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Safety Considerations

Safety Precautions

This product is intended for professional integration into a complete system. If you install the
product incorrectly, it may present a safety hazard. The product and system may use high
voltages and currents, carry a high level of stored electrical energy, or control mechanical
equipment that can cause injury.

You should give close attention to the electrical installation and system design to avoid
hazards either in normal operation or in the event of equipment malfunction. System design,
installation, commissioning and maintenance must be carried out by personnel who have the
necessary training and experience. Read and follow this safety information and the instruction
manual carefully.

Enclosure

This product is intended to be mounted in an enclosure which prevents access except by
trained and authorized personnel, and which prevents the ingress of contamination. This
product is designed for use in an environment classified as pollution degree 2 in accordance
with IEC664-1. This means that only dry, non-conducting contamination is acceptable.

Setup, Commissioning and Maintenance

It is essential that you give careful consideration to changes to drive settings. Depending on
the application, a change could have an impact on safety. You must take appropriate
precautions against inadvertent changes or tampering. Restoring default parameters in certain
applications may cause unpredictable or hazardous operation.

Safety of Machinery

Within the European Union all machinery with which this product is used must comply with
Directive 89/392/EEC, Safety of Machinery.

The product has been designed and tested to a high standard, and failures are very unlikely.
However the level of integrity offered by the product’s control function – for example stop/
start, forward/reverse and maximum speed – is not sufficient for use in safety-critical
applications without additional independent channels of protection. All applications where
malfunction could cause injury or loss of life must be subject to a risk assessment, and further
protection provided where needed.

General warning
Failure to follow safe installation guidelines can cause death or serious injury. The voltages used in
this unit can cause severe electric shock and/or burns, and could be lethal. Extreme care is necessary
at all times when working with or adjacent to this equipment. The installation must comply with all

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Summary of Contents for FM-3

Page 1: ...Reference Manual P N 400508 01 Revision A8 Date March 10 2004 Control Techniques Drives Inc 2000 2004 FM 3 Programming Module ...

Page 2: ......

Page 3: ...he right to change the design or operation of the equipment described herein and any associated motion products without notice Control Techniques also assumes no responsibility for any errors that may appear in this document Information in this document is subject to change without notice P N 400508 01 Revision A8 Date March 10 2004 Control Techniques Drives Inc 2000 2004 FM 3 Programming Module R...

Page 4: ... any fashion without written approval of Control Techniques EMERSON Motion Control EMERSON Motion Control PowerTools AXIMA Motion Made Easy Control Techniques is a division of EMERSON Co Control Techniques Inc is not affiliated with Microsoft Corporation owner of the Microsoft Windows and Windows NT trademarks This document has been prepared to conform to the current released version of the produc...

Page 5: ...using our website The website includes technical notes frequently asked questions release notes and other technical documentation This direct technical support connection lets you request assistance and exchange software files electronically Technical Support 952 995 8033 or 800 893 2321 Email service emersonct com Control Techniques Motion Made Easy products are backed by a team of professionals ...

Page 6: ...engineers provides complete customer support for tough or complex applications Our engineers offer you a broad base of experience and knowledge of electronic motion control applications Customer Service Sales 952 995 8000 or 800 893 2321 Email customer service emersonct com Authorized Control Techniques distributors may place orders directly with our Customer Service department Contact the Custome...

Page 7: ...sed without the safety alert symbol indicates a potentially hazardous situation that if not avoided may result in property damage This Represents bold Characters that you must type exactly as they appear For example if you are directed to type a setup you should type all the bold characters exactly as they are printed italic Placeholders for information you must provide For example if you are dire...

Page 8: ...he hazards involved In addition this individual has the following qualifications Is trained and authorized to energize de energize clear and ground and tag circuits and equipment in accordance with established safety practices Is trained in the proper care and use of protective equipment in accordance with established safety practices Is trained in rendering first aid Reference Materials The follo...

Page 9: ...ioning and Maintenance It is essential that you give careful consideration to changes to drive settings Depending on the application a change could have an impact on safety You must take appropriate precautions against inadvertent changes or tampering Restoring default parameters in certain applications may cause unpredictable or hazardous operation Safety of Machinery Within the European Union al...

Page 10: ... plug and socket When unplugged the pins of the plug may be connected to the drive input which is only separated from the charge stored in the bus capacitor by semiconductor devices To avoid any possibility of electric shock from the pins if they are accessible a means must be provided for automatically disconnecting the plug from the drive that is a latching contactor Grounding Earthing equipoten...

Page 11: ...rs 31 Setup View 31 Status Online Tab Online Only 34 Information Tab Online Only 37 User Units View 38 Master Units View 42 Position View 46 Velocity View 50 Ramps View 52 Torque View 54 Tuning View 56 Faults View 59 PLS View 61 Setup NVM View 64 User Variables View 65 User Bits View 67 I O Setup Group 72 Assignments 72 Assignments View 72 Selector View 77 Input Lines View 81 Output Lines View 82 ...

Page 12: ...ing and Deleting Programs 131 Run Anytime Programs 132 Example Programs 134 Parameter Descriptions 143 Installation 183 Basic Installation Notes 183 Mechanical Installation 183 Software Installation 185 Starting and Exiting PowerTools 186 Accessing Help 187 Quick Start 189 Basic Setup Steps 189 Example Application Start Up 205 Tuning Procedures 213 PID vs State Space 213 Tuning Procedure 214 Tunin...

Page 13: ... Fault Codes 226 Analog Outputs 234 Diagnostic Analog Output Test Points 236 Drive Faults 238 Error Messages 238 Programming Error Messages 240 Online Status Indicators 245 Specifications 249 Dimensions and Clearances 249 Cable Diagrams 251 Glossary 265 Index 273 ...

Page 14: ...xii ...

Page 15: ...owerTools Pro software1 Setup views have the same look and feel as dialog boxes The wiring of input and output functions is done through assignments in the software PowerTools Pro is an easy to use Microsoft Windows based setup and diagnostics tool Figure 1 EN Drive with FM 3 Function Module Note that the drive s firmware is disabled whenever a Function Module such as the FM 3 module is attached T...

Page 16: ...2 FM 3 Programming Module Reference Manual Figure 2 FM 3 Programming Module Features ...

Page 17: ... to another drive without losing setup parameters The FM 3 module allows you to set up 55 different indexes Jog functions and multiple Homes It also provides eight digital input lines and four digital output lines in addition to the four input and three output lines available on the drive Software Interface The FM 3 module is set up using PowerTools Pro software PowerTools Pro is an easy to use Wi...

Page 18: ...the Position view the position assignments are displayed Keypad Interface The keypad on the front of the FM 3 module provides navigation through a menu of common parameters and displays of current functions Navigation through the menu is accomplished with the six keys located below the display The top two keys are called the soft keys because they relate to the commands located directly above each...

Page 19: ...m the Menu screen the user selects a group of drive parameters to work with The group names are scrolled using the left right direction keys The groups correspond roughly to the tabs used by the PowerTools software The groups are shown cyclically and wrap around The drive parameters available with the FM 3 keypad are arranged into seven groups see list below Upon power up the FM 3 module will disp...

Page 20: ...Security 1 Security 1 Security 1 Security 0 Security 0 Security 0 Security 0 Security 0 Security 0 Security 0 Security 3 Security 1 Security 3 Security 1 Security 1 Security 1 Security 1 Security 1 Security 1 Security 1 Security 1 Security 1 Security 1 Security 0 Security 0 Security 0 Security 0 Security 0 Security 0 Security 0 Security 0 Security 1 Security 1 Security 1 Security 1 Security 1 Log ...

Page 21: ...alue will appear The parameter value is updated about five times a second How Motion Works The FM 3 module provides four types of motion jogging homing indexing and gearing Only one index jog home or gear may be in process at any given moment exclusionary motion types Through assignments and programs the FM 3 module can sequentially run various motion routines The Positive direction parameter affe...

Page 22: ...itiated in one of three ways with the Initiate Destination function found in the Assignments view through a program or with the Online tab A Home or Define Home is required to set the Absolute Position Valid so that any index to absolute position can work The FM 3 module can home the motor to an external sensor the motor s encoder marker pulse or to a sensor and then to the encoder marker pulse ...

Page 23: ...ker will establish the most accurate and repeatable home position This method will position the motor relative to the location of the rising edge of the encoder marker pulse Most applications will use a sensor and marker to find an accurate home position in the vicinity of the home sensor Several parameters affect how the Home function operates Each of these parameters are explained in detail on t...

Page 24: ...d Marker Sensor Selecting Sensor means the rising edge of the Home Sensor input function is used to establish the home reference position Figure 7 Sensor Home Reference Position Marker Selecting Marker means the rising edge of the motor s encoder marker channel is used to establish the reference position Figure 8 Marker Home Reference Position ...

Page 25: ...acy your application requires will determine the Home Reference option you select Homing to an external sensor only will establish a repeatable home position within 0 04 revolutions at 3000 RPMs 800 µsec sensor capture interval Note The data above assumes the use of a perfectly repeatable home sensor In Sensor and Marker applications the marker must be at least 800 µsec after the rising edge of th...

Page 26: ...re is always an offset inherent in the homing process The user may either specify a desired offset or allow the drive to calculate an offset automatically The drive calculates an offset that guarantees that the motor will not have to backup to get to the offset position This is very convenient for unidirectional applications The calculated offset is the distance travelled during deceleration ramp ...

Page 27: ...posite direction To enter a specified home offset select the Specified Offset radio button PowerTools Pro always displays the calculated offset value as a reference If the home reference is detected before the axis has reached its peak velocity the axis will still continue to the precise offset position Figure 12 Calculated Home Offset Peak Velocity Not Reached If the Home Reference is detected af...

Page 28: ...t the offset position or backing up after the home sensor Figure 14 Specified Home Offset Greater than Calculated Offset Figure 15 Specified Home Offset Backup Required End of Home Position The End of Home Position End Posn defines the home position in relation to the machine s coordinate system At the completion of the home the value of the End of Home Position is put into the command position Sp...

Page 29: ...ation In this example the system uses an external sensor and the motor s encoder marker channel to establish a Home Reference Position This is the most accurate and most common way to home Figure 16 Home to Sensor and Marker Example When the FM 3 module sees the Home Initiate it accelerates the motor to the Home Velocity The motor continues at that velocity until it first senses the Home Sensor in...

Page 30: ...or marker 4 Go to offset 2 0 Revs 5 Set feedback position equal to End of Home Position Figure 17 Home Velocity Profile Figure 18 Home Move Sequence Velocity Time Sensor Back off Sensor Marker 100 100 100 Sensor Marker Home Move Back Off Sensor Start of Home 1 2 Offset Offset Move 2 0 Revs Final Position End of Home Position 4 5 ...

Page 31: ... it accelerates the motor to the Home Velocity The motor continues at that velocity until it first senses the Home Sensor input The motor continues on at the home velocity until the marker is activated The rising edge of the motor s encoder marker channel is used to establish the reference position After sensing the rising edge of the motor s marker channel the device will continue moving and will...

Page 32: ...uence that moves the motor a specific incremental distance or to an absolute position This motion sequence includes an acceleration ramp to a programmed velocity a run at velocity and a deceleration to a stop Figure 21 Index Motion Sequence Velocity Time Acceleration Deceleration Run at Velocity ...

