CPX terminal. Description Electronics. CMAX axis controller. Type CPX CMAX C1 1. System description. controller

Transcription

1 CPX terminal Description Electronics CMAX axis controller Type CPX CMAX C1 1 System description CMAX axis controller Mounting, installation and diagnostics Positioning system Description en 0908NH [ ]

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3 Contents and general safety instructions Original de Edition en 0908NH Designation P.BE CPX CMAX SYS EN Orderno (Festo AG&Co. KG, D73726 Esslingen, 2009) Internet: E mail: service_international@festo.com The copying, distribution and utilisation of this document as well as the communication of its contents to others with out expressed authorization is prohibited. Violations will give rise to compensation. All rights are reserved, in par ticular the right to carry out patent, registered design or ornamental design registration. I

4 Contents and general safety instructions Interbus, DeviceNet, PROFIBUS, CC Link, EtherNet/IP, PROFINET, Adobe Reader und TORX are registered trademarks of their respective trademark holders in certain countries. II

5 Contents and general safety instructions Contents Intended use Safety note Target group Service Required software versions for the CPX nodes Important user instructions Notes on this description Glossary VII VIII X X XI XII XIV XVII 1. CMAX system overview CMAX axis controller Connection and display components of the CMAX CMAX function CMAX in the CPX terminal Structure of a positioning system Parameterisation and commissioning options Festo Configuration Tool (FCT) FHPP communication profile III

6 Contents and general safety instructions 2. Fitting and pneumatic installation General notes on mounting and installation Mounting/dismounting the CMAX Installation of the drive and position measuring system General mechanical requirements Drive, shock absorbers and fixed stops Position measuring system Load VPWP proportional directional control valve Approved drive/valve combinations Mounting the VPWP proportional directional control valve Mounting the CASM sensor interface Pneumatic installation Compressed air supply Filter regulator Air reservoir (optional) VPWP proportional directional control valve Tubing and fittings Electrical installation Earthing Axis interface VPWP proportional directional control valve CASM sensor interface Ensuring protection class IP Power supply Determining the current consumption Power supply concept, formation of power zones Disconnecting the load voltage in connection with a brake or clamping unit IV

7 Contents and general safety instructions 4. Commissioning Overview/procedure for commissioning Instructions for commissioning Installing the Festo Configuration Tool and FCT CMAX plug in Preparations for commissioning Checking the axis string Switching on the power supply, switch on behaviour Establishing a connection to the PC Commissioning with the FCT (overview) Overview of commissioning steps Operation instructions CMAX control General operation instructions Structure of the cyclical I/O data Defining the operating mode with CCON Controlling the CMAX in record select operating mode Controlling the CMAX in direct operating mode Execute record (record select mode) Direct mode Acknowledge error Flow charts for programming Establish ready status Start record Acknowledge malfunction Switch operating mode V

8 Contents and general safety instructions 5. Diagnostics and error handling Summary of diagnostics options Malfunctions and warnings Error numbers on the CPX terminal Malfunction groups: Classification according to the cause Error level and reset type: Classification according to effect and acknowledgement Error numbers and warning numbers Diagnostics via LEDs CMAX specific LEDs Axis specific LEDs LEDs on the VPWP LEDs on the sensor interface LEDs on the displacement encoder (DGCI only) Diagnostics via the display/7 segment display Error status Status display Diagnostic functions with the CPX MMI Error display ([Diagnostics] menu) Information on the CMAX ([Module data] menu) A. Technical appendix A 1 A.1 CMAX technical data A 3 A.2 Replacing components A 6 A.3 Additional pneumatic circuits A 7 A.4 Index A 8 VI

9 Contents and general safety instructions Intended use The CPX CMAX C1 1 axis controller documented in this description is intended exclusively for use in Festo CPX terminals for installation in a machine or an automation system. In connection with a CPX terminal with suitable CPX bus nodes or CPX FEC, as well as with enabled drives with a displacement encoder as well as a VPWP proportional direc tional control valve, CMAX serves as a position controller with position and force control for pneumatic drives. The CPX terminal may only be used with the CMAX as follows: As intended for the industrial environment In its original condition without unauthorised modifica tions. Only the conversions or modifications described in the documentation supplied with the product are per mitted. In perfect technical condition. Only in combination with approved components (valves, drive/displacement encoder combinations, see section 1.2). The limit values specified for pressures, temperatures, electri cal data, torques etc. should be observed. Please comply with regulations of the trade associations, the German Technical Control Board (TÜV), the VDE or the relevant national regulations. VII

10 Contents and general safety instructions Safety note Protection against dangerous movements Warning High acceleration forces at the connected actuators! Unexpected motions can cause collisions and severe injuries. Dangerous movements can occur due to the faulty control ling of connected actuators, e.g. due to: Dirty or faulty wiring/cabling Component operating errors Measured value and signal generator errors Faulty or non EMC compliant components Errors in the higher order control system. Simply switching off the compressed air supply or load voltage are not suitable locking procedures. In the event of a fault, this could lead to unintentional movement of the drive. Before mounting, installation and maintenance work, put the system into a safe state (e.g. by putting the drive in a safe position and deactivating the controller). Always make sure that the compressed air and power supplies are switched off and locked before working in the machine area. Make sure that no persons are in the operating range of the drive or any other connected actuators. Do not switch on the compressed air until the system is correctly installed and parameterised. VIII

