Soft Stop SPC11. Manual Electronic/ Pneumatics. System Description Soft Stop Type SPC Manual en 1406e [ ]

Transcription

1 Soft Stop SPC11 Manual Electronic/ Pneumatics System Description Soft Stop Type SPC Manual en 1406e [ ]

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3 Contents and general instructions Original... de Edition... en 1406e Designation... P.BE-SPC11-SYS-EN Order no (Festo AG & Co. KG, D Esslingen, 2006) Internet: The reproduction, distribution and utilization of this document as well as the communicaton of its contents to others without express authorization is prohibited. Offenders will be held liable for the payment of damages. Allrights reserved in the event of the grant of a patent, utility module or design. I

4 Contents and general instructions II

5 Contents and general instructions Contents Designated use... Service... Target audience... Notes on the use of this manual... Important user instructions... Product-specific terms and abbreviations... V VI VI VII IX XI 1. Summary of components Structure Method of operation Display and connecting elements of the SPC Fitting Fitting the SPC Installation General instructions on installation Notes on installing the pneumatic components Additional pneumatic circuits Installing the electronic components Connecting elements of the SPC Connecting the operating voltage and I/Os Connecting the proportional directional control valve and the measuring system Commissioning General instructions on commissioning Basic principles of configuring and operating the SPC Pre-parameterising in the office Parameters A, C and S Parameters L and r (only with type SPC11-INC) III

6 Contents and general instructions Parameter o (options) Behaviour on stopping via I Set parameters Changing parameters Commissioning procedure Preparations for the teach procedure Start the teach procedure Teach the intermediate positions Conclude teach procedure Carry out teach procedure again Instructions on operation Switch-on behaviour after successful commissioning Timing diagram during switch-on The first positioning task Controlling the SPC Use the taught intermediate position as the sensor position Diagnosis and error treatment Error messages on the SPC Faults during operation Acknowledging a fault Optimising the positioning behaviour A. Start-up via digital inputs/outputs... A-1 A.1 The SPC11 remote inputs... A-3 A.2 Remarks on start-up via digital inputs/outputs... A-4 A.2.1 Setting time-dependency diagram parameters... A-6 A.2.2 Initiating and starting teach procedure time-dependency diagram... A-7 A.2.3 Teaching the intermediate position time dependency diagram... A-8 B. Technical appendix... B-1 B.1 Technical specifications... B-3 B.2 Index... B-5 IV

7 Contents and general instructions Designated use The SPC11 has been designed to be fit into a machine or an automated system. In conjunction with permitted drives and measuring systems as well as with a proportional directional control valve type MPYE-5-..., the SPC11 enables: fast movement into the mechanical end positions and one or two selectable intermediate positions manual movement between the end positions. Depending on the drive used, fixed stops may be necessary in order to protect the drive. The end positions can be set by means of fixed stops. The end position cushioning, movement to the intermediate positions and manual positioning are electronically controlled. The SPC11 may only be used as follows: in accordance with designated use in its original state without any modifications by the user in faultless technical condition only in conjunction with permitted drive/measuring system combinations. When used together with commercially available components, such as sensors and actuators, the specified limits for pressures, temperatures, electrical data, torques etc. must be observed. National and local safety regulations (such as workers compensation associations, TÜV technical inspection associations, VDE Engineer s Association) must also be observed. V

8 Contents and general instructions Service Please consult your local Festo repair service if you have any technical problems. Target audience This manual is directed exclusively at technicians trained in control and automation technology. VI

9 Contents and general instructions Notes on the use of this manual This system manual contains basic general information on operating, fitting, installing and commissioning the SPC11. This manual refers to the versions listed in the following: Note Observe the expanded functions of the previous version. Type Version New in this version Soft Stop SPC SPC11-POT-TLF SPC11-POT-LWG SPC11-MTS-AIF-2 SPC11-MTS-AIF SPC11-INC from software status Optimised control behaviour with or Version ) short measuring systems. Optimised behaviour with stop function (see chapter 4.2.4). Soft Stop SPC SPC11-POT-TLF SPC11-POT-LWG SPC11-MTS-AIF SPC11-INC from software status or Version ) SPC TLF SPC LWG SPC AIF SPC11-INC Fault acknowledgement possible via input I6 2) The following options can be set: 3) Output O5 can deliver Ready or Error signal, Input I4 can be used for Stop signal or Move signal (P.04). The following can be switched off: Positioning time monitoring Constant adaptation Soft end position behaviour 1) Software status (SW) see rating plate; after being switched on, the software version is displayed briefly. 2) Theremustbea0-signalatinputRemote(I8). 3) About the o-parameter (see chapter 4.2). Special information on installing and commissioning the SPC11 in conjunction with the drive you are using can be found in the manual Drive-Specific Supplement. VII

10 Contents and general instructions Description Title Contents System Description SPC11 Soft Stop electronics/ pneumatics (this manual) Drive-specific supplement for operating the SPC11 with a certain drive (e.g. DSMI-...) P.BE-SPC11-SYS... P.BE-SPC General instructions on installing and commissioning Special installation and commissioning instructions as well as parameter settings for the relevant drive 1) 1) These manuals contain the permitted drive-valve combinations, cylinder diameters, lengths and massloadsaswellastheparametersettingsvalidhereforthespc11. Note For installation and commissioning you will require the system manual as well as the Drive-Specific Supplement manual for the drive used. VIII

