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Festo CMMD-AS series, Installation Manual

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Festo CMMD-AS series Installation Manual Download Page 79

4. Functional safety engineering 

Festo P.BE-CMMD-AS-HW-EN 1002NH  

 

79 

An overview of the various stop categories is provided by the following table. 

 

Stop category 

Type 

Handling 

0  

Uncontrolled shutdown through 
immediate switching off of the energy. 

EMERGENCY OFF or EMERGENCY STOP 

1 

Controlled shutdown through switching 
off of the energy when a standstill has 
been reached. 

EMERGENCY-STOP 

2 

Controlled standstill without switching 
off of the energy. 

Not suitable for EMERGENCY OFF 
or EMERGENCY STOP 

Table 4.3 Stop categories 

 

Summary of Contents for CMMD-AS series

Page 1: ...Beschneiden Oben 61 5 mm Unten 61 5 mm Links 43 5 mm Rechts 43 5 mm Motor controller Description Fitting and Installation Typ CMMD AS Description 571 734 en 1002NH 751 593 ...

Page 2: ......

Page 3: ..._571 734 Festo AG Co KG D 73726 Esslingen 2010 Internet 0Hhttp www festo com E mail service_international festo com The copying distribution and utilisation of this document as well as the communication of its contents to others without expressed authorization is prohibited Offenders will be held liable for compensation of damages All rights reserved in particular the right to register patents uti...

Page 4: ...me of manual Festo P BE CMMD AS HW DE 1002NH File name File saved at Consec no Description Index of revisions Date of amendment 001 Produced 1002NH Trademarks Microsoft Windows CANopen CiA and PROFIBUS are registered brands of the respective trademark owners in certain countries ...

Page 5: ...ic shock 20 2 4 5 Protection against dangerous movements 20 2 4 6 Protection aganst touching hot components 21 2 4 7 Protection when handling and assembling 22 3 Product description 23 3 1 General information 23 3 2 Device description 23 3 3 Bus connection 24 3 4 Performance characteristics 24 3 5 Interfaces 27 3 5 1 Overview of the setpoint value interfaces 27 3 5 2 Analogue setpoint specificatio...

Page 6: ...fety functions error messages 60 3 7 9 Behaviour when switching off enable 60 3 7 10 Oscilloscope function 62 3 7 11 Jog and teach function I O 63 3 7 12 Position record linking with positioning torque control switching 68 3 7 13 On the fly measurement 74 3 7 14 Endless positioning 74 3 7 15 Relative positioning records 76 3 7 16 Adjustment to the axis and motor construction set 76 4 Functional sa...

Page 7: ...ction 95 4 3 10 Determination of the brake time 95 4 3 11 Setting the delay time 96 5 Mechanical installation 97 5 1 Important instructions 97 5 2 Mounting 98 6 Electrical installation 100 6 1 Device view 100 6 2 Interfaces 102 6 3 Entire system CMMD AS 103 6 4 Interfaces and plug assignments 105 6 4 1 I O interface X1 1 2 105 6 4 2 Shaft encoder motor EnDat 2 1 and 2 2 X2 1 2 108 6 4 3 Safe stop ...

Page 8: ...ing readiness for operation 117 7 7 Timing diagram switch on sequence 118 8 Service functions and error messages 119 8 1 Protective and service functions 119 8 1 1 Overview 119 8 1 2 Temperatur monitoring for motor and power section shaft encoder monitoring 119 8 1 3 Short circuit monitoring of the output stage overload current and short circuit monitoring 119 8 1 4 Voltage monitoring for the inte...

Page 9: ...Interfaces 127 A 3 1 I O interface X1 1 2 127 A 3 2 Shaft encoder motor X2 1 2 128 A 3 3 CAN bus X4 128 A 3 4 RS232 RS485 X5 128 A 3 5 Motor connection X6 1 2 129 A 3 6 Power supply X9 130 A 3 7 Increment generator interface X10 1 2 130 B Index 131 ...

Page 10: ...for further information CANopen manual P BE CMMS CO Description of the implemented CANopen protocol as per DSP402 PROFIBUS manual P BE CMMS FHPP PB Description of the implemented PROFIBUS DP protocol DeviceNet manual P BE CMMS FHPP DN Description of the implemented DeviceNet protocol FHPP manual P BE CMM FHPP Description of the implemented Festo profiles for handling and positioning 1 2 Type code ...

Page 11: ...CMMD AS HW EN 1002NH 11 1 3 Scope of delivery The delivery includes Number Delivery 1 Servo motor controller CMMD AS C8 3A 1 CD parametrisation software documentation S7 module GSD EDS firmware 1 Plug range Table 1 1 Scope of delivery ...

Page 12: ...mation and remarks Caution Failure to comply can result in severe property damage Warning Failure to comply can result in property damage and personal injury Warning DANGER Considerable property damage and personal injury can occur if these instructions are not observed Warning Dangerous voltage The safety instructions contain reference to dangerous voltages which may occur Accessories Environment...

Page 13: ...ning instructions on the product itself technicians working with this product must be adequately familiar with the erection mounting setting up and operation of the product as well as with all warnings and precautionary measures in accordance with the operating instructions in this product manual and must be sufficiently qualified for this task Training and instructions on or authorization to swit...

Page 14: ...er to be opened by the user Correct project planning is required for the motor controller to function properly Warning DANGER Incorrect handling of the motor controller and failure to observe the specified warning instructions as well as incorrect manipulation of the safety devices can lead to damage to property bodily injury electric shock or in extreme cases death 2 3 Hazards due to improper use...

Page 15: ...Warning Use only accessories and spare parts which are approved of by the manufacturer Warning The motor controllers must be connected to the mains network in accordance with EN standards and VDE or appropriate national regulations so that they can be disconnected with suitable de energising devices e g power switch fuse circuit breaker Warning For switching the control contacts gold contacts or c...