11 Contents and general safety instructions The holding brakes controlled by the drive controller are not appropriate for personal protection by themselves. Lock vertical axes additionally to keep them from falling down or sinking when the compressed air and load volt age are switched off, e.g. by means of: mechanical locking of the vertical axis external braking/safety catch/clamping device sufficient counterbalance of the axis. If used in safety applications, additional measures are necessary, e.g. in Europe the standards listed under the EU machine guidelines must be observed. Without addi tional measures in accordance with statutory minimum requirements, the product is not suitable for use in safety related sections of control systems. Protection from pressurised tubing Caution Danger of injury through inappropriate handling of pres surised tubing! Uncontrolled movements of the connected actuators and uncontrolled movements of loose tubing can cause injury to human beings or damage to property. Do not connect, disconnect or open pressurised lines. The lines must always be exhausted before removal (release compressed air). Use suitable protective equipment (e.g. safety goggles, safety shoes, etc.). IX

12 Contents and general safety instructions Target group This manual is intended exclusively for technicians trained in control and automation technology, who have experience in installing, commissioning, programming and diagnosing posi tioning systems. Service Please consult your local Festo Service agent if you have any technical problems. X

13 Contents and general safety instructions Required software versions for the CPX nodes Particular software versions for the CPX node are required for operating the CMAX (versions as of August 2009): CPX node Required version 1) Use Special features 2) CPX FEC From Revision 18 (R18) On request Max. 8 CMAX modules CPX FB6 (Interbus) From Revision 22 (R22) On request Max. 1 CMAX module CPX FB11 (DeviceNet) From Revision 20 (R20) Suitable Max. 8 CMAX modules CPX FB13 (PROFIBUS DP) From Revision 23 (R23) Suitable Max. 8 CMAX modules Acyclic services, DPV1 (then max. 7 CMAX modules) CPX FB14 (CANopen) From Revision 20 (R20) On request Max. 3 CMAX modules CPX FB23 (CC link) From Revision 19 (R19) On request Max. 8 CMAX modules CPX FB32 (Ethernet/IP) From Revision 14 (R14) On request Max. 8 CMAX modules CPX FB33 (PROFINET, M12) From Revision 7 (R7) On request Max. 8 CMAX modules CPX FB34 (PROFINET, RJ45) From Revision 7 (R7) On request Max. 8 CMAX modules CPX FB38 (EtherCAT) All On request Max. 8 CMAX modules CPX CEC In preparation On request Max. 8 CMAX modules 1) Revisions version (Rev...) see name plate. Older revisions are not suitable for use with CMAX and cannot lead to the intended behaviour. 2) Depending on the CPX node functions used, the address range and therefore the maximum number of modules can be further restricted, if necessary. Tab.0/1: Overview CPX nodes Please also observe the notes on the software version in the documentation for the CPX node. To commission the CMAX, you will require the Festo configur ation tool with a CMAX plug in. You can find this on the Festo website at: è Downloads Download Area: Software, drivers and firmware Enter search term: CMAX XI

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

15 Contents and general safety instructions Identification of specific information The following pictograms designate texts that contain special information. Pictograms Information: Recommendations, tips and references to other sources of information Accessories: Information about necessary or useful accessories for the Festo product. Environment: Information on the environmentally friendly use of Festo products. Text designations Bullet points indicate activities that may be carried out in any order. 1. Numerals denote activities which must be carried out in the specified sequence. Arrowheads indicate general lists. XIII

16 Contents and general safety instructions Notes on this description This description refers to the following versions: CPX CMAX C1 1 axis controller starting from software version V1.0 This description contains special information on the mode of operation, mounting, installation and commissioning of the CMAX axis controller with the modules and components on the axis string (see Tab.0/2). Information about the activation, programming and diagnosis of a CMAX with the used CPX node can be found in the CMAX communication profile" description. Special information about the configuration for certain CPX nodes can be found in the corresponding supplementary description. See Tab.0/3. General basic information on the mode of operation, mount ing, installing and commissioning CPX terminals can be found in the CPX system description, type P.BE CPX SYS.... XIV

17 Contents and general safety instructions This description contains information on the following modules and components of the positioning system: Module/component type CMAX C1 1 Description CMAX axis controller with 7 segment display as well as an axis interface to the VPWP. The CMAX is a CPX module (technology module) in a CPX terminal. VPWP... CASM S D2 R3 CASM S D3 R7 DGCI... DGP(L)... with MLO POT... TLF DNCI... DNC... with MLO POT... LWG DNCM... DSMI... VPWP proportional directional control valve with connections to the CMAX and to the displacement encoder or sensor interface. The position measuring system or sensor interface is connected to the VPWP. Additional digital output with a load voltage supply for activating a brake or clamping unit. Sensor interfaces with a connection to the VPWP, for connecting special position measuring systems to the axis string: analogue, absolute displacement encoders (potentiometers) digital, incremental displacement encoders Enabled drives with position measuring systems: 1) Linear drive with permanently integrated position measuring system. (digital, absolute) Linear drive with external position measuring system (potentiometer, absolute) Standard cylinder with integrated position measuring system (encoder, incremental) Standard cylinder with external position measuring system (potentiometer, absolute) Standard cylinder with external position measuring system (potentiometer, absolute) Semi rotary drive with integrated position measuring system (potentiometer, absolute) 1) Support for other drives in preparation Tab.0/2: Overview of positioning system modules and components XV

