Control Techniques FM-3 Reference Manual

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FM-3 Programming Module

Reference Manual

P/N 400508-01

Revision: A8

Date: March 10, 2004

FM-3

Programming Module

Reference Manual

Information furnished by Control Techniques Drives Inc. (Control Techniques) is believed to be accurate and reliable. However, no responsibility is assumed by Control Techniques for its use. Control Techniques reserves the right to change the design or operation of the equipment described herein and any associated motion products without notice. Control Techniques also assumes no responsibility for any errors that may appear in this document. Information in this document is subject to change without notice.

P/N 400508-01

Revision: A8

Date: March 10, 2004

© Control Techniques Drives, Inc. 2000-2004 Part Number: 400508-01 Revision: A8 Date: March 2004 Printed in United States of America Information in this document is subject to change without notice. No part of this document may be

reproduced or transmitted in any form or by any means, electronic or mechanical, for any purpose, without the express written permission of Control Techniques.

The following are trademarks of Control Techniques and may not be reproduced in any fashion without written approval of Control Techniques: EMERSO N M otion Control, EMERSON Motion Control PowerTools, AXIMA, “Motion Made Easy.”

Control Techniques is a division of EMERSON Co. Control Techniques, Inc. is not affiliated with Microsoft Corporation, owner of the Microsoft,

Windows, and Windows NT tradema rks.

This document has been prepared to conform to the current released version of the product. Because of our extensive development efforts and our desire to further improve and enhance the product, inconsistencies may exist between the product and documentation in some instances. Call your customer support representative if you encounter an inconsistency.

Customer Support

Control Techniques 12005 Technology Drive Eden Prairie, Minnesota 55344-3620 U.S.A.

Telephone: (952) 995-8000 or (800) 893-2321 It is Control Tech niques’ goal t o ensure yo ur greatest possible satis faction with the operation

of our products. We are dedicated to providing fast, friendly, and accurate assistance. That is why we offer you so many ways to get the support you need. Whether it’s by phone, fax or modem, you can access Control Techniques support information 24 ho urs a day, seven days a week. Our wide range of services include:

FAX (952) 995-8099

You can FAX questions and comments to Control Techniques. Just send a FAX to the number listed above.

Website and Email www.emersonct .com

Website: www.emersonct.com Email: info@emersonct.com If you have Internet capabilities, you also have access to technical support using our website.

The website includes technical notes, frequently asked questions, release notes and other technical documentation. This di rect technical suppo rt connection lets you request assistance and exchange software files electronically.

Technical Support (952) 995-8033 or (800) 893-2321

Email: service@emersonct.com Control Techniques’ “Motion Made Easy” products are backed by a team of professionals

who will service your installation. Our technical support center in Eden Prairie, Minnesota is ready to help you solve those occasional prob lems over the telephone. Our techni cal support center is available 24 hours a day for emergency service to help speed any problem solving. Also, all hardware replacement parts, if needed, are available through our customer service organization.

When you call, please be at your computer, with y our documen tation easily available, and b e prepared to provide the following information:

• Product version number, found by choosing About from the Help menu

• The type of controller or product you are using

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• Exact wording of any messages that appear on your screen

• What you were doing when the problem occurred

• How you tried to solve the problem Need on-site help? Control Techniques provides service, in most cases, the next day. Just call

Control Techniques’ technical support center when on-site service or maintenance is required.

Training Services (952) 995-8000 or (800) 893-2321

Email: training@emersonct.com Control Techniques maintains a highly trained s taf f of ins tructo r s to familiarize customers

with Control Techniqu es’ “Motion Made Easy” prod ucts and their applicatio ns. A number of courses are offered, many of which can be taught in your plant upon request.

Application Engineering (952) 995-8000 or (800) 893-2321

Email: applengr@emersonct.com An experienced staff of factory application engi neers provides complete customer support for

tough or complex applications. Our engineers offer you a broad base of experience and knowledge of electronic motion control applications.

Customer Service (Sales) (952) 995-8000 or (800) 893-2321

Email: customer.service@emersonct.com Authorized Control Techniques distributors may place orders directly with our Customer

Service department. Contact the Customer Service department at this number for the distributor nearest you.

Document Conventions

Manual conventions have been established to help you learn to use this manual quickly and easily. As much as possible, these conventions correspond to those found in other Microsoft® Windows® compatible software documentation.

Menu names and options are printed in bold type: the File menu. Dialog box names begin with uppercase letters: the Axis Limits dialog box. Dialog box field names are in quotes: “Field Name.” Button names are in italic: OK button. Source code is printed in Courier font: Case ERMS.

In addition, you will find the following typographic conventions throughout this manual.

This Represents

bold

italic

ALL CAPITALS Directory names, file names, key names, and acronyms. SMALL CAPS Non-printable ASCII control characters. KEY1+KEY2

example: (Alt+F) KEY1,KEY2

example: (Alt,F)

Characters that you must type exactly as they appear. For example, if you are directed to type a:setup, you should type all the bold characters exactly as they are printed.

Placeholders for information you must provide. For example, if you are directed to type filename, you should type the actual name for a file instead of the word shown in italic type.

A plus sign (+) between key names means to press and hold down the first key while you press the second key.

A comma (,) between key names means to press and release the keys one after the other.

Note

For the purpose of this manual and p roduct , “Note” indicates essential inform ation about the product or the respective part of the manual.

EN Only

For the purpose of thi s manual and product , the “EN” symbol indicates information about the EN drive specifically.

Throughout this manual, the word “drive” refers to an EN or MDS drive.

“Warning” indicates a potentially hazard ous situation that, if not av oided, co uld result in death or serious injury.

“Caution” indicates a potentially hazardous situation that, if not avoided, may result in minor or moderate injury.

“Caution” used without the safety alert symbol indicates a potentially hazardous situation that, if not avoided, may result in property damage.

Safety Instructions

General Warning

Failure to follow safe installation guidelines can cause death or serious injury. The voltages used in the product can cause se vere electric shock and/or burns and could be lethal . Extreme care is necessary at all times when working with or adjacent to the product. The installation must comply with all relevant safety legislation in the country of use.

Qualified Per s on

For the purpose of this manual and product, a “qualified person” is one who is familiar with the installation, construction and operation of the equipment and the hazards involved. In addition, this individual has the following qualif ications:

• Is trained and authorized to energize, de-energize, clear and ground and tag circuits and equipment in accordance with established safety practices.

• Is trained in the proper care and use of protective equipment in accordance with established safety practices.

• Is trained in rendering first aid.

Reference Materials

The following related reference and installation manuals may be useful with your particular system.

• Function Module Installation Manual (P/N 400506-03)

• Epsilon Eb and EN Drives Reference Manual (P/N 400501-01)

• PowerTools Software User’s Guid e (P/N 400503-01)

• FM-3 and FM-4 Connectivity Modules Reference Manual (P/N 400508-04)

• Modular Drive System (MDS) Reference Manual (P/N 400525-01)

Safety Precautions

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

You should give close attention to the electrical installation and system design to avoid hazards either in normal op eration or in the event of eq uipmen t malf unction . Sy stem des ign, installation, commiss ionin g and mainten ance mu st be carri ed out b y perso nnel who hav e the necessary training and experience. Read and follow this safety information an d the instruction manual carefully.

