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Festo CMMS-ST-*-G2 Series, Assembly And Installation Manual

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Festo CMMS-ST-*-G2 Series Assembly And Installation Manual Download Page 95

 

4. Functional safety engineering 

Festo.P.BE-CMMS-ST-G2-HW-EN 1008NH 

 

95 

 

Warning 

The standard motor holding brake or an external motor holding 
brake controlled by the drive controller is not suitable for 
protecting people. 

•

 

Vertical axes must be additionally secured against falling or 
sliding down when the 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. 

 

 

Note 

If EMERGENCY STOP is requested, the external brake is 
immediately switched on, if needed. 

 

 

Note 

The holding brake of the EMMS-ST-…-S

B

/-SE

B

 is not suitable for 

braking the motor and does not have a safety function. 

 

 

 

Note 

The time delay of the PNOZ relay must be adjusted for the 
application (see 

 

4.3.13). If this time delay is set too low, the drive 

performs an STO function when the time has passed and the brake 
will be worn.    

4.3.10

 

Restoration of normal operation 

Before switching it on again, make sure that all hazards have been eliminated and the 
system can be 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.  

4.3.11

 

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 checked regularly (e.g. monthly) via 
the PLC. In addition, the “Acknowledgment of driver supply” signal must be checked for 
plausibility. 

4.3.12

 

Determination of the brake time 

The brake time can easily be determined through the FCT Trace function. The brake time 
can vary greatly due to different loads. Determine the values for the maximum brake time. 
To do this, input the following settings under the point “Configure measurement data”. 

Summary of Contents for CMMS-ST-*-G2 Series

Page 1: ...Trimming On top 61 5 mm Underneath 61 5 mm Left 43 5 mm Right 43 5 mm Motor controllers Description Assembly and installation Type CMMS ST G2 Description 573 125 en 1008NH 754 125 ...

Page 2: ...4 Festo P BE CMMS ST G2 HW EN 1008NH ...

Page 3: ...AG Co KG D 73726 Esslingen Federal Republic of Germany 2010 Internet http www festo com E mail service_international festo com The copying distribution and utilization of this document as well as the communication of its contents to others without express authorization is prohibited Offenders will be held liable for the payment of damages All rights reserved in particular the right to file patent ...

Page 4: ...G Name of manual MOTOR CONTROLLERS CMMS ST C8 7 G2 G2 File name File saved in No Description Index of revisions Date of change 001 Produced 1008NH 29 07 2010 Microsoft Windows CANopen CiA and PROFIBUS are registered brands of the respective trademark owners in certain countries ...

Page 5: ...against dangerous movements 21 2 4 6 Protection against touching hot components 22 2 4 7 Protection when handling and assembling 22 3 Product description 23 3 1 General data 23 3 2 Performance characteristics 23 3 3 Interfaces 25 3 3 1 Control interfaces 25 3 3 2 Overview of interfaces 25 3 3 3 Analogue setpoint specification 26 3 3 4 Interfaces for direct synchronous operation 27 3 3 5 I O functi...

Page 6: ... control 60 3 5 11 Error messages 62 3 5 12 Behaviour when switching off enable 62 3 5 13 Oscilloscope function 64 3 5 14 Jog and teach function I O 65 3 5 15 Position record linking with positioning torque control switching 71 3 5 16 On the fly measurement 77 3 5 17 Endless positioning 77 3 5 18 Relative positioning records 78 4 Functional safety engineering 79 4 1 General remarks and intended us...

Page 7: ...ermination of the brake time 95 4 3 13 Setting the delay time 97 5 Mechanical installation 98 5 1 Important information 98 5 2 Assembly 100 6 Electrical installation 101 6 1 Device view 101 6 2 Interfaces 103 6 3 CMMS ST complete system 104 6 4 Interfaces 106 6 4 1 I O interface X1 106 6 4 2 Increment generator input X2 109 6 4 3 Plug allocation for Safe standstill X3 110 6 4 4 Field bus CAN X4 11...

Page 8: ...120 8 1 Protective and service functions 120 8 1 1 Overview 120 8 1 2 Overload current and short circuit monitoring 120 8 1 3 Voltage monitoring for the intermediate circuit 120 8 1 4 Temperature monitoring for the heat sink 120 8 1 5 I t monitoring 121 8 1 6 Power monitoring for the brake chopper 121 8 1 7 Commissioning status 121 8 2 Operating mode and error messages 121 8 2 1 Operating mode and...

Page 9: ...Festo P BE CMMS ST G2 HW EN 1008NH 9 B Glossary 134 C INDEX 135 ...

Page 10: ...rical installation and an overview of the range of functions See the following manuals on the CMMx product family for further information CANopen manual P BE CMMS CO Description of the implemented CANopen protocol as per CiA DSP 402 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 proto...

Page 11: ... technology ST Stepper motor Rated motor current C8 8 A Input voltage 7 48 V DC Configuration G2 2nd Generation 1 3 Scope of delivery The delivery includes Number Delivery 1 CMMS ST C8 7 G2 stepping motor controller 1 CD configuration software documentation S7 module GSD EDS firmware 1 Brief description 1 NEKM C 1 plug assortment Table 1 1 Scope of delivery ...

Page 12: ...rmation and remarks Caution Failure to comply can result in severe material damage Warning Failure to comply can result in material damage and personal injury Warning DANGER Considerable material 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 Environmen...

Page 13: ...alified personnel should be allowed to handle the electric systems Trained and qualified personnel For the purpose of this manual and the warning instructions on the product itself technicians working with this product must be adequately familiar with the setting up mounting commissioning and operation of the product as well as with all warnings and precautionary measures in accordance with the op...