11 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. Please 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. IX

12 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 S 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. X

13 Contents and general instructions Product-specific terms and abbreviations The following product-specific abbreviations are used in this manual: Term/abbreviation 0-signal 1-signal Absolute path measuring system Amplification stage Cushioning stage Drive I Incremental path measuring system O Parameters PLC/IPC System parameters Teach procedure Meaning Input or output supplies 0 V Input or output supplies 24 V Path measuring system with fixed (absolute) assignment of measurement variable and reading The amplification stage influences the acceleration behaviour of the drive, for example. The amplification stage should usually be set as specified in the Drive-Specific Supplement manual. If the positioning behaviour is later optimised, only the cushioning stage should be modified. The positioning behaviour is determined by the amplification and cushioning stages. The cushioning stage serves to optimise the approach behaviour when moving to the end positions. The term drive is used in this manual for the linear unit (DGP(I)(L)-...), cylinder (DNC(I)-...) or rotary drive (DSMI). Digital input Path measuring system in which the measurement variable refers to a reference point and is determined by counting equally large measurement steps (increments). Digital output Parameters which must be set in order that the system can be operated. The amplification stage, the cushioning stage and the system parameter belong here. Programmable Logic Controller/Industrial PC Characteristic value which describes the system structure, the features and components of the drive used. Duringthe teach procedure, the SPC11 checksthe set parameters, learns the position of the mechanical fixed stops as well as various characteristic system values and saves these in the integrated EEPROM. XI

14 Contents and general instructions XII

15 Summary of components Chapter 1 Summary of components 1-1

16 1. Summary of components Contents 1. Summary of components Structure Method of operation Display and connecting elements of the SPC

17 1. Summary of components 1.1 Structure In conjunction with permitted drives and measuring systems as well as with a proportional directional control valve type MPYE-5-..., the SPC11 enables: fast movement into the mechanical end positions and one or two selectable intermediate positions manual movement between the end positions. The end position cushioning, movement to the intermediate positions and manual positioning are electronically controlled. A distinction is made between the following types of SPC11: Type SPC11-POT-TLF SPC11-POT-LWG SPC11-MTS-AIF-2 SPC11-MTS-AIF SPC11-INC Description Enables connection to the linear potentiometer type MLO-POT-...-TLF. Enables connection to the connecting rod potentiometer type MLO-POT-...-LWG and the rotary drive with integrated measuring system type DSMI-... Enables connection of the linear drive with digital measuring system type DGCI-.... Enables connection of the linear drive with integrated digital measuring system type DGPI(L) AIF or the digital measuring system type MME-MTS-...-AIF. Enables connection of an incremental measuring system (e.g. piston rod drive with integrated incremental measuring system type DNCI ). 1-3

18 1. Summary of components The diagram below shows the basic layout of a drive with the SPC11 using, as an example, a linear unit with a linear potentiometer P.02 P Drive (linear unit) 2 Measuring system (here, external linear potentiometer) 3 Fixed stops 4 Line voltage connection and I/O coupling (e.g with PLC) 5 Soft Stop SPC11 6 Proportional directional control valve type MPYE Service unit (without lubricator, with 5 μm filter) 8 Compressed air source (5 to 7 bar) Fig. 1/1: Layout of a drive with SPC11 (example linear drive) With the SPC11, movement is controlled. During commissioning, the end positions (cylinder end positions or position of the fixed stops) as well as the desired intermediate positions are learnt by the SPC

19 1. Summary of components During operation, the SPC11 controls movement of the moveable mass into the saved end positions and intermediate positions at the highest possible speed. Shortly before the learnt end position or intermediate position is reached, the moveable mass is braked so that it comes to a standstill. To keep the moveable mass in the learnt end position, it is pressed against the fixed stop (typically at a pressure that is slightly less than the operating pressure). Advantages Compared to impact-limited drives with pulse-valve control, this control procedure permits higher positioning speeds. Also, the following measures, which would be required for controlling a drive with a pulse valve, are no longer necessary: the use of restrictors the use of limit switches the use of mechanical end position cushioning (shock absorbers) the maintenance of fixed stops. Compared with impact-limited drives with pulse-valve control, the SPC11 permits: higher machine cycle times less vibration of the system lower maintenance costs. 1-5

20 1. Summary of components Components In order to implement fast positioning with electronically closed-loop controlled end position cushioning, you will require the following components: the Soft Stop SPC11 a proportional directional control valve type MPYE a service unit with a 5 μm filter, without lubricator a permitted path measuring system (external or integrated with the drive) a drive, if possible with mechanical guide if possible, two fixed stops (depending on the drive used) a24vdcpowersupply if necessary, components for a pneumatic emergency stop circuit possible components for additional pneumatic circuits (see chapter 3.2.1). 1-6

21 1. Summary of components 1.2 Method of operation Tasks of the SPC11 The SPC11 takes over the following tasks: It ascertains characteristic system values of the connected components It saves the desired end positions and intermediate positions It specifies the end positions and intermediate positions It compares the nominal and actual positions and controls positioning by appropriate actuation of the proportional directional control valve (status control). Method of operation The SPC11, the valve, the drive and the measuring system are connected together to form a closed-loop control circuit. In this closed-loop control circuit, the position of the moveable mass represents the control variable. This control circuit is therefore also called positioning control. In the following text, the term moveable mass also refers to piston, slide and flange shaft. The following diagram shows the basic layout of a positioning control circuit with the SPC