Enclosure

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

Safety Considerations

Setup, Commissioning and M aintenance

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

Safety of Machinery

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

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

General warning

Failure to follow safe installation guidelines can cause dea th or seriou s injury. The voltage s used in this unit can cause severe electric shock and/or burns, and could be lethal. Extreme care is necessary at all times when work ing with or a djacent to th is equipment. T he installatio n must comply with all

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relevant safety legislation in the country of use.

AC supply isolati on device

The AC supply must be removed from the drive using an approved isolation device or disconnect before any servicing work is performed, other than adjustments to the settings or parameters specified in the manual. The driv e contain s capacitors whi ch remain charged to a poten tially lethal voltage after the supply has been removed. Allow at least 3 mi nutes after removing the suppl y before carrying out any work whic h may involve contact with electrical connections to the drive.

Products connected by plug and socket

A special hazard may exist where the drive is incorporated into a product which is connected to the AC supply by a plug and socket. When unplugged, the pi ns of the plug may be connected to the drive input, which is only separated from the charge stored in the bus capacitor by semiconductor devices. To avoid any possibility of electric shock from the pins, if they are accessible, a means must be provided for automatically disconnecting the plug from the drive (that is, a latching contactor).

Grounding (Earthing, equipotential bonding)

The drive must be grounded by a conductor sufficient to carry all possible fault current in the event of a fault. The ground connections shown in the manual must be followed.

Fuses

Fuses or over-current protection must be provided at the input in accordance with the instructions in the manual.

Isolation of control circuits

The installer must ensure that t he external control circuits are isolated from human contact by at least one layer of insulation rated for use at the applied AC supply voltage.

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Table of Contents

Introduction 1 Operational Overview 3

Software Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

PowerTools Pro Setup Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Keypad Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

How Motion Works. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

How Jogging Works . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

How Home Works. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

How Indexes Work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

How Communications Work. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Brake Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Setting Up Parameters 31

Setup View. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Status Online Tab (Online Only). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Information Tab (Online Only). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

User Units View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Master Units View. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Position View. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Velocity View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Ramps View. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Torque View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Tuning View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Faults View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

PLS View. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Setup NVM View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

User Variables View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

User Bits View. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

I/O Setup Group. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

Assignments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

Assignments View. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

Selector View. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

Input Lines View. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

Output Lines View. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

Analog Inputs View. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

Motion Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

Jog View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

Home View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

Index View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

Gearing View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

Stopping Motion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

Network Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

Modbus View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

DeviceNet View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

Profibus View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

Ethernet View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

Programming 115

Program Toolbar Icons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

Programs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119

Program Instruction Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119

Adding and Deleting Programs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131

Run Anytime Programs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132

Example Programs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134

Parameter Descriptions 143 Installation 183

Basic Installation Notes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183

Mechanical Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183

Software Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185

Starting and Exiting PowerTools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186

Accessing Help . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187

Quick Start 189

Basic Setup Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189

Example Application Start Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205

Tuning Procedures 213

PID vs. State-Space. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213

Tuning Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214

Tuning Parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216

Determining Tuning Parameter Values. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218

Diagnostics and Troubleshooting 225

Diagnostic Display. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225

Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226

Analog Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234

Diagnostic Analog Output Test Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236

Drive Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238

Error Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238

Programming Error Messages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240

Online Status Indicators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245

Specifications 249

Dimensions and Clearances. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249

Cable Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251

Glossary 265 Index 273

xii

FM-3 Programming Module Reference Manual

Introduction

The FM-3 module is a compact and rugged function module that attaches to the front of the drive. It provides eight digital input lines and four digital output lines, in addition to the four input and three output lines available on the drive.

Unlike other function modules, the FM-3 module offers complex motion profiling. A complex motion profile consists of two or more indexes that are executed in sequence such that the final velocity of each index except the last is non-zero. Logical instructions between index statements can provide a powerful tool for altering motion profiles "on the fly". The FM-3 module defines complex motion by a configuration file that includes setups, function

assignments and programs . The configuration file is created using PowerTools Pro software Setup views have the same look and feel as dialog boxes. The wiring of input and output functions is done through assignments in the software. PowerTools Pro is an easy-to-use Microsoft® Windows® based setup and diagnostics tool.

Figure 1: EN Drive with FM-3 Function Module

Note that the drive’s firmware is disabled whenever a Function Module such as the FM-3 module is attached. Therefore, if the drive’s hardware is FM compatible, then the drive’s firmware can be any version because the programming features reside in the function module’s flash memory. Flash files used fo r firmware up grad es are available on the Control Techniques webpage.

The FM-3 module stores drive setup parameters within the module itself. This allows you to transfer the FM-3 module to another drive without losing setup parameters.

1.In this manual, Emerson Motion Control PowerT ools Pro software will be refer red to as PowerTools Pro.

FM-3 Programming Module Reference Manual

Figure 2: FM-3 Programming Module Features

FM-3 Programming Module Reference Manual

Operational Overview

This section provides a complete functional description of the FM-3. It is intended to provide you with a thorough understanding of all operations. The description includes references to many FM-3 module and drive parameters which can be displayed and/or edited using PowerTools Pro software, or through any Modbus interface.

The FM-3 module augments the drive by providing the ability to implement programs written using PowerTools Pro. When a FM-3 module is attached to an drive, it overrides the operation and user accessible features o f the d rive. The drive’s basic operating modes (Pulse, Velocity and Torque) are not available when a F M-3 module is attached.

The FM-3 module stores drive setup parameters within the module itself. This allows you to transfer the FM-3 module to another drive without losing setup parameters.

The FM-3 module allows you to set up 55 different indexes, Jog functions and mult iple Homes. It also provides eight digital input lines and four digital output lines in addition to the four input and three output lines available on the drive.

Software Interface

The FM-3 module is set up using PowerTools Pro software. PowerTools Pro is an easy-to-use Windows® based setup and diagnost ics tool. It provides you with the ability to create, edit and maintain your drive’s setup. You can download or upload your setup data to or from a device. You can also save it to a file on your PC or print it for review or permanent storage.

PowerTools Pro Setup Software

PowerTools Pro is designed to be the easiest to use software available for single axis motion controllers.

Features

• “Hierarchy View” for quick navigation to any setup screen

• Simple I/O function assignments

• Powerful online diagnostic capabilities

•Programming

FM-3 Programming Module Reference Manual

Figure 3: Hierarchy View

The “Hierarchy View” (sho wn above) contains expa ndable groups of parameters. The groups can be expanded and contracted just like folders in Windows Explorer. Left clicking on a view name in the Hierarchy view dis plays that View on the right side of the comp uter scr een.

To setup a drive the user simply steps through the Hierarchy View from top to bottom. Simple applicati ons can be set up in a matt er of mi nutes. Many of t he views have Assignm ent tabs that display t he assignments pertaining to the view (i.e. on the Positio n view, the position assignments are displayed).

Keypad Interface

The keypad on the f ront of the FM-3 module provides navi gation through a menu of common parameters and displays of current functions. Navigation through the menu is accomplished with the six keys located below the display. The top two keys are called the "soft keys" because they relate to the comm ands located directly above each key on the LCD. These keys are used to select the operation (e.g. Mo dify, Ok, Cancel), parameter grou p, and/or to validate information. The four arrow keys are used to navigate through parameter groups, select a specific parameter to be modified, and to modify digital and numeric data.