Page 33: ...ample a short move with long acceleration and deceleration ramps may not reach the target velocity entered Indexes cannot be initiated when any other motion jogging homing or program is in progress Indexes can be aborted with the Stop destination found in the Ramps group on the Assignments View The FM 3 module supports five types of indexes absolute incremental registration rotary plus and rotary ...

Page 34: ...Index Example 1 In the example above the current position is 1 rev If this index is initiated the motor will travel to a position of 5 revs no matter where it is sitting before the move From 3 revs it will travel 2 revs to finish at 5 revs If the absolute index to 5 revs is initiated a second time immediately after the index no motion will occur because the motor will already be at a position of 5...

Page 35: ...mental index motion is determined by the sign or of the Index Distance parameter Incremental Index Figure 25 Incremental Index Example In the example above the motor starts at 1 rev travels a distance of 2 revs and stops at 3 revs If the same index is initiated a second time the FM 3 module would move the motor another 2 revs to a position of 5 revs If initiated a third time the motor would travel...

Page 36: ...regardless of the starting point A Rotary Plus Index moves to the specified position but is forced in a positive direction Similarly a Rotary Minus index moves to the specific position but is forced in a negative direction Rotary Plus and Minus Indexes are usually used in rotary applications therefore the rotary rollover feature on the Setup Position view in the PowerTools Pro software must be ena...

Page 37: ...ve the starting position is at 90 and 80 is the specified position A Rotary Minus index would travel 10 in the negative direction At the completion of this index the motor position would be 80 Example 7 If the starting position is 15 and the specified position is 270 a Rotary Minus index would travel 105 in the negative direction How Communications Work Uploading Uploading is the process of readin...

Page 38: ...the FM 3 module the user will be required to select how to handle the NVM parameters upon downloading The dialog box asking the user to select one of three options for the download is shown below A description of each of the options is as follows Overwrite This option will overwrite all the parameters stored in NVM with the current values in the user configuration PowerTools Pro file The values th...

Page 39: ...rameters will be sent to the FM 3 module without stopping motion or disabling the drives Because of this it is important to use caution when changing motion parameters while the motor is in motion The Update to RAM button saves the parameters only to RAM and not to Non Volatile Memory NVM Therefore if the system power is removed any changes made using the Update to RAM button will be lost In order...

Page 40: ...er parameter is changed If the user performs a full download while the button is enabled when the download is complete the Update to RAM button will be disabled If the user modifies parameters and disconnects the update button will be disabled and the changes will not be sent Options Preferences Ptools Operation This menu controls the pop ups that the user encounters when uploading and downloading...

Page 41: ... When this checkbox is selected PowerTools Pro will poll the drive on download for all of the values that have been added to the NVM list PowerTools Pro then stores these values into a temporary memory location and after the program download is complete PowerTools Pro reinstates these values to the parameters before the drive can be enabled Ask on each download This option was created for users wh...

Page 42: ... Download feature allows the user to download a configuration that prevents anyone from uploading the file or going online with the system This is used to protect a file from being accessed by unauthorized personnel If a secure file is downloaded to the system all diagnostics capabilities in the software are lost The only way to go online with the system again is to download the original non secur...

Page 43: ...t be opened or modified The file extension cannot be changed to allow the user to open it The secure file is only valid for use by the secure download function If a user attempts to upload a secure file a message will appear indicating that the file residing in the system has been protected by the user An example of this is shown below Brake Operation MG motor brake operation is controlled by the ...

Page 44: ... function when active will engage the brake unless overridden by the Brake Release function This function lets you externally engage the brake while allowing the drive to also control the brake during fault and disabled conditions Brake Disengaged The Brake Disengaged source function is used to control the motor holding brake If the Brake function is off the brake is mechanically engaged When the ...

Page 45: ...f the view see Figure 28 The Setup view is divided into six groups with an explanation of each function The groups are Identification Configuration Drive Encoder Output Positive Direction Update Rate and Switching Frequency Status Online will be shown when online with the FM 3 module Figure 28 Setup View Identification Group The identification group consists of the Device Name and the Target Drive...

Page 46: ...tting up Motor Type List Box Select the motor you want to use PowerTools Pro software will only display the motor models that are compatible with the drive you selected and any user defined motors Selecting the wrong motor type can cause instability and may cause property damage to the motor and or drive EN Only EN Line Voltage List Box Line Voltage specifies the applied power and adjusts the inte...

Page 47: ...ns in which CCW motor rotation is considered to be motion in the positive direction increasing absolute position Update Rate Group This parameter configures the interrupt interval for the FM 3 processor This defines how often the motion program is interrupted and the Control Loop is processed In the Control Loop the feedback information is processed and a new position command is generated Also in ...

Page 48: ...hing frequency can be modified to change system performance Available selections are 5 kHz and 10 kHz For more information on this setting refer to the MDS Reference Manual P N 400525 01 Status Online Tab Online Only The Status Online tab see Figure 29 is visible when online and consists of the Motor Position group Motor Velocity group Control Loop group Master Feedback group and the Torque group ...

Page 49: ...mmanding the motor to run at This command is generated by the drive velocity control loop and position loop It is displayed in user units Velocity Feedback This is the feedback or actual velocity It is calculated using the change in position of the motor encoder It will always return the actual motor velocity even in synchronized applications in which the master axis is halted during a move Contro...

Page 50: ... taken to process the control loop since the Status Online tab was brought up The higher the value the more time available to run user programs For Averages less than 150 usec it is recommended to switch the update rate to the next higher value Master Feedback Group Master Position Used for synchronized motion this displays the position of the master encoder in units defined on the Master Units Se...

Page 51: ...le to the EN 204 which does not have an internal shunt resistor This parameter is applicable to the EN 208 and EN 214 Information Tab Online Only Drive Information Group Firmware Part Number Displays the part number of the drive firmware you are using Firmware Revision Displays the revision of the drive firmware you are using Serial Number Displays the serial number of the drive with which you are...

Page 52: ...ormation for distance velocity and accel decel units are set up here and used throughout the system setup By selecting User Units in the Hierarchy View the User Units View will appear on the right see Figure 30 Figure 30 User Units View Distance Group Units Name This is a 10 character name for the distance user units you want to use in your application ...

Page 53: ... units back to actual motor revolutions This scaling factor is as follows Characteristic Distance This is the distance the load travels in user units when the motor travels the characteristic length in motor revolutions Characteristic Length This is the distance the motor travels in whole number of revolutions to achieve one characteristic distance of load travel Distance Scaling Examples A 1 5 di...

Page 54: ...eed the drive will obtain a trajectory fault at speeds near this velocity To alleviate this issue simply remove decimal places from your user units and or change the characteristic distance numerator of your scaling parameters to be a smaller number that it was The red background indicating module trajectory faults will go away when the user unit setup is scaled for a realistic accuracy based on t...

Page 55: ... real time velocity parameters throughout the software Using a high number of decimal places will improve velocity resolution but will also limit the maximum velocity You can select from zero to six decimal places of programming resolution Acceleration Group Time Scale List Box From this list box select the acceleration time scale to be used for all real time profiles The time scale selected will ...

Page 56: ...f torque in user torque units will be set equal to the Percent Continuous Current This parameter is used to scale the actual torque back into the user defined units The units of this parameter are ContinuousCurrent This scaling factor is used along with the user torque to establish a relationship between torque user units and actual torque Master Units View Master Units setup provides the setup pa...

Page 57: ...tor on the FM 3 module If Motor Encoder default is selected then the encoder signals from the motor that the FM 3 drive is controlling will be sent out the FM 3 Sync Output connector If Drive Encoder Input is selected then the synchronization signals sent to the Drive 44 pin command connector will be sent to the FM 3 Sync Output connector If Module Encoder Input is selected then the same signal co...

Page 58: ...al places of programming resolution Scaling The scaling factor is defined as MasterAxis CharacteristicDistance MasterAxis Counts The numerator top value of the scaling fraction is the Characteristic Distance The denominator bottom value of the scaling fraction is the of Counts The Characteristic Distance is the number of Master Distance Units that will be traveled per number of counts in the botto...

Page 59: ... The table below can be used to best determine the proper filter settings for your application Filter parameters cannot be changed using the Update to RAM feature Changes must be fully downloaded before taking effect The gray box in the table above denotes the default setting for the master filter parameters Enable Check Box The enable check box is used to turn on or turn off the Master Position F...

Page 60: ...o drive positioning In Figure 32 Position has been selected in the Hierarchy View The right side of the view is divided into groups An explanation of the groups and their functions is provided below Figure 32 Position View Settings Group Define Home Position This is the value to which the position command will be set when the Define Home destination is activated This is used in applications which ...

Page 61: ... less than the In Position Window for the InPosn source to activate If set to zero default then InPosn will activate as soon as motion stops and the following error is less than the In Position Window parameter Limits Group Enable Following Error Check Box Check this box to enable or disable if not checked the Following Error Limit If enabled a fault will be generated if the absolute value of the ...

Page 62: ...greater than or equal to the parameter Software Travel Limit A falling edge will be generated as soon as the above is not true Software Travel Limit If the absolute position is less than or equal to this value the Software Travel Limit Minus Activate shall activate A rising edge occurs when the absolute position is less than or equal to the parameter Software Travel Limit A falling edge will be ge...

Page 63: ...line Tab not shown While online the following real time data will be displayed Motor Position Group Position Command This is the commanded position in user units generated by the FM 3 module Position Feedback This is the feedback position of the motor in user units Following Error The Following Error is the difference in user units between the Position Command and the Position Feedback It is posit...

Page 64: ...ter is used to scale all motion It can be described as scaling in real time The default setting of 100 will allow all motion to occur in real time A setting of 50 will scale time so that all moves run half as fast as they do at 100 A setting of 200 will scale time so that all moves run twice as fast as they would at 100 FeedRate Override is always active and affects all motion including accels dec...

Page 65: ... is changed to 50 it will take 0 5 seconds to decelerate to 50 velocity A user wishes to accelerate from 100 programmed velocity to 175 in 0 5 Seconds Therefore the value they need to enter for FeedRate Decel Accel is calculated as follows Online Tab not shown If online this view will show the limits group and the velocity group Velocity Group Velocity Command The Velocity Command is the actual co...

Page 66: ...iles By selecting Ramps in the Hierarchy View the Ramps View will appear on the right see Figure 34 Figure 34 Ramps View Settings Group The Settings Group contains the Acceleration Type List Box Acceleration Type Press the arrow by the Acceleration Type list box It will display the various acceleration types 5 8 S Curve 1 4 S Curve Linear and S Curve ...

Page 67: ...celeration Linear Peak Acceleration Average Acceleration Ramps Group Stop Deceleration The value you enter here defines the deceleration rate which is used when the Stop destination is activated The default is 100 RPM second The Stop destination is found in the Ramps Group in the Assignments view Feedhold Decel Accel When the Feedhold destination is activated the motor will decelerate to a stop in...

Page 68: ...ear on the right see Figure 35 The right part of the screen is divided into groups An explanation of the groups and their functions is provided below Figure 35 Torque View Settings Group Torque Level This parameter sets the activation point for the Torque Level Active source If set to 100 the Torque Level Active source will activate any time the Torque Command reaches or exceeds 100 continuous Thi...

Page 69: ...nation is active To make the Torque Limit always active assign the Torque Limit Enable destination to the Initially Active source on the Assignments view Peak Torque Displays the Peak Torque for the motor drive combination setup in the Setup View Online Status Tab If online this view will show the Torque Command Limited Torque Foldback RMS and Shunt Power RMS ...