Page 14: ...ble for safe operation of the stepping motor controller immediately If the stepping motor controller is sold rented and or passed on in any other way these safety instructions must also be passed on with it The operator may not open the stepping motor controller for safety and warranty reasons Correct planning is required for the stepping motor controller to function properly Warning DANGER Incorr...

Page 15: ...ntional movement of the motors 2 4 Safety instructions 2 4 1 General safety instructions Warning The stepping motor controller conforms to protection class IP20 and contamination class 1 Ensure that the working environment also complies with this protection contamination class Warning Use only accessories and spare parts which are approved by the manufacturer Warning In accordance with the EN stan...

Page 16: ... are not permitted if unless explicitly approved by the manufacturer See Chapter 6 5 Instructions on safe and EMC compliant installation Page 114 for the instructions for EMC compliant installation The manufacturer of the system or machine is responsible for ensuring that the limit values required by the national regulations are observed Warning See this product manual for the specifications conne...

Page 17: ...embling and maintaining the system the relevant DIN VDE EN and IEC regulations as well as all national and local safety and accident prevention regulations must always be observed The system manufacturer or the user is responsible for ensuring that the following regulations are observed Warning The stepping motor controller may only be operated maintained and or serviced by persons qualified and t...

Page 18: ...cleaning long periods out of use Warning Proceed carefully when mounting Ensure that no drilling chips metal dust or mounting material screws nuts wire cuttings fall into the stepping motor controller during mounting work and subsequent operation Ensure that the external power supply of the controller 24 V is switched off The intermediate circuit or the load voltage must always be switched off bef...

Page 19: ...mponents in these devices are always under dangerous tension Warning Dangerous voltage High voltage Danger of death or serious bodily injury due to electric shock For operation the relevant DIN VDE EN und IEC regulations as well as all national and local safety and accident prevention regulations must always be observed The system manufacturer or the user is responsible for ensuring that the follo...

Page 20: ...tion note the amount of intermediate circuit voltage especially with regard to insulation and protective measures Make sure that the earthing the cross section size of the conductor and the corresponding short circuit protection are correct 2 4 4 Protection by low voltage PELV against electric shock All connections and terminals with voltages from 5 to 60 volts on the stepping motor controller are...

Page 21: ... the drive components exclude to a large extent the possibility of incorrect operation of the connected drives With regard to the protection of human beings especially the danger of bodily injury and or material damage one must not rely on this fact alone Until the fitted monitoring functions become effective you must reckon with at least one incorrect drive movement the extent of which depends on...

Page 22: ...and assembling Handling and assembling certain components in an unsuitable manner can cause injuries under unfavourable circumstances Warning DANGER Danger of injury as a result of incorrect handling Bodily injury caused by squeezing shearing cutting impact The following safety measures apply here Warning Observe the general regulations on setting up and safety when handling and mounting Use suita...

Page 23: ...AN bus Other fieldbus systems can also be implemented via the technology module slot The parameterisation tool FCT Festo Configuration Tool makes possible simple operation and start up of the servo positioning controller Graphic depictions and pictograms make intuitive parameterisation possible 3 2 Performance characteristics Compactness Small dimensions Complete integration of all components for ...

Page 24: ...gear unit 64 Position sets 8 travel profiles Wide range of homing methods Integrated sequence control Automatic sequence of position sets without a higher level controller Linear and cyclic position sequences Adjustable delay times Waiting positions and conditional jump targets Definable stop positions for uncritical standstill points Interpolating multi axis movement With a suitable controller th...

Page 25: ...dbus DeviceNet FHPP Table 3 1 Control interfaces 3 3 2 Overview of interfaces Setpoint interface Interface Setpoint specification via Function Operating mode Reference Analogue X1 10V Analogue setpoint specification Speed control Torque control 3 3 3 Table 6 2 ff Pulse direction of interface X1 24 V Mode 3 X10 5 V CW CCW CLK DIR Synchronisation 3 3 4 Table 6 5 Table 6 14 A B signals I O mode 3 sta...

Page 26: ...P 402 Speed control Torque control Positioning control 3 4 2 Table 6 8 Table 3 2 Interfaces 3 3 3 Analogue setpoint specification The analogue setpoint specification 10VDC can be configured as setpoint specification for Speed setpoint value Torque setpoint value Required connection with analogue setpoint specification The connection plan shows the switch position in the active operating state The ...

Page 27: ...Pulse direction signals over X10 max 150 kHz 24V DC Pulse direction signals over X1 max 20 kHz Output Generation of increment generator signals X10 Based on the encoder data the motor controller generates the tracking signals A B as well as the zero pulse of an increment generator The number of lines can be set in the FCT plug in with values between 32 1024 As from FCT plug in V1 1 values up to 20...

Page 28: ...ware through selection of the control interface Synchronisation on the Application data page in the Operating modes selection tab Via X1 digital I O interface through selection of mode 3 Note With setting of synchronisation via FCT the controller only reacts via the synchronisation interface All other functions of the positioning operating mode are no longer available Note After the change of conf...

Page 29: ...tput stage enable DIN5 Controller enable DIN6 Limit switch 0 DIN7 Limit switch 1 Required I O triggering during synchronisation via mode switchover with 24 VDC frequency signals The connection plan shows the switch position in the active operating state The limit switches are set by default to opener configuration over FCT ...

Page 30: ...EN 1008NH Required I O triggering during synchronisation via mode switchover with 5 VDC frequency signals The connection plan shows the switch position in the active operating state The limit switches are set by default to opener configuration over FCT ...