22 1. Summary of components 1 Measuring system 2 Actual position value 3 SPC11 4 Valve control (nominal value) 5 Proportional directional control valve 6 Drive, e.g. linear drive Fig. 1/2: Positioning control circuit with pneumatic components The measuring system registers continuously the position of the moveable mass and transmits this in the form of an electric signal to the SPC11. The SPC11 compares the current position with the target position (the taught end positions Po.1 and Po.2 or the intermediate positions Po.3 and Po.4) and calculates from this value the positioning signal for the proportional directional control valve. The proportional directional control valve controls the drive by pressurising one cylinder chamber and exhausting the other. The flow is blocked in the valve slide mid-position. 1-8

23 1. Summary of components 1.3 Display and connecting elements of the SPC11 The diagram below shows the display and connecting elements of the SPC Control: operating voltage connection and I/O coupling 2 Valve: valve connection 3 Display 4 Operating buttons 5 Type plate see side 6 Groove for identification signs (type IBS 6x10) 7 Measuring system connection (here type SPC11-POT-TLF) 8 Earth (ground) connection Fig. 1/3: Display and connecting elements of the SPC11 With the SPC11-POT-... and SPC11-MTS-..., the connecting cable for the measuring system is firmly connected to the SPC11. With the SPC11-INC or the SPC11-MTS-AIF-2, the measuring system connection is in the form of a socket. 1-9

24 1. Summary of components 1-10

25 Fitting Chapter 2 Fitting 2-1

26 2. Fitting Contents 2. Fitting Fitting the SPC

27 2. Fitting Note When fitting the pneumatic components, observe also the notes on fitting in the operating instructions supplied and the notes on installation in chapter Fitting the SPC11 The SPC11 can be fastened to a flat surface with the aid of the support brackets. The diagram below shows the mounting surface and the dimensions for the four threaded holes screw size M4. Fasten the SPC11 with at least 3 screws. approx mm mm 78 mm 63 mm 42 mm mm 1 1 Plug in fitted state Fig. 2/1: Fitting dimensions of the SPC11 2-3

28 2. Fitting 2-4

29 Installation Chapter 3 Installation 3-1

30 3. Installation Contents 3. Installation General instructions on installation Notes on installing the pneumatic components Additional pneumatic circuits Installing the electronic components Connecting elements of the SPC Connecting the operating voltage and I/Os Connecting the proportional directional control valve and the measuring system

31 3. Installation 3.1 General instructions on installation Warning Sudden unexpected movements of the connected actuators and uncontrollable movements of loose tubing can cause injury to human beings and damage to property. Before carrying out installation and/or maintenance work, switch off the operating voltage and the compressed air supply either simultaneously or in the following sequence: 1. compressed air supply 2. operating voltage. Caution The use of components which have not been released for operation with the SPC11 may lead to malfunctioning. Use only the special matching components from Festo for setting up and wiring the system. 3-3

32 3. Installation 3.2 Notes on installing the pneumatic components Note Observe the following instructions on installing the pneumatic components. Only then can you guarantee faultless operation Notes on installation, see the following pages 7 Fig. 3/1: Overview of pneumatic installation 3-4

33 3. Installation Compressed air supply ( 1 ) S Use only dried, non-lubricated, 5 μm filtered compressed air from 5 to 7 bar. You will require a service unit with a 5 μm filter for protecting the proportional directional control valve against damage. Service unit ( 2 ) S Use a service unit consisting of a compressed air filter and a regulating valve (e.g. type LFR-...-D-... with 5 μm filter element) as well as a safety start-up valve (e.g. HEL ): without lubricator witha5μm filter with sufficiently large standard flow corresponding to the air requirement of the connected drive during positioning. Reference value: twice the rated flow of the valve (type MPYE-5-...), e.g.: Valve type MPYE-5-1/8-LF-010B MPYE-5-1/8-HF-010B MPYE-5-1/4-010B MPYE-5-3/8-010B Service unit LFR-M1-G1/8-C10RG or LFR-1/8-D-5M-MINI LFR-M1-G1/4-C10RG or LFR-1/4-D-5M-MINI LFR-M2-G1/4-C10RG or LFR-3/8-D-5M-MIDI LFR-M2-G3/8-C10RG or LFR-3/4-D-5M-MAXI S Use a microfilter if you cannot avoid slight oil mist from the compressed air supply. 3-5

34 3. Installation Compressed air reservoir ( 3 ) If the positioning behaviour does not conform to your requirements, and if you ascertain fluctuations in pressure of over 1 bar at the measuring point, then proceed as follows: S Fit a compressed air reservoir (e.g. type VZS-...-B) between the service unit and the proportional directional control valve. In this way you can reduce fluctuations in pressure during operation. You can compensate for slight excesses in the permitted pressure by using supply tubing with a larger diameter. Reservoir volume: The reservoir volume should be at least four times as large as thevolumeofthedriveused. V P =4*V Z V P= buffer volume V Z = cylinder volume (linear drive: V Z =r 2 * ð*l Z ) L Z = cylinder stroke length 3-6