Page 70: ...art of the screen is divided into groups An explanation of the groups and their functions is provided below For help on calculating tuning parameters and more in depth tuning information turn to Tuning Procedures on page 213 Figure 36 Tuning View Load Group Inertia Ratio Inertia Ratio specifies the load to motor inertia ratio and has a range of 0 0 to 50 0 If the exact inertia is unknown a conserv...

Page 71: ...his frequency will be filtered at a rate of 40 dB per decade The default value is 600Hz Tuning Group Response The Response adjusts the velocity loop bandwidth with a range of 1 to 500 Hertz In general it affects how quickly the drive will respond to commands load disturbances and velocity corrections A good value to start with the default is 50 Hz The maximum value recommended is 80 Hz Enable Feed...

Page 72: ...using the Position Error Integral Time Constant parameter This parameter determines how quickly the drive will correct for in position following error The time constant is in milliseconds and defines how long it will take to decrease the following error to 37 percent of the original value In certain circumstances the value actually used by the drive will be greater than the value specified here Mi...

Page 73: ... View Active Faults Group The Active Faults group contains the Active Faults window Active Faults Window This window displays any active faults in the system Those faults which do not require a reboot can be cleared by clicking on the Reset button For more detailed fault information refer to Diagnostics and Troubleshooting on page 225 ...

Page 74: ...is parameter shows the numbers of times the drive that the FM 3 is attached to has been powered up since the last reset be the factory Power Up Time This parameter shows the time in hours since the drive was last powered up Total Power Up This parameter shows the total time that the drive has been powered up since reset by the factory ...

Page 75: ...feedback position commanded position or master feedback position Eight global PLS s are available for a single application To operate a PLS first it must be enabled see the PLS enable destinations in the assignments view and then the Absolute Position Valid source must be active Each PLS has its own OnPoint and Off Point as well as a Rollover Point The terms OnPoint and Off Point assume movement i...

Page 76: ...tatus will be active when the selected source position is between the PLS OnPosn and the PLS OffPosn Assume that the PLS Direction is set to Both When traveling in the positive direction and the feedback position reaches the OnPosn the PLS Status will activate As the motor continues in the same direction the PLS Status will deactivate when feedback position reaches or exceeds the OffPosn If motor ...

Page 77: ...e the RotaryRolloverPosn for this PLS Rollover Point This parameter is the absolute position of the first repeat position for this PLS When enabled it causes the PLS to repeat every time this distance is passed The repeating range begins at an absolute position of zero and ends at the RotaryRolloverPosn For example in a rotary application a PLS could be setup with an OnPosn of 90 degrees and an Of...

Page 78: ...ng parameters to NVM could shorten the life of your FM 3 or FM 4 The Non Volatile memory list displays the parameters that will be saved after power down A command to store these parameters into the NVM is given to the module whenever a parameter on the list changes value via a program or a communications network Currently the NVM in the FM 3 will accept at a minimum 1 million writes before the FM...

Page 79: ...he User Variables view located under the Setup group in the hierarchy The User Variables view is shown in Figure 40 below Figure 40 User Variables View The following parameters are part of the User Variable definition Name This is a twelve character string that allows the user to assign a descriptive name to the parameter Spaces are not allowed in the name of a user variable Decimal This parameter...

Page 80: ... in the list can be deleted To delete the last variable simple click on the down arrow next to the Number of User Variables window User variables are all of a Global type meaning that they can be accessed from any program Online Tab not shown While online with the FM 3 an online tab will be shown on the lower half of the User Variables view This online tab will show the current value of each of th...

Page 81: ...e the Initial Value On or Active simply enable the checkbox for that bit The default value for each User Bit will be Off or Inactive User Bits are configured on the User Bits view as shown in Figure below User Bits may be accessed in the User Program Several examples of this are shown below Bit Raise_Table ON Wait For Bit Vacuum_ON OFF Wait For Bit RunPart_A OR Bit RunPart_B OR Bit RunPart_C If Bi...

Page 82: ...be added or deleted The default number of User Bits available is 32 To add an additional 32 bits simply click on the Up Arrow on the spinner box at the top of the User Bits view see Figure 41 To decrease the number of User Bits by 32 click the Down Arrow on the spinner box When decreasing the number of User Bits it is always the last 32 bits in the list that will be eliminated ...

Page 83: ...dividual bits If the individual bit value of the 32 bit mask is 1 then the corresponding bit from the written 32 bit parameter is passed through and the resulting value stored in the specific bit will be the written bit value If the bit value of the 32 bit mask is 0 then that particular bit is blocked or masked and the resulting bit value does not change Original Value AND NOT 32 Bit Mask or Value...

Page 84: ...ally ON or 1 is indicated by a shaded square and OFF or 0 is indicated by an empty square Bit 31 is the most significant bit in the word and bit 0 is the least significant bit If the bit is shaded it means that particular bit will be passed through when written Each additional group of 32 User Bits that are added a new Mask parameter will appear for that group Mask 0 will control the mask for User...

Page 85: ...cimal value to the parameter normal notation is used For examples of writing the Mask to a value in a program see below For example BitRegister 0 ValueMask 0xFFFF0000 This example writes a 1 into all bits of the upper sixteen bits and 0 into each of the lower sixteen bits using hexadecimal value To write the same value using decimal notation the following instruction would be used For example BitR...

Page 86: ...r output line on the drive or the FM 3 module External controllers such as a PLC or other motion controllers may be connected to affect or monitor the device s operation The drives are equipped with five optically isolated input lines one dedicated to a Drive Enable function and three optically isolated output lines The FM 3 module has an additional eight input and four output lines The drive s in...

Page 87: ... expanding individual groups you will see more detailed parameters For example if you expand the Inputs source group you will see DriveInput 1 through ModuleInput 8 as shown in Figure 45 You can use these events to trigger certain actions or destinations on the right side of the view To make an assignment in the FM 3 module occur you must tie a source to a destination Any source can be tied to any...

Page 88: ...n highlighted and the Assign button has just been clicked Once an assignment has been made you will see the Assigned to and the Set From columns be filled in for the specific sources and destinations This indicates what destination s an individual source has been assigned to and what source s an individual destination is assigned to Any source can be assigned to up to ten different destinations ma...

Page 89: ...n will be active when the source it is assigned to becomes active and is inactive when the source is inactive Making an assignment Active Off means that the destination will be active when the source it is assigned to is inactive and will be inactive when the source is active The polarity of the assignment can also be changed to Custom when required Custom polarity allows you to make a destination...

Page 90: ...hoose Options Preferences User Levels Easy mode filters out all but the most commonly used sources and destinations Detailed mode filters out less expanding the list of sources and destinations for more complex configurations Too Much mode does not filter at all and provides all sources and destinations Only Show Assigned This checkbox removes the unassigned sources and destinations from this view...

Page 91: ...mand complete signal at the end of indexes and jogs will automatically capture data A subsequent index jog or dwell can then use the captured data to start itself extremely accurately at the end of the previous motion PLS Status A rising or a falling edge of a Global PLS will automatically capture data for use in initiating motion In order to accurately initiate motion from a Global PLS an assignm...

Page 92: ... of the binary select lines a selector selection source will be active when the Selector SelectorInitiate destination is activated At the top of the Selector view the Selector Input Destinations field defines how many binary select lines will be used The number of Selector Selections is a direct result of the number of select lines The formula is as follows of selections 2n where n is the number o...

Page 93: ...at is activated is determined by the status of the Selector Select lines when the Selector Selector Initiate bit is activated Each select line has a specific binary value The binary value is determined as follows Sn x 2n where Sn Status of Selector Select line n Sn 0 if Selector Select line n is inactive and Sn 1 if Selector Select line n is active The sum of all the binary values determines which...

Page 94: ... Selector Select1 is active and Selector Select0 is active then the total binary value would be as follows S2 0 S1 1 and S0 1 Therefore Total Binary Value 0 x 22 1 x 21 1 x 20 Total Binary Value 0 2 1 Total Binary Value 3 Therefore Selector Selection3 would activate The Selector Select lines can change without any action until the Selector SelectorInitiate destination is activated Selector Selecti...

Page 95: ...can assign a descriptive name to each input and make the setup easier to follow The length of the text string is limited by the column width with a maximum of 12 characters Simply double click on the Name field of any input line to assign a name to it Debounce You can program a Debounce Time to any input line which means the motion profile will need to be steady for at least the debounce time befo...

Page 96: ...r is used to determine the Home Reference Position the debounce time ensures a minimum pulse width Output Lines View The Output Lines View displays any functions that have been assigned to the drive or module hardware outputs See Figure 51 Figure 51 Output Lines View Names Descriptive text names can be assigned to individual output lines to make the setup easier to follow ...

Page 97: ...View The drive has a 14 bit analog to digital converter A D which is used to transform the analog voltage to a usable parameter in the FM 3 module The analog input is scanned every 100 microseconds User Units This parameter allows the user to enter a 12 character string to be used as units for the analog input parameter Decimal This parameter defines how many digits up to six are used after the de...

Page 98: ...l read the current value on the analog channel and enter it into the Maximum Voltage edit box Minimum Value Enter the minimum value in analog user units that the minimum analog voltage should correspond to Minimum Voltage Enter the minimum voltage that will be seen on the analog input terminals The user can enter the value in this field by hand or set the analog source to it s minimum value and cl...

Page 99: ... to Realtime or Synchronized motion This choice is made on each motion view The units are customized in the Setup Group Realtime units are defined on the User Units View and Synchronized units are defined on both the User Units View and the Master Units View Each of the motion views when online have an Online tab that displays feedback information and provides buttons to initiate motion ...

Page 100: ...scroll box allows you to select between Jog0 and Jog1 setup views Jog Name This is a descriptive character string which can be assigned to the specific jog Giving a name to a jog can make the motion setup easier to follow Time Base This list box allows the user to select between a jog that is based on time Realtime as defined by user units normally in seconds or a time based on Master position via...

Page 101: ... Sources Jog AnyCommandComplete The Jog AnyCommandComplete source will activate when either Jog0 or Jog1 completes its deceleration ramp and reaches zero commanded velocity It will deactivate when any Jog is initiated again If the Stop destination is used during a Jog then the Jog AnyCommandComplete will not activate Jog Accelerating This source is active while a jog is accelerating to its target ...

Page 102: ...ction The jog velocity is determined by which jog Jog0 or Jog1 is active or not A jog stops when this destination is deactivated If the jog velocity is negative Jog MinusActivate will cause the motor to jog in the positive direction Jog Select0 This destination is used to select between Jog0 and Jog1 When the Jog Select0 destination is not active the target velocity for the jog is the Jog 0 Veloci...

Page 103: ...e The Jog destinations cannot be initiated when any other motion type homing indexing or programs is in progress If both jog input functions are On there is no motion after a jog deceleration they effectively cancel each other The drive s display will show R for ready If the device is jogging with the Jog PlusActivate destination active and the Jog MinusActivate destination activates the motor wil...

Page 104: ...e Ramps group in the Assignments view will override the Jog operation and decelerate the motor to zero speed at the stop deceleration rate If the motor reaches a Travel Limit you can Jog off the Travel Limit in the opposite direction Use Jog PlusActivate to move off a Travel Limit ...

Page 105: ...iting and allows you to scroll through multiple home sequences using the up and down arrows The first release only allows for one home sequence Name Allows you to assign a descriptive name to the home sequence up to 10 characters in length Home Reference This parameter determines the signal used as the reference The parameter can have one of three different values Sensor Marker or Marker then Sens...