Page 31: ...nt on ramps tmc x ms dependent on MC window Fig 3 1 Signal sequence with Synchronisation selection operation mode with activation of synchronisation through START DIN8 Note Starting with Firmware 1 3 0 1 7 the message Position synchronised is output at DOUT2 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 lon...

Page 32: ...eed within the set message window is reached If overshooting occurs during the catch up phase or the message window is set too low the message may come several times or flicker Starting with FW 1 3 0 1 7 the message Position synchronized is output at DOUT2 The deviation is configured via the tolerance window for Motion Complete in the FCT 3 3 5 I O functions and device control Limit switch The lim...

Page 33: ...0 Positioning Mode 1 Jog function Mode 2 Set linking Mode 3 Synchronisation Table 3 4 Mode switching 3 3 6 RS232 interface diagnosis parameterisation interface The RS232 interface is intended as a configuration interface Parameters Signal level In accordance with RS232 specification or RS 485 specification Baud rate 9600 baud to 115 kBaud ESD protection ESD protected 16 kV driver Port Null modem s...

Page 34: ...rocess or reject these received characters General commands Command Syntax Response New initialisation of the positioning controller RESET None bootup message Save the current parameter set and all position sets in the non volatile flash memory SAVE DONE Setting the baud rate for serial communication BAUD9600 BAUD19200 BAUD38400 BAUD57600 BAUD115200 Unknown command Any ERROR Read the version numbe...

Page 35: ...less than the lower limit the data were limited to the lower limit and then accepted 0x0000 0005 Data are greater than the upper limit the data were limited to the upper limit and then accepted 0x0000 0008 Data are outside the valid value range and were not written 0x0000 0009 Data are currently outside the valid value range and were not written Table 3 10 Return values Function commands Command S...

Page 36: ...etely wired null modem cable All pins of the cable must be occupied according to the following specification also see chapter 6 4 5 Pin Brief description Name Signal direction Description 1 DCD Data carrier detect Transfer device end device Data carrier signal was recorded by transfer device 2 RxD Receive x Data Transfer device end device Line at the end device that receives a data bit from the tr...

Page 37: ... For configuration the following settings are required in the Work station window On the Application Data page in the Operating Mode Settings tab set the control interface to RS 485 On the page Controller control interface do not activate the mode selection Then with the Download buttons load the changed configurations into the motor controller and save them permanently with the Save button With a...

Page 38: ...he first five characters The bootup message of the boot loader as well as the bootup message of the firmware are sent in the RS232 mode Example Profile position mode via RS 485 If the CMMS ST G2 is operated via RS 485 control can take place just as with operation via RS232 see chapter Example Profile position mode via RS232 page 38 If required the node number is simply written in front of the comm...

Page 39: ...f travel can be written via the COB 6081_00 profile velocity the final speed via the COB 6082_00 end velocity The speeds are thereby written in speed units That means they depend on the set CAN factor group The default setting here is 1 212 revolutions min 20 bit portion before the point 12 bit portion after the point Command 608100 03E80000 Speed of travel 1000 RPM The acceleration can be written...

Page 40: ...51010 0002 4 As a result the release can be granted via the CAN control word COB 6040_00 Command 604000 0006 Command Shutdown Command 604000 0007 Command Switch on Disable Operation Command 604000 000F Command Enable Operation 5 Activation of the Homing mode 6 The homing mode is activated via the COB 6060_00 Mode of Operation 7 Command 606000 06 Homing Mode 8 Start homing 9 Homing is started via t...

Page 41: ...software control The internal braking resistor is protected against overloading via software and hardware Note If the maximum braking energy of the braking resistor is exceeded the message 070 Overvoltage in intermediate circuit is output and the end stages switched off 3 3 10 Control interface X1 The control interface X1 is designed as D Sub 25 pin The following signals are available Pin Name Mod...

Page 42: ...it switch 1 Limit switch 1 Limit switch 1 23 DIN8 Start for positioning procedure Teach Start record linking Start record synchronisation 11 DIN9 High speed input 0 jog mode 1 record linking 1 slave synchronisation 24 DOUT0 Ready for operation output high active 12 DOUT1 Default motion complete output high active Speed 0 reached 25 DOUT2 Default start ack output low active Teach ack Default start ...

Page 43: ...x next for record linking step criterion DIN 10 11 Mode 3 2x pulse direction CLK DIR or CW CCW on DIN2 3 1x start sync DIN8 Table 3 15 Control interface X1 The digital inputs are designed to be configurable Mode DIN9 DIN12 Function 0 0 0 Positioning 1 0 1 Jog mode 2 1 0 Record linking 3 1 1 Synchronisation Table 3 16 Mode switching To be able to switch between different I O configurations DIN12 an...

Page 44: ...meter sets can be loaded or firmware can be downloaded A menu in the configuration software allows you to specify a set of parameters on the memory card and load it or save it Note When a parameter set is loaded from the memory card the newest parameter set is always loaded Also the parameter set can be used to specify whether firmware and or a parameter set is to be loaded from the memory card au...

Page 45: ...ce with the CiA Draft Standard Proposal DSP402 have been implemented Independent of the field bus a factor group can be used so that application data can be transferred into user specific units Required I O connection for field bus control The connection plan shows the switch position in the active operating state The limit switches are set by default to opener configuration over FCT 3 4 1 FHPP FH...

Page 46: ...ively if the CANopen protocol in accordance with CiA DS 301 with application profile CiA DSP 402 is activated then the positioning mode CiA profile position mode homing mode CiA homing mode interpolated position mode CiA interpolated position mode speed control CiA profile velocity mode and force mode CiA torque profile mode can be used Communication can take place optionally over SDOs service dat...