The operation of the arrow keys is dependent upon the type of parameter which is being modified.

Operational Overview

Figure 4: FM-3 Display Screen and Keypad

On the Menu screen, the drive type and axis address are always shown on the top line of the display. The second line shows the motor type. If a user defined motor is selected, the user defined motor name will appear. The third line shows two parameter group names, one above each of the soft keys.

From the Menu screen, the user selects a group of drive parameters to wor k wi t h. The g rou p names are scrolled using the left/right direction keys. The groups correspond roughly to the tabs used by the PowerTools software. The groups are shown cyclically and wrap around.

The drive parameters available with the FM-3 keypad ar e arranged into seven grou ps (see list below). Upon power-up the FM-3 module will display the default parameter groups “SECUR” (left soft key) and “QUICK” (right soft key).

• QUICK (Quick)

• PROG (Program)

• INDEX (Index)

• HOME (Home)

• JOG (Jog)

• RAMPS (Ramps)

• SECUR (Security)

FM-3 Programming Module Reference Manual

Security: 1

Screen

EN-204 Adr01 MG-316 SECUR

PBus-

Group

Slave Address

MODIF MENU

Security: 1

Baud Rate

Security: 0

Network Sts

Security: 0

Module Sts

MODIF MENU

Security: 0

MasterAddr

Security: 0

MsgProcessed

Security: 0

DVNET+

Group

MacID

MODIF MENU

Security: 1

Baud Rate

MODIF MENU

Security: 1

Network Sts

MENUMODIF

Security: 0

Module Sts

Security: 0

Net OK

Security: 0

Conn Type

Security: 0

Mster MacID

Security: 0

Transmit Cntr

Security: 0

Receive Cntr

Security: 0

SECUR

Group

Auto Log Out

MODIF MENU

Security: 3

Password 1

MODIF MENU

Security: 3

Password 2

MODIF MENU

Security: 3

Log Out Now?

Security: 0

* Jog Group contains 2 Jogs (Jog.0 and Jog.1) Index Group contains 7 Indexes (Index.0 to Index.7) Prog Group contains 4 Programs (Prog.0 to Prog.3)

+ DeviceNet Group is only available on FM-3DN and FM-4DN modules

- Profibus Group is only available on FM-3PB and FM-4PB modules On all screens with < > symbols, scroll left and right to select the specific Instance

RAMPS

Group

Stop

MODIF MENU

Security: 0

Stop.Decel

MODIF MENU

Security: 1

JOG*

Group

<Jog.0.Vel>

MODIF MENU

Security: 1

<Jog.0.Accl>

MODIF MENU

Security: 1

<Jog.0.Decl>

MODIF MENU

Security: 1

<Jog.0.Plus>

MODIF MENU

Security: 1

<Jog.0.Mius>

MODIF MENU

Security: 1

Posn Fdbk Ct

Security: 0

HOME Group

Home.0.Vel

MODIF MENU

Security: 1

Home.0.Accl

MODIF MENU

Security: 1

Home.0.Decl

MODIF MENU

Security: 1

Home.0.Init

MODIF MENU

Security: 1

Calc Offset

Security: 1

Spec Offset

MODIF MENU

Security: 1

Select Offst

MODIF MENU

Security: 1

INDEX*

Group

<Ind.0.Vel>

MODIF MENU

Security: 1

<Ind.0.Accl>

MODIF MENU

Security: 1

<Ind.0.Decl>

MODIF MENU

Security: 1

<Ind.0.Dist>

MODIF MENU

Security: 1

<Ind.0.Init>

MODIF MENU

Security: 1

PROG*

Group

<Prg.0.Init>

MODIF MENU

QUICK

Group

Posn Fdbk

GRAPH MENU

Security: 0

Vel Fdbk

GRAPH MENU

Security: 0

Following Er

GRAPH MENU

Security: 0

Axis Address

MODIF MENU

Security: 0

Baud Rate

MODIF MENU

Security: 3

DriveInput

Security: 0

ModuleInput

Security: 0

DriveOutput

Security: 0

ModuleOutput

Security: 0

Fault Sts 1

Security: 3

Fault Sts 2

Security: 0

Clear Fault?

OK MENU

Security: 0

Module Rev

Security: 0

Boot Rev

Security: 0

Parameter Screens

After selecting a group using one of the soft keys, the FM-3 module will display a Parameter screen for that group. This screen could be either the first screen in the group or the last screen you used in that group. The FM-3 module keeps track of the last Parameter screen viewed in

each group and returns to that screen when you come back to the group. This is reset on power-up and the FM-3 keypad displays the first Parameter screen in the group.

In this screen, the parameter name is shown on the first line of the display. The up/down arrow keys are used to scroll through the parameters available in the selected group.The second line displays the condition or value of parameters. The third line displays the soft key actions.

The left/right arrow keys are used to scroll through the parameters when the “<“ and “>” symbols are shown.

Numeric parameter units are sometimes shown before the actual value, because the parameter value and the units cannot be displayed on one line. The unit of measure will appear on the second line for about one second. Then the actual parameter value will appear. The parameter value is updated about five times a second.

How Motion Works

The FM-3 module provides four types of motion: jogging, homing, indexing, and gearing. Only one index, jog, home, or gear may be in process at any given moment (exclusionary motion types). Through assignments and programs, the FM-3 module can sequentially run various motion routines. The Positive direction parameter af fect s all m otion types by specifying which direction of motor revolution (CW or CCW) is considered motion in the “+” direction.

Operational Overview

How Jogging Works

Jogging produces rotation of the motor at controlled velocities in a positive or negative direction.

Assignments to jogs are level sensitive such that when the jog input is turned on, jogging begins and continues jogging until the jog input is removed.

Each jog has its own acceleration and deceleration ramp along with a specified velocity. Jogging has no distance parameter associated with it. If trying to move a specific distance or to a known position, then an index is used.

FM-3 Programming Module Reference Manual

Figure 5: Jog Tab

How Home Works

The Home is used in applications in which the axis must be precisely aligned with some part of the machine. The Home is initiated in one of three ways: with the Initiate Destination function found in the Ass ignments view, throu gh a program, or with t he Online tab. A Home or Define Home is required to set the Absolute Position Valid so that any index to absolute position can work.

The FM-3 module can home the motor to an external sensor, the motor’s encoder marker pulse, or to a sensor and then to the encoder marker pulse.

Operational Overview

Figure 6: Basic Home Function, Example

The figure above show a basic home f unction us ing a ball scr ew. This examp le us es most o f the setup features in the PowerTools Pro Home tab.

Home Sequence

1. Back off the sensor (if on the sensor. This step is optional).

2. Move to the external home sensor to establish a home reference point.

3. Next it will move to the Offset position.

4. Then the command and feedback positions are set to the value entered into the End of Home Position.

Homing to the motor’s encoder marker will establish the most accurate and repeatable home position. This method will position the motor relative to the location of the rising edge of the encoder marker pulse. Most applications will use a sensor and marker to find an accurate home position in the vicinity of the home sensor.

Several parameters affect how the Home function operates. Each of these parameters are explained in detail on the following pages.

Note

The Home function will NOT be initiated when any other motion command is in progress .