18 Contents and general safety instructions Manual for CMAX axis controller Type Title Contents Electronics de scription Communica tion profile de scription CMAX axis controller system description" P.BE CPX CMAX SYS... CMAX communication profile" P.BE CPX CMAX CONTROL... Mounting, installation, commissioning and diagnosis of the CMAX axis controller Activation, programming and diagnosis of a CMAX with the used CPX node Online help Operating in structions Help for the Festo configur ation tool with CMAX plug in Operating instructions for the used components Configuration and commissioning of the CMAX axis controller with the FCT è Downloads Download Area: Software, drivers and firmware Enter search term: CMAX Tab.0/3: Documentation for the positioning system with CMAX XVI

19 Contents and general safety instructions Glossary The following product specific terms and abbreviations are used in this description: Term/abbreviation 0xA0 (A0 h ) Absolute position measuring system Adaptation Axis string Bus node Control interface CPX modules CPX node CPX terminal Drive Festo Configuration Tool (FCT) Festo Handling and Posi tioning Profile (FHPP) Festo Parameter Channel (FPC) Meaning Hexadecimal numbers are marked by a prefixed 0x" or by a subscript h.". A position measuring system with fixed (absolute) assignment of the measured value (position, angle, etc.) and measured variable, for digital" or potentiometer" CMAX. CMAX function to improve non optimal switch on behaviour automati cally during operation Totality of all modules and cables which are connected via the axis inter face to the CMAX Establish the connection to specific fieldbuses. Transmit control signals to the connected modules and monitor their operation (as CPX module: CPX bus node). Connection for all modules and cables in the axis string. Collective term for the various modules which can be integrated in a CPX terminal. Collective term for all CPX bus nodes or the CPX FEC Complete system consisting of CPX modules with or without pneumatics. In this description, the term drive" represents linear drives (DGCI, DGP), standard cylinders, positioning drives (DNC, DNCI, DNCM) or swivel modules (DSMI). Software with standardised project and data management for supported device types. The special requirements of a device type are supported with the necessary descriptions and dialogues by means of plug ins. Fieldbus data profile for Festo position controllers FHPP specific parameter access XVII

20 Contents and general safety instructions Term/abbreviation Functions Homing I I/Os Identification Incremental position measuring system Jog mode Meaning Special functions in the different operating modes. e.g.: Jog mode Homing By means of homing, the reference position and thereby the origin of the dimension reference system of the axis are defined. Digital input. From the point of view of the master controller, the CMAX status outputs are module input data. See section 4.5. Digital inputs and outputs. System function where specific characteristics of the connected axis are determined by means of an identification run, e.g. break away forces, frictional behaviour, dynamics (maximum accelerations and speeds), etc. A position measuring system in which the measured variable refers to a reference point and is determined by counting equally large measure ment steps (increments) with the CMAX encoder". Manual travel in positive or negative direction. Function for setting positions by approaching the target position, e.g. by teaching records. Logic 0 Input or output provides 0 V (also LOW, FALSE or logical 0). Logic 1 Input or output provides 24 V (also HIGH, TRUE or logical 1). O OB Operating mode Parameter PLC/IPC PNU Position control Digital output From the point of view of the master controller, the CMAX control inputs are module output data. See section 4.5. Output byte Type of CMAX control, function or setpoint specification Various settings which must be defined for system operation and be saved in CMAX. Programmable logic controller; for short: Controller (also IPC: industrial PC). Parameter number each parameter has a number and subindex. Control mode where a defined position is approached and held with control. XVIII

21 Contents and general safety instructions Term/abbreviation Pressure/force control Project zero point (PZ) Record Reference point (REF) Software end position Meaning Control mode where a defined force is applied via pressure control. In the following, the term force control" will be used. Dimension reference point for all positions in positioning tasks (project zero point). The project zero point forms the basis for all absolute posi tion specifications (e.g. in the position set table or in direct mode). The point of reference for the project zero point is the axis zero point. Positioning command defined in the position set table, consisting of target position, positioning mode, speed, acceleration,... Point of reference for the incremental displacement encoder. The reference point defines a known position within the drive s travel. Programmable stroke limit (point of reference = axis zero point) Upper software end position Max. limit position in the positive direction (increasing actual values). Lower software end position Min. limit position in negative direction (decreasing actual values). Tab.0/4: Terms and abbreviations XIX