35 3. Installation Compressed air tubing and screw connectors ( 4 ) S Use only straight screw connectors. If angled connectors cannot be avoided, use plug connectors from the Quick Star series. S S S S S Cut compressed air tubing and hoses to the required size, as specified in the manual for the drive used. Arrange the tubing between the valve (MPYE-5-...) and the drive symmetrically. Use only clean compressed air tubing and connectors. Details on permitted temperatures and pressure ranges for tubing and connectors can be found in the products catalogue. Do not install restrictors in the supply lines. Arrange the tubing so that it does not project into the positioning range. For good positioning behaviour during operation, fluctuations in pressure of max. 1 bar are permitted in front of the proportional directional control valve. In order to check the stability of the supply pressure, you can fit a pressure measuring point directly in front of the proportional directional control valve. 3-7

36 3. Installation Proportional directional control valve ( 5 ) Arrange the tubing between the valve (MPYE-5-...) and the drive symmetrically. Recommendation for linear drives and drives with piston rod: tubing length = cylinder length. The diagram below shows as an example the tubing of a cylinder with an MPYE when an SPC11 is used Proportional directional control valve type MPYE Service unit with 5 μm filter, without lubricator Fig. 3/2: Pneumatic circuit diagram Fit the valve in accordance with the operating instructions supplied with the valve. 3-8

37 3. Installation S If the proportional directional control valve is to be used in an environment subjected to heavy electrical interference, it should be insulated from the mounting surface. Fitting onto moving parts S If fitted to moving parts, the proportional directional control valve must be mounted at right-angles to the direction of movement. Acceleration forces then have no influence on the valve slide setting Fitting at right angles to the direction of movement 2 Not permitted 3 Proportional directional control valve type MPYE Fig. 3/3: Fitting to moving parts Use silencers with a large flow rate UC-M5, U-1/8, U-1/4 or U-3/8. 3-9

38 3. Installation Reducing loud exhaust noises S S Fit larger silencers with the aid of tubing or: Pass the ducted exhaust into a small compressed air reservoir and exhaust this with a large silencer. Make sure that there is sufficient flow through the screw connectors and tubing (with PUN-8 tubing length max. 1 m) Ducted exhaust 2 Compressed air reservoir 3 Silencer Fig. 3/4: Ducted exhaust 3-10

39 3. Installation Drive ( 6 ) Use only the permitted combinations of drives and measuring systems approved of by Festo for the SPC11. The drive-valve combinations, cylinder diameters, cylinder lengths and mass loads permitted for the drive used can be found in the Drive-Specific Supplement manual. Connect the drive, guide, measuring system and the load free of play in the direction of movement and flush with each other. Ifnecessary,provideasufficientlylargesupplyofenergyin order to minimise the effects of transverse forces on the positioning behaviour. Observe the maintenance intervals specified in the operating instructions for the drive (see operating instructions for the cylinder/drive or the guide). 3-11

40 3. Installation Path measuring system ( 7 ) See also Drive-Specific Supplement. S Fit the measuring system and the drive symmetrically so that the centre of the usable measuring system stroke corresponds to the centre of the complete cylinder stroke. With type MLO-POT-...-TLF: The remaining path of the measuring system slide must be identical in the cylinder end positions on both sides. 1 Remaining slide path 1 1 Fig. 3/5: Symmetrically mounted measuring system (with type MLO-POT-...-TLF) With type MLO-POT-...-LWG: The remaining slide path of the measuring system must be identical in the cylinder end positions on both sides and can be calculated as follows: Calculation formula Description (L M -L Z ) 2 = L R Cylinder length L M Measuring system length L Z L R Remaining slide path 3-12

41 3. Installation With type MME-MTS-...-AIF: Note The mechanical work path (possible slide path) of measuring system type MME-MTS-...-AIF is longer than the electrical work path (usable stroke length). Fit measuring system type MME-MTS-...-AIF so that the electrical work path (see type designation MME-MTS-...-AIF) of the measuring system is symmetrical to the complete cylinder stroke. 1 Remaining slide path Electrical work path (usable stroke length) 3 Mechanical work path (possible slide path) 2 3 Fig. 3/6: Usable stroke length with type MME-MTS-...-AIF 3-13

42 3. Installation Fixed stops ( 8 ) Fixed stops may be necessary, depending on the drive used. See also Drive-Specific Supplement. Mass load ( 9 ) Fit the mass load free of play. Possible moveable mass loads see Drive-Specific Supplement. 3-14

43 3. Installation Additional pneumatic circuits You may require additional pneumatic circuits in order to attain a particular status for the system in certain applications. Choose between the following alternatives based on the design and operating characteristics of your system: drive pressureless driveclamped drive moves while throttled to the left or right end position. Please note If the operating voltage supply for the SPC11 is switched off, the proportional directional control valve type MPYE-... will move to the mid-position. Due to the asymmetrical voltage-pressure curve of the proportional directional control valve when the supply pressure is switched on, the slide can move slowly into one of the end positions. Circuit variants The following four diagrams show as an example four variants ofcircuitsforalineardrive. For requirements and recommendations concerning the components used, see Fig. 3/11 and Fig. 3/

44 3. Installation Variant 1: Drive pressureless 1A 1V1 1V2 1V3 1V4 1G1 1R1 Fig. 3/7: Drive pressureless 3-16