Page 16: ...ontroller must be taken from this product manual and complied with Warning DANGER The general installation and safety regulations for working on high voltage systems e g DIN VDE EN IEC or other national and international regulations must be observed Failure to observe these regulations can lead to bodily injury death or considerable damage to property The following precautionary measures also appl...

Page 17: ...he motor is switched off with for example mechanical locking of the vertical axis external braking safety catch or clamping devices or sufficient weight compensation of the axis Warning The internal brake resistance can cause dangerous intermediate circuit voltage during operation and up to several minutes after the motor controller is switched off If touched this can lead to fatal or serious inju...

Page 18: ... ensuring that his system is brought into a safe state if the electric device fails Warning DANGER The motor controller and in particular the brake resistance can take on high temperatures which can cause severe bodily burns on contact 2 4 3 Protection aganst touching electric components This section concerns only devices and drive components with voltages over 50 V It is dangerous to touch compon...

Page 19: ...g also for brief measuring and test purposes always connect the protective conductor to all electric devices or connect to an earth cable in accordance with the connection diagram Otherwise high voltages may occur on the housing These could cause an electric shock Warning Do not touch the electrical connection points of the components when the device is switched on Warning Before touching electric...

Page 20: ...work 2 4 5 Protection against dangerous movements During startup the safety functions used e g Safe halt must be checked for proper functioning The user shall establish a regular inspection of the safety function Dangerous movements can be caused by incorrect control of connected motors There are various causes Causes Unsafe or faulty circuitry or cabling Faults in operating the components Faults ...

Page 21: ...y regulations applicable to the system must be observed here as well Undesired movements of the machine or other incorrect functions can occur as a result of switching off avoiding or failing to activate safety devices 2 4 6 Protection aganst touching hot components Warning DANGER Surfaces of the device housing may be hot up to approx 85 C see chapter 8 Danger of injury Danger of burning Warning D...

Page 22: ...ing cutting impact The following safety measures apply here Warning Observe the general regulations on setting up and safety when handling and mounting Use suitable mounting and transport devices Take suitable measures to prevent clamping and squashing of fingers Use only suitable tools If specified use special tools Use lifting devices and tools in a correct manner If necessary use suitable prote...

Page 23: ...een the boards in the CMMD AS to exchange power between the two boards and also permit communication between the axis controllers Both axes use both the same mains connection and the same 24V connection These connections are connected in the device The intermediate circuits are connected internally The braking resistors are wired parallel internally so that double sustained brake performance is av...

Page 24: ...nswer be returned over the fieldbus This means that the processing time of the fieldbus protocols depending on the fieldbus can be twice as long as with the CMMS AS Example Processing time for 8 bytes of control data 8 bytes of parameter data 16 bytes of data per axis and data direction CMMS AS 1 6 ms CMMD AS 2 x 1 6 ms 3 2 ms 3 4 Performance characteristics Flexible power management The nominal c...

Page 25: ...ution 12 bit analogue input Jog Teach operation Simple coupling to a higher level controller via I O Synchronous operation Master slave operation Extension and field bus module PROFIBUS DP DeviceNet Integrated CANopen interface Open interface in accordance with CANopen Festo Handling and Positioning Profile FHPP Protocol in accordance with the CANopen standards DS 301 and DSP 402 Contains Interpol...

Page 26: ...e output stage Certification of BG in preparation Less external circuitry Shorter response times in the event of an error Faster restart intermediate circuit remains charged Interpolating multi axis movement With a suitable controller the CMMD AS can perform path movements with interpolation via CANopen To do this position setpoints are specified by the controller in a fixed time slot pattern In b...

Page 27: ...s 2 CW CCW pulse CW pulse CCW CLK DIR Pulse Direction Synchronisation Chapter 3 5 3 page 28 A B track signals X10 1 5 V RS422 axis 1 X10 2 5 V RS422 axis 1 Encoder Input slave Emulation master Synchronisation Chapter 3 5 3 page 28 Digital inputs out puts X1 1 24 V DC axis 1 X1 1 24 V DC axis 2 Record selection Jog Teach operation Linked position records Start and stop functions Positioning control...

Page 28: ...it switches are set by default to opener configuration over FCT 3 5 3 Interfaces for direct synchronous operation The motor controller permits a master slave operation which hereafter is designated synchronisation The controller can function either as a master or slave If the motor controller works as master it can provide RS422 A B signals to the increment generator output X10 When the motor cont...

Page 29: ... 32 2048 Changes to this interface only become effective after a Reset download secure reset An RS422 power driver provides the signals to X10 differentially Input Processing of frequency signals X10 The signals are evaluated optionally as A B track signals of an increment generator or as pulse direction signals CW CCW or CLK DIR of a stepping motor control The signal form is selected in the FCT T...

Page 30: ...e synchronisation interface All other functions of the Positioning operating mode are no longer available Note After the change of configuration with FCT with the Download buttons load the changed configurations into the motor controller and save them permanently with the Save button With a Reset or switching off and back on of the motor controller the new configuration is activated To ensure flex...

Page 31: ... Required I O triggering during synchronisation via mode switchover with 24 VDC frequency signals 14530d_1 The connection plan shows the switch position in the active operating state The limit switches are set by default to N C contact configuration over FCT ...

Page 32: ... Required I O triggering during synchronisation via mode switchover with 5 VDC frequency signals 14531d_1 The connection plan shows the switch position in the active operating state The limit switches are set by default to N C contact configuration over FCT ...

Page 33: ...ronising The signal MC is set as long as the drive is at a standstill during active synchronisation DIN8 START set That is the MC signal is set as long as the window for DZ 0 has not been left The signal Position synchronous during activation of synchronisation DIN8 START on high is not set until the Target Reached window has been left But since synchronisation is switched onto a running master an...