Page 106: ...its If on sensor Group These radio buttons determine how the system reacts if the Home SensorTrigger is already active when the home is initiated Back off before homing Radio Button If this radio button is set the drive will back off the sensor before beginning the home It does this by moving the direction opposite to that specified by the sign of the home velocity It continues moving in this dire...

Page 107: ...per limit on the incremental distance traveled during a home If no home reference is found in this distance the motor will decelerate to a stop at the limit distance and activate the Home LimitDistHit source End of Home Position This parameter defines the position at the completion of the home This defaults to 0 0 such that at the end of a home the Feedback Position and the Commanded Position are ...

Page 108: ...e Home AtVel This source activates when the home reaches its target velocity It deactivates when a home deceleration ramp begins Home AtVel will not be activated during the back off sensor portion of the home Home CommandComplete The Home CommandComplete source will activate when the specific home completes its deceleration ramp It will remain active until the specific home is initiated again If t...

Page 109: ...edge sensitive The home position is determined when the Home Sensor destination is activated If the device receives a Home Initiate input while the Home SensorTrigger is active you can choose to have the motor back off of the home sensor before it initiates the home function or move forward to the next sensor If debounce is used on the hardware input that the Home SensorTrigger is assigned to the ...

Page 110: ...e motion sequence that moves the motor a specific incremental distance or to an absolute position The index is initiated with the Index Initiate destination or from a program Figure 58 Index View Index Number The Index Number parameter selects the index number with a scroll box ...

Page 111: ...ed in applications which use rotary rollover These absolute indexes are forced to run in a specific direction regardless of the starting point Time Base This list box selects the Time Base for the index velocity and acceleration deceleration Real time and Synchronized are the allowed selections Distance Position The Distance Position parameter is a signed value which specifies the distance the ind...

Page 112: ...ssible to calculate the necessary velocity accel and decel If Registration type is selected then the Time checkbox will become disabled Based on the Distance entered or Position for Absolute indexes and the Time value specified the calculations could result in extremely high Velocities Accels and Decels To avoid damage to mechanical parts or potentially dangerous situations the user is allowed to ...

Page 113: ... performed as desired The internal calculation are performed only when the index is initiated and therefore is the only time the flag will activate The Index ProfileLimited flag will remain active until cleared using the Index ResetProfileLimited assignment or program instruction In this situation the index will still operate but the time will be extended In other words the profile will be perform...

Page 114: ...s desired to be twice the acceleration a number twice the value of max acceleration would we entered for maximum deceleration If the Maximum Velocity is low enough such that the profile will become trapezoidal some duration at max velocity Even in trapezoidal moves the same ratio of acceleration and deceleration is maintained The calculations are based on the assumption that Feedrate Override is s...

Page 115: ...nd deactivate At the end of Index 0 position feedback is equal to 5 Revs If we initiate Index 0 again Index 0 PLSStatus will activate 1 Rev into the index or at 6 Revs It will remain active until position feedback reaches 9 Revs and deactivate This index could be run over and over again and Index 0 PLSStatus will activate 1 Rev from the starting position and deactivate 4 Revs from the starting pos...

Page 116: ...emental distance the motor will travel after a valid registration sensor or analog limit value has been detected This is a signed parameter so if an index is travelling in the negative direction the offset needs to be negative and continue in the same direction If the registration offset is zero or less than the decel distance shown on the calculations tab the motor will decelerate at the programm...

Page 117: ...dex decels down to zero velocity completing the move at the Limit Distance At this point the Index LimitDistHit source would activate Or The Torque Command reaches or exceeds 50 continuous and the index continues at speed before decelerating to zero velocity at the registration point plus the Registration Offset distance If the Registration Offset distance is in the opposite direction from the mov...

Page 118: ...urce is active while an index is decelerating from its target velocity Once the index reaches zero velocity or its next target velocity the Index Decelerating source will deactivate Index LimitDistHit Activated when the registration sensor is not found before the Limit Distance is traveled If the Registration Window is enabled the sensor must be activated inside the window to be recognized Index P...

Page 119: ...ion is captured and is used as the registration point for registration type indexes Adding and Deleting Indexes Adding or removing indexes from the user configuration can be done in three ways Indexes may only be added or deleted while offline Toolbar Icon Method The Add Index icon shown below will add a new index to the user configuration Indexes are added in sequential order Clicking on the icon...

Page 120: ...f the view and right click on your mouse A selection menu will appear allowing you to add a New Index or Delete an Index Click on New Index and an index will be added in sequential order and you will be brought to the Index setup screen allowing you to enter the index parameters Deleting an Index Navigate to the Indexes View Select the Index you wish to delete and then right click on your mouse A ...

Page 121: ... be positive or negative and is a signed 32 bit parameter The resolution of the parameter is determined by the number of decimal places configured for the Master Velocity Units on the Master Setup screen By default gearing does not use acceleration or deceleration ramps with respect to the master encoder This means that once gearing is activated peak torque is available to try to achieve the speci...

Page 122: ...s traveling when gearing is activated Figure 62 below demonstrates that the faster the Master Velocity the longer it will take to reach the programmed ratio If the Master Axis is not moving when gearing is initiated then the follower locks into its programmed gear ratio instantly no acceleration time required Figure 62 Gearing Acceleration Ramp Description The GearRatio can be changed on the fly w...

Page 123: ... program the Gear Stop instruction is used to stop the gearing motion Stopping Gearing Motion The method used to stop gearing motion depends on how the gearing was initiated If gearing was initiated using an Assignment then simply deactivating the Gear Active destination will cause gearing motion to stop If gearing was initiated from within a program then the Gear Stop command must be used to stop...

Page 124: ...g a realtime deceleration ramp even if the timebase of the motion being stopped is synchronized This can help in applications that use synchronized motion if the master stops and then the user wishes to break out of the synch motion without performing an synchronized deceleration ramp Neither the CommandComplete signals from motion objects nor the ProgramComplete signals will activate if they have...

Page 125: ...ual P N 400508 04 Modbus View The Modbus View is used to assign Modbus addresses to individual parameters By selecting Modbus in the Hierarchy View the Modbus View will appear on the right see Figure 63 The right part of the screen displays all of the drive parameters The number of parameters that appear depends on the User Level Figure 63 Modbus View ...

Page 126: ...log box will appear This will automatically assign the next available modbus address or allow you to enter a different Modbus address Once you click on OK then you will be able to read or write the parameter at that address Figure 64 Modbus Address Assignment Box Address ranges are as follows Any individual Modbus address can be deleted by highlighting the parameter you wish to delete and clicking...

Page 127: ...es MME Power CD Profibus View For those modules that have the Profibus option please refer to the FM 3 and FM 4 Connectivity Reference Manual P N 400508 04 which can be found on the Control Techniques MME Power CD Ethernet View For those modules that have the Ethernet option please refer to the FM 3 and FM 4 Connectivity Reference Manual P N 400508 04 which can be found on the Control Techniques M...

Page 128: ...114 FM 3 Programming Module Reference Manual ...

Page 129: ...he Program View will appear in the right see Figure 65 The left side of this view contains the program instructions The right side of the Program view contains the Program Toolbar above the program Figure 65 Program View FM 3 Programming Module Reference Manual ...

Page 130: ...ve been undone in the program Find This icon allows the user to search for a given string inside the program Modifying several parameters in the Find dialog box i e Search Up Search Down Match Case etc can customize the search Find Next This icon will find the next instance of the string last searched for This allows you to quickly find all the matches to your search with out re entering the selec...

Page 131: ...ce a red dot next to the line of code with the error For help on what the particular error is click on the Red Dot Help icon and then click on the line of code with the red dot next to it PowerTools Pro will attempt to give a detailed description of the error Drag In I O Clicking on this icon will bring up the Drag In I O pop up window From this window the user can drag Drive and Module Input Outp...

Page 132: ...e enabled in order to run a program Only available while online Program Where Am I Clicking on this icon will show the line of the program that is currently being executed A blue arrow will point to the line in the program that was executing when the icon was clicked The arrow will not continue to follow program flow If the program is not currently running then the arrow will point to the top of t...

Page 133: ...ctly related to each other The memory is setup such that if you require 99 programs maximum each program can have an average of 10 program steps each If the number of programs is reduced to a minimum you could have as many as 1024 steps in a single program Program Instruction Types Program Flow Instructions If Then Endif This is a program flow control instruction used to selectively run a section ...

Page 134: ...he Endif is executed Examples If DriveInput 1 ON Then The following two lines are executed if DriveInput 1 ON DriveOutput 1 ON DriveOutput 2 OFF Else The following two lines are executed if DriveInput 1 OFF DriveOutput 1 OFF DriveOutput 2 ON Endif If ModuleInput 5 ON Then Set fast velocity if ModuleInput 5 ON Jog 0 Vel 1 0 in s Else Set slow velocity if ModuleInput 5 OFF Jog 0 Vel 0 1 in s Endif F...

Page 135: ...t 2 OFF Repeat the three lines of code below as long as ModuleInput 1 is ON and ModuleInput 2 OFF Index 1 Initiate Incremental Dist 5 250in Vel 10 0in s Dwell For Time 1 000 seconds Loop Do While TRUE Repeat until the program is halted Index 1 Initiate Incremental Dist 5 250in Vel 10 0in s Dwell For Time 1 000 seconds Loop Wait For This program flow instruction is used to halt program execution un...

Page 136: ...racter Examples Wait For Time 5 000 seconds Do While TRUE Repeat until the program is halted Index 1 Initiate Incremental Dist 25 250in Vel 10 0in s Wait For AtVel Turn Output 1 ON for 1 second after the index reaches its target velocity DriveOutput 1 ON Wait For Time 1 000 seconds DriveOutput 1 OFF Wait For Index AnyCommandComplete Loop Call Program This program flow instruction is used to call a...

Page 137: ...ndition has been met Examples If DriveInput 1 OFF Then End Endif If DriveInput 1 ON Then DriveOutput 1 ON End Endif Formula This program instruction can be used to enter a formula or assignment into a program All FM 3 parameters are available for use in a formula They may be dragged and dropped into a formula but the program User Level will determine how many appear for dragging and dropping see t...

Page 138: ... conjunction with the GoTo instruction to cause program flow to transfer to a specified location within a program The destination label is allowed to be above or below the GoTo instruction within the same program It is not possible to GoTo a label outside of the program containing the GoTo instruction nor is it possible to use a GoTo Label to exit out of a For Count Next loop In either of these co...

Page 139: ...on character Labels are not case sensitive Example Do While TRUE If DriveInput 1 ON Then GoTo RunIndex1 Go to RunIndex1 label Else GoTo RunIndex2 Go to RunIndex2 label EndIf RunIndex1 If Input 1 is on resume here Index 1 Initiate GoTo EndLoop GoTo EndLoop label RunIndex2 If Input 1 is off resume here Index 2 Initiate EndLoop Wait For Index AnyCommandComplete Loop See the Label instruction for addi...

Page 140: ...the master encoder signal This is typically used in synchronized motion applications This dwell does not begin until all other motion has completed When the dwell begins program flow will wait until the specified master distance has passed The units for the dwell value are specified in the Master Units View Example Do While TRUE Index 0 Initiate Synch Incr Dist 5 0 Inches Vel 1 Inches MstrInch Dwe...