45 3. Installation Variant 2: Drive clamped 1A 1V1 1V2 1V3 1G1 1R1 Fig. 3/8: Drive clamped 3-17

46 3. Installation Variant 3: Drive moves while throttled to right-hand end position 1A 1V1 1V2 1V3 1V4 1G1 1R1 Fig. 3/9: Drive moves while throttled to right-hand end position 3-18

47 3. Installation Variant 4: Drive moves while throttled to left-hand end position 1A 1V1 1V4 1V2 1V3 1G1 1R1 Fig. 3/10: Drive moves while throttled to left-hand end position 3-19

48 3. Installation Components for variants Identifying components Requirements Recommendation/type 1V1, 1V2 5/2-way valve sliding piston valve with positive cover with control air with reversible flow direction flow rate coordinated to the proportional directional control valve used (1V3) For MN1H: Type MN1H-5/2-D-1-FR-S-C Type MN1H-5/2-D-2-FR-S-C 1V3 1V4 1R1 1G1 Proportional directional control valve type MPYE-... flow matches the drive used (1 A) For suitable valve-drive combinations, see the drive-specific supplement for the drive used. Exhaust restrictor with silencer specifies the speed at which the drive moves into the desired end position; adjustable with appropriate silencer screwed directly into the restrictor must be fitted near valves 1V1, 1V2. Compressed air regulating valve with 5 ìm filter cartridge standard flow matched to the air requirement of the connected drive Requirements see also section 3.2 Compressed air reservoir (optional) Requirements see section 3.2 Type MPYE B Type GRLA-...-B with U-... Type LFR-...-D-5M-... Type CRVZS-... Fig. 3/11: Components for variants

49 3. Installation Component Type/size MPYE M /8LF /8HF / /8-... GRLA-...-B...-M / / / /8-... MN1H-5/2-...-FR-S-C...-D D LFR MINI...-1/ /4-... LFR MIDI...-1/ /2-... LFR MAXI...-1/2-... Fig. 3/12: Dimensions for variants

50 3. Installation 3.3 Installing the electronic components Caution Cables with high levels of noise can cause electromagnetic interference. Do not place the following cables in the vicinity of cables with high levels of interference: measuring system cable proportional directional control valve cable. Caution An incorrect connection assignment may cause damage to the SPC11. Use only the original cables. Make sure that the connection assignments of the measuring system cables and valve cables are correct. Caution Incorrect or missing earthing can cause interference. When using the DGP(L) and the DNC(I): Connect the drive with low impedance (short cable with large cross-sectional area) to the earth potential, if the drive is not mounted on an earthed machine stand. 3-22

51 3. Installation Connecting elements of the SPC11 The diagram below shows the connecting elements of the SPC11, using the SPC11-POT-TLF as an example. 1 Measuring system connection (here for type MLO-POT-...-TLF or DNCM-...) 2 Earth (ground) connection Valve connection 4 Operating voltage connection as well as inputs and outputs 1 4 Fig. 3/13: Connecting elements of the SPC

52 3. Installation Connecting the operating voltage and I/Os Warning Danger of electric shock S Only use PELV circuits in accordance with IEC/EN (protective extra-low voltage, PELV) for the electrical power supply. Also observe the general requirements for PELV circuits as per IEC/EN S Only use voltage sources which guarantee reliable electrical isolation of the operating voltage in accordance with IEC/EN The use of PELV circuits ensures protection from electric shock (protection from direct and indirect contact) in accordance with IEC/EN (Electrical equipment of machines, General requirements).a 24 V power supply unit used in the system must satisfy the requirements of EN for DC power supply (behaviour during power interruptions, etc.). Caution In order to avoid interference caused by electromagnetic influences: S Connect the earth connection on the left-hand side of the housing with low impedance (short cable with large cross-sectional area) to the earth potential. S Use only the following original cable to connect the line voltage and inputs/outputs. Original cable to connect the line voltage and inputs/outputs. Type designation KMPV-SUB-D-15-5 KMPV-SUB-D Cable length 5m 10 m 3-24

53 3. Installation The operating voltage is supplied together with the circuit for the inputs/outputs via the 15-pin plug marked with Control (see Fig. 3/14). Pin 15 (white-yellow): Pin 14 (brown-green): Tolerance: DC +24 V 0 V -10%to+25% Connect a protective conductor with sufficient cross sectional area to the drive, if this is not mounted on an earthed machine stand. The following diagram shows the pin numbering of the Control connection. The pin assignment with core colours for the original cable KMPV-SUB-D can be found in the following section. 1 Pin 1 8 Pin 8 9 Pin 9 ae Pin ae 9 Fig. 3/14: Control connection Short description of the I/O signals at the Control connection The function of the input I4 and outputs O4 and O5 can be configured (see section 4.2.3). The following tables describe the factory settings. Further information on the I/O signals can be found in section