Page 34: ...Complete in the FCT 3 5 4 I O functions and device control Digital inputs The digital inputs provide the elementary control functions To allow positioning targets to be saved the CMMD AS motor controller has a target table in which positioning targets can be saved and called up later Six digital inputs allow you to select the targets another input is used as the start input Two inputs are used to ...

Page 35: ...ts These analogue signals serve to specify setpoints speed or torque for the control Basic functions The existing digital inputs are already allocated to the basic functions in standard applications The analogue input AIN0 is also available as a digital input for use of further functions such as the jog function route program and synchronisation Mode switching allows you to switch between the foll...

Page 36: ...Please note that immediately after a reset the motor controller independently issues a bootup message via the serial interface A reception program on the controller must either process or reject these received characters General commands Command Syntax Response New initialisation of the servo positioning controller RESET None bootup message Save the current parameter set and all position sets in t...

Page 37: ...a CO ON nnnn nnnn HHHHHHHH or ON EEEEEEEE Reading an upper limit of a CO OX nnnn nnnn HHHHHHHH or OX EEEEEEEE Reading an actual value of a CO OI nnnn nnnn HHHHHHHH or OI EEEEEEEE nnnn Number of the communication object CO 16 bit hexadecimal format HHHHHHHH 32 bit data values hexadecimal format EEEEEEEE Return value in case of an access fault Table 3 8 Parameter commands The meaning of the return v...

Page 38: ...nse Regulating torque OW 0030 00000004 OK or OW EEEEEEEE Speed control OW 0030 00000008 Positioning OW 0030 00000002 Table 3 11 Operating mode Faulty return values can be called up due to invalid values that do not come from the above named group The current operation mode can be read by using the OR command Example Profile position mode via RS232 Note If you want to perform a positioning a homing...

Page 39: ...00 RPM The acceleration can be written via the COB 6083_00 profile acceleration the deceleration via the COB 6084_00 profile deceleration and the quick stop ramp via the COB 6085 quick stop deceleration The accelerations are thereby written in acceleration units That means they depend on the set CAN factor group The default setting here is 1 28 revolutions min s 24 bit portion before the decimal 8...

Page 40: ..._00 Mode of Operation Command 606000 06 Homing mode 6 Start reference travel 7 Homing is started via the CAN control word COB 6040_00 8 Controller enable is controlled via bit 0 3 9 The homing is started via a rising edge at bit 4 Command 604000 001F 10 After homing has been ended the status of the motor controller must be reset Command 604000 000F Bring motor controller into Ready status 3 5 6 Co...

Page 41: ... Note The reply sends the following characters to the first five positions XRnn with nn node number of the device All devices react to the node number 00 as Broadcast In this way each device can be addressed without knowing the node number The commands of type OW OR etc support an optional check sum This check sum is formed without the first five characters The bootup message of the boot loader as...

Page 42: ...ler 5 V 0 5 IA 200 mA max Sense lines for power supply not supported Table 3 12 Signal description of shaft encoder motor EnDat 2 1 and 2 2 X2 3 5 9 Brake chopper Brake control A brake chopper with a braking resistor is integrated into the output stage If the permitted load capacity of the intermediate circuit is exceeded during the energy recovery the braking energy may be converted to heat by th...

Page 43: ...dge error DIN5 2 x limit switch DIN6 DIN7 6 x position selection DIN0 DIN3 DIN10 DIN11 1 x start positioning DIN8 2 x mode shift DIN9 DIN12 1 x stop DIN13 Mode 1 2 x jog mode DIN10 DIN11 1 x teach DIN8 Mode 2 1 x halt route program DIN3 1 x start route program DIN8 2 x next for route program step enabling condition DIN 2 11 Mode 3 2 x pulse direction CLK DIR or CW CCW on DIN2 DIN3 1 x start sync D...

Page 44: ...processing of incremental encoder or pulse direction signals The signals are evaluated optionally as A B track signals of an increment generator or as pulse direction signals CW CCW CLK DIR of a stepping motor control The signal form is selected via software The number of steps per revolution can be parametrised Beyond that an additional electronic gear can be parameterized 3 5 13 SD card holder M...

Page 45: ...aster first loads its firmware from the SD card With the start of the application the RESET pilot line for the slave is switched inactive Now the slave takes over the master function on the SSIO interface and directly accesses the SD card to load the same firmware from the SD card Only after completion of the firmware download is the cyclical and synchronous SSIO communication established between ...

Page 46: ...erned with the specific characteristics of the respective busses or controllers PLC but receives a preparametrised profile in order to place his drive into operation in the shortest possible time and control it Among the operation types FHPP distinguishes between record selection and direct operation With record selection the position records stored in the motor controller are used In direct opera...

Page 47: ...operating modes can be used Positioning mode CiA profile position mode Homing mode CiA homing mode Interpolating position mode CiA interpolated position mode Speed control CiA profile velocity mode Force mode CiA torque profile mode Communication can take place optionally over SDOs service data objects and or PDOs process data objects Two PDOs are available for each sending direction transmit rece...

Page 48: ...signed The data for the two controllers is sent in a shared telegram Baud rates up to 12 MBaud are supported FHPP is used as communication protocol with the control and operating modes described in chapter 3 6 1 3 6 4 DeviceNet The motor controller is connected to the DeviceNet network with a corresponding extension module CAMC DN which can be plugged into the extension slot Ext 1 If the module is...

Page 49: ...open with automatic interpolation between the setpoints Operating mode Function Setpoint value interface Setpoint specification via Regulating torque Analogue setpoint X1 Fieldbus Direct mode Speed control Analogue X1 CW CCW signals X1 24 V mode 3 X10 5 V CLK DIR pulse direction signals X1 24 V mode 3 X10 5 V Fieldbus Direct mode Master Slave A B signals I O start synchronization X10 X1 mode 3 Pos...