22 Contents and general safety instructions XX

23 CMAX system overview Chapter 1 1 1

24 1. CMAX system overview Contents 1. CMAX system overview CMAX axis controller Connection and display components of the CMAX CMAX function CMAX in the CPX terminal Structure of a positioning system Parameterisation and commissioning options Festo Configuration Tool (FCT) FHPP communication profile

25 1. CMAX system overview 1.1 CMAX axis controller Connection and display components of the CMAX The following connection and display components can be found on the CMAX: 1 Status LED See section X: Axis interface (connection for VPWP) 5 4 Dx Dy X Y 1 3 Inscription labels (accessories) 4 3 character display See section Name plate (on side surface) 3 2 Fig.1/1: Connection and display components of the CMAX 1 3

26 1. CMAX system overview CMAX function The CMAX axis controller, together with a VPWP proportional directional control valve and a drive with a position measur ing system, forms a positioning system for pneumatic axes (see section 1.2). The positioning system permits: Travel at selectable speed in any positions (position con trol) The approach of a position and applying a defined force (force control). Mode of operation CMAX functions The CMAX takes over the following functions: Parameter storage (hardware configuration, records, con troller settings, etc.) It ascertains system characteristic values of the con nected components (identification). Specifies setpoint values (position or force) Tracks setpoint and actual values (position or force con trol) by appropriately activating the proportional direc tional control valve. Mode of operation The CMAX, valve, drive and displacement encoder are connected to form a closed loop control circuit. 1 4

27 1. CMAX system overview CMAX in the CPX terminal The CMAX is integrated in a CPX terminal as a CPX module and is controlled by the CPX node via the internal bus using 8bytes of module output and 8 bytes module input data. See section 4.5. Information about the control and parameterisation of the CMAX via the CPX node can be found in the CMAX communi cation profile" description, P.BE CPX CMAX CONTROL.... The descriptions are also available as PDF files: è Downloads Manual 1 5

28 1. CMAX system overview 1.2 Structure of a positioning system A positioning system typically consists of the following com ponents (see Fig.1/2): 1 CPX terminal with CMAX VPWP proportional directional control valve 3 A sensor interface with displacement encoder cable (optional, depending on the displacement encoder used) 4 Drive with position measuring system (in this example a DNCI) 5 Pneumatic tubing 6 Axis string 6 5 Fig.1/2: Structure of positioning system Specific information on the structure is provided in chapters 2 and

29 1. CMAX system overview 1.3 Parameterisation and commissioning options Tab.1/1 provides an overview of the commissioning, parameterising and teaching options. Operated via Properties For details, see FCT CMAX plug in Master controller, CPX node (CPX bus node or CPX FEC) Easy commissioning thanks to special dialogues and functions. Direct on site" operation with drive monitoring is possible PC must be connected on site with the diagnostic interface of the CPX terminal. Parameterisation of several positioning systems is possible. Commissioning and teaching require additional measures for the necessary drive monitoring. Additional programming required. Chapter 4, help for FCT CMAX plug in CMAX communication profile" description, P.BE CPX CMAX CON TROL... Tab.1/1: Commissioning, parameterising and teaching options Festo Configuration Tool (FCT) The Festo Configuration Tool (abbreviated as FCT) is the soft ware platform for configuring and commissioning various Festo components and devices. The CMAX plug in for the FCT helps to carry out all the steps necessary for commissioning a CMAX. An overview for commissioning with the FCT can be found in chapter 4. The help for the FCT contains the complete information on operating the Festo Configuration Tool. The device specific plug ins each have their own help files. 1 7

30 1. CMAX system overview FHPP communication profile Festo has developed an optimised data profile, the Festo Handling and Positioning Profile (FHPP)", tailored to handling and positioning functions. The FHPP allows the various Festo fieldbus systems and con trollers to be uniformly controlled and programmed. It also uniformly defines the following for the user: Operating modes I/O data structure Parameters Sequence control. Basic information can be found in section 4.5. More detailed information about FHPP can be found in the CMAX communication profile" description. 1 8

31 Fitting and pneumatic installation Chapter 2 2 1

32 2. Fitting and pneumatic installation Contents 2. Fitting and pneumatic installation General notes on mounting and installation Mounting/dismounting the CMAX Installation of the drive and position measuring system General mechanical requirements Drive, shock absorbers and fixed stops Position measuring system Load VPWP proportional directional control valve Approved drive/valve combinations Mounting the VPWP proportional directional control valve Mounting the CASM sensor interface Pneumatic installation Compressed air supply Filter regulator Air reservoir (optional) VPWP proportional directional control valve Tubing and fittings

33 2. Fitting and pneumatic installation 2.1 General notes on mounting and installation Information about mounting the CPX terminal can be found in the CPX system description (P.BE CPX SYS..). Note Using components that have not been approved for oper ation with the CMAX may lead to malfunctions. Use only the special matching components from Festo for setting up and wiring the system. When mounting the components, also observe the mounting instructions in the operating instructions supplied and the instructions in this chapter. Only then can you guarantee trouble free operation. Section Section 2.2 Section 2.4 Section Section Section Section Section 2.3 Section Section 2.5 Fig.2/1: Overview of mounting and pneumatic installation 2 3