54 3. Installation Inputs on the 15-pin Control plug (I = input) Pin Pin assignment and core colours Description 1 I8 Remote white 1-signal deactivates operating buttons and activates the relevant remote inputs (pins 2...4) 2 I7 {/ With 0-signal at I8 (remote): Input without function. With 1-signal at I8 (remote): Function of the operating buttons {/ callable 3) 3 I6 Reset Error 1) Enter/Teach/ Esc green With 0-signal at I8 (remote): Faults are acknowledged via a rising edge at this input: With 1-signal at I8 (remote): Function of the operating buttons Enter/Teach/Esc can be called up 3) 4 I5 +/} yellow With 0-signal at I8 (remote): Input without function. With 1-signal at I8 (remote): Function of the operating buttons +/} callable 3) 5 I4 P.04 2) grey With 0-signal at the inputs P.01, P.02 and P.03: With factory setting P.04: A 1-signal (min. switch-on duration 20 ms) issues the order to move to the taught intermediate position P.04. 4) 6 I3 P.03 pink With 0-signal at the inputs P.01, P.02 and P.04: A 1-signal (min. switch-on duration 20 ms) at this input issues the order to move to the taught intermediate position P.03. 4) 7 I2 P.02 blue With 0-signal at the inputs P.01, P.03 and P.04: A 1-signal (min. switch-on duration 20 ms) at this input issues the order to move to the end position P.02. 4) 8 I1 P.01 red With 0-signal at the inputs P.02, P.03 and P.04: A 1-signal (min. switch-on duration 20 ms) at this input issues the order to move to the end position P.01. 4) 1) Available from Version A prerequisite is a 0-signal at input I8 (remote). 2) Function of I4 can be configured (see section 4.2.3); P.04 (factory setting) or Stop 3) See appendix A 4) A change of direction is possible at any time. 3-26

55 3. Installation Outputs on the 15-pin Control plug (O = output) Pin Pin assignment and core colours Description 9 O5 Error 1) black Factory setting: Provides a 1-signal when an error occurs (see chapter 5). Provides a 0-signal in the normal operating state 10 O4 P.04 2) violet Factory setting: Supplies a 1-signal if the moveable mass is in the taught intermediate position P.04. Supplies a 1-signal for 50 ms if intermediate position P.04 is overrun. 11 O3 P.03 grey-pink Supplies a 1-signal if the moveable mass is in the taught intermediate position P.03. Supplies a 1-signal for 50 ms if intermediate position P.03 is overrun. 12 O2 P.02 red-blue Supplies a 1-signal if the moveable mass is in end position P O1 P.01 white-green Supplies a 1-signal if the moveable mass is in end position P.01 (on the side with the electrical connection for the potentiometer). 1) Function of O5 can be configured (see section 4.2.3); Error (factory setting) or Ready 2) Function of O4 can be configured (see section 4.2.3); P.04 (factory setting) or Stop Linevoltageonthe15-pin Control plug Pin Pin assignment and core colours Description 14 0V brown-green 0V V supply white-yellow DC+24 V (tolerance -10 % to + 25 %) 3-27

56 3. Installation Connection example type SPC Note With measuring systems type MLO-POT-...-LWG: In order to earth the system, connect the earthing cable on the flat plug of the measuring system to the earth connection on the SPC V 0V O1: P.01 O2: P.02 O3: P.03 O4: P.04 *) O5: Error *) I1: P.01 I2: P.02 I3: P.03 I4: P.04 *) I5: +/} I6: Enter/Teach/Esc I7: {/ I8: Remote white-yellow brown-green white-green red-blue grey-pink violet black red blue pink grey yellow green brown white *) The function of this input/output can be configured (see section 4.2.3). 1 Pin assignment for Control connection with core colours for cable KMPV-SUB-D O... = output, I... = input 2 Sensors for moving to the positions (P.04 only for factory setting) 3 With linear drives, end position P.01 lies on the side with the electrical connection to the measuring system 4 Earth/ground Fig. 3/15: Connection example type SPC

57 3. Installation Connecting the proportional directional control valve and the measuring system Connecting the measuring system Use only the permitted combinations of drives and measuring systems approved of by Festo for the SPC11. The connecting cable for the measuring system is connected either fixed to the SPC11 or to the drive. Note Interference due to electromagnetic influences can be avoided if a short cable is used. Use only the original cable. Observe also, where applicable, the operating instructions for the measuring system. Fasten the plug with the aid of the integrated screw, in order to prevent unintentional loosening, e.g. due to shock. Connecting the proportional directional control valve The valve connection provides the power supply for the valve and the control voltage for positioning the valve slide. Use only the original cable for connecting the valve. Type designation KMPYE-AIF-1-GS-GD-2 KMPYE-AIF-1-GS-GD-0,3 Cable length 2m 0.3 m 3-29

58 3. Installation 1 Pin 1 4 Pin Pin Fig. 3/16: Valve connection, pin assignment and core colours Pin Pin assignment and core colours of the cable type KMPYE-... Pin no. on the valve plug 1 24 V load voltage for the valves (blue) 1 2 0V(brown) V (green) 2 4 Vs (positioning signal V) (yellow) 3 5 Signal GND (grey) 4 6 n.c.: not connected (pink) 7 24 V supply for the valves (white) 1 Tighten the plugs with the aid of the union nut in order to prevent unintentional loosening, e.g. due to shock. 3-30