Page 50: ... setpoint value selectors are implemented in the firmware Selector for the speed setpoint Auxiliary value selector whose setpoint value is added to the speed setpoint The position of the setpoint value selectors is saved in non volatile parameters Depending on the prefix the speed setpoint is disabled via the signal of the corresponding limit switch input The limit switch inputs also affect the ra...

Page 51: ... also volatile position data records for positioning via the fieldbus The position records are made up of a position value and a motion profile The following parameters can be set for the eight positioning profiles Travel speed Acceleration Delay Smoothing Time Start delay Final speed Wait for current positioning reject or ignore initial instruction From every position record any other position re...

Page 52: ...sto P BE CMMD AS HW EN 1002NH Required I O interface for positioning 14532d_1 The connection plan shows the switch position in the active operating state The limit switches are set by default to N C contact configuration over FCT ...

Page 53: ...evaluation 2 FE 1 FF Index Impuls 1 Limit switch 18 12 17 11 Fixed stop 18 EE 17 EF 1 7 Zero pulse 34 22 33 21 Save current position 35 23 35 23 Table 3 15 Methods of homing Method 1 Negative proximity switch with index pulse If negative limit switch inactive Run at search speed in negative direction to the negative limit switch Run at crawl speed in positive direction until the limit switch becom...

Page 54: ... travel speed to axis zero point 18 Positive limit switch 5 If positive limit switch inactive Run at search speed in positive direction to the positive limit switch Run at crawl speed in negative direction until limit switch becomes inactive This position is saved as a reference point If configured Run at travel speed to axis zero point 17 Negative stop 1 2 6 Run at search speed in negative direct...

Page 55: ...r release START 1 0 1 0 1 0 1 0 1 0 1 0 1 0 Limit switch E0 1 0 DOUT0 READY DOUT1 MC DOUT2 ACK DOUT3 ERROR Statusword referenced 1 Limit switch E1 0 1 0 t1 t1 tx tx tx tx 0 1 STOP t1 1 6 ms tx x ms dependent on ramps Fig 3 4 Signal sequence with start of the homing run and with positive design ...

Page 56: ...0 1 0 1 0 1 0 1 0 1 0 1 0 Limit switch E0 1 0 DOUT0 READY DOUT1 MC DOUT2 ACK DOUT3 ERROR Statusword referenced 1 Limit switch E1 0 Drive is moving 1 0 neg pos t1 t1 tx tx tx tx 1 0 STOP t1 1 6 ms tx x ms dependent on ramps Fig 3 5 Signal sequence with faulty interruption contour error ...

Page 57: ...ry generator Based on the data record loaded the necessary internal pre calculations are made The pre calculations can take from 1 6 to 5 ms The following configurable options are available for processing the start signal A start signal detected during an ongoing positioning run is ignored ignoring After a start signal is detected during an ongoing positioning run the run continues to the end wait...

Page 58: ...T13 T12 T10 T11 T9 T8 T6 T5 T4 T3 T2 T1 RESET Power ON Boot program Firmware download Initialisation Ready for operation Initialise SD card Load save SD card parameters From all except RESET Power ON Error condition Acknowledge error Activate output stage Regulating torque Speed control Positioning controller Jog mode Homing ...

Page 59: ...speed acceleration Selection I O mode DIN9 0 DIN12 1 Jog DIN10 1 Jog DIN11 1 T10 Selection I O mode DIN9 0 DIN12 1 T11 Selection of the homing method and parametrisation of the speeds and accelerations in the commissioning software Selection I O mode 0 DIN9 0 DIN12 0 Selection of positioning record 0 Start for positioning process DIN8 1 T12 Drive is referenced T13 DIN5 0 T15 DIN5 0 T16 DIN5 0 T17 ...

Page 60: ...n fault Check sum error on parameter transmission Communications errors Following error Homing Overload current short circuit in the power end stage Encoder system Watchdog processor monitoring 3 7 9 Behaviour when switching off enable Controller enable Drive is moving 0 1 0 1 0 1 0 1 0 Holding brake Current carrying 1 DOUT0 READY Output stage release 1 0 ty t1 tx Motor controlled t1 1 6 ms tx x m...

Page 61: ...oving 0 1 0 1 0 1 0 1 0 Holding brake current carrying 1 DOUT0 READY Output stage release 1 Motor controlled 0 ty t1 t1 1 6 ms tx x ms dependent on brake ramps Fig 3 8 Behaviour when switching off end stage enable Note The holding brake of the EMMS AS is not suitable for braking the motor ...

Page 62: ...he oscilloscope function implemented in the firmware of the controller is an important aid to help the commissioning party to optimise the controller settings without using a separate measuring device The function allows important signal sequences to be recorded over time It consists of three blocks The initialisation section which runs at low priority and performs pre calculations for the actual ...

Page 63: ... set target position The status of the digital position inputs DIN0 DIN3 DIN10 and DIN11 is thereby evaluated and the target position saved at the corresponding location General Information All positions of the positioning record table can be taught pos 1 63 With falling edge of DIN8 the current position is taken over into the positioning record which is selected with DIN0 DIN3 DIN10 and DIN11 The...

Page 64: ...nction The jog and teach function is started in I O operation through selection of mode 1 Required I O triggering with jog teach 14528d_1 The connection plan shows the switch position in the active operating state The limit switches are set by default to N C contact configuration over FCT ...

Page 65: ...ct description Festo P BE CMMD AS HW EN 1002NH 65 Settings in the FCT The parameters set here are valid for jogging via I O interface and jogging via FCT The acceleration also applies with Single Step over FCT ...

Page 66: ...am ENABLE START TEACH STOP DIN10 Jog Drive is moving 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 neg DIN11 Jog 1 0 pos DOUT0 READY DOUT1 MC DOUT2 ACK TEACH DOUT3 ERROR t1 t1 tx tx t1 1 6 ms tx x ms dependent on brake ramps Fig 3 10 Signal sequence with jogging positive and negative ...