34 2. Fitting and pneumatic installation 2.2 Mounting/dismounting the CMAX The CMAX is mounted in an interlinking block (see also section 3.4) of the CPX terminal. See Fig.2/2. Note Always switch off the power supply before mounting/ dismounting CPX modules. Note The CMAX contains electrostatically sensitive devices. Therefore, do not touch any of the components. Observe the handling specifications for electrostatically sensitive devices. Removal Remove the CMAX as follows: 1. Loosen the four screws of the CMAX with a T10 Torx screwdriver. 2. Pull the CMAX carefully and without tilting away from the contact rails of the interlinking block. 1 CMAX 2 Interlinking block 4 3 Contact rails 4 Torx T10 screws Fig.2/2: Mounting/dismounting the CMAX 2 4

35 2. Fitting and pneumatic installation Mounting Mount the CMAX as follows: 1. Place the CMAX in the interlinking block. Make sure that the grooves with the power contact terminals on the bot tom of the CMAX lie above the contact rails. 2. Push the CMAX carefully and without tilting as far as possible into the interlinking block. 3. Tighten the screws only by hand. Place the screws so that the self cutting threads can be used. 4. Tighten the screws with a size T10 Torx screwdriver with a torque of 0.9 to 1.1 Nm. The parameterisation is saved in the CMAX. Therefore, after replacing a CMAX, check the parameters and, if necessary, repeat the commissioning process. See chapter 4. Observe the instructions in section A

36 2. Fitting and pneumatic installation 2.3 Installation of the drive and position measuring system Use only the drive/displacement encoder combinations approved by Festo for the CMAX. Note In order to avoid damage due to uncushioned movement into the end positions: Use appropriate shock absorbers. Define the software end positions. To avoid damage to the displacement encoder when the displacement encoder is shorter than the drive stroke: Limit the travel range with additional end stops. Tab.2/1 shows the approved drive/displacement encoder combinations: Drive Displacement encoder Sensor Design Type Design, function Type interface Linear drive DGCI Digital (absolute) Integrated DGP(L) Potentiometer (absolute) MLO POT TLF... CASM S D2 R3 Cylinder DNCI Encoder (incremental) Integrated CASM S D3 R7 DNC Potentiometer (absolute) MLO POT LWG... CASM S D2 R3 DNCM Potentiometer (absolute) Integrated CASM S D2 R3 Semi rotary drive DSMI Potentiometer (absolute) Integrated CASM S D2 R3 Tab.2/1: Drive overview (as of August 2009) Further drives are in preparation. 2 6 Festo P.BE CPX CMA X SYS EN en 0908NH

37 2. Fitting and pneumatic installation General mechanical requirements Note Connect the drive, guide, displacement encoder and load with as little backlash as possible and align them flush with each other. Mechanical backlash, e.g. between the cylinder piston rod and the mass to be moved, leads to poor movement be haviour (the backlash presents the controller with con stantly changing mass"). Important for positioning accuracy: The cylinder, guide, position measuring system and load must be rigid in the direction of movement, have very little backlash and must be connected flush with each other. The backlash between the drive, guide, mass and position measuring system must be smaller by a factor of 10 than the required tolerance (max. 0.1 mm). Note Transverse loads falsify the measuring results and could damage the displacement encoder. Use an external guide for the effective load in order to prevent transverse loads on the drive. Use mounting attachments which will withstand the acceleration forces long term. If necessary, provide a sufficiently large energy chain in order to minimise the effects of bending forces on the positioning behaviour. Festo P.BE CPX CMA X SYS EN en 0908NH 2 7

38 2. Fitting and pneumatic installation Note Please observe the notes in the operating instructions for the drive used. Make sure that the following are complied with: the permitted lateral force the permitted longitudinal force the permitted mass moment of inertia the maximum permitted speeds and swivel frequencies Drive, shock absorbers and fixed stops Drive Note With all work, be sure to follow the mounting instructions in the operating instructions. Use only the permitted drives with suitable guide listed in Tab.2/1 (as of August 2009). Consult Festo if you wish to use other drives. Drive DGP(L) DNC Tab.2/2: Notes Completely unscrew the adjusting screws for the end position cushioning (PPV) on both sides. Note The following DNC variants are not permitted for use with the CMAX: Slow speed variant S10 Low friction variant S11 Temperature resistant variant S6 (only on request). Use only: DNC variants with permitted maximum piston speed Vmax > 1 m/s. For standard cylinders with end position cushioning PPV: Completely unscrew the adjusting screws for the end position cushioning (PPV) on both sides. Instructions for the drives DGP(L) and DNC 2 8 Festo P.BE CPX CMA X SYS EN en 0908NH

