protection against incorrect polarity No Yes Electrical isolation No Optocoupler Number of digital logic inputs 6 Input current at 24 V input voltage [ma] >4 >7 Max. permitted input voltage [DCV] Min. input voltage [DCV] 0-30 Outputs Number of digital logic outputs 2 Overload protection Yes Maximum current [ma] Rated current [ma] A-5

126 A. Technical appendix A.2 Accessories Connection Accessories Designation Length [m] Voltage supply Power supply cable KPWR-MC-1-SUB-9HC /5/10 Serialinterface Programming cable KDI-MC-M8-SUB Homing Switch Switch, magnetic Switch, inductive SMT-8M-...-M8D SIEN-...-M8B-... Connecting cable with screw-type lock KM8-M8-GSGD /1/2/5 Field bus connection incl. logic power supply Field bus adapter (IP54) FBA-CO-SUB-9-M12 User's manual in paper form German English French Italian Spanish Swedish P.BE-MTR-DCI-IO-DE P.BE-MTR-DCI-IO-EN P.BE-MTR-DCI-IO-FR P.BE-MTR-DCI-IO-IT P.BE-MTR-DCI-IO-ES P.BE-MTR-DCI-IO-SV A-6

127 A. Technical appendix A.3 Motor characteristic curves 1 Drive output torque of gear shaft M [Nm] 2 Current I [A] 3 Recommended mode 4 Impermissible range 5 Overload range A-7

128 A. Technical appendix MTR-DCI G7 n[rpm] 1 2 I[A] M[Nm] n[rpm] MTR-DCI G I[A] M[Nm] Fig. A/1: Motor characteristic curves MTR-DCI-32 A-8

129 A. Technical appendix n[rpm] MTR-DCI G I[A] M[Nm] n[rpm] MTR-DCI G I[A] M[Nm] Fig. A/2: Motor characteristic curves MTR-DCI-42 A-9

130 A. Technical appendix MTR-DCI G7 n[rpm] 1 2 I[A] n[rpm] MTR-DCI G M[Nm] I[A] M[Nm] Fig. A/3: Motor characteristic curves MTR-DCI-52 A-10

131 A. Technical appendix MTR-DCI G7 n[rpm] 1 2 I[A] M[Nm] n[rpm] MTR-DCI G I[A] M[Nm] Fig. A/4: Motor characteristic curves MTR-DCI-62 A-11

132 A. Technical appendix MTR-DCI G22 n[rpm] 1 2 I[A] M[Nm] Fig. A/5: Motor characteristic curves MTR-DCI-62 A-12