Page 67: ...N10 Jog Drive is moving 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 DIN11 Jog 1 0 DOUT0 READY DOUT1 MC DOUT2 ACK TEACH DOUT3 ERROR t1 t1 tx tx t1 tx t1 t1 tx tx t1 1 6 ms tx x ms dependent on brake ramps Fig 3 11 Signal sequence when both signals are activated simultaneously briefly staggered ...

Page 68: ...e program are All 63 position records of the positioning record table per axle can be set in the route program The positioning records of the two axes cannot be combined with each other Besides linear sequences ring shaped linkages are also allowed endless linkage For each route program step a free following position can be set As a step enabling condition 2 digital inputs per axle are available a...

Page 69: ...ime for bridging the acceleration phase has expired Standstill here does not just mean the end of the position record MC but also running to block at any desired location Time measurement starts when the position record starts 5 Time TIM Continues when the programmed time has expired Time measurement begins with the start of the position record 6 NEXT positive edge NRI Continues immediately after ...

Page 70: ...les with end speed 0 Note Position records containing an end speed 0 must NOT be used for individual records since the end speed condition can only be reached in linkages Activation of record linking Record linking is started in I O operation through selection of mode 2 ...

Page 71: ...ner configuration over FCT With removal of DIN3 Halt record linking the ongoing record linking is stopped at the current position If DIN3 returns the record linking is automatically continued from this position With removal of DIN9 Mode shift the ongoing record linking is ended The ongoing position record is still run to the end With removal of DIN13 Stop record linking is interrupted Record linki...

Page 72: ...ART STOP Positioning record Drive is moving 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 DOUT0 READY DOUT1 MC DOUT2 ACK DOUT3 ERROR t1 t1 t1 t1 t1 tx 1 t1 1 6 ms tx x ms dependent on positioning 1 Applies for positioning records with end speed 0 Fig 3 13 Signal sequence at the start of a sequence ...

Page 73: ...1 t1 t1 tx t1 t1 1 6 ms tx x ms dependent on brake ramps Fig 3 14 Signal curve with abort through STOP input ENABLE START STOP Positioning record Drive is moving 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 HALT 1 0 DOUT0 READY DOUT1 MC DOUT2 ACK DOUT3 ERROR t1 t1 t1 t1 t1 tx tx tx tx t1 1 6 ms tx x ms dependent on brake ramps Fig 3 15 Signal sequence with interruption and continuation through HALT input ...

Page 74: ...monitored is selected The Flying Measure function supports continuous sampling i e the configured edge is monitored and the stored actual position values are overwritten with each sample event 3 7 14 Endless positioning For applications such as synchronised conveyor belt or Round switch table endless positioning is possible in one direction via relative positioning records No endless positioning i...

Page 75: ...3 Product description Festo P BE CMMD AS HW EN 1002NH 75 For linear axes For rotational axes ...

Page 76: ...ller calculates with whole numbers integers For positioning records that do not have a whole number as the result the controller rounds up to the next whole number This can result in deviations with endless positioning Example Round switch table 4 positions 90 65536 4 16384 Integer 6 positions 60 65536 6 10922 666 The controller positions at 10923 3 7 16 Adjustment to the axis and motor constructi...

Page 77: ...ust design the safety system for the entire machine including all integrated components This also included the electric drives The new EN ISO 13849 standard uses a changed risk graph for risk analysis and a deviating principle to achieve the requirements compared to EN 9549 1 Starting point for evaluation of the risk reduction contribution L Low contribution to risk reduction H High contribution t...

Page 78: ...of the CMMD AS family the STO and SS1 safety functions have been implemented through external circuitry Galvanic isolation does not occur with the STO function As a result this does not have any protective function against electric shock In the sense of the standards an EMERGENCY OFF system cannot be implemented with the STO because this requires the complete system to be switched off via a mains ...

Page 79: ... Type Handling 0 Uncontrolled shutdown through immediate switching off of the energy EMERGENCY OFF or EMERGENCY STOP 1 Controlled shutdown through switching off of the energy when a standstill has been reached EMERGENCY STOP 2 Controlled standstill without switching off of the energy Not suitable for EMERGENCY OFF or EMERGENCY STOP Table 4 3 Stop categories ...

Page 80: ...laces wear and tear on the brake Therefore use motors without holding brakes for the STO function Application examples for the STO function Manual manipulation during set up Manual manipulation during changeover Eliminating malfunctions The use of the integrated solution offers several advantages Advantages Fewer external components e g fuses Less cabling effort and less space required in the cont...

Page 81: ... brake is released 2 shut down path 1 shut down path Discharge curve of electrolytic capacitors for the supply of the pulse amplifiers OFF ON OFF Ramp can be set via Festo Configuration Tool FCT fixed 0V Can be set via Festo Configuration Tool FCT Releasing motor holding brake X6 Y 1 2 released 24V Controller enabling X1 Y DIN5 Output stage enabling X1 Y DIN4 Floating feedback contact for driver s...

Page 82: ...on the display goes out at time t3 5 The time for the end stage enable X1 1 2 DIN4 is largely freely selectable t4 t1 The enable may occur at the same time as the relay is activated but it must occur approx 10 µs t5 t4 before the rising edge of the controller enable X1 1 2 DIN5 depending on the application 6 The rising edge of the controller enable at time t5 releases the motor holding brake if pr...

Page 83: ...4 Functional safety engineering Festo P BE CMMD AS HW EN 1002NH 83 4 2 3 Switching example STO 4711d_21 Fig 4 3 Circuitry example STO Peripherals ...

Page 84: ...4 Functional safety engineering 84 Festo P BE CMMD AS HW EN 1002NH 4711d_21 Fig 4 4 Circuitry example STO CMMD AS ...