Page 47: ...configured over the DIP switches on the front side of the controller Baud rates up to 12MBaud are supported FHPP with the above described control and operating modes is used as communication protocol 3 4 4 DeviceNet The controller is connected to the DeviceNet network with a corresponding expansion module CAMC PB which can be plugged into the expansion slot X7 If the module is plugged in it automa...

Page 48: ...kes place up to a maximum set amount In combination with the controller CMMS ST Servo Light operation is made possible closed loop The EMMS ST SB SEB possesses an integrated holding brake 3 5 Function overview 3 5 1 Operating modes Setpoint specification via increment generator signals suitable for frequencies up to 150 kHz Analogue speed specification with 12 bit resolution Move to reference poin...

Page 49: ...X1 24V Mode3 X10 5 V CLK DIR Pulse direction signals X1 24V Mode3 X10 5 V Fieldbus Direct mode Speed adjustment Master Slave A B signals I O start synchronisation X10 X1 Mode3 I O Record selection Fieldbus Direct mode Fieldbus Record selection I O Record selection Fieldbus Direct mode Homing Fieldbus Record selection I O Jog mode Fieldbus Direct mode Positioning controller Teach in function via I ...

Page 50: ...de switchover ENABLE STOP DIN12 1 0 1 0 1 0 1 0 0 1 0 1 0 1 0 1 0 DIN9 1 0 1 DOUT0 READY DOUT1 MC DOUT2 ACK DOUT3 ERROR 2 1 1 3 4 1 t1 t1 t1 t1 t1 START t1 1 6 ms 1 Position 2 Sequences Record linking 3 Jog Teach 4 Synchronisation Fig 3 3 Timing for activation of the individual operating modes ...

Page 51: ...tpoint The speed setpoint is converted by the controller into the corresponding frequency to actuate the stepper motors The speed setpoint without the correction value is reached via a setpoint ramp Four acceleration ramps can be configured in the range of one controller cycle of up to approx 10 s The setpoint ramp can be deactivated 3 5 4 Suppression of ranges When speeds close to the mechanical ...

Page 52: ...100 the warning message 0310 I t fault motor occurs and the maximum current is limited to the rated current The I t time of the motor can be set via the FCT parameterisation software 3 5 6 Positioning controller A positioning control system is set above the current controller Up to 64 positions homing 63 positions can be selected and run via a trajectory generator There are also volatile position ...

Page 53: ...d directly You can transition to a new position record without first coming to a standstill The parameter sets can be called up via Digital inputs position record 0 63 RS232 interface for test purposes only or a Fieldbus interface Required I O connection for positioning The connection plan shows the switch position in the active operating state The limit switches are set by default to opener confi...

Page 54: ...ethods can be chosen for the homing run Run to Positive method Negative method Graphical representation Dec Hex Dec Hex Limit switch with zero pulse evaluation 2 02 1 01 Fixed stop with zero pulse evaluation 2 FE 1 FF Limit switch 18 12 17 11 Fixed stop 18 EE 17 EF Zero pulse 34 22 33 21 Save current position 35 23 35 23 Table 3 18 Homing methods ...

Page 55: ...ulse This position is saved as the reference point If configured Run at travel speed to axis zero point 2 Positive stop with index pulse Run at search speed in positive direction to stop Run at crawl speed in negative direction to next index pulse This position is saved as the reference point If configured Run at travel speed to axis zero point 17 Negative limit switch If negative limit switch ina...

Page 56: ...rence point If configured Run at travel speed to axis zero point 34 Index pulse in positive direction Run at crawl speed in positive direction to index pulse This position is saved as the reference point If configured Run at travel speed to axis zero point 35 Current position The current position is saved as the reference point If configured Run at travel speed to axis zero point Note if the refer...

Page 57: ...duct description Festo P BE CMMS ST G2 HW EN 1008NH 57 3 5 8 Timing diagrams for homing run 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 58: ...3 Product description 58 Festo P BE CMMS ST G2 HW EN 1008NH t1 1 6 ms tx x ms dependent on ramps Fig 3 5 Signal sequence with faulty interruption contour error ...

Page 59: ...selected positioning record is loaded to the trajectory generator Based on the data record loaded a necessary internal pre calculation is made The pre calculations can take from 1 6 to 5 ms The following configurable options are available for processing the start signal After a start signal is detected during a current positioning run the run continues to the target position After a start signal i...

Page 60: ...T5 Torque control was selected in the commissioning software Setpoint specification via AIN0 AGND T22 T25 T24 T23 T20 T21 T18 T19 T17 T16 T15 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 Re...

Page 61: ...tion of the homing method and configuration 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 DIN4 0 T18 Write or read request to SD card such as Load parameters Save parameters Firmware download T19 The SD card was init...

Page 62: ...error with increment generator only Homing run Overload current short circuit in the power end stage Encoder system Watchdog processor monitoring All error messages are documented in chapter 8 2 2 Error messages 3 5 12 Behaviour when switching off enable Controller enable Drive is moving 1 0 1 0 1 0 1 0 Holding brake Current carrying 1 0 DOUT READY Output stage release 1 0 tx Motor controlled ty t...

Page 63: ... 0 1 0 1 0 1 0 Holding brake current carrying 1 0 DOUT0 READY Output stage release 1 Motor controlled 0 ty t1 t 1 1 6 ms ty x ms dependent on set switch off delay Fig 3 8 Behaviour when switching off end stage enable Note The holding brake of the EMMS ST SB SEB is not suitable for braking the motor ...

Page 64: ...S ST SB SEB is not suitable for braking the motor 3 5 13 Oscilloscope function The implemented oscilloscope function is an important aid to help the commissioning party 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 an...

Page 65: ...ositive negative if there is a positive signal to the digital input The digital input DIN8 serves to take over the 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 t...