39 2. Fitting and pneumatic installation Shock absorbers / fixed stops Shock absorbers or fixed stops are recommended, depending on the specific application and the drive used. These fulfil the following functions: Protection of the drive or position measuring system Definition or setting of the end positions, as needed Note Damage due to uncushioned travel into the end positions. Carry out commissioning again after adjusting the fixed stops or when components and tubing have been re placed. Use suitable external stops or shock absorbers / fixed stops from Festo. Information on mounting the Festo shock absorbers / fixed stops is provided in the operating instructions for the drive or the assembly instructions for the shock absorbers / fixed stops. Festo P.BE CPX CMA X SYS EN en 0908NH 2 9

40 2. Fitting and pneumatic installation Position measuring system Tab.2/3 provides instructions on mounting the displacement encoder. Drive Position measuring system Mounting instructions DGCI DGP(L) DNCI DNC DNCM DSMI Permanently integrated position measuring system. External position measuring system of type MLO POT... TLF. Integrated position measuring system. External position measuring system of type MLO POT... LWG. External position measuring system already mounted on delivery Integrated position measuring system. Only use a displacement encoder and drive with the same stroke length. The displacement encoder must be longer than the drive stroke used. An electric reserve 0.3% of the nominal length must be available. For safe and quick mounting of the displace ment encoder: Use the BB TLF DGPL... mounting kit. Mount the displacement encoder electrically isolated on the mounting surface using the clamps provided. When used under difficult environmental condi tions (dusty environment): Mount the displacement encoder with the actuator slide facing downwards. The draining edge on both sides prevents excessive dirt from accumulating on the bearing surface. Use only a displacement encoder and standard cylinder with the same stroke length. Mount the displacement encoder and standard cylinder symmetrically (middle of the displace ment encoder stroke must be aligned with the middle of the entire cylinder stroke). Always leave the displacement encoder mounted on the standard cylinder. Observe the instructions in the operating instructions. Tab.2/3: Instructions for mounting the position measuring systems 2 10 Festo P.BE CPX CMA X SYS EN en 0908NH

41 2. Fitting and pneumatic installation Note If the positioning range of the drive is longer than the effective stroke of the displacement encoder: Limit the positioning range using shock absorbers or stops, so that the position measuring system covers the complete possible positioning range. In this way you can protect the displacement encoder from damage. External potentiometer position measuring system If analogue displacement encoders are used (e.g. type MLO POT...), the following applies: In combination with the CMAX, an electric reserve of 0.3% of the nominal length is required at both end positions (does not apply for the integrated system in the case of DSMI). Example: Nominal length of the displacement encoder: 1000 mm Electric effective length: Approx mm } Permissible effective path: mm If the slide of the displacement encoder leaves the permissible effective path, the CMAX will generate a corresponding error message. To avoid these error messages, limit the positioning range so that the slide of the displace ment encoder is always within the permissible effective path. Festo P.BE CPX CMA X SYS EN en 0908NH 2 11

42 2. Fitting and pneumatic installation Load For good positioning behaviour, the CMAX must be adjusted to the load. Here, the load represents the total mass to be moved with the positioning drive, including the weight of the piston and the slide. It consists of the mass of the workpiece which generally changes during the process and all other parts of the drive with mass, such as pistons, piston rods, slides, workpiece grippers or gripper units, etc. which are defined during the design engineering, and generally do not change: Load = workpiece mass + total moving mass without workpiece There is a maximum and a minimum permissible load. The permissible load depends on: the type of drive used the diameter of the drive used the selected mounting position the operating pressure. Make sure that in all load situations the effective load: is at least equal to the minimum permissible load. This especially applies when there is no workpiece. If necessary, fasten an additional mass / load to the slide. The maximum permissible load must not be exceeded. See Tab.2/4 and Tab.2/ Festo P.BE CPX CMA X SYS EN en 0908NH

43 2. Fitting and pneumatic installation Note Minimum load. A pneumatic positioning axis always requires a minimum load. You can find these values in tables Tab.2/4 and Tab.2/6. If necessary, this minimum load must be ensured through the use of an additional weight. For every positioning job, you have the option of specifying the respectively existing load, thereby adjusting the con troller setting of the CMAX to the various loads. Note If the load varies from positioning job to positioning job (e.g. due to changing workpieces) by more than 30%, the load in the positioning job must be adjusted to the actual parameters. Load for linear drives and piston rod cylinders Determine the permissible load using Tab.2/4: Mounting position Maximum load Minimum load horizontal (á = 0 ) m max 0.1 * m max vertical (á = 90 ) 0.33 * m max 0.1 * m max diagonal (0 < á < 90 ) (1 2/3 sin á) * m max 0.1 * m max á = mounting position in [ ] m max = d³ * p sys * (maximum load for horizontal mounting position [kg] ) d = cylinder diameter [mm] p sys = supply pressure [bar] Tab.2/4: Maximum and minimum load Example: Load for DNCI 32 with p = 6 bar. Festo P.BE CPX CMA X SYS EN en 0908NH 2 13