Page 141: ...file The last index in a complex profile must have a deceleration ramp This is accomplished using a standard Index Initiate rather than a Index CompoundInitiate The final index will honor the deceleration ramp If the last index is not long enough to perform a decel ramp at the programmed rate the motor will backup at the end of the last index Each index can be used in multiple places as both a sta...

Page 142: ...tput 3 ON Turns ON immediately after Index 2 is started Wait For Index AnyCommandComplete DriveOutput 1 OFF Turns OFF after Index 2 s command is completed DriveOutput 2 OFF Turns OFF after Index 2 s command is completed DriveOutput 3 OFF Turns OFF after Index 2 s command is completed Home Initiate This program instruction is used to initiate the home A comment is automatically inserted after the H...

Page 143: ...nput 3 OFF Stop when the input goes OFF Jog Stop Decelerate to a stop Endif Loop Jog PlusInitiate This program instruction is used to initiate jogging in the positive direction The Jog Stop instruction is used to stop jogging motion A comment is automatically inserted after the Jog PlusInitiate instruction which shows key data about the particular jog The comment starts with the apostrophe charact...

Page 144: ...ine guarantees that all motion profiles occur at the right time with respect to each other If Index0 takes 3 seconds to complete and Index1 takes 5 seconds to complete by initiating Index0 and then Index 1 in a program the user would expect these profiles to take a total of 8 seconds to complete It is possible though that because of processor timing Index 1 does not start at exactly the same time ...

Page 145: ...on Method Add Program Button The Add Program button shown below will add a new program to the user configuration Programs are added in sequential order Clicking on the button will add a program and bring you to the program editing screen allowing you to enter program instructions Delete Program Button The Delete Program button shown below will delete a program from the user configuration The highe...

Page 146: ...ing a Program Navigate to the Programs view in the hierarchy Select the program you wish to delete and then right click on your mouse A selection menu will appear allowing you to add a New Program or Delete a Program Click on Delete Program and the selected program will be deleted from the configuration Run Anytime Programs The FM 3 programming environment has been designed to automatically stop a...

Page 147: ...rogram will stall on that particular line of the program but the program will not stop Certain conditions will still cause a program designated as Run Anytime to stop These conditions are listed below Stop Function is activated Run Anytime program has a program fault Multiple programs may be configured as Run Anytime programs and can be called from a program the same as any other program If a Run ...

Page 148: ...olute position and return Index 2 Initiate Absolute Posn 10 000in Vel 5 0in s Index 1 Initiate Absolute Posn 0 000in Vel 10 0in s Wait For Index AnyCommandComplete Out and Return More Complex Description Home Wait For an input Move out to an absolute position set an output dwell for 1 second clear the output return to home position repeat the out and return sequence until the stop input halts the ...

Page 149: ...ion Index synchronized to find the front edge of product wait for input from a lug sensor and repeat Do While TRUE Repeat until the program is halted Index 0 Initiate Sync Registration Offset 0 500 Dist 50 000 Vel 1 000in in Registration move to product sensor Go to head of next product Wait For Index AnyCommandComplete Wait For ModuleInput 2 ON Wait for lug sensor on master conveyor Loop Elevator...

Page 150: ...tput function could be assigned to an output to indicate when the axis has completed the index and the following error is less than a specified amount Since the indexes are to absolute positions they can be adjusted to calibrate the stop positions to account for mechanical non linearity in the particular rotary table A rollover position of 360 00 degrees would be entered into the setup screen so t...

Page 151: ... input If PLS 0 Status ON Then If the PLS is already on you are too late ModuleOutput 4 ON Set a Too Late out put End Drop out of the program Endif Wait For PLS 0 Status ON Start the Index when PLS 0 goes on every 100 inches Index 1 Initiate Incremental Sync Dist 20 0in Vel 1 0in in Index 0 Initiate Absolute Sync Posn 0 0in Vel 2 0in in Wait For Index AnyCommandComplete Loop Synchronized Jog with ...

Page 152: ...ood product into a box Inputs are used to adjust the index distance It would be much simpler to adjust the index distance with an OIT 3165 operator interface panel but inputs could be used as described below ModuleOutput 3 OFF ModuleOutput 4 OFF Do While TRUE Repeat until the program is halted If ModuleInput 2 ON Then Fill a box if the Go input is on Index 1 Initiate Incremen tal Dist 16 00oz Vel ...

Page 153: ... positions using Jog Jog Jog Fast and Learn inputs The second program is called several times by the first program The third program steps through the learned positions Learn Program Program 0 Home 0 Initiate Sensor Offset 0 000in Vel 10in s Index 1 Initiate Move to position 1 Wait For Index AnyCommandComplete Call Program 1 Program 1 allows the axis to be jogged into position If ModuleInput 1 ON ...

Page 154: ...position Endif Wait For ModuleInput 1 OFF Wait until the Learn input goes off Wait For ModuleInput 2 OFF Wait until the Skip input goes off Subroutine for Jogging the Axis into the Desired Position Program 1 Allow jogging until either the Learn input ModuleInput 1 or the Skip input ModuleInput 2 goes ON Do While ModuleInput 1 OFF AND ModuleInput 2 OFF If ModuleInput 3 ON Then Jog if the Jog input ...

Page 155: ...n s Wait For InPosn ModuleOutput 1 ON Turn on ModuleOutput 1 for 1 second Wait For Time 1 000 seconds ModuleOutput 1 OFF Index 2 Initiate Absolute Posn 20 000in Vel 7in s Wait For InPosn ModuleOutput 1 ON Turn on ModuleOutput 1 for 1 second Wait For Time 1 000 seconds ModuleOutput 1 OFF Index 3 Initiate Absolute Posn 5 250in Vel 10in s Wait For InPosn ModuleOutput 1 ON Turn on ModuleOutput 1 for 1...

Page 156: ...142 FM 3 Programming Module Reference Manual ...

Page 157: ...ng up or slowing down Therefore this source can sometimes be active when the motor is decelerating This could be true when compounding indexes together Acceleration Type AccelType This parameter is used to select the accel decel type for all motion homes jogs and indexes The S Curve ramps offer the smoothest motion but lead to higher peak accel decel rates Linear ramps have the lowest peak accel d...

Page 158: ...is source is active during the At Velocity segment and is activated based on the commanded velocity not the feedback velocity During synchronized motion AtVel can be active without actual motor movement Bit Number Value Bit B This read write bit may be used in a program as an intermediary variable bit controlled by the user Bit B is one of 32 bits that make up the BitRegister parameter Assigned to...

Page 159: ...b The drive and module outputs are limited to 150 mA capacity therefore a suppressed relay is required to control the brake coil Model BRM 1 may be used Brake Release Brake Release This destination will release the brake under all conditions even when Brake Activate is engaged When this input function is active the Brake Disengaged output function source will be activated This is used as a manual ...

Page 160: ...e stored in the DefineHomePosn variable On the rising edge of the DefineHome function the Commanded Position is set equal to the DefineHomePosn and the AbsolutePosnValid source is activated Characteristic Distance DistUnits CharacteristicDist This parameter is the distance the load travels in user units when the motor travels the characteristic length in motor revolutions This parameter is used al...

Page 161: ...racters in length Drive Ambient Temperature DriveAmbientTemp This parameter should be set to reflect the ambient air temperature near the drive heatsink during normal operation This will determine the amount of regenerative power that can be dissipated by the EN drive s internal shunt resistor When that calculated value is exceeded by the Shunt Power RMS parameter a shunt fault will occur Valid on...

Page 162: ...rceEnable parameter is activated then the state of the DriveInput Force bit will override the current input state Drive Input Name DriveInput Name This is a text string up to 12 characters that can be assigned to a given input It allows the user to use application specific terminology in naming digital inputs Drive Input Raw DriveInput Raw This displays the raw state of the digital input without d...

Page 163: ...utput resolution in increments of one line per revolution Allowable range is from one line per revolution up to the actual density of the encoder in the motor If the Encoder output scaling is set greater than the motor encoder density the output scaling will be equal to the motor encoder density Drive Output Encoder Scaling Enable DriveOutputEncoder ScalingEnable When on this parameter enables the...

Page 164: ...s indicates the specific fault is active and a 0 is inactive Drive OK Fault DriveOK Active when there are no faults Inactivated when any fault except travel limits occur Drive enable has no effect on this event Faulted Fault Faulted Any fault will activate this event Module Faults Bitmap Fault ModuleFaultsBitmap This parameter is a 32 bit register which holds all of the module fault status bits Fo...

Page 165: ...compensation When feedforwards are enabled the accuracy of the Inertia and Friction settings are very important If the Inertia setting is larger than the actual inertia the result could be a significant overshoot during ramping If the Inertia setting is smaller than the actual inertia following error during ramping will be reduced but not eliminated If the Friction is greater than the actual frict...

Page 166: ...mmed velocity When FeedRate Deactivate is disabled FeedRate Override will be enabled and index and home motion is subject to scaling by the FeedRate Override parameter The default value for FeedRate Override is 100 so even when FeedRate Override is enabled default motion will run at programmed velocity FeedRate Override FeedRateOverride This parameter is used to scale all motion It can be describe...

Page 167: ... This parameter is used when the FollowingErrorEnable bit is set This limit is compared to the absolute value of the FollowingError If the FollowingError is greater than the FollowingErrorLimit a following error fault will be generated Friction Friction This parameter is characterized in terms of the rate of friction increase per 100 motor RPM If estimated always use a conservative less than or eq...

Page 168: ... When gearing from a program the Gear Initiate instruction is used Gear at Velocity Gear AtVel The Gear AtVel source indicates that the motor is running at the programmed gear ratio In early releases of Gearing acceleration and deceleration will not be used with gearing so this source will always be active when gearing is active Gear Command Complete Gear CommandComplete This source will activate ...

Page 169: ...ecelerating If Gear DecelEnable is activated this source is activated during the time between Gear Initate Off and Gear CommandComplete On Gear Recovery Distance Gear RecoveryDist This variable measures the distance the follower loses from the master This distance lost is measured between a Gear Initiate and the Gear At Velocity Any Command Complete Home AnyCommandComplete This source is active wh...

Page 170: ...e Calculated Offset Home CalculatedOffset The Calculated offset is the distance travelled during the deceleration ramp from the home velocity to a stop Calculated by PowerTools Command Complete Home CommandComplete This source is active when the specified home command is completed if a stop is activated before the home has completed the function or if the Home Limit Distance has been exceeded it w...

Page 171: ...itiate the specified home Home will not initiate if an index jog program or stop is currently active Limit Distance Home LimitDist This parameter places an upper limit on the incremental distance traveled during a home If no home reference is found the motor will decelerate to a stop at the limit distance and activate the Home LimitDistHit event Enable Limit Distance Home LimitDistEnable This para...

Page 172: ...sensor Home Reference Home Reference This parameter determines how the reference position is determined The parameter can have one of three different values Sensor Marker Sensor then Marker When the home reference is Sensor the rising edge of the Home Sensor input function is used to establish the reference position When the home reference is Marker the rising edge of the motor encoder s marker ch...

Page 173: ...s for Max Velocity Max Acceleration and Max Deceleration are such that the distance cannot be covered in the specified time the Index ProfileLimited flag will activate when the index is initiated The Index ProfileLimited flag will remain active until cleared using the Index ResetProfileLimited assignment or program instruction In this situation the index will still operate but the time will be ext...