Page 66: ...And so when jog teach without FCT is used an SD card may not be plugged in or Read from SD after restart must be inactive otherwise when the controller is restarted the old values will be read off the SD card again Activating jog teach function The jog teach function is started in I O operation through selection of mode 1 ...

Page 67: ...Festo P BE CMMS ST G2 HW EN 1008NH 67 Necessary I O connection with jog teach The connection plan shows the switch position in the active operating state The limit switches are set by default to opener configuration over FCT ...

Page 68: ...1008NH Settings in the FCT The parameters set here are valid for jogging via I O interface jogging via FCT and for jogging teaching via field bus if no other values are specified via the field bus The acceleration also applies with individual step via FCT ...

Page 69: ...3 Product description Festo P BE CMMS ST G2 HW EN 1008NH 69 I O timing diagrams t1 1 6 ms tx x ms dependent on brake ramps Fig 3 10 Signal sequence with jogging positive and negative ...

Page 70: ...IN10 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 t 1 1 6 ms tx x ms dependent on brake ramps Fig 3 11 Signal sequence when both signals are activated simultaneously briefly staggered ...

Page 71: ...d in a sequence These positions are travelled to one after another The characteristics of positioning record linking are All 63 position records of the position record table can be set Besides linear sequences ring shaped linkages are also allowed endless linkage For each step a free following position can be set As step criterion 2 digital inputs are available as NEXT 1 and NEXT 2 There are 7 pos...

Page 72: ...rogrammed time for bridging the acceleration phase has expired Standstill here does not just mean the end of the position record MC but also running to the 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 imm...

Page 73: ...files with end speed 0 Note Position record profiles that contain an end speed 0 must NOT be used for individual records since the drive would continue to run uncontrolled Activation of record linking Record linking is started in I O operation through selection of mode 2 ...

Page 74: ...figuration 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 switchover 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 linking...

Page 75: ...ng 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 t 1 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 with DIN0 DIN2 positioning record 1 7 ...

Page 76: ...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 t1 t1 1 6 ms tx x ms dependent on brake ramps Fig 3 14 Signal sequence with interruption through Stop input t1 1 6 ms tx x ms dependent on brake ramps Fig 3 15 Signal sequence with interruption and continuation through HALT input ...

Page 77: ...tored is selected The On the Fly Measurement function supports continuous sampling i e the configured edge is monitored and the stored actual position values are overwritten with each sample event 3 5 17 Endless positioning For applications such as synchronised conveyor belt or rotary indexing table endless positioning is possible in one direction via relative positioning records No endless positi...

Page 78: ...ctivated 3 5 18 Relative positioning records When using relative positioning records observe the following The controller is a 16 bit controller That means the controller calculates internally with 65536 increments per revolution The controller 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 num...

Page 79: ...hine manufacturer must carry out a risk assessment as per the EC machinery directive 2006 42 EC On the basis of this risk assessment the machine manufacturer must design the safety system for the entire machine including all integrated components This also includes the electric drives The new EN ISO 13849 standard uses a changed risk graph for risk assessment and a deviating principle to achieve t...

Page 80: ...efinition EN 60204 1 Danger case EMERGENCY OFF Electrical safety in case of emergency by switching off the electrical energy to all or part of the installation EMERGENCY OFF is to be used where a risk of electric shock or other electrical risk exists EMERGENCY STOP Functional safety in an emergency by bringing a machine or movable parts to a standstill EMERGENCY STOP is used to stop a process or a...

Page 81: ... to X2P Fixed or adjustable relapse delay Cancelling the time delay via Reset button 1 or comparable safety switch device with corresponding safety contacts Table 4 2 Overview of the safety function in accordance with EN 61800 5 2 An overview of the various stop categories is provided by the Table 4 3 Stop category Type Handling 0 Uncontrolled shutdown through immediate switching off of the energy...

Page 82: ... manner after at most 3 2 ms At the same time the automatic brake control is activated If you use motors with a holding brake each STO disconnection places wear and tear on the brake Therefore use the SS1 function for STO motors without holding brakes A description of the SS1 function can be found in the next chapter 4 3 Application examples for the STO function are manual actions during setup cha...

Page 83: ...4 Functional safety engineering Festo P BE CMMS ST G2 HW EN 1008NH 83 4 2 2 STO timing diagram tx 1 6 ms controller cycle time Fig 4 2 Timing diagram for the STO safety function ...

Page 84: ...tact opens the H on the display goes out at time t3 5 The time for the end stage enable X1 DIN4 is largely freely selectable t4 t1 The enable may occur at the same time as the relay is controlled but it must occur approx 10 祍 t5 t4 before the rising edge of the controller enable X1 DIN5 depending on the application 6 The rising edge of the controller enable at time t5 releases the motor holding br...

Page 85: ...4 Functional safety engineering Festo P BE CMMS ST G2 HW EN 1008NH 85 4 2 3 CMMS ST STO sample circuit Fig 4 3 Circuit diagram for STO safety function with CMMS ST G2 ...

Page 86: ...moval of the end stage enable and disconnection of the driver supply via X3 Pin 2 The unintended opening of the protective doors 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 Pin 5 and 6 is closed At least 30 ms after the potential free acknowledgment contact closes an H is displayed on the 7 segmen...

Page 87: ... safety engineering Festo P BE CMMS ST G2 HW EN 1008NH 87 Fig 4 4 Safe Torque Off block diagram as per EN 61508 SIL 2 Caution If the Safe torque off function is not required then pins 1 and 2 on X3 must be bridged ...