44 2. Fitting and pneumatic installation Mounting position Maximum load Minimum load horizontal (á = 0 ) m max = 32 2 * 6 * = kg 0.1 * m max = 4.92 kg vertical (á = 90 ) 0.33 * m max = kg 0.1 * m max = 4.92 kg diagonal (45 ) (1 2/3 sin 45 ) * m max = kg 0.1 * m max = 4.92 kg Tab.2/5: Load example Instructions for coupling (piston rod drives) If a coupling is required between the piston rod and the guide: Check the backlash of the coupling. The following applies here: Coupling backlash 0.05 mm Adjust the coupling backlash accordingly, if necessary. If there is too much coupling backlash, this may cause: Noise due to knocking on the coupling Increased coupling wear Worsened operating behaviour. Make sure that the coupling backlash does not exceed 0.05 mm. Mounting instructions Mount the load backlash free, if necessary with a guide Festo P.BE CPX CMA X SYS EN en 0908NH

45 2. Fitting and pneumatic installation Mass moment of inertia for semi rotary drives Permissible mass moments of inertia for the DSMI swivel module in electronically regulated operation with the CMAX are shown in the following table: Swivel module Permissible mass moment of inertia [kgm 2 * 10 4 ] DSMI DSMI Tab.2/6: Permissible mass moment of inertia Festo will support you in calculating the mass moment of inertia with software for calculating 2nd degree mass moments of inertia for various basic bodies and standard parts from Festo (e.g. DSMI push on flange). è Downloads Download Area: Software, drivers and firmware Enter search term: mass moment of inertia Note Natural vibrations of the load can lead to malfunctions. Fasten the load so that vibration is kept to a minimum. Avoid masses on long, flexible lever arms. Festo P.BE CPX CMA X SYS EN en 0908NH 2 15

46 2. Fitting and pneumatic installation 1 Favourable natural vibration behaviour Unfavourable natural vibration behaviour Fig.2/3: Example: Favourable and unfavourable natural vibration behaviour of the mass Mass moment of inertia for semi rotary drives The mass moment of inertia must not change during the movement. For this reason, the following applies for the mounting position, depending on the load: Centre of gravity in the axis of rotation Mass is rotationally symmetrical: } any mounting position permissible. Centre of gravity in the axis of rotation Mass is rotationally asymmetrical: } only vertical mounting position permissible, drive shaft points upward or downward (see example Fig.2/3). Centre of gravity outside of the axis of rotation (not recommended): } only vertical mounting position permissible, drive shaft points upward or downward Festo P.BE CPX CMA X SYS EN en 0908NH

47 2. Fitting and pneumatic installation 2.4 VPWP proportional directional control valve Approved drive/valve combinations Tab.2/7 contains the approved drive/valve combinations (as of August 2009). Use the specified fittings and tubing or appropriate tubes with the corresponding flow rates. VPWP sizes 2 and 10 are in preparation. Depending on the application, you can also use sizes 4 or 8 after consulting with Festo. Drive Valve Fitting Tubing Type Size Length Valve Drive DGCI VPWP 2... QSM M5 6 QSM M5 6 PUN 6x VPWP 4... QS 1/8 6 QSM M5 6 PUN 6x VPWP 2... QSM M5 6 QS 1/8 6 PUN 6x VPWP 4... QS 1/8 8 QS 1/8 8 PUN 8x VPWP 6... QS 1/8 8 QS 1/8 8 PUN 8x VPWP 2... QSM M5 6 QS 1/8 6 PUN 6x VPWP 4... QS 1/8 8 QS 1/8 8 PUN 8x VPWP 6... QS 1/8 8 QS 1/8 8 PUN 8x VPWP 4... QS 1/8 8 QS 1/4 8 PUN 8x VPWP 6... QS 1/8 8 QS 1/4 8 PUN 8x VPWP 8... QS 1/4 10 QS 1/4 10 PUN 10x VPWP 4... QS 1/8 8 QS 3/8 8 PUN 8x VPWP 6... QS 1/8 8 QS 3/8 8 PUN 8x VPWP 8... QS 1/4 10 QS 3/8 10 PUN 10x VPWP QS 3/8 12 QS 3/8 12 PUN 12x2 2 17

48 2. Fitting and pneumatic installation Drive Valve Fitting Tubing Type Size Length Valve Drive DGP(I)(L) VPWP 4... QS 1/8 8 QS 1/8 8 PUN 8x VPWP 6... QS 1/8 8 QS 1/8 8 PUN 8x VPWP 4... QS 1/8 8 QS 1/8 8 PUN 8x VPWP 6... QS 1/8 8 QS 1/8 8 PUN 8x VPWP 4... QS 1/8 8 QS 1/4 8 PUN 8x VPWP 6... QS 1/8 8 QS 1/4 8 PUN 8x VPWP 8... QS 1/4 10 QS 1/4 10 PUN 10x VPWP 6... QS 1/8 8 QS 1/4 8 PUN 8x VPWP 8... QS 1/4 10 QS 1/4 10 PUN 10x VPWP 8... QS 1/4 10 QS 3/8 10 PUN 10x VPWP QS 3/8 12 QS 3/8 12 PUN 12x2 DNCI, VPWP 2... QSM M5 6 QS 1/8 6 PUN 6x1 DNC, DNCM VPWP 4... QS 1/8 8 QS 1/8 8 PUN 8x1.25 > 400 VPWP 6... QS 1/8 8 QS 1/8 8 PUN 8x VPWP 4... QS 1/8 8 QS 1/4 8 PUN 8x1.25 > 300 VPWP 6... QS 1/8 8 QS 1/4 8 PUN 8x VPWP 4... QS 1/8 8 QS 1/4 8 PUN 8x VPWP 6... QS 1/8 8 QS 1/4 8 PUN 8x1.25 > 900 VPWP 8... QS 1/4 10 QS 1/4 10 PUN 10x VPWP 6... QS 1/8 8 QS 3/8 8 PUN 8x VPWP 8... QS 1/4 10 QS 3/8 10 PUN 10x1.5 > 1000 VPWP QS 1/4 10 QS 3/8 10 PUN 10x1.5 DSMI 25 (270 ) VPWP 2... QSM M5 6 QSM M5 6 PUN 6x1 40 (270 ) VPWP 4... QS 1/8 8 QS 1/8 8 PUN 8x1.25 Tab.2/7: Drive/valve combinations 2 18