Page 174: ...vent Limit Value Index AnalogLimitValue This preset value is compared to the selected AnalogLimitType to determine the registration point At Velocity Index AtVel This source activates when the target index velocity is reached If Feedrate override is changed or FeedHold is activated AtVelocity shall remain active Index AtVel will deactivate at the start of any deceleration or acceleration During a ...

Page 175: ...ity the Index Decelerating source will deactivate Distance Index Dist This parameter is the Incremental distance that the index will travel or the absolute position for the specified index in user units If an index type of Registration is selected then this is a limit distance or the maximum distance the index will travel if a registration sensor is not seen Index Time Index IndexTime This paramet...

Page 176: ... this parameter enables the PLS programmable limit switch function for the specified index It can be controlled from index view check box or from a program PLS Off Point Index PLSOffDist This an incremental distance from the start of the index to the Index PLS off point This is an unsigned value and is relative only to starting position of this index Index direction does not affect this parameter ...

Page 177: ...ndowEnd This parameter defines the end of the Registration Sensor Valid Window relative to start position of this index This is an unsigned value and is relative only to starting position of this index Index direction does not affect this parameter The Registration Window start position is greater than or equal to the Registration point and less than the Registration Window End position If a regis...

Page 178: ...ration will be used as maximum values and the Index Time parameter will determine how long it takes to perform an index Velocity Index Vel This parameter sets the target velocity of the specific index The units for this parameter are specified in the User Units Setup view When an index is initiated it will ramp up to this velocity at the specified acceleration rate and run at speed until it decele...

Page 179: ...yCommandComplete The Jog AnyCommandComplete bit will activate when either Jog 0 or Jog 1 completes its deceleration ramp and reaches zero commanded speed It deactivates when another jog is initiated Minus Activate Jog MinusActivate This destination is used to initiate jogging motion in the negative direction using the jog parameters of the jog selected by the Jog select input function Jogging will...

Page 180: ... motion is initiated in programs using the Jog MinusActivate or Jog PlusActivate instructions and using the Jog Stop will cause the motor to decelerate to a stop at the Jog Decel rate for the jog that is active Acceleration Jog Accel This parameter is the average acceleration ramp for the specific jog Accelerating Jog Accelerating This source is active while a jog is accelerating to its target vel...

Page 181: ... this bit is active jogging motion will be initiated in the negative direction at the specified jog velocity Initiate Plus Jog PlusInitiate This is used inside a program to initiate a specific jog When this bit is active jogging motion will be initiated in the positive direction at the specified jog velocity Time Base Jog TimeBase The time base selects either realtime which allows velocities accel...

Page 182: ...nced This is the state of the input after the debounce is taken into account Module Input Debounce Time ModuleInput DebounceTime The Module Input Debounce Time parameter is the minimum time a digital input must be on in order to be recognized by the FM 3 This feature helps prevent false triggering in applications in electrically noisy environments Module Input Force ModuleInput Force Input can be ...

Page 183: ...ebounce and forcing are taken into account Module Output Force ModuleOutput Force A module output can be forced either On or Off If the ForceEnable bit is activated the ModuleOutput State will be set to this value Module Output Enable Force ModuleOutput ForceEnable If ModuleOutput ForceEnable is activated then the state of the ModuleOutput Force bit will override the current output state Module Ou...

Page 184: ...f set to Both the PLS will activate regardless of whether the axis is moving in the positive or negative direction If set to Plus the PLS will activate only when the axis is moving in the positive direction If set to Minus the PLS will activate only when the axis is moving in the negative direction A flying cutoff or flying shear application may use this feature to activate the PLS to fire the kni...

Page 185: ...e direction the PLS Status will activate when position feedback reaches the OffPosn and will deactivate when it continues past the OnPosn The important thing to remember is that the PLS Status will be active if between the PLS On and Off points If using negative values for your OnPosn and OffPosn the most negative value should go in the OnPosn parameter and the least negative value should go in th...

Page 186: ...to three different sources MotorPosnFeedback MotorPosnCommand or MasterPosnFeedback This parameter determines which position signal the PLS uses to reference its OnPosn and OffPosn in order to determine its PLS Status parameter PLS Status PLS Status This source is active when the position of the PLS source motor or master is greater than or equal to the OnPosn and less than the OffPosn Positive Di...

Page 187: ...er than the value specified here Min Time Constant 1000 Response For example with Response set to 50 the minimum time constant value is 1000 50 20 msec Position Feedback PosnFeedback Feedback position is the actual motor position in user units PosnCommand minus the PosnFeedback is the FollowingError Position Feedback In Counts PosnFeedbackInCounts Motor encoder position in encoder counts since pow...

Page 188: ...ogram It allows the user to give a descriptive name to programs for ease of use Program Complete Program ProgramComplete This source is activated when a specific program ends normally If the program ends due to a fault or the stop destination this source does not activate Deactivates when the specific program is initiated again Response Response The Response parameter adjusts the velocity loop ban...

Page 189: ...s to the selector usually assigned to input lines This is level sensitive Selection Selector Selection This source selects Decimal outputs from the selector assigned to indexes homes or programs Initiate Selector SelectorInitiate When this destination is activated the selector checks the status of all Selector Select destinations to determine which Selector Selection to activate ShuntActive ShuntA...

Page 190: ...e unless enabled and Absolute Position Valid is active Software Travel Limit Plus Activate SoftwareTravelLimitMinusPosn The SoftwareTravelLimitMinusActive source will activate when the SoftwareTravelLimitMinusPosn is reached or exceeded Motion will come to a stop using the TravelLimitDecel Software travel limits are not active unless enabled and Absolute Position Valid is active Software Travel Li...

Page 191: ...ey will decelerate to zero speed at the Stop Decel ramp When Stop is active all Jog Home Index and Program initiate destinations will be ignored When it is deactivated all level sensitive and active input functions Jog 0 PlusActivate Jog 0 MinusActivate etc will become operational For example if the Jog PlusActivate input function is active when the Stop input function is deactivated the Jog Plus ...

Page 192: ...r than the TorqueLimit and the TorqueLimitEnable input function is active Travel Limit Deceleration TravelLimitDecel This parameter defines the ramp used to decelerate the motor to a stop when any travel limit is activated Travel Limit Disable TravelLimitDisable TravelLimitDisable can be used from the Assignments screen or through a user program It can be used to temporarily disable the travel lim...

Page 193: ...s source is active motion is allowd in the positive direction only Travel Limit Plus Activate TravelLimitPlusActivate This destination is used to activate the travel limit plus fault It should be assigned to the travel limit plus sensor When it is activated the drive will decelerate to a stop using the deceleration rate defined in the TravelLimitDecel parameter This is level sensitive Travel Limit...

Page 194: ...places in 6 0 000000 When assigning the value of a User Variable to different parameters make sure that the parameter and the User Variable have the same number of decimal places Variable Value Var Var Value This parameter specifies the current value of a user variable In a program the Value portion of the parameter name can be left off For example Var Var0 Value 12345 is the same as Var Var0 1234...

Page 195: ...ts i e user distance units are inches and velocity units are feet per minute instead of inches per minute To do this simply enter 12 to set 1 foot equal to 12 inches 1 velocity unit 12 distance units Range is 1 to 1000 integers only Units Name VelocityUnits Name If the user wants the velocity units to have a different distance scaling than the distance units a name can be entered here up to 12 cha...

Page 196: ...182 FM 3 Programming Module Reference Manual ...

Page 197: ...when its attached to an drive If a FM 3 module is moved from one drive to another it will detect the difference in serial numbers and generate an Invalid Configuration fault Two aligning tabs a locking latch and a 100 pin connector are used to attach the FM 3 module to an EN drive All electrical connections between the FM 3 module and the EN drive are accomplished with the single connector located...

Page 198: ...erator interface panels and PLC s Control Techniques Motion Interface panels are supplied with a Modbus master communications driver Serial Communications Specifications Max baud rate 19 2k default Start bit 1 Stop bit 2 Parity none Data 8 1 Grip the FM on each side of the LCD 4 Continue pulling the top of the FM away from the drive until the connector clears the drive Lift the FM out of the align...

Page 199: ... MB for minimum installation Optional Windows compatible printer Modem and Internet access Preparing for PowerTools Pro Installation Close all programs and turn off virus protection software to prevent installation conflicts If you have another version of PowerTools on your computer and do not want to overwrite that version change the default installation folder for PowerTools during installation ...

Page 200: ... into the Control Techniques PowerTools PRO directory Note To complete the installation for Windows 98 NT and XP you may be required to restart Windows Refer to the readme htm file which appears at the end of the installation for more information If You Need Help with Installation If you encounter problems while installing PowerTools Pro software call Technical Support at 952 995 8033 24 hour assi...

Page 201: ...hich you will construct the entire FM 3 setup Exiting the Software Choose File from the menu then click Exit If you are using the keyboard press the shortcut key combination Alt F X If you made changes PowerTools displays an Alert dialog box asking whether you want to save your current work Click the Yes button or press Enter to save your work or click the No button to quit without saving Accessin...

Page 202: ...FM 3 Programming Module Reference Manual Click the Help button on a dialog box or tab Click the Help icon on the toolbar Click the Context Sensitive Help button on the toolbar and then the field on the tab ...

Page 203: ... The communication status remains offline until the configuring is complete and you download the application to the FM 3 Step 2 Enter All Setup Data General Setup View The FM 3 software view is broken up into two areas The left side view contains the configuration hierarchy window which acts as a navigation frame Some elements in the hierarchy can be expanded to show more detailed setup views Elem...

Page 204: ... the following parameters before entering other setup views Drive Type Select from the list box the type of drive to which the FM 3 module is attached Motor Type Select from the list box the type of motor being used in this application EN Only EN Line Voltage Select from the list box the line voltage applied 115VAC or 230VAC Target Drive Address Enter the Modbus address for this drive FM 3 module ...

Page 205: ...parameter The parameters you must fill out are as follows Units Name Enter the character string you wish to use for your distance units Decimal Places Enter the number of digits after the decimal place you wish to use in all distance parameters throughout the software i e index distances positions PLS On Off points Use the spinner window Up down buttons to increase or decrease the number of digits...

Page 206: ...the FM 3 4 with a red background on the User Unit Limited Speed the drive will obtain a trajectory fault at speeds near this velocity To alleviate this issue simply remove decimal places from your user units and or change the characteristic distance numerator of your scaling parameters to be a smaller number than it was The red background indicating module trajectory faults will go away when the u...

Page 207: ...ts If enabled the software travel limits are not active unless the Absolute Position Valid Source is active For more information please see Software Travel Limits information in the Setting Up Parameters section of the Reference Manual Software Travel Limit and If the position feedback ever exceeds these values when traveling in a positive or negative direction the motor will come to a stop at the...

Page 208: ...in the User Units setup view under the Acceleration group Torque View If your application calls for specific torque levels and limits use the parameters on this view Tuning View Control Techniques Drives are designed to handle a 10 1 inertia mismatch without a tuning requirement If you have calculated and know the inertia mismatch the value can be entered on the Tuning view for ideal drive respons...

Page 209: ...hy The Assignments define how the system operates Sources located on the left side of the view are functions or events that activate based on drive motor activity Destinations located on the right side of the view are functions that need to be triggered or activated i e Index Initiate Program Initiate etc The example application requires initiating three indexes using three separate hardware input...