Page 88: ...or error detection of the impulse block and also for suppressing error message E 05 2 Driver supply undervoltage which occurs in normal operation Potential free acknowledgment contact The integrated Safe torque off circuit also has a potential free acknowledgment contact X3 Pin 5 and 6 for the presence of the driver supply This is an N C contact It must be connected to the higher order controller ...

Page 89: ...ring Festo P BE CMMS ST G2 HW EN 1008NH 89 4 3 2 SS1 timing diagram Fig 4 5 Timing diagram for the SS1 safety function tv t PNOZ XV2p The switch off delay tv takes off as soon as a standstill is recognised by the motor controller ...

Page 90: ...ly relay control 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 end stage enable X1 DIN4 is largely freely selectable t4 t1 The enable may occur at the same time as the relay is controlled but it must occur approx 10 祍 t5 t4 before the rising edge of the ...

Page 91: ...ime the internal 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 the Safe torque off can now be activated driver supply relay and end stage enable switched off at the same time Time t11 t10 depends on the application ...

Page 92: ...4 Functional safety engineering 92 Festo P BE CMMS ST G2 HW EN 1008NH 4 3 6 Parameterisation example FCT Fig 4 6 Parameterisation example ...

Page 93: ...4 Functional safety engineering Festo P BE CMMS ST G2 HW EN 1008NH 93 4 3 7 CMMS ST G2 SS1 sample circuit Fig 4 7 Circuit diagram for SS1 safety function with CMMS ST G2 ...

Page 94: ...uces the ramp function of the controller The controller brakes with the set Quick Stop delay After reaching a speed of 0 the drive is controlled at this setpoint value for a parameterisable switch off delay time ty This adjustable time is the delay required 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 ...

Page 95: ...n STO function when the time has passed and the brake will be worn 4 3 10 Restoration of normal operation Before switching it on again make sure that all hazards have been eliminated and the system can be 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 11 Testing the safety function For each on off ...

Page 96: ... so determine the brake time from the measurement curve This is stored under the point Measurement data Note FCT PlugIn version V1 0 The maximum time until the drive is at speed 0 after the controller enable is removed is 499 2 ms If this time is exceeded the Quick Stop delay must be set to a higher value FCT PlugIn version V1 1 The maximum time until the drive is at speed 0 after the controller e...

Page 97: ...ead brake time 210 ms Fig 4 9 Typical measurement curve for determining the brake time 4 3 13 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 the determined brake time Otherwise the drive would not brake in the defined manner but run out uncontrollably ...

Page 98: ...r as an integrated device for control cabinet assembly only The mounting position is vertical with the power supply lines X9 leading upwards Mount with the clip to the control cabinet plate Mounting clearance For sufficient ventilation 100 mm of clearance to other assemblies is required above and below the device Pay attention to the fastening interval of 69 mm ...

Page 99: ...5 Mechanical installation Festo P BE CMMS ST G2 HW EN 1008NH 99 Fig 5 1 CMMS ST stepping motor controller Installation clearance ...

Page 100: ...motor controller They are used to attach the stepping motor controller vertically to a control cabinet mounting plate The clips are part of the radiator profile ensuring an optimal heat transfer to the control cabinet plate Use size M4 screws to attach the CMMS ST stepping motor controller Fig 5 2 CMMS ST stepping motor controller Assembly ...

Page 101: ...o P BE CMMS ST G2 HW EN 1008NH 101 6 Electrical installation 6 1 Device view 1 Status display 2 S1 Field bus settings and boot loader 3 Technology module optional 4 M1 SD memory card 5 X4 CAN bus 6 X5 RS232 485 Fig 6 1 CMMS ST view ...

Page 102: ...6 Electrical installation 102 Festo P BE CMMS ST G2 HW EN 1008NH 1 Earthing bolt 2 X9 Power supply 3 X10 Increment generator interface 4 X1 I O interface Fig 6 2 CMMS ST top view ...

Page 103: ...ower output stage is connected to contacts ZK and 0 V The motor is connected with the four terminals A B The connection of the optional shaft encoder via the d sub plug to X2 is illustrated in the diagram Fig 6 4 The CMMS ST stepping motor controller must first be fully wired Only then can the operating voltages be activated for the intermediate circuit and the power supply If the polarity of the ...

Page 104: ... in Fig 6 4 The following components are required to operate the stepping motor controller Components Power pack for the control voltage Power pack for the power supply Stepper motor controller CMMS ST Motor with motor cable Increment generator cable for motors with increment generators A PC with a serial connection cable is required for parameterising ...

Page 105: ...ation Festo P BE CMMS ST G2 HW EN 1008NH 105 1 Main switch 2 Fuse 3 Power pack for control voltage 4 Power pack for power supply 5 CMMS ST 6 PC 7 Motor Fig 6 4 Complete structure of CMMS ST with motor and PC 7 4 1 2 3 5 6 ...

Page 106: ...e output for setpoint potentiometer 5 Unassigned 6 GND24 Reference potential for digital inputs and outputs 7 DIN1 Record selection 1 high active 8 DIN3 Record selection 3 high active 9 DIN5 Controller enable high active 10 DIN7 Limit switch 1 11 DIN9 High speed input 12 DOUT1 24 V 100 mA Output freely programmable Default Motion complete high active 13 DOUT3 24 V 100 mA Output freely programmable...

Page 107: ...imit switch 1 11 DIN9 Mode switch 0 12 DOUT1 24 V 100 mA Output freely programmable default motion complete high active 13 DOUT3 24 V 100 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 4 Analogue monitor output 0 18 24 V 24 V 100 mA 24 V supply carried out 19 DIN...