Page 85: ... contacts K1 or K2 13 14 and 23 24 open immediately This results in the immediate removal of the output stage enable and disconnection of the driver supply via X3 pin 2 The unintended opening of the protective door must be prevented in the system Approx 80 ms after opening of the PNOZ contacts for switching off the driver supply the acknowledgment contact X3 1 or X3 2 pin 5 and 6 is closed t11 t12...

Page 86: ...output stage enable must be checked regularly e g monthly via the PLC 4711d_21 Fig 4 5 Block diagram STO Caution If the STO function is not required pins 1 and 2 of X3 1 2 must be bridged A second channel is required for the STO function as per EN 61508 SIL 2 i e a restart must be reliably prevented via two separate completely independent paths These two paths for interrupting the power supply sup...

Page 87: ... the existence of the driver supply This is an N C contact It must be connected to the higher order controller for example The function of switching off the end stage enable must be checked regularly via the PLC e g monthly contact open driver supply available If an error occurs in the plausibility check the control system must prevent further operation for example by switching off the intermediat...

Page 88: ...lay until brake is released 2 shut down path 1 shut down path Discharge curve of electrolytic capacitors for the supply of the pulse amplifiers OFF ON OFF Both ramps ca be set separately via Festo Configuration Tool FCT fixed 0V Can be set via Festo Configuration Tool FCT Releasing motor holding brake X6 Y 1 2 released 24V Controller enabling X1 Y DIN5 Output stage enabling X1 Y DIN4 Floating feed...

Page 89: ...ontact X3 1 2 pins 5 and 6 for plausibility checking of the relay activation opens a maximum of 20 ms after t1 t2 t1 and the driver supply is switched off 4 Approx 10 ms after the acknowledgment contact opens the H on the display goes out at time t3 5 The time for the output stage enable X1 1 2 DIN4 is selectable t4 t1 The enable may occur at the same time as the relay is activated but it must occ...

Page 90: ... end stage enable is switched off by the microprocessor t10 The holding brake is always applied when the braking ramp time set switch off delay has expired even when the drive has not come to a stop within this time 4 From time t10 SS1 can now be activated switch off driver supply relay activation and end stage enable at the same time Time t11 t10 depends on the application and must be defined by ...

Page 91: ...4 Functional safety engineering Festo P BE CMMD AS HW EN 1002NH 91 4 3 5 Parameterization example FCT ...

Page 92: ...4 Functional safety engineering 92 Festo P BE CMMD AS HW EN 1002NH 4 3 6 Sample circuit SS1 4711d_21 Fig 4 7 Sample circuit SS1 Peripherals ...

Page 93: ...4 Functional safety engineering Festo P BE CMMD AS HW EN 1002NH 93 4711d_21 Fig 4 8 Sample circuit SS1 CMMD AS ...

Page 94: ...equired to apply the motor holding brake This time depends on the holding brake used and must be parameterised by the user For applications without a holding brake this time can be set to 0 After this time the internal output stage enable is switched off by the After the delay time of the PNOZ has expired the two delay contacts of K1 37 38 and 47 48 open Then the activation of the driver supply re...

Page 95: ...safely placed in operation again If there are areas inside that can be entered a manual acknowledgement must be made via the optional S2 button 4 3 9 Testing the safety function For each on off cycle of the machine the PILZ device PNOZ XV2P checks whether the relays of the safety equipment open and close properly The function of switching off the output stage enable and controller enable must be c...

Page 96: ...ve the controller enable and so determine the brake time from the measurement curve This is stored under the point Measurement data A possible measurement curve could look as follows Graphically read brake time 210 ms 4711d_2 Fig 4 9 Brake time measurement curve 4 3 11 Setting the delay time The delay time of the PILZ PNOZ XV2P can be set manually at the device This delay time must be larger than ...

Page 97: ...ontrol cabinet plate Mounting clearance For sufficient ventilation 100 mm of clearance to other assemblies is required above and below the device The motor controllers of the CMMx family are designed such that they can be mounted on a heat dissipating mounting panel if used as intended and installed correctly We wish to point out that excessive heating can lead to premature aging and or damage to ...

Page 98: ...ance 5 2 Mounting The motor controller CMMD AS is attached vertically to a control cabinet mounting plate with mounting brackets The mounting brackets are engaged in the radiator profile ensuring an optimal heat transfer to the control cabinet plate Please use size M5 screws to attach the CMMD AS motor controller ...

Page 99: ...5 Mechanical installation Festo P BE CMMD AS HW EN 1002NH 99 Fig 5 2 Motor controller CMMD AS Mounting ...

Page 100: ... P BE CMMD AS HW EN 1002NH 6 Electrical installation 6 1 Device view 1 Status display 2 S1 Fieldbus settings and boot loader 3 Ext 1 2 Technology module optional 4 M1 SD memory card 5 X4 CAN bus 6 X5 RS232 485 Fig 6 1 View CMMD AS Front ...

Page 101: ...HW EN 1002NH 101 1 Earthing screw 2 X9 Power supply 3 X10 Increment generator output 4 X1 I O interface Fig 6 2 Top view CMMD AS 1 X3 Safe halt 2 X2 Increment generator output 3 X6 Motor connection 4 Screened connection Fig 6 3 Bottom view CMMD AS ...

Page 102: ...ure sensor PTC SI sensor or N C contact is connected to the MTdig and MTdig terminals KTY81 KTY84 can be used as analogue temperature sensors Not in the FCT and not with EMMS AS motors The motor brake is connected to the terminals Br and Br The motors protective earth conductor is connected to PE of the X6 plug The motor shield is connected to the housing of the CMMD AS using the screened connecti...

Page 103: ...own in 220HFig 6 4 To operate the motor controller the following components are needed Components 24V power supply unit for control voltage supply see chapter A 3 2 Power supply see Chapter A 3 2 Motor controller CMMD AS Motor EMMS AS Cable set consisting of motor and encoder line NEBM A PC with a serial connection cable is required for parameterizing ...