Establishing a Home Reference Position

The first step in setting up a home is to select the desired home reference type. The Home Reference parameter selected determines how the Home Refe r e nce Position is established.

FM-3 Programming Module Reference Manual

PowerTools Pr o allows selection o f one of three diff erent Home References: Sensor, Marker, or Sensor and Marker.

Sensor

Selecting Sensor means the ri sing edge of the Home Sensor inpu t function is used to establish the home reference position.

Figure 7: Sensor Home Reference Position

Marker

Selecting Marker means the rising edge of the motor’s encoder marker channel is used to establish the reference position.

Figure 8: Marker Home Reference Position

Operational Overview

Sensor and Marker

Selecting Sensor and Marker means the reference position is establis hed using the first marker rising edge after the device sees the rising edge of the Home Sensor input function.

Figure 9: Sensor and Marker Home Reference Position Example 1

Accuracy and Repeatability

The amount of accuracy your application requires will determine the Home Reference option you select. Homing to an external sensor only will establish a repeatable home position within

0.04 revolutions at 3000 RPMs (800 µsec sensor capture interval).

Note

The data above assumes the use of a perfectly repeatable home sensor.

In Sensor and Marker app lications, the mar ker must be at least 8 00 µsec after the rising edge of the sensor input to be considered a valid marker pulse.

Note

At 1000 RPM, the motor will travel 0.0133 revolutions (or 4.8°) in 800 µsec.

FM-3 Programming Module Reference Manual

Sensor Min.

800 µsec

Sensor

Marker

Direction of Tr avel

Figure 10: Sensor and Marker H ome Reference Position Example 2

The Home Sensor must be “On” for at least 800 µsec to guarantee that it will be recognized.

Figure 11: Sensor and Marker H ome Reference Position Example 3

Home Offset

The Home Offset is the distance from the Reference Position to the final stopping point at the end of the homing sequence. Regardless of the value you enter for the Offset or which Home Reference you choose, there is always an offset inherent in the homing process.

The user may either specify a desired offset or allow the drive to calculate an offset automatically. The drive calculates an offset that guarantees that the motor will not have to backup to get to the offset position. This is very convenient for unidirectional applications.

On Time

Sensor

800 µsec

The calculated offset is the distance travelled during deceleration ramp from the home velocity to a stop plus the distance travelled at the home velocity for 800 µsec. This extra distance is used to guarantee that the motor will not need to backup after the deceleration ramp.

Operational Overview

Calculated

The Specified Offset allows the user to choose an exact offset from the Home Reference. Once the home reference is detected, the device will do whatever is necessary to reach the

offset position. This may be as simple as a deceleration to a stop, a continuation at speed followed by a deceleration to a stop, or a deceleration followed by a move in the opposite direction.

To enter a specified home offset, select the Specified Offset radio button. PowerTools Pro always displays the calculated offset value as a reference. If the home reference is detected before the axis has reached its peak velocity, the axis will still co nti nue to the precise offset position.

Figure 12: Calculated Home Offset, Peak Velocity Not Reached

If the Home Reference is detected after the axis has reached its peak velocity, the axis will decelerate to the precise offset position.

Home Offset

Figure 13: Calculated Home Offset, Peak Velocity Reached

FM-3 Programming Module Reference Manual

Two examples below show operation when the specified offset is greater or less than the calculated offset. This causes the axis to continue on at speed before decelerating and stopping at the offset position, or backing up after the home sensor.

Specified Offset

Figure 14: Specified Home Offset, Greater than Calculated Offset

Specified Offset

Figure 15: Specified Home Offset, Backup Required

End of Home Position

The End of Home Position (End Posn) defines the home position in relation to the machine’s coordinate system. At the completion of the home, the value of the End of Home Position is put into the command position.

Home Limit Distance

This parameter places an upper limit on the incremental distance the motor will travel during the home.

If no reference is found, the system will decelerate and stop at the limit distance. The Home Limit Distance Hit function will be activated if the home stops at the limit d istance without finding the reference. Additionally, the Home.CommandComplete f unc tio n will not turn “On” if the limit distance is hit.

Home Examples

Example 1: Linear Application

In this example, the system uses an external sensor and the motor’s encoder marker channel to establish a Home Reference Position. This is the most accurate and most common way to home.

Operational Overview

Figure 16: Home to Sensor and M arker, Ex ample

When the FM-3 module sees the Home Initiate, it accelerates the motor to the Home Velocity. The motor continues at that velocity until it first senses the Home Sensor in put. It continues

at the same velocity until the motor’s encoder marker channel is sensed. The rising edge of the motor’s encoder marker chan nel is used to establish the reference position. Once the home reference is detected, the motor decelerates to a stop and moves to the offset position.

FM-3 Programming Module Reference Manual

Home Sequence

1. If on sensor then back off (if enabled)

2. Search for se nsor

3. Search for marker

4. Go to offset (2.0 Revs)

5. Set feedback position equal to End of Home Position

Velocity

+ 100

Back off

Sensor

- 100

Figure 17: Home Velocity Profile

Start of Home

Marker

Sensor

+ 100

Time

Marker

Back Off Sensor

Home Move

Offset Move

2.0 Revs

Offset

Figure 18: Home Move Sequence

Final Position = End of Home Positio

Operational Overview

Example 2: Rotary Application

This example uses an external sensor and the motor’s encoder marker pulse to establish a home reference position.

Figure 19: Home Sensor and Marker then Offset, Example

When the device sees the rising edge of the Home Initiate function, it accelerates the motor to the Home Velocity. The motor continues at that velocity until it first senses the Home Sensor input. The motor continues on at the home velocity until the marker is activated.

The rising edge of the motor’s encoder marker channel is used to establish the reference position.

After sensing th e rising edge of the mo tor’s marker channel, the dev ice will cont inue movi ng and will decelerate to a stop at the specified offset position.

Figure 20: Home Velocity Profile

FM-3 Programming Module Reference Manual

How Indexes Work

An index is a complete motion sequence that moves the motor a specific incremental distance or to an absolute position. This motion sequence includes an acceleration ramp to a programmed velocity, a run at velocity, and a deceleration to a stop.

Velocity

Run at Velocity

Acceleration

Figure 21: Index Moti on Sequence

Deceleration

Time

Operational Overview

Figure 22: Indexes View

Indexes use acceleration and deceleration ramps which may or may not reach the specified velocity depending on the total distance and the ramp values. For example, a short move with long acceleration and deceleration ramps may not reach the target velocity entered.

Indexes cannot be initiated when any other motion (jogging, homing, or program) is in progress. Indexes can be aborted with the Stop destination found in t he Ramps group on the Assignments View.

The FM-3 module supports five types of indexes: absolute, incremental, registration, rotary plus and rotary minus.

FM-3 Programming Module Reference Manual

Absolute Index

Absolute vs. Incremental

The difference between absolute and incremental index e s is that absolute indexes move to a specific absolute position and incremental indexes move the motor a specific distance. The figures and explanations below demonstrate this concept.

Absolute Indexes

Absolute indexes are used in applications where the motor must trav el to a s pecific po sition, regardless of where the motor is when the index is initiated.

The FM-3 module calculates the distance required to mov e to t he spe cif ied p ositi on f rom the current position.