59 Commissioning Chapter 4 Commissioning 4-1

60 4. Commissioning Contents 4. Commissioning General instructions on commissioning Basic principles of configuring and operating the SPC Pre-parameterising in the office Parameters A, C and S Parameters L and r (only with type SPC11-INC) Parameter o (options) Behaviour on stopping via I Set parameters Changing parameters Commissioning procedure Preparations for the teach procedure Start the teach procedure Teach the intermediate positions Conclude teach procedure Carry out teach procedure again Instructions on operation Switch-on behaviour after successful commissioning Timing diagram during switch-on The first positioning task Controlling the SPC Use the taught intermediate position as the sensor position

61 4. Commissioning 4.1 General instructions on commissioning This chapter describes parameterising and commissioning with the aid of the three buttons on the SPC11. A 1-signal at the Remote input (I8) blocks the SPC11 buttons. Button functions can then be called up via the digital inputs (I5...7). Detailed information on this can be found in appendix A. Warning During commissioning and during operation the moveable mass is moved at the highest possible acceleration and speed. Make sure that: Nobody can place his/her hand in the positioning range of the moveable mass, unless the compressed air supply is switched off. The complete positioning range is free collision contours. Warning Incorrectly set parameters can damage the fixed stops and the drive. Be very careful when setting the parameters. 4-3

62 4. Commissioning Basic principles of configuring and operating the SPC11 Parameters The SPC11 must be familiar with certain conditions of use. These conditions of use are described by the following parameters: Display Parameters Description Amplification stage Cushioning stage System parameters Nominal strokelength of the drive Offset axis zero point Influences the acceleration behaviour of the drive Influences the run-inbehaviour when moving to the end positions and intermediate positions. Characteristic values for setting up the drive with reference to the drive type First character: Characteristic value for the ratio of drive and measuring system length Second character: Characteristic value for the ratio of drive length and drive diameter. Nominal stroke length in 1 mm increments (e.g. nominal stroke 300 mm: L = 300) Offset between the end position P.01 and the axis zero point in 1 mm increments Dependent on drive, valve and mass load; see Drive-Specific Supplement Only with the use of an incremental path measuring system 1) (see section 4.2.2) Option parameters (Options) Permits various options (e.g. Ready signal instead of Error signal, Stop signal instead of P.04 etc., see section 4.2.3) 1) e.g. with drive DNCI in connection with type SPC11-INC 4-4

63 4. Commissioning The parameters can be entered: before commissioning (pre-parameterising without drive in the office) when commissioning. Button functions The SPC11 buttons are only active when a 0-signal is present at the Remote input (I8). Button Description {/- Reduce the input value or position value 1) (the drive moves in the direction of the measuring system zero point) Enter/Teach (> 2s) Esc (< 1s) Hold the button pressed down for at least 2 seconds in order to confirm parameter values or to start the teach procedure. Press the button briefly in order to interrupt the procedure. +/} Increase the input value or position value 1) (the drive moves away from the measuring system zero point). 1) Press the button briefly in order to modify the value by 1. Hold the button pressed down in order to modify the value continuously. A1-signalattheremoteinput(I8)blockstheSPC11buttons. Functions can then be called up via the digital inputs. Detailed information on this can be found in appendix A. 4-5

64 4. Commissioning Display on the SPC11 ThedisplayontheSPC11indicates: parameters or status information. The first position of the display shows identifying letters for parameters or status information. The last two positions show the appropriate value, the stage or the number. 1 Identifying letters for parameters or status type Value, stage or status information 3 Point for separation 3 Fig. 4/1: Composition of the display on the SPC11 4-6

65 4. Commissioning Possible status information Display Description When the letter (t) flashes: The SPC11 waits for the teach task. When the dots (...) flash: The teach procedure is being carried out. Only with type SPC11-MTS-AIF: The SPC11 checks whether the measuring system is connected (find measuring system). When the SPC11 is switched on: The moveable mass stands uncontrolled and is not in a taught position (P.01...P.04). The outputs O1...4 therefore supply a 0-signal. In operation (e.g. manual positioning): The moveable mass stands controlled but is not in a taught position (P.01...P.04). The outputs O1...4 therefore supply a 0-signal. The moveable mass stands in end position P.01 (end position when measuring system is connected). The moveable mass stands in end position P.02 (opposite end position). The moveable mass stands in intermediate position P.03 (taught intermediate position). The moveable mass stands in intermediate position P.04 (taught intermediate position). Stop signal over Stop input I4 Fault number (Error; value range: ); see chapter 5 Reference travel is being carried out. 4-7

66 4. Commissioning 4.2 Pre-parameterising in the office Parameters A, C and S The permitted values of the parameters A, C, and S for the driveyouareusingcanbefoundintheappropriateaxisspecific supplement Parameters L and r (only with type SPC11-INC) The parameters L and r are only queried when incremental path measuring systems are used (e.g. positioning drive DNCI in connection with type SPC11-INC). With incremental path measuring systems, the SPC11 requires the following information: Nominal stroke length (L) of the drive (see type plate) Offset axis zero point (r) offset between the end position P.01 and the axis zero point (see Fig. 4/2). 1 Axis zero point (pistonrodrunin 2 Offset axis zero point (r) 3 Fixed stop (here for end position P.01) P.01 P.02 Fig. 4/2: Reference points for incremental path measuring systems with SPC11-INC 4-8