Page 108: ... 24 V 100 mA 24 V supply carried out 19 DIN0 Record selection 0 high active 20 DIN2 Record selection 2 high active 21 DIN4 End stage enable high active 22 DIN6 Limit switch 0 23 DIN8 Start record linking 24 DOUT0 24 V 100 mA Ready for operation output high active 25 DOUT2 24 V 100 mA Output freely programmable default start ack high active Table 6 4 Pin allocation I O interface X1 Mode 2 Pin Name ...

Page 109: ...mA Setpoint reached output high active Table 6 5 Pin allocation I O interface X1 Mode 3 6 4 2 Increment generator input X2 Pin Name Value Specification 1 A 5 V Ri 120 Ohm Increment generator signal A positive polarity 2 B 5 V Ri 120 Ohm Increment generator signal B positive polarity 3 N 5 V Ri 120 Ohm Increment generator zero pulse N positive polarity 4 GND Reference GND for the encoder 5 VCC 5 V ...

Page 110: ...ntact 6 NC2 Max 60V AC 30V DC 2 A Table 6 7 Pin allocation Safe standstill X3 6 4 4 Field bus CAN X4 Pin Name Value Specification 1 2 CANL 5 V Ri 60 Ohm CAN low signal line 3 GND CAN GND electrically connected to GND in the controller 4 5 Screening Connection for the cable screen 6 GND CAN GND electrically connected to GND in the controller 7 CANH 5 V Ri 60 Ohm CAN high signal line 8 9 Table 6 8 P...

Page 111: ...e two motor strings The cable screen is fitted to the controller housing 5 T 6 T Motor temperature sensor either N C contact or PTC in preparation 7 BR 8 BR Motor holding brake 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 3 pin socket MSTB 2 5 3 ST 5 08 BK Plugged 547 452 Table 6 12 Plug ver...

Page 112: ...ro pulse N Positive polarity acc to 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 5 V Ri 120 Ohm Increment generator signal A Pulse CLK Clockwise cycles CW Negative polarity as per RS422 7 B DIR 5 V Ri 120 Ohm Increment generator signal B Direction DIR Anticlockwise cycles CCW Negative polarity as per RS422 8 N 5 V Ri 120 ...

Page 113: ...the SD card 9 10 Baud rate 11 Activation of the CAN interface 12 Terminating resistor Table 6 15 Assignment of the DIP switches DIP switches ON OFF Meaning 1 ON 2 ON 3 OFF 4 ON 5 ON 6 OFF 7 ON DIP switch 1 is the lowest bit 1011011 91 Table 6 16 Sample node number DIP switches ON OFF Meaning 9 ON 10 OFF Dip switch 9 is the low value bit 00 125 kBaud 01 250 kBaud example 10 500 kBaud 11 1000 kBaud ...

Page 114: ...the following components Components Power supply Stepper motor controllers Motor Electromechanical components Design and type of wiring Higher order control system In order to increase the interference immunity and decrease the interference emission the CMMS ST already has integrated motor throttles and mains filters which means that the CMMS ST stepping motor controller can be operated without ad...

Page 115: ... cable is fitted to the housing of the CMMS ST stepping motor controller screen connection terminals The cable screen is also always fitted to the corresponding stepping motor controller to prevent leaked current flowing back to the controller which caused it 4 Signal lines must be separated as far as possible from the power cables They should not be routed parallel to one another If crossovers ca...

Page 116: ...se contact your motor cable vendor if necessary Use of a dU dt filter on the motor output Filter on the voltage supply connection Mains filter 6 5 6 ESD protection Caution If non assigned plug connectors are used there is a danger that damage may occur to the device or to other parts of the system as a result of ESD electrostatic discharge Protective caps are available from specialised retailers t...

Page 117: ...damage injury electric shock or in extreme cases even to fatalities 7 2 Tools material Tools Slotted head screwdriver Phillips screwdriver Serial interface cable Increment generator cable Motor cable Power supply cable Control cable 7 3 Connecting the motor Connecting the motor 1 Insert the motor cable plug in the corresponding socket on the motor and secure it 2 Insert the PHOENIX plug into the s...

Page 118: ...r the CMMS ST stepping motor controller and secure the locking screws 3 Check all plug connectors once again 7 6 Checking readiness for operation Checking readiness to operate 1 Make sure that the controller enable switch is switched off 2 Switch on the power supplies for all devices The READY LED on the front of the device should now light up If the READY LED does not light up there is a fault If...

Page 119: ...eed Setpoint Speed actual value t1 t2 t3 t4 a b Output stage release t2 DOUT0 READY t1 approx 500 ms Execution of boot program and application start t2 1 6 ms t3 10 ms Depends on the operating mode and the state of the drive t4a N x 1 6 ms Can be parameterised brake parameter run start delay tF t4b approx 300 ms Time for determination of commutator position Fig 7 1 Timing diagram switch on sequenc...

Page 120: ...e 24 V supply voltage fails approximately 20 ms remain to save parameters and shut down the controller in a defined manner 8 1 2 Overload current and short circuit monitoring The overload current and short circuit monitoring is triggered as soon as the current in the intermediate circuit exceeds twice the maximum current of the controller It detects short circuits between two motor phases and shor...

Page 121: ...ed before it is commissioned again at the customer s premises The configuration software queries the commissioning status and prompts the user to configure the stepping motor controller At the same time the device indicates that it is ready for operation but has not yet been configured by displaying A on the 7 segment display 8 2 Operating mode and error messages 8 2 1 Operating mode and error dis...

Page 122: ...res for the error messages are compiled in the table below Error message Main index Sub index Meaning of error message Measures Error reaction 01 0 Stack overflow Wrong firmware Reload standard firmware if necessary Contact Technical Support PS off 02 0 Undervoltage in intermediate circuit Undervoltage monitoring is configured using the FCT Measure intermediate circuit voltage Check configuration ...