Absolute Index

Start Position = 1 Rev Index Position = 5 Revs

Figure 23: Absolute Index Example 1

In the example above, the current position is 1 rev. If this index is initiated, the motor will travel to a position o f 5 revs no m atter where it i s sitting bef ore the move. Fr om 3 revs, i t will travel 2 revs to finish at 5 revs. If the absolute index to 5 revs is initiated a second time immediately after the index, no motion will occur because the motor will already be at a position of 5 revs.

The direction of an Absolute Index is determined by the starting position and the absolute index position. If the starting position for the above index is 9 revs, then the motor will rotate in the negative direction to end up at 5 revs. The diagram below shows this.

Start Position = 9 Revs Index Position = 5 Revs

Figure 24: Absolute Index Example 2

Operational Overview

Incremental Index

Absolute indexes with Rotary Rollover enabled wi ll take the shortest path to the position entered in the index position parameter.

Note

Absolute indexes move to positions re lative to where the machine was homed using the Home, or the DefineHome destination.

Incremental Indexes

An incremental index will move the motor a specified distance in the + or - direction regardless of the starting position. The directio n of the incremen tal index motion is determined by the sign (+ or -) of the Index Distance parameter.

Incremental Index

Start Position = 1 Rev Index Distance = 2 Revs

Figure 25: Incremental Index Example

In the example above, the motor starts at 1 rev, travels a distance of 2 revs and stop s at 3 revs. If the same index is initiated a second time, the FM-3 module would move the m otor another 2 revs to a position of 5 revs. If initiated a third time, the motor would travel another 2 revs to a final position of 7 revs. The example below shows this operation.

Figure 26: Incremental Index Example 2

Start Position = 1 Rev Index Distance = 2 Revs

FM-3 Programming Module Reference Manual

Registration Index

A Registration Index is used in applications where the motor must move until an object is detected and then move a specific distance from the point of detection, such as finding a registration mark and moving a distance beyond.

The Registration Index consists of two parts. The first part accelerates the motor to the target velocity and continues at this velocity until it receives a registration trigger (sensor or analog). Upon receipt of a registration trigger, the regis tration offset will be executed at the target velocity. The Sensor Limit Distance Hit source can be used to turn on an output, if a sensor input or analog limit is not received within the Limit Distance. A registration window can also be used to determine the validity of a registration trigger. If a regi str a tion trigger is received outside of the registration window, it will be ignored.

Rotary Plus and Rotary Minus Indexes

Rotary Plus and Rotary Minus Indexes provide forced directional control of moves to absolute positions. The position entered for a Rotary Plus or Minus type index must be within the rotary range (i.e. 0 ≤ Position < Rotary Rollover Point). All other parameters function the same as they do with absolute indexes. An Absolute Index is a direct move to a specific position, regardless of the starting point. A Rotary Plus Index moves to the specified position, but is forced in a positive direction. Similarly, a Rotary Minus index moves to the sp ecific position, but is forced in a negative direction.

Rotary Plus and Minus Indexes are usually used in rotary applications, therefore the rotary rollover feature on the S etup - Positio n view in the Power Tools Pro softwar e must be enabled to use them.

1. In the fo llowing examples the term “D” = (absolute position specified) - (current position). If “D” is negative, motion in the negative direction is implied.

2. In the following examples the Rotary Rollover parameter on the Setup - Position view is set to 360.00°. This means that with each revolution of the motor (or rotary table), feedback will count up to 359.99°, then roll over to Ø°.

Indexes with Rotary Rollover Enabled

Incremental move distances can be outside of the rotary rollover range. See the Setting

Up Parameters section for an explanation of Rotary Rollover.

Example 1: If the starting position is at Ø° and 720° is the specified distance, an

Incremental index would move 2 revolutions in the positive direction. At the completion of this index the motor position would be Ø°.

Absolute indexes will take the shortest path to the specified position. Absolute index

positions must be within the rotary rollo ver r a nge.

Example 2: If the starting position is at 90° and 80° is the specified position, an Absolute index would travel 10° in the negative direction. At the completion of this index the motor position would be 80°.

Operational Overview

Example 3: If the starting position is 45° and 315° is the specified position, an Absolute

index would travel 90° in the negative direction because that is the shortest path between 45° and 315°.

Rotary Plus indexes will move to the specified position and are forced in a positive (or

plus) direction. Rotary Plus index distances must be within the rotary rollover range.

Example 4: As in example 2 abov e, the starting position is at 90° and 80° is the specified

position. A Rotary Plus index would travel 350° in the positive direction. At the completion of this index the motor position would be 80°.

Example 5: If the starting position is 10° and the specified position is 350°, a Rotary Plus

index will travel 340° in the positive direction.

Rotary Minus indexes move to the specified position, but are forced to travel in the negative (or minus) direction. Rotary Minus index positions must be within the rotary rollover range.

Example 6: As in examples 2 and 4 above, the starting position is at 90° and 80° is the

specified position. A R ot ary Mi nus index would travel 10° in the negati ve di rect ion. A t the completion of this index the motor position would be 80°.

Example 7: If the starting position is 15° and the specified position is 270°, a Rotary

Minus index would travel 105° in the negative direction.

How Communications Work

Uploading

Uploading is the process of reading information back from the drive to the PowerTools Pro configuration screens.

To upload inform ation from a driv e, click on the upload button on the PowerTools Pro t oolbar or select upload from the Device menu.

Downloading

Downloading is the process of s ending your co nfiguration created with PowerTools Pro from the PC to the FM-3 module. Changes made in PowerTools Pro will no t take effect until th e information has been downloaded or the Update to RAM button has been clicked.

To download information to a FM-3, click on the download button on the PowerTools Pro toolbar or select download from the Device menu. Powe rTools Pro will lead the us er through a series of dialog boxes that determine what baudrat e and which communicat ions port on the user’s P C will be u s ed.

FM-3 Programming Module Reference Manual

NVM Options for Uploading and Downloading

Uploading

When uploading from a FM-3 module, the values that were last downloaded are uploaded and put into a PowerTools Pro configuration file. At the completion of the upload, the user will be asked if they wish to upload the NVM values. This dialog box is shown below.

By selecting Yes, the values of all parameters stored in NVM will be uploaded and en tered into the PowerTools Pro file values. If No is selected, the values entered into the PowerTools Pro file will remain the same as those that were last downloaded to the FM-3 module.

Downloading

When downloading to the FM-3 module the user will be required to select how to handle the NVM parameters upon downloading. The dialog box asking the user to select one of three options for the download is shown below.

A description of each of the options is as follows: Overwrite – This option will overwrite all the parameters stored in NVM with the current

values in the user configuration (PowerTools Pro file). The values that are in NVM prior to the download will be lost.

Update – This option will upload the curre nt NVM parameter values from the FM-3 module and enter them into the user configu ration (PowerTools Pro file). Once the NVM values have been stored in the file, the file is fully downloaded.

Keep – This option will download the entire user configuration, but then NVM parameters will be restored to the value prior to download. This is similar to the Update option, but the

Operational Overview

Keep option does not upload the NVM values into the user configuration (PowerTools Pro file).