Page 210: ... This makes the configuration easier to follow Debounce This is the minimum time a specific input must be on for recognition by the drive FM 3 This helps prevent false triggering for applications in electrically noisy environments The units for this parameter are seconds with resolution of 0 001 seconds The Output Lines view shows assignments that have been made to the Outputs group of Destination...

Page 211: ...red by your application Select either the Jog0 or Jog1 to enter the specific Jog parameters Figure 80 shows Jog1 setup view renamed Jog Fast Once in the individual jog views the up and down arrows next to the Jog Number parameter can be used to scroll between the jog views see Figure 80 The following jog parameters have been defined on this view Jog Name Jog0 has been named Jog Slow and Jog1 named...

Page 212: ...s used as the home reference The available options are an external sensor the encoder marker pulse or both If sensor is selected the home profile will travel at its target velocity until the Home 0 SensorTrigger is activated Velocity Is the target velocity for the home move The home move travels at this velocity until the home reference is seen and then stops If the motor overshoots the sensor a r...

Page 213: ...ance after the home reference was detected In order to decelerate to a stop immediately upon detecting the home reference select the Calculated Offset radio box Limit Distance Is the maximum incremental distance the home move will travel without seeing a home reference signal If the home move does travel this distance without seeing a home reference it will come to a stop exactly at this point and...

Page 214: ...pe Selects the desired type of index from the list box An Absolute index means the load will travel to an exact position with respect to the home reference point This index will cause motion in either a positive or negative direction depending on current position of the load with respect to the home reference point An Incremental index means that the load travels an exact distance from the start o...

Page 215: ... This is the target velocity of the index profile The velocity parameter is unsigned and is always greater than zero Direction of the index is not determined by the velocity but by the Distance Position parameter Acceleration Is the average acceleration rate used when accelerating to the target index velocity Deceleration Is the average deceleration rate used when decelerating to zero speed or to ...

Page 216: ...roup in the hierarchy window and select Program 0 Figure 84 shows the programming window and the available instructions Figure 84 Program View The window in the middle of the view allows selection from a list of Program Flow and Motion instructions To insert an instruction into the programming window you can use the drag and drop method also used in making assignments Simply position your mouse po...

Page 217: ...rarchy button can be used on any view in the PowerTools Pro software but will primarily be of use in the Programs view and the Assignments view Figure 85 Program View Expanded A comment is automatically inserted after the index instruction which shows key data about the specific index Notice comments start with the apostrophe character A Wait For Index AnyCommandComplete instruction is automatical...

Page 218: ...Manual Now the program is complete and is ready to be run In order to run the program the drive must be enabled and the setup parameters must be downloaded Once the download is complete verify the drive is enabled and initiate your program ...

Page 219: ... After opening a new Configuration Window and inputting information on the Setup view move to the User Units view User Units View This example requires use of distance units Inches versus the default units revs The example has a linear device that moves 1 00 Inch per 1 motor Revolution Figure 73 shows the Setup group in the hierarchy expanded with the User Units element selected The parameters you...

Page 220: ...ches or one motor revolution and the Software Travel Limits of 20 and 0 Inches To setup following error limit and software travel limits fill out the following parameters in the Limits Group Enable Following Error Enable this checkbox Following Error Limit The example uses a limit of 0 25 Inches Enable Software Travel Limits Enable this checkbox Software Travel Limit and If the position feedback e...

Page 221: ...mpletes Therefore Index Complete sources will be assigned to the hardware Output destinations Figure 88 shows this process Figure 88 Assignments View The Input Lines view shows all of the assignments that have been made to the Inputs group of Sources After all assignments for the example application have been made the Input Lines view should look like Figure 89 ...

Page 222: ...r an input line The following parameters have been filled in for each input line The Output Lines view shows assignments that have been made to the Outputs group of Destinations in the assignment view Assignments to this view are made in the same way as assignments to the Input Lines view After all assignments have been made for the example application the Output Lines view will look like Figure 9...

Page 223: ...a 12 character string that gives a descriptive name to an index Index Type Select the desired type of index from the list box Index0 has been defined as an Absolute type of index This means the load will travel to an exact position with respect to the home reference point This index will cause motion in either a positive or negative direction depending on current position of the load with respect ...

Page 224: ...on The sign of this parameter determines direction of travel for the load The distance of Position C has been set to 2 5 inches Velocity Is the target velocity of the index profile The velocity parameter is unsigned and is always greater than zero Direction of the index is determined not by the velocity but by the Distance Position parameter Acceleration Is the average acceleration rate used when ...

Page 225: ...input is used to activate which functions This example specifies that the indexes must be initiated from assignments as well as from a program So a program must be created using the guidelines below Upon initiating the program it will wait until DriveInput 1 is activated then run all three indexes with a 1 second dwell in between each and then loop back to the top of the program The program will r...

Page 226: ...xample program uses an expression of TRUE which is always evaluated as True 1 Therefore the program will run continuously Wait For This program instruction halts program execution until the expression becomes True Once True the program continues with the next line of code The example program uses a Wait For DriveInput 1 so that the program will wait until DriveInput 1 is activated then continue on...

Page 227: ...surable parameters can be specified which will set up the internal control functions to optimize the drive performance The parameters include Inertia Ratio Friction Response and Line Voltage All the values needed for optimization are real world values that can be determined by calculation or some method of dynamic measurement PID vs State Space The power of the state space control algorithm is tha...

Page 228: ...rther tuning is needed based on axis performance The setup procedures explained here assume that you are using PowerTools FM 3 software or an FM P Initial settings Set the drive tuning parameters as follows Inertia Ratio 0 Friction 0 Response 50 High Performance Gains Enabled Feedforwards Disabled Tuning steps If your Inertia Ratio is greater than 10 times the motor inertia go directly to the Inte...

Page 229: ...higher with a lower inertia mismatch If your system has some torsional compliance such as with a jaw type coupling with a rubber spider or if there is a long drive shaft the Response should be decreased The highest recommended Response with High Performance Gains enabled is 100 Hz Also enabling the Low Pass Filter helps diminish the resonant frequency of torsionally compliant loads In such cases u...

Page 230: ...be used If you enter an inertia value higher than the actual inertia the resultant motor response will tend to be more oscillatory If you enter an inertia value lower than the actual inertia but is between 10 and 90 percent of the actual the drive will tend to be more sluggish than optimum but will usually operate satisfactorily If the value you enter is less than 10 percent of the actual inertia ...

Page 231: ...l generally should be decreased as the load to motor inertia ratio increases or if High Performance Gains are enabled Feedforwards Feedforward gains are essentially open loop gains that generate torque commands based on the commanded velocity accel decel and the known load parameters Inertia Ratio and Friction Using the feedforwards reduces velocity error during steady state and reduces overshoot ...

Page 232: ...Voltage specifies the applied power and adjusts the internal gains to compensate for it This parameter has two choices 115 VAC and 230 VAC If the Line Voltage is set to 230 VAC when the actual applied voltage is 115 VAC the motor will be slightly less responsive to commands and load disturbances The Line Voltage must never be set to 115 VAC if the applied voltage is actually 230 VAC This can cause...

Page 233: ...s can be used if necessary If your application has travel limits it may be helpful to use an external position controller to prevent the axis from exceeding the machine limits Set up a trapezoidal profile as shown In the procedure below the Torque Command and Velocity Feedback parameters can be measured using the drive s analog outputs PowerTools software or an FM P With vertical loads the test re...

Page 234: ... value at higher speed TCL Torque Command Limited at lower speed RPMH Higher RPM velocity RPML Lower RPM velocity FV Friction value The figure below shows the relationship of Torque Command to the Velocity Feedback There is increased torque during the Accel ramp Ta constant torque Tc during the constant velocity portion of the ramp and decreased torque Td during the decel ramp Figure 94 Trapezoida...

Page 235: ... or with the Watch Window To best determine the inertia use both acceleration and deceleration torque values The difference allows you to drop the constant friction out of the final calculation If your application exerts a constant unidirectional loading throughout the travel such as in a vertical axis the inertia test profiles must be performed in both directions to cancel out the unidirectional ...

Page 236: ...que required during deceleration ramping while moving up against the constant force Tad unsigned percent continuous torque required during acceleration ramping while moving down aided by the constant force Tdd unsigned percent continuous torque required during deceleration ramping while moving down aided by the constant force Ramp Units Conversion If you are using an external position controller t...

Page 237: ...30 6 87 30 600 NT 345 6 72 30 600 NT 355 5 97 30 600 MG 316 3 17 30 600 MG 340 3 14 30 600 MG 455 2 44 30 600 NT 345 EN 214 6 72 30 600 NT 355 5 97 30 600 MG 455 2 44 30 600 MG 490 1 85 30 600 MG 4120 1 69 30 600 NT 207 Eb 202 7 27 30 600 NT 212 5 37 30 600 MG 205 4 77 30 600 MG 208 3 63 30 600 NT 207 Eb 203 7 27 30 600 NT 212 7 22 30 600 MG 205 4 77 30 600 MG 208 4 63 30 600 MG 316 2 67 30 600 NT...

Page 238: ...224 FM 3 Programming Module Reference Manual ...

Page 239: ...d drive system is functioning normally and is ready to execute a motion command Drive Type Address Motor Type Menu Groups Brake Engaged Output Off Motor brake is mechanically engaged This character will only appear if the Brake output function is assigned to an output line See Brake Operation section for detailed description of Brake Output function Drive Type Address Motor Type Menu Groups Disabl...

Page 240: ...s are automatically cleared when the fault condition is removed The table below lists all the fault codes in priority order from highest to lowest This means that if two faults are active only the higher priority fault will be displayed Indexing Index is executing Drive Type Address Motor Type Menu Groups Decelerating from Stop Deceleration ramp after the Stop function is activated The ramp is dis...

Page 241: ...Power Module High DC Bus Reset Button or Input Line Yes High DC Bus Low DC Bus Reset Button or Input Line Yes Low DCBus Encoder State Cycle Power Yes Encoder State Encoder Hardware Cycle Power Yes Encoder HW Motor Overtemp Reset Button or Input Line Yes MotorOvrTemp RMS Shunt Power Reset Button or Input Line Yes RMS ShuntPowr Overspeed Reset Button or Input Line Yes Over Speed Segment Display Faul...

Page 242: ...o reset this timer every 10 ms the drive hardware will be reset all inputs and outputs will be cleared Off and a Watchdog Timer fault is generated Power Up Test This fault indicates that the power up self test has failed This fault cannot be reset with the reset command or reset button NVM Invalid At power up the drive tests the integrity of the non volatile memory This fault is generated if the c...

Page 243: ...y damage may occur to the drive motor or both if the fault is cleared using the Reset button when the setup data in the FM does not match the current drive and motor Power Module This fault is generated when a power stage over temperature over current or loss of power stage logic supply occurs This can be the result of a motor short to ground a short in the motor windings a motor cable short or th...

Page 244: ...This fault is generated when RMS shunt power dissipation is greater than the design rating of the internal shunt Overspeed This fault occurs when the actual motor speed exceeds the Overspeed Velocity Limit parameter This parameter can be accessed with PowerTools Pro software Max Following Error This fault is generated when the following error exceeds the following error limit default following err...

Page 245: ...ower stage over temperature over current or loss of power stage logic supply occurs This can be the result of a motor short to ground a short in the motor windings a motor cable short or the failure of a switching transistor Low Bus This fault will occur whenever the voltage on the DC bus drops below 96 volts The most likely cause of this fault is a reduction or loss of AC power A 50 ms debounce t...