Page 123: ...ted e g by withdrawal of controller enable or by a limit switch 12 2 CAN communication error Common error 1 Error when sending a message e g no bus connected 2 Timeout when receiving the SYNC messages in interpolated position mode PS off 1 14 9 Motor identification fault Error when automatically determining the motor parameters 2 Initialisation fault Error initialising the default parameters 16 3 ...

Page 124: ...g SD card Warn 1 1 SD initialisation error Error on initialisation communication not possible PS off 1 29 2 SD parameter record error Checksum incorrect File missing Incorrect file format Error when saving the parameter file to the SD card PS off 1 0 I t motor I t at 100 I t monitoring of the motor has responded motor mechanical system blocked or sluggish Warn 1 31 1 I t controller I t at 100 I t ...

Page 125: ... too small for the maximum velocity permitted Risk of computational overrun in trajectory calculation PS off 0 Limit switch error Negative hardware limit switch reached Check parameters wiring and limit switches 1 Limit switch error Positive hardware limit switch reached Check parameters wiring and limit switches 43 9 Limit switch error Both hardware limit switches active at the same time Check pa...

Page 126: ...ion module is attempting to read an unknown KO Unknown DeviceNet error PS off 1 DeviceNet initialisation error DeviceNet extension module initialisation error Node number exists twice 65 1 DeviceNet communication error IO connection timeout PS off 1 2 General arithmetic error The FHPP factor group cannot be calculated correctly PS off 70 3 Operating mode error Prohibited change of operating mode e...

Page 127: ...8NH 127 Error messages can be acknowledged by the configuration interface the field bus control word a falling edge at DIN5 controller enable Note Starting with Firmware 1 3 0 1 7 errors that are parameterised as warnings are automatically acknowledged if the cause is no longer present ...

Page 128: ...th low voltage guideline EMC law Current oscillations EN 50 178 EN 61 800 3 EN 61 000 3 2 Further certifications UL CSA Specifications on EN ISO 13849 1 PL performance level d MTTFd Mean Time To Failure dangerous Channel 1 switching off PWM signals via X1 Channel 2 switching off driver supply via X3 617 06 years 2853 88 years PFH Probability of Failure per Hour 8 32 x 10 8 Table A 1 Technical data...

Page 129: ...or N C contact Rcold 1 kΩ Rhot 10 kΩ Analogue sensor Silicon temperature probe e g KTY81 84 R25 1 kΩ or R25 2 kΩ Table A 5 Technical data Motor temperature monitoring in preparation A 2 Operation and display components The CMMS ST stepping motor controller has two LEDs on the front and one seven segment display for showing the operating status Element Function Seven segment display Displays the op...

Page 130: ...gic supply Output current 100 mA Number 4 Output reaction time 2 ms Protective function Polarity reversal short circuit inductive load Table A 8 Technical data Digital outputs Analogue inputs Values Signal level 10 10 V Configuration Differential input Input reaction time 250 μs Protective function Overvoltage to 30 V Table A 9 Technical data Analogue inputs Analogue outputs Values Signal level 0 ...

Page 131: ... differential RS422 Angle resolution Max 12 bit Number of lines of the increment generator 500 Limit frequency 100 kHz Encoder supply 5 V 5 100 mA Table A 12 Increment generator input X2 A 3 3 CAN bus X4 Communication interface Values Signal level 2 V Protection 3 24 V Protocol CANopen CiA DS 301 CiA DSP 402 and FHPP Baud rate Max 1 MBaud Terminating resistor 120 Ω Table A 13 Technical data CAN bu...

Page 132: ...J 150 C Loads R 24 Ω L approx 10 H C 10 nF Switching delay 1 ms Table A 16 Technical data Holding brake A 3 6 Power supply X9 Features Values Load supply voltage 48 VDC Alternative DC supply 24 48 VDC Nominal input current 8 A Minimum intermediate circuit voltage 12 48 V configurable Control section supply voltage 24 VDC 20 Control section nominal current 0 2 A Maximum current incl holding brake 1...

Page 133: ... Table A 18 Technical data Internal braking resistor X9 A 3 7 Increment generator interface X10 Increment generator interface Values Operating modes A B or CLK DIR input signals A B N output signals Angle resolution number of lines 32 2048 Tracking signals According to RS422 standard Output impedance 120 Ω Table A 19 Increment generator interface X10 ...

Page 134: ...mmunity Sufficient interference immunity of an electrical system or electrical device against external electrical magnetic or electromagnetic noise via lines or space Interference emission Sufficiently low interference emission of electrical magnetic or electromagnetic interference of an electrical system or an electrical device on other devices in the environment via lines and space ...

Page 135: ...F FCT 23 FHPP Documentation 10 Field bus control I O connection 45 Firmware download 44 Frequency ranges 51 Frequency signals A B 25 CLK DIR 25 CW CCW 25 G Glossary 134 EMC Interference emission 134 Interference immunity 134 EMC 134 H Holding brake 48 63 64 111 Homing run timing 57 I I O connection analogue setpoint specification 26 field bus control 45 jog teach 67 positioning 53 record linking 7...

Page 136: ...ection 53 Positioning controller 52 PROFIBUS Documentation 10 R Record linking I O connection 74 timing 75 Resonance 51 S Safe Stop 1 81 Safe Torque OFF 81 Safety instructions 12 15 Scope of delivery 11 SS1 81 Step criteria 72 STO 81 Stop category 81 Switching off of enable timing 62 Switch on sequence timing 119 Synchronisation 27 activate 28 I O connection 29 30 timing 31 T Timing homing run 57 ...

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