The following table shows an example of how these options work:

PT Pro file value for

Index.0.Vel

NVM value for

Index.0.Vel

Updating to RAM

The Update to RAM button can be used to send changes to the FM-3 module without performing a complete download. The Update to RAM button is found in the PowerTools Pro toolbar. This operation will send only those changes that have been made since the last Update to RAM or Device – Download to the FM-3. The changes will take effect immediately upon clicking on the button.

Before

Download

150 150 500 150

500 150 500 500

Overwrite

Option

After Download

Update Option

Keep Option

The parameters will be sent to the FM-3 module without stopping motion or disabling the drives. Because of this, it is important to use caution when changing motion par ameters while the motor is in motion.

The Update to RAM button saves the parameters only to RAM and not to Non-Volatile Memory (NVM). Therefore, if the system power is removed, any changes made using the Update to RAM button will be lost. In order to save changes to NVM, a full-download must be performed.

The flowchart below describes a typical process using the Update to RAM to make change s, and then downloading when complete to save changes to NVM.

FM-3 Programming Module Reference Manual

Figure 27: Update to RAM Flow Chart

The Update to RAM button operates according to the following rules: If no parameters have been modified by the user, the Upd ate to RAM button will be disabled. If the user modifies a parameter that does not require a full download, the Update to RAM

icon will be enabled. If while the icon is enabled, the user modifies a parameter that requires a full download, the

Update to RAM icon will become disabled. When the user clicks on the Update to RAM icon, all the modified parameters are transmitted

to the FM-3. Once transmitted, the icon will become disabled again until another parameter is changed.

If the user performs a full download while the button is enabled, when the download is complete, the Update to RAM button will be disabled.

If the user modifies parameters , and dis connects, the update button will be dis abled, and the changes will not be sent.

Options/Preferences/Ptools Operation

This menu controls the pop-ups that the user encounters when uploading and downloading the FM-3/4 configuration.

Download Section:

“Ignore saving file on Ptools/Drive revision conversion.”

On a download PowerTools Pro checks the firmware revision of the module that it is about to be downloaded to and is required to make changes to the files that are to be downloaded to older firmware revisions. This checkbox allows the user to avoid saving the newer file before converting it to a previous revision.

“Overwrite – Reset the NVM configuration”

Operational Overview

When this checkbox is selected the “Overwrite” function will default on ever y download to the module. This function will overwrite the entire FM-3 configuration including user defined NVM parameters as set in the NVM setup area of PowerTools Pro.

Note

It is required to Overwrite the Non-Volatile Memory on the first download to the module since no Non-Volatile Memory parameters have been loaded into the drive on initial startup.

“Update – Upload the values into the current Update PowerTools Pro configuration”

When this checkbox is selected the “Update” function will Update the NVM on every dowload to the module. Upon download the Update function uploads the configured NVM from the drive and places the data into the PowerTools Pro configuration file. The software then downloads this newly updated file to the module.

“Keep – Remember the values and res tore them after the download”

This option was created to allow users to save the values that have been changed via HMI, PLC or internally in a program so long as they have been added to the NVM list. When this checkbox is selected PowerTools Pro will poll the drive on download for all of the values that have been added to the NVM list. PowerTools Pro then stores these values into a temporary memory location and after the program download is complete PowerTools Pro rein states these values to the parameters before the drive can be enabled.

“Ask on each download”

This option was created for users who want control of whether they will overwrite or keep the NVM on download. When this checkbox is selected, PowerTools Pro will display a pop-up window that gives the user the option to Overwrite, Update, or Keep as described above.

Upload Section:

“Always convert Application to latest Ptool capabilit y”

When this checkbox is selected, PowerTools Pro will automatically update an uploaded file to match the current functionality of PowerTools Pro.

"Always leave Application matching Module capability”

When this checkbox is selected, PowerTools Pro will default to upload and disp lay the configuration to match the firmware revision and capabilities of the module.

“Ask on each upload”

When this checkbox is selected, PowerTools Pro will default to asking the user to convert the application to the latest PowerTools Pro capability, or leave the application to match module capability.

FM-3 Programming Module Reference Manual

Upload Non-Volatile Memory (NVM) Section:

“Always upload NVM”

When this checkbox is selected, PowerTools Pro will default on an upload to uploading all of the parameters that have been mapped to the NVM and updating the display of these parameters in PowerTools Pro.

“Always bypass NVM upload”

When this checkbox is selected, PowerTools Pro will not upload the NVM and the values that were originally downloaded to the drive will be displayed in the PowerTools Pro configuration.

“Ask on each upload”

When this checkbox is selected, PowerTools Pro will default to asking t he u ser vi a a pop -up window whether to upload the NVM or to bypass the NVM upload.

Secure Downloading

The Secure Download feature allows the user to download a configuration that prevents anyone from uploading the file, or going online with the system. This is used to protect a file from being accessed by unauthorized personn el. If a secure file is downloaded to the system, all diagnostics capabilities in the software are lost. The only way to go online with the system again is to download the origin al (non-secure) file over the secure version, or to download a completely new file.

Before performing a secure download, the file must first be saved in the secure file format. To do this, open the file you wish to save in the secure format using PowerTools Pro. Then click File\SaveAs on the Menu Bar. The following SaveAs window should appear on your screen

On this window, check the “Save also as secure download format” check box located at the bottom of the window, then click on the Save button. Doing this will save your file in BOTH

Operational Overview

the standard file format (. fm3), as well as in the secure file format (.fm3s) . The “s” at the end of the file extension stands for “secure”. The secure file will be saved to the same directory as the standard file.

To perform the Secure Download, close all open files in PowerTools Pro. Then click on Device\ Secure Download on the menu bar as shown below.

A window will then pop up asking the user to select the secure file that they wish to download. Select the secure file that was just saved, and then click on the “Open” button. This will download the secure file to the target device.

A secure file (.fm3s) cannot b e opened o r modified . The file extens ion cann ot be changed to allow the user to open it. The secure file is only valid for use by the secure download function. If a user attempts to upload a secure file, a message will appear indicating that the file residing in the system has been protected by the user. An example of this is shown below.

Brake Operation

MG motor brake operation is controlled by the Brake Release and Brake Control destinations. These destinations can be used together to control the state of the Brake source. The table below shows the relationship between the Brake sources and destinations (see “Diagnostic Display”).

Note

No motion should be commanded while the brake is engaged.

Brake Release Destination Off On Brake Ac tivate Destination On Off On Off

Drive Power

Stage

Enabled

Disabled

0111 0011

FM-3 Programming Module Reference Manual

Brake Release

The Brake.Release destination function will release the brake under all conditions. When this function is active, the Brake output will be on (that is, release brake). This function overrides all other brake control, thus allowing the brake to be released while a fault is active or the power stage is disabled. See also Brake source function.

Brake Acti va te

The Brake.Activate destination function, when active, will engage the brake unless overridden by the Brake Release function. This function lets you externally engage the brake while allowing the drive to also control the brake during fault and disabled conditions.

Brake Dise nga g ed

The Brake.Disengaged source function is used to control the motor holding brake. If the Brake function is off, the brake is mechanically engaged. When the brake is engaged, the diagnostic display on the front of the drive will display a “b”.

The drive outputs are limited to 150 mA capacity, therefore, a suppressed relay is required to control motor coil. Control Techniques offers a relay, model # BRM-1.

FM-3 Programming Module Reference Manual

Setting Up Parameters

Setup View

The Setup View contains all of the primary system setup parameters. These parameters mus t be setup prior to using your system.