Page 246: ...outputs will be cleared Off and a Watchdog Timer fault is generated Overspd This fault occurs when the actual motor speed exceeds the Overspeed Velocity Limit parameter This parameter can be accessed with PowerTools Pro software Inv Cfg The FM module was not on this drive during its previous power up and it is not known if the setup data in the FM module matches the drive and motor combination to ...

Page 247: ...tents of the non volatile memory are invalid Pwr On FlwErr This fault is generated when the following error exceeds the following error limit default following error limit is 2 revs With PowerTools Pro you can change the Following Error Limit value on disable in the Position view Trav This fault is caused when the Travel Limit input function is active Trav This fault is caused when the Travel Limi...

Page 248: ...er on the FM 3DN Buss offs are generally caused by either DeviceNet wiring issues or devices with different baud rate settings residing on the same network DupMacID This fault occurs when the FM 3DN s MacID is the same as another MacID on the network Logic power must be cycled or an appended program downloaded via PowerTools Pro to the FM 3DN Analog Outputs The drive has two 10 bit Analog Outputs ...

Page 249: ...235 Diagnostics and Troubleshooting Torque Command Percent of continuous torque Analog Output Scale units Velocity Feedback RPM volt Torque Command Percent of continuous torque volt ...

Page 250: ... to avoid shorting to each other However if signals do get shorted to GND the drive will not be damaged because the circuitry is protected Figure 96 Diagnostic Output Test Points Channel 2 Analog GND MDS Drive Module VDC 10 3 0 J6 SERIAL J4 OUTPUT COMMAND INPUT 3 2 1 1 4 3 2 J5 RESET VDC 10 3 0 J6 SERIAL J4 OUTPUT COMMAND INPUT 3 2 1 1 4 3 2 J5 SERIAL COMMAND RESET SERIAL COMMAND EN Drive ...

Page 251: ...237 Diagnostics and Troubleshooting Figure 97 Diagnostic Cable DGNE Diagram ...

Page 252: ...faults that can be reset with the Reset Faults button simply click the Reset Faults button in the Drive Faults Detected dialog box or push the Reset button on the front of the drive where the fault occurred Viewing Active Drive Faults To view all active drive faults select the View Faults command from the Device menu The dialog box displayed is the same as Active Drive Faults dialog box described ...

Page 253: ... to the right of the is an expression The Parser is an internal component of PowerTools software that reads your program text file and generates executable code used by the FM3 Module firmware The parser detects errors that are reported to you as Red Dot Error Messages Your program errors are displayed in the program view in Red Dot Error Messages They are indicated with red dots To get further in...

Page 254: ...Your Application has This message lets the user know that there are errors such as Red Dot errors in one or more programs The operation i e file save was completed however other operations such as download would fail for this application The message will provide more information such as which program is invalid to help the user correct the problem Error A FM3 number s decimal Point resolution can ...

Page 255: ... can only be assigned an Event or Boolean The Variable is an Input event It only accepts types consisting of Boolean and events Error Program Instance does not Exist You attempted the Call Program but the program does not exist Error Single value expressions can only be Boolean constants Events or Boolean variables This message occurs in conditional Expressions i e If then Variables are type ident...

Page 256: ...vent or Boolean value The Variable only accepts types consisting of Boolean and events Error The destination variable does not accept Data The Variable s internal data type attribute was not found Error The destination variable does not accept negative numbers You attempted to assign a negative number to an unassigned variable Error The destination variable is Read Only This message occurs when tr...

Page 257: ...he mix of variable or expressions types can not be compared This message occurs in conditional Expressions i e If then Variables are type identified so equation and assignments x 9 can be verified In an expression numerical Boolean and event values can be compared for equality conditions Selections and text can not be used Error The mix of variable or expression types can not be multiplied or divi...

Page 258: ...equire an instance number index 1 vel All the components identifying the variable must be available to qualify the variable Error This variable cannot be assigned a selection value The variable that you are attempting to define with a selection does not accept selection values Error This variable type cannot be assigned a value The Variable is of a type that does not accept any assignments A Sourc...

Page 259: ...elow To setup the Watch Window select Tools Watch Window from the PowerTools Pro menu bar If not online with the module Watch Window will be a greyed out choice on the menu Upon selecting Watch Window the following window will appear Figure 99 Watch Window The Select Drive Parameters window as seen in Figure 100 allows the user to specify which parameters are to be seen in the Watch Window To sele...

Page 260: ...ve been added to the Watch Window Once the selections have been saved the Restore Selections button can be used to monitor all the same parameters the next time the user opens the Watch Window Therefore if there is a list of helpful diagnostic parameters the user wishes to see when online those specific parameters can be saved and recalled in the Watch Window at any time The settings are saved in ...

Page 261: ...in the Select Drive Parameters window by group The Group defaults to ALL so that parameters from all groups are seen If the user wishes to only see those parameters from a specific group the click on the Group list box and select the group of parameters they wish to see Global Where Am I Button The Program View when online and executing a program or sequence of programs can display current program...

Page 262: ...248 FM 3 Programming Module Reference Manual ...

Page 263: ...10 30 VDC ON State Current 2mA 6 5mA OFF State Voltage 0 3VDC OFF State Current 0 400µA Outputs Max ON State Voltage I O Supply Voltage 1 5V Max ON State Current 150mA Max OFF State Current 100µA 7 187 182 5 2 5 63 5 1 25 31 75 485 485 SHLD 1 2 3 4 5 6 7 8 1 2 3 4 Programming Module Inputs Outputs 10 30 VDC Exp I O Sync Input Sync Output FM 3 Programming Module Reference Manual ...

Page 264: ...250 FM 3 Programming Module Reference Manual AX4 CEN CDRO ...

Page 265: ...251 Specifications Cable Diagrams ...

Page 266: ...252 FM 3 Programming Module Reference Manual SNCE XXX Cable SNCDD 001 5 Cable ...

Page 267: ...253 Specifications SNCO 003 Cable SNCI 003 Cable ...

Page 268: ...254 FM 3 Programming Module Reference Manual SNCLI 003 Cable ...

Page 269: ...255 Specifications CMDX XXX Cable Note Some CMDX cables may have White Yellow and Yellow White wires in place of the White Orange and Orange White shown in the figure above pins 6 and 21 ...

Page 270: ...M 3 Programming Module Reference Manual CMDO XXX Cable Note Some CMDO cables may have White Yellow and Yellow White wires in place of the White Orange and Orange White shown in the figure above pins 6 and 21 ...

Page 271: ...257 Specifications CDRO XXX Cable 8 9 24 23 38 37 11 12 34 16 14 15 29 4 19 26 40 18 17 31 33 43 44 41 27 ...

Page 272: ...258 FM 3 Programming Module Reference Manual TIA XXX Cable DDS XXX Cable ...

Page 273: ...259 Specifications TERM H Head Terminator TERM T Tail Terminator Note See the Multi drop Communications section for resistor values ...

Page 274: ...260 FM 3 Programming Module Reference Manual CMDS XXX Cable CMMS XXX Cable ...

Page 275: ...261 Specifications CFCS XXX Cable ...

Page 276: ...262 FM 3 Programming Module Reference Manual CFCO XXX Cable ...

Page 277: ...263 Specifications CFOS XXX Cable ...

Page 278: ...264 FM 3 Programming Module Reference Manual ...

Page 279: ...the mouse When On it displays an X in a square when Off the square is blank Unlike option radio buttons check boxes do not affect each other any check box can be On or Off independently of all the others Complex Motion A string of multiple motion commands and logical instructions that form a repeatable operation For the FM 3 the configuration file defines complex motion by setups functional assign...

Page 280: ... the user has filled in the necessary information the dialog box disappears DIN Rail Deutsche Industrie Norm Rail DLL In Microsoft Windows a Dynamic Link Library contains a library of machine language procedures that can be linked to programs as needed at run time Downloading The transfer of a complete set of parameters from an FM to a drive Drive Servo drive or amplifier EEPROM An EEPROM chip is ...

Page 281: ...ntain its current value until the input level changes past the point that set the current output value The difference in response of a system to an increasing input signal versus a decreasing input signal I O Input Output The reception and transmission of information between control devices In modern control systems I O has two distinct forms switches relays etc which are in either an on or off st...

Page 282: ... number that is the least important or having the least weight LED Light Emitting Diode used on the front display of drives and function modules List Box In a dialog box a list box is an area in which the user can choose among a list of items such as files directories printers or the like mA Milliamp which is 1 1000th of an Ampere MB Mega byte MODBUS Communication Protocol by Modicon The drive fol...

Page 283: ...transistor These optical components provide electrical isolation Output Function See source The terminals at which energy is taken from a circuit or device Output Line The actual transistor or relay controlled output signal Parameters User read only or read write parameters that indicate and control the drive operation These variables generally hold numerical data defined in the Setup Views PC Per...

Page 284: ...M is considered volatile because its contents are lost during a power loss RMS Root Mean Squared For an intermittent duty cycle application the RMS is equal to the value of steady state current which would produce the equivalent heating over a long period of time ROM ROM is an acronym for Read Only Memory A ROM contains computer instructions that do not need to be changed such as permanent parts o...

Page 285: ...ue that encompasses numeric boolean input function and output functions VDC Volts Direct Current Velocity The rate of change in position in a given direction during a certain time interval View Portion of screen within frame Windows Microsoft Microsoft Windows is an operating system that provides a graphical user interface extended memory and multi tasking The screen is divided into windows and th...

Page 286: ...272 FM 3 Programming Module Reference Manual ...

Page 287: ...nt 73 D DDS XXX Cable 258 Delete All Book Marks 117 Delete Program Button 131 Deleting a Program 132 Deleting An Assignment 74 Diagnostic Display 225 Digital Inputs and Outputs 82 Disable Error Check 118 Do While Loop 121 Drag In I O 117 Drag In Operands 117 Drag In Variables 118 Drive Faults 238 Dwell for Master Dist 126 Dwell For Time 125 E Else 120 Encoder Hardware 230 Encoder State 230 End 123...

Page 288: ... Fault 229 M Modbus Communications 184 Motion Instructions 125 Motion Modifers 130 Motor Over Temperature Fault 230 N Next Book Mark 117 Non volatile Memory Invalid 228 O Over Speed Fault 230 P Power Stage Fault 229 Power Up Self Test Failure 228 Previous Book Mark 117 Program Flow Instructions 119 Program Instruction Types 119 Program Toolbar Icons 116 Program Where Am I 118 Programming Error Mes...

Page 289: ...i Setup 31 Setup Commissioning and Maintenance vii status codes decimal point 225 Ready 225 Ready to Run 225 Stop All 118 T TERM H Head Terminator 259 TERM T Tail Terminator 259 TIA XXX Cable 258 U Undo Last Change 116 Using Last 130 W Wait For 121 Wait For Time 122 Watchdog Timer 228 ...

Page 290: ...276 FM 3 Programming Module Reference Manual ...

Page 291: ......

Page 292: ...mation about Control Techniques Motion Made Easy products and services call 800 893 2321 or contact our website at www emersonct com Control Techniques Drives Inc Division of EMERSON Co 12005 Technology Drive Eden Prairie Minnesota 55344 U S A Customer Service Phone 952 995 8000 or 800 893 2321 Fax 952 995 8129 Technical Support Phone 952 995 8033 or 800 893 2321 Fax 952 9995 8020 Printed in U S A...

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