Page 104: ...rical installation 104 Festo P BE CMMD AS HW EN 1002NH 1 Power switch 2 Fuse 3 Power supply unit for control voltage 4 CMMD AS 5 EMMS AS 6 PC Fig 6 4 Complete structure of CMMD AS with motor and PC 5 1 2 3 4 6 ...

Page 105: ...aximum 30 V input voltage 3 DIN10 Record selection 4 high active 4 VREF 10 V 4 Reference output for setpoint potentiometer 5 free 6 GND24 Ass GND Reference potential for digital inputs and outputs 7 DIN1 Record selection 1 high active 8 DIN3 Record selection 3 high active 9 DIN5 Controller release EN high active 10 DIN7 Limit switch 1 11 DIN9 Digital I O control interface Mode selection high activ...

Page 106: ...ion 0 jog mode high active Fieldbus control interface Sample input high speed input 12 DOUT1 24 V100 mA Output freely programmable default motion complete high active 13 DOUT3 24 V100 mA Output freely programmable default error low active 14 AGND 0 V Reference potential for the analogue signals 15 DIN13 Stop input low active 16 DIN11 Jog high active 17 AMON0 0 10 V Analogue monitor output 0 18 24 ...

Page 107: ...ation Value Mode 3 Synchronisation 1 AGND 0 V Screen for analogue signals 2 DIN12 Mode switch slave synchronisation 1 synchronisation 3 DIN10 4 VREF 10 V 4 Reference output for setpoint potentiometer 5 Free 6 GND24 Reference potential for digital inputs and outputs 7 DIN1 Record selection 1 high active 8 DIN3 24 V Direction_24 CCW 9 DIN5 Controller release high active 10 DIN7 Limit switch 1 11 DIN...

Page 108: ...5 m 50 m line to and from Double wiring Voltage drop with single wiring Udiff 0 18 V Pin Designation Value Specification 1 MT 3 3 V 3 mA Motor temperature sensor NC PTC KTY Not occupied with NEBM lines 2 U_SENS 5 V 0 5 Imax 200 mA Connected internally with pin 3 3 GND 0V Reference potential for encoder supply and motor temperature sensor 4 n c 5 DATA 5 Vss RI 120 Bidirectional RS485 data cable dif...

Page 109: ...pply and for the PLC Table 6 7 Pin allocation Safe halt X3 1 2 6 4 4 Field bus CAN X4 Pin Designation Value Specification 1 2 CANL 5 V Ri 60 CAN low signal line 3 GND 0 V CAN GND electrically connected to GND in the controller 4 5 Screening Connection for the cable screen 6 GND 0 V CAN GND electrically connected to GND in the controller 7 CANH 5 V Ri 60 CAN high signal line 8 9 Table 6 8 Pin alloc...

Page 110: ...ng flange is specially shaped for this Table 6 11 Pin allocation Motor connection X6 6 4 7 Power supply X9 Version on controller Counterplug Plugged optional plug set Material number Combicon 7 pin socket MSTB 2 5 7 G ST 5 08 BK Plugged 547 452 Table 6 12 Plug version Power supply X9 Pin no Designation Value Specification 1 L1 Single phase 95 255 V AC suitable for USA EU mains voltage Mains voltag...

Page 111: ...ty in accordance with RS422 4 GND Reference GND for the encoder 5 VCC 5 V 5 100 mA Auxiliary supply max load 100 mA short circuit proof 6 A CLK CW 5 V Ri 120 Incremental encoder signal A Pulse CLK Cycles clockwise CW Negative polarity in accordance with RS422 7 B DIR CCW 5 V Ri 120 Incremental encoder signal B Direction DIR Cycles counterclockwise CCW Negative polarity in accordance with RS422 8 N...

Page 112: ...the SD card 9 Baud rate 10 11 Activation of the CAN interface 12 Terminating resistor Table 6 15 Assignment of the DIP switches DIP switches ON OFF Significance 1 ON DIP switch 1 is the lowest bit 1011011 91 2 ON 3 OFF 4 ON 5 ON 6 OFF 7 ON Table 6 16 Sample node number DIP switches ON OFF Significance 9 ON DIP switch 9 is the low order bit 00 125 kBaud 01 250 kBaud example 10 500 kBaud 11 1000 kBa...

Page 113: ...e PE connection on the mains side and the screen of the encoder cable are also carried on this star point This star point must be connected to the central mass of the entire switching cabinet short cable to mounting panel using a cable with a large conductive area copper strap With greater lengths special EMC protective measures must be observed Warning All PE cables must be connected before commi...

Page 114: ... includes grids connected only to industrial plants For the CMMD AS motor controller without external filtering measures the following applies EMC class Range Compliance with EMC requirements Interference emission Second environment industrial Motor cable length up to 15 m Interference immunity Second environment industrial Regardless of motor cable length Table 6 18 EMC requirements Second enviro...

Page 115: ...h of unscreened wires 35 mm Connect total shield flat at the motor to the plug or motor housing length max 40 mm 6 5 6 Operation with long motor cables For applications with long motor cables and or if the wrong motor cables are selected with excessive cable capacity the filters may be subjected to thermal overload In order to avoid such problems we strongly recommend the following procedure for a...

Page 116: ...ock or in extreme cases death 7 2 Tools material Tool Screwdriver size 1 Serial interface cable Incremental encoder cable Motor cable Power supply cable Control cable 7 3 Connect the motor to the motor controller Connect motor 1 Insert the motor cable plug in the corresponding socket on the motor and secure it 2 Insert the PHOENIX plug into the socket X6 1 or X6 2 of the motor controller 3 Clamp t...