By selecting Setup in the Hierarchy View, the Setup view will appear on the right sid e of the view (see Figure 28). The Setup view is divided into six groups, with an ex planation of each function. The groups are Identification, Configuration, Drive Encoder Output, Positive Direction, Update Rate and Switching Frequency. Status Online will be shown when online with the FM-3 module.

Figure 28: Setup View

Identification Group

The identification group consists of the Device Name and the Target Drive Address.

FM-3 Programming Module Reference Manual

Name

This is a 12-character alpha/numeric user-configured name for this axis. Enter this name for the device you are currently setting up. Assigning a unique name for each device in your system allows you to quickly identify a device when downloading, editing, and troubleshooting. All keyboard characters are valid. This will default to Axi s 1.

Target Drive Address

This is the Modbus address of the target drive to which you will download the configuration. The default target drive address is 1.

Configura tion Group

The configuration gr oup consists of li st boxes for Drive Ty pe, Motor Type, and Lin e Voltage.

Drive Type List Box

Select the drive model for the system you are currently setting up.

Motor Type List Box

Select the motor you want to use.PowerTools Pro software will only display the motor models that are compatible with the drive you selected and any user defined motors.

Selecting the wrong motor type can cause instability and may cause property damage to the moto r and/or dr ive.

EN Only

Line Voltage List Box

Line Voltage specifies the applied power and adjusts the internal gains to compensate for it. This parameter has two choices: 115 VAC and 230 VAC. If the Line Voltage is set to 230 VAC when the actual applied voltage is 115 VAC, the motor will be slig htly less responsive to commands and load disturbances.

The Line voltage must never be set to 115 VAC if the applied voltage is actually 230 VAC. This can cause drive instability and failure, resulting in property damage.

Drive Encoder Output Group

The drive encoder output group consists of the encoder scaling check box and encoder scaling.

Encoder Scaling Check Box

This check box enables the Scaling parameter of the Drive Encoder Output.

Encoder Scaling

This parameter defines the encoder resolution (lines per re volution) of the drive's encoder output. This feature allows you to change the drive encoder output resolution in increments of 1 line per revolution up to the density of the encoder in the motor. If the Encoder Output Scaling parameter is set to a value higher than the motor encoder density, the drive encoder output density will equal that of the motor encoder.

Positive Direction Group

The Positive Direction group consists of a clockwise (CW) Motor Rotation Radio Button or a counter-clockwise (CCW) Motor Rotation Radio Button.

The motion will move in either CW direction or counter-clockwise CCW direction. Perspective of rotation is defined as you face the motor shaft from the front of the motor.

CW Motor Rotation Radio Button

Setting Up Parameters

Select this radio button for applications in which CW motor rotatio n is consid er ed to be motion in the positive direction (increasing abso lute position).

CCW Motor Rotation Radio Button

Select this radio button for applications in which CCW motor rotation is co nsidered to be motion in the positive direction (increasing abso lute position).

Update Rate Group

This parameter configures the interrupt interval for the FM-3 processor. This defines how often the motion program is interrupted and the Control Lo op is processed. In the Control Loop, the feedback information is processed and a new position command is generated. Also in the Control Loop, the I/O is scanned. After Control Loop is complete, all messages are handled. Messages are Modbus data, DeviceNet data, Keypad/Display information, and are only processed if a message is wai ting. If no device is querying data from t he FM-3 or sending data to the FM-3, then messages do not take up any time. Once messages have been processed, the remainder of the int errupt is dedi cated to runni ng the motion programs of user programs.

Available selections for Trajectory Update are 800, 120 0, and 1600 microseconds. The l onger the update, the more time is dedicated to the user programs, and the less time dedicated to servo performance. Th e shorter the updat e , the mor e precis e the servo perform ance, b ut less time is available to process user progra ms. Diagnostics are available on the Status Online tab when online with the device to help select the ideal setting. (See description of Control Loop Group of online parameters for further information)

FM-3 Programming Module Reference Manual

Switching Frequ ency Group

This parameter defines the s witching frequency of the electro nic amplifier. For EN drives, the switching frequency must be 20 kHz and cannot be changed. For MDS, the switching frequency can be modified to change system performance. Available selections are 5 kHz, and 10 kHz. For more information on this setting refer to the MDS Reference Manual, P/N 400525-01.

Status Online Tab (Online Only)

The Status Online tab (s ee Figure 29) is visible when online and consists of the Motor Position group, Motor Velo city gr oup, C ontro l Loop g roup, Mas ter Feedb ack grou p, and the Torque group.

Figure 29: Setup View - Online Status Tab

Motor Position Group

Position Command

Position command is the commanded motor position sent to the drive by the FM-3 module. This parameter does not take following error into account. See also PosnFeedback and FollowingError. Units are in user units.

Position Feedback

Feedback position is the actual motor position in user units. PosnCommand minus the PosnFeedback is the FollowingError

Following Error

The Following Error is the difference between the Position Command and the Position Feedback. It is positive when the Position Command is greater than the Positio n Feedb ack.

Encoder Position

Motor encoder position in encoder counts. This position reflects the feedback position of the motor and is not scaled into user units. This is a signed 32 bit value.

Setting Up Parameters

Motor Veloci ty Group

Velocity Command

The Velocity Command is the velocity that the FM-3 module is commanding the motor to run at. This command is generated by the drive velocity control loop and position loop. It is displayed in user units.

Velocity Feedback

This is the feedback (or actual) velocity. It is calculated using the change in position of the motor encoder. It will always return the actual motor velocity - even in synchronized applications in which the master axis is halted during a move.

Control Loop Group

Changing the Trajectory Update Rate can have a major effect on the performance of your servo system. A longer trajectory update rate mean s that more time is available to process user programs. A shorter update rate means that the control loop is updated more often and provides the most accu rate p erfo rmance. W ithout pro per diagnostics, it can be impossible to tell how much time is being consumed by the control loop update, and how much time is available to run user programs.

The Control Loop group of parameters on the Status Online tab shows the user how much time is available to run programs. There are two parameters available to help with this. They are as follows:

FM-3 Programming Module Reference Manual

Control Loop Limit

This parameter shows the lowest measured time difference (in microseconds) between the Trajectory Update Rate and the time taken to process the control loop since the last reset. Certain features in the FM-3 require more time to process (i.e. PLS, Capture, Compound Indexes), and therefore will cause lower limits. The software records the lowest measured value and displays it as the limit. To reset the limit to the average and continue tracking the lowest value, the user can click on the Limit button. If the Limit reaches 0, a fault will be generated. If a Limit of less th en 75 - 100 usec is seen, it is recommended to swi tch the update rate to the next higher value.

Margin Average

This parameter shows a running average of the difference (in microseconds) between the Trajectory Update Rate and the time taken to process the control loop since the Status Online tab was brought up. The high er the val ue, the more time available to run user programs. For Averages less than 150 usec, it is recommended to switch the update rate to the next higher value.

Master Feedback Group

Master Position

Used for synchronized motion, this displays the position of the master encoder in units defined on the Master Units Setup View.

Encoder Position

This displays the position of the master encoder in counts.

Master Velocity

This displays the velocity of the master encoder in master units/second.