67 4. Commissioning Nominal stroke length (L) of the drive [mm] Nominal stroke length (L) of the drive, see type designation on the type plate(e.g.type DNCI P-A has a nominal stroke length of 300 mm). Offset axis zero point (r) [mm] For a good positioning behaviour, the SPC11 must know the positioning range used by the drive. The offset axis zero point specifies the offset between the end position P.01 and the axis zero point. With an offset of 0 cm, the end position P.01 lies in the axis zero point. Remarks on reference travel With incremental path measuring systems, the measurement variable refers to a reference point and is determined by counting equally large measurement steps (increments). The relationship between measurement variable and current position is created through the reference travel. Referencing in the teach procedure In the teach procedure (see also section 4.3.1), the end positions P.01 and P.02 are approached. This creates the relationship between measurement variable and current position. Reference travel is not necessary. Reference travel after POWER ON After the SPC11 operating voltage is switched on again, the relationship between measurement variable and current position is lost. Reference travel into the end positions P.01 or P.02 is necessary (see also section 4.4). 4-9

68 4. Commissioning Parameter o (options) With this parameter, you can change the signal behaviour of the SPC11 and switch off certain standard functions (from Version 1.41). Please note The factory setting (o-parameter = 0) means: No option selected. Standard behaviour active. Standard behaviour at factory setting (o-parameter = 0): Output O5 supplies Error signal Positioning time monitoring (10 s) active Constant adaptation active Soft end position behaviour active Input I4 can be used for the positioning order to the taught intermediate position P.04 In the factory setting (o-parameter = 0), the above behaviour is identical to the previous version (there no options were selectable). Internally, the decimal value is interpreted as binary. A specific option is assigned to each bit (see following table). Only allowable option combinations can be set. This results in a possible value range of 00 to 79 for the o-parameter. 4-10

69 4. Commissioning Parameter o (options) Bit Decimal value at 1 Option 0 1 Output O5: Ready signal (instead of Error signal) 1 2 Switch off positioning time monitoring 2 4 Switch off constant adaptation 3 8 Switch off soft end position behaviour 4 16 Parameterise DNCI/DDPC with L < 999 mm Description Use O5 for Ready signal instead of Error signal. Permits monitoring of operational readiness: The output O5 supplies a 1-signal if the SPC11 is ready to operate. A 0-signal at this output indicates that the SPC11 is not yet ready to operate, or there is a system or positioning error. Switches off the time monitoring during a positioning order. It is then not monitored whether the position is reached within approx. 10 s. Switch off constant adaptation. Adaptation is then active after operating voltage is switched on only within the first 20 strokes. 1) Switches off soft end position behaviour. Travelling into the end position takes place with somewhat more remaining energy. You can reduce the cycle time with this function (up to max. 15 %, depending on drive and mass load). From FW 1.81: For long drives DNCI/DDPC: with bit 4 of the O parameter, 1000 mm is added to the length set with the L parameter. After switch-off and switch-on or with a new parameterisation, this is indicated with "L. 1". As a result, lengths of up to 1999 mm can be set. 1) With oscillating mass load, constant adaptation can negatively influence travel behaviour. 4-11

70 4. Commissioning Parameter o (options) Bit Decimal value at 1 Option 5 32 Input I4: Stopwithout return travel (instead of positioning tast to P.04) 6 64 Input I4: Stopwith return travel (instead of positioning task to P.04) Description Use I4 for Stop signal instead of Move signal (to P.04). Permits stopping the drive even during the teach procedure. Output O4 supplies a 1-signal. One of the following options can be selected: Stop without return travel (bit 5): With the 0 signal at input I4, the drive stops with the brake incline determined in the teach procedure. 2) 3) Stop with return travel (bit 6): With a 0-signal at input I4, the current position is taken over as the Stop position after an internally required signal processing time. The drive is braked with maximum power and travelled back to the Stop position. 2) For instructions on stopping, see section ) A stop during the teach procedure stops the drive without control. The procedure must then be restarted. A stop during the first travel task causes error E19. The drive is uncontrolled. Direction of movement recognition remains active. 3) The brake inclines are dependent on direction and are automatically determined in the teach procedure. 4-12

71 4. Commissioning Determine value of the o-parameter Different combinations of options are possible. You determine the value to be set through addition of the individual decimal values of the desired options. Example: Options Bit Calculation UseO5forReadysignal-insteadof Errorsignal 0 +1 Switch off soft end position behaviour 3 +8 Use I4 for Stop signal (stop with return travel) instead of Move signal Total(valuetobeset) =73 Alternative calculation Bit no Bit value Calculation 1* * *2 6 =

72 4. Commissioning Behaviour on stopping via I4 The drive can be stopped via Input I4 if the o-parameter is configured accordingly. Possible conditions after stop signal via input I4 Stop time Condition after stop Display Please note Teach procedure Reference travel Teachingof P.03 Operation Drive is uncontrolled. Output O4 supplies 1-signal. Drive is controlled. Output O4 supplies 1-signal. Drive is controlled. Output O4 supplies a 1-signal if the drive is stopped. Restart teach procedure (by Teach button/input) Restart reference travel to P.01 or P.02 Continue teaching of P.03 Continue operation 1 Resetting I4 triggers a command to stop the drive according to the configured o- parameter 2 O4 is set as soon as the drive has stopped The axis moves Stop input I4 Yes No When I4 is set, the current actual position is used as the reference position Stop output O Display 1 0 Fig. 4/3: Stopping sequence diagram 4-14