49 2. Fitting and pneumatic installation Mounting the VPWP proportional directional control valve 1 M3 screws with retaining washers Mount the VPWP proportional directional control valve on an even surface with two M3 screws and one retaining washer each. See Fig.2/4. Tightening torque: 1.5 Nm ±10% 2 Earth terminal (see section 3.1) Fig.2/4: Mounting the VPWP When mounting on moving parts: Attach the VPWP perpendicular to the direction of move ment. Acceleration forces then have no influence on the valve slide setting. 1 Mounting at right angles to the direc tion of movement Impermissible: Mounting in the direction of move ment 3 3 VPWP proportional directional control valve Fig.2/5: Mounting the VPWP on moving parts 2 19

50 2. Fitting and pneumatic installation H rail mounting You will require the following mounting kit to mount the VPWP on H rails. Valve Mounting P. No. Type VPWP 2,... 4, CPASC1 BG NRH VPWP 8, CPV10 VI BG NRH Tab.2/8: VPWP H rail mounting set Mounting onto an H rail: 1. Ensure that the mounting surface can carry the weight of the VPWP. 2. Mount the H rail (DIN mounting rail EN TH35). Be sure to leave sufficient space for connecting the supply cables and tubes. 3. Screw the 2 clips from the mounting kit to the VPWP using the screws provided (see Fig.2/6). Tightening torque: 1.5 Nm. Make sure that the fixing bolts of the clip engage in the recess of the VPWP. 4. Hang the VPWP on the H rail. Secure against tipping or slipping on both sides by using the H rail clamping. 2 20

51 2. Fitting and pneumatic installation 1 Fixing bolts (underneath the VPWP 8/10) 2 M4x10 screw 3 H rail 4 H rail clamping Fig.2/6: Mounting the VPWP on an H rail 2 21

52 2. Fitting and pneumatic installation 2.5 Mounting the CASM sensor interface Mount the CASM... sensor interface on an even surface with two M4 screws and one retaining washer each. See Fig.2/7. The symbol marks the position of the mounting screws. The outer mounting screw also serves for earthing ( 1 ). Tightening torque: 2 Nm. 1 Mounting screw (connect earthing) 1 Approx. 30 mm S1 S2 Approx. 126 mm Fig.2/7: Mounting the CASM Mounting on H rails as per EN is possible with mounting kit CP TS HS35. See Fig.2/8. 1 H rail 1 Fig.2/8: Mounting the CASM on H rail 2 22

53 2. Fitting and pneumatic installation 2.6 Pneumatic installation Note Observe the following instructions for installing the pneu matic components. Only then can you guarantee trouble free operation. Section Section Section Section Section Fig.2/9: Overview of pneumatic installation Compressed air supply Requirements of the compressed air supply: Use only dry, unlubricated, 5 m filtered compressed air. Permissible pressure range: bar. 2 23

54 2. Fitting and pneumatic installation Filter regulator Use a filter regulator consisting of a compressed air filter and a regulating valve (e.g. LFR... D... with 5ìm filter cartridge) in conjunction with a soft start valve (e.g. HEL): without lubricator with a 5 m filter with sufficiently large standard nominal flow rate corresponding to the air requirement of the connected drive during positioning. Reference value: twice the stan dard nominal flow rate of the valve (type VPWP), e.g.: Valve (fitting) VPWP 2... (M5) VPWP 4... (1/8) VPWP 6... (1/8) VPWP 8... (1/4) VPWP (3/8) Filter regulator LFR 1/8 D 5M MINI or MS4 LFR 1/4 D7 CRM AS LFR 1/8 D 5M MINI or MS4 LFR 1/4 D7 CRM AS LFR 1/4 D 5M MINI or MS4 LFR 1/4 D7 CRM AS LFR 3/8 D 5M MIDI or MS6 LFR 1/4 D7 CRM AS LFR 3/4 D 5M MAXI or MS6 LFR 3/8 D7 CRM AS Tab.2/9: Selection of filter regulator Use a fine filter or micro filter if you cannot avoid slight oil mist from the compressed air supply. 2 24