Torque Group

Torque Command

This displays the torque command value before it is limited. The torque command may be limited by either the Torque Limit (if the Torque Limit Enable destination is active) or current foldback. Units for this parameter are defined in the Torque Group on the User Units View.

Limited Torque

This is the actual torque commanded to the motor. This value is the result after the TorqueCommand is limited by the current foldback or the TorqueLimit value (if enabled).

Foldback RMS

This parameter accurately models the thermal heating and cooling of the drive and motor. When it reaches 100 percent, current foldback will be activated. See the Diagnostics section for an explanation of foldback.

Shunt Power RMS

This parameter models the thermal heating and cooling of the drive internal shunt. This parameter indicates the percent of shunt capacity utilization. When this value reaches 100 percent, the drive will generate an RMS Shunt Power Fault. This parameter is not applicable to the EN-204 which does not have an internal shunt resistor. This parameter is applicable to the EN-208 and EN-214.

Information Tab (Online Only)

Drive Information Group

Firmware Part Number

Setting Up Parameters

Displays the part number of the drive firmware you are using.

Firmware Revision

Displays the revision of the drive firmware you are using.

Serial Number

Displays the serial number of the drive with which you are currently online.

Module Information Group

Firmware Part Number

Displays the part number of the FM-3 firmware you are using.

Firmware Revision

Displays the revision of the firmware in the FM-3 module with which you are currently online.

Serial Number

Displays the serial number of the FM-3 module with which you are currently online.

FM-3 Programming Module Reference Manual

User Units View

The User Units View is used to scale the desired application units into known valu es. All information for distance, velocity, and accel/decel units are set up here and used throughout the system set u p .

By selecting User Units in the Hierarchy View, the User Units View will appear on the right (see Figure 30).

Figure 30: User Units View

Distance Group

Units Name

This is a 10-character name for the distance user units you want to use in your application.

Setting Up Parameters

Decimal Places

The number of decimal places set in this parameter determines the number of digits after the decimal point used in all distance and position parameters throughout the software. Using a high number of decimal places will improve position resolution, but will also limit the range of absolute position. You can select from zero to six decimal places of accuracy.

Note

When the number of decimal p laces are changed in an existing configuration file the Index accel and decel parameters need to be checked.

Scaling

A Characteristic Distance and Length must be established to allow the FM-3 module to scale user units back to actual motor revolutions. This scaling factor is as follo ws:

Scaling

Characteristic Distance

This is the distance the load travels (in user units) when the motor travels the characteristic length (in motor revolutions).

Characteristic Length

This is the distance the motor travels (in whole number of revolutions) to ac hieve one characteristic distance of load travel.

Distance Scaling Examples:

A 1.5" diameter pulley is used to drive a conveyor belt, and the user wishes to use units of inches instead of revolutions.

Units Name — Set to Inches Decimal Places — Set to desired accuracy 0.000 In one revolution of the motor (or pulley), the belt will travel a distance of one pulley

circumference.

Characteristic Distance

-------------------------------------------------------= Characteristic Length

= 1.5" x π = 1.5 x 3.14... = 4.712 inches / revol ution

Scaling

Characteristic Distance = 4.712

--------------------------------------------------------------------------Characteristic Length = 1

FM-3 Programming Module Reference Manual

If the user decides to put a 5:1 reducer on the system, the user simply needs to change the Characteristic Length.

Now the belt travels 4.71" in 5 motor revolutions.

Scaling

Keep in mind that the characteristic length is always a whole number and the valid range is from 1 to 2000.

Characteristic Distance = 4.712

--------------------------------------------------------------------------Characteristic Length = 5

Note

User Units may affect end motor speed and could cause trajectory faults.

Because of internal math in the FM-3 and FM-4, s ome user unit combinations may cause module or drive trajectory faults. The maximum motor velocity allowed by the drive is detailed under the distance section of the User Units View and is labeled “User Un it Limited Speed”. When the user unit setup is altered in such a way that the maximum motor speed allowed by the drive is less than the maximum speed allowed by the chosen motor, the readout of maximum motor speed allowed by the drive changes to have a red background. If a configuration is downloaded to the FM-3/4 with a red background on the “User Unit Limited Speed”, the drive will obtain a trajectory fault at speeds near this velocity. To alleviate this issue, simply remove decimal places from your user units, and/or change the characteristic distance (numerator) of your scaling parameters to be a smaller number that it was. The red background indicating module trajectory faults will go away when the user unit setup is scaled for a realistic accuracy based on the encoder counts per revolution.

Velocity Group

Enable Separate Distance Units Check Box

If checked, separate distance and velocity units, name and scaling will be enabled. If not enabled, the velocity units, name and scaling will be defined by the Distance Group.

Scaled Distance Name

If the user wants the velocity units to have a different distance scaling than the distance un its a name can be entered here up to 10 characters. For example, the user distance units could be inches while the velocity units are feet per minute.

Velocity Distance Units Scale Factor

This parameter scales the Velocity Distance Units back to actual distance units. To do this, enter the number of distance user units that are equal to one velocity scaled distance unit.

Setting Up Parameters

Separate Distance Units Example:

A user has an application using a leadscrew with a 0.5"/turn lead. The user wants to have Distance Units of Inches, but wants Velocity Units of Feet so mot ion can be programmed in feet/minute.

Distance Units Name — Set to Inches Enable Separate Distance Units — Enabled (checked) Scaled Distance Name — Set to Feet Velocity Distance Units Scale Factor — # of Distance Units / 1 Scaled Distance Unit 1 Foot = 12 Inches Velocity Distance Units Scale Factor = 12

Time Scale List Box

The time can be one of two values: seconds or minutes. This selection sets the real-time velocity time scale.

Decimal Places

The number of decimal places set in this parameter determines the number of digits after the decimal point used in all real-time velocity parameters throughout the software. Using a high number of decimal places will improve velocity resolution, but will also limit the maximum velocity. You can select from zero to six decimal places of program ming resolution.

Acceleration Group

Time Scale List Box

From this list box, select the acceleration time scale to be used fo r all real-time prof iles. T he time scale selected will be used for both acceleration and deceleration parameters. You can select from milliseconds or seconds.

Decimal Places

The number of decimal places set in this parameter determines the number of digits after the decimal point used in all real-time accel/decel parameters throughout the software. Using a high number of decimal places will improve accel/decel resolution, but will also limit the maximum accel/decel rate. You can select from zero to six decimal places of programming resolution.

Torque Group

Units Name

10-chara cter name for the tor que user units.

FM-3 Programming Module Reference Manual

Decimal Places

The number of decimal places set in this parameter determines the number of digits after the decimal point used in all torque p arameters th roughout the softwar e. Using a high number of decimal places will improve torque resolution, but will also limit the maximum torque. You can select from zero to six decimal places of programming resolution.

Scaling

The amount of torque in user torque units will be set equal to the Percent Continuous Current. This parameter is used to scale the actual torque back into the user defined units. The units of this parameter are % ContinuousCurrent. This scaling factor is used along with the user torque to establish a relationship between torque user units and actual torque.

Master Units View

Master Units setup provides the setup parameters for use with sy nch r onized motion. This setup window determines how the encoder signal s are interpreted and establishes the scaling for all master units (master distance, master velocity, etc.).

Figure 31: Master Units View

Encoder Setup Group