Page 117: ...ug of the serial interface cable into socket X5 RS232 COM of the motor controller and tighten the locking screws 3 Check all plug connectors once again 7 6 Checking readiness for operation Check operating status 1 Make sure that the controller enable switch is switched off 2 Switch on the power supplies for all devices The READY LEDs on the front of the device should now light up 3 Check the safet...

Page 118: ...ed on Holding brake released Speed Setpoint Speed actual value t1 t2 t3 DOUT0 READY t4 Output stage release t2 t2 t1 approx 500 ms Execution of boot program and application start t2 1 6 ms t3 10 ms Dependent on the operating mode and the status of the drive t4 N x 1 6 ms Can be parametrised brake parameter run start delay tF Fig 7 1 Timing diagram switch on sequence ...

Page 119: ...ler in a defined manner 8 1 2 Temperatur monitoring for motor and power section shaft encoder monitoring Faults in the shaft encoder causes the power output stage to be switched off For incremental encoders the commutator signal is checked Measurement and monitoring of the motor temperature The motor controller CMMD AS has a digital input at X6 1 2 to record and monitor the motor temperature for E...

Page 120: ... stage and in the motor Since the power loss which occurs in the power electronics and in the motor increases by its square as the current flow increases in a worst case scenario the square of the current value is usually assumed for the power loss 8 1 6 Temperature monitoring for the heat sink The heat sink temperature of the final output stage is measured with a linear temperature sensor Tempera...

Page 121: ...0 Search phase 1 Slow moving phase 2 Travel to zero position The digits are sequentially displayed E xxy Error message with index xx and sub index y xxy Warning message with index xx and sub index y Warnings are shown at least twice on the 7 segment display Table 8 1 Operating mode and error display 8 2 2 Error messages When an error occurs the CMMD AS motor controller shows a warning message cycl...

Page 122: ...r defective Check configuration of angle encoder interface Encoder signals are faulty Check installation for EMC recommendations PS off 2 Encoder supply fault 6 SINCOS RS 485 communication error 8 Internal angle encoder error 11 1 Error during homing Homing was interrupted e g by withdrawal of controller release 12 1 Communication error CAN Bus OFF The CAN chip has switched off communication due t...

Page 123: ... off 1 31 0 I t motor Motor blocked Warn 1 1 I t servo controller Check power dimensioning of drive package PS off 1 32 0 Error ZK precharge Intermediate circuit could not be loaded PS off 8 Error controller enable without ZK Power failure with granted controller release PS off 35 1 Time out for quick stop Increase Quick Stop ramp PS off 40 0 Software end position positive Warn 1 1 Software end po...

Page 124: ...ff 1 6 DeviceNet communication error Common fault PS off 1 65 0 DeviceNet assembly error PS off 1 1 DeviceNet communication error Common fault PS off 1 70 2 General arithmetic error The FHPP factor group cannot be calculated correctly PS off 3 Operating mode error Change in operating mode when output stage is released PS off 1 76 0 Error in SSIO communication master slave Common error 1 Checksum e...

Page 125: ...ee declaration of conformity CE conformity with EMC guideline see declaration of conformity Further certifications UL CSA in preparation Table A 1 Technical data Ambient conditions and qualifications Key features Values Device dimensions HxWxD 180 x 110 x 160 mm excl clip Weight approx 2 5 kg Table A 2 Technical data Dimensions and weight Area Values Maximum motor cable length for interference emi...

Page 126: ...2 1 End stage enabled bar Motor turning speed control operating mode segment rotation Positioning operation display P with alternating record number Error with number flashing error number three position A 2 2 Control elements The node number can be set via DIP switches on the front of the device 7 x node number 1x Load firmware from SD card 2 x Baud rate 1 X CAN on off 1 x Terminating resistor Th...

Page 127: ...tput current 100 mA Number 4 Output reaction time 2 ms Protective function Polarity reversal short circuit inductive load Table A 7 Technical data Digital outputs Analogue inputs Values Signal level 10 10 V Version Differential input Resolution 12 bit Input reaction time 250 µs Protective function Overvoltage up to 30 V Table A 8 Technical data Analogue inputs Analogue outputs Values Signal level ...

Page 128: ...y SCLK 1 MHz Generator supply from the controller 5 V 0 5 IA 200 mA maximum Sense line for power supply not supported Table A 10 Shaft encoder motor X2 A 3 3 CAN bus X4 Communication interface Values Protocol CANopen DS301 DSP402 and FHPP Baud rate Max 1 MBaud Terminating resistor 120 Ω can be activated via DIP switches Table A 11 Technical data CAN bus X4 A 3 4 RS232 RS485 X5 Communication interf...

Page 129: ...external filter measures are planned Output data Output data X6 1 and X6 2 Values Rated motor current 4 Aeff per axis Motor current peak 10 Aeff per axis Max output frequency 10 kHz Supply voltage for supply voltage 230 V AC 320 V Table A 13 Technical data Motor connection data X6 Brake output Key features Values Voltage range 18 30 V Output current 1 0 A Short circuit overcurrent protection 4 A T...

Page 130: ... section 16 W Table A 15 Technical data Power data X9 Note To release the holding brake the voltage tolerances at the holding brake connection terminals must be maintained Characteristics Value internal External values Braking resistance 115 50 Pulse power 1400 W 3200 W Rated output 30 W 200 W Response threshold 380 400 V 380 400 V Hysteresis 10 V 10 V Table A 16 Technical data Braking resistor X9...

Page 131: ... connection diagram 64 timing 66 N Note General 13 Security 12 Symbols 12 O Operating mode shift timing 50 P PNOZ X2P 78 PNOZ XV2P 78 Position record table 63 Positioning connection diagram 52 Positioning controller 51 R Record linking connection diagram 71 S Safe Stop 1 78 Safe Torque OFF 78 Safety instructions 12 15 Scope of delivery 11 Setpoint value selectors 50 SS1 78 timing 88 Start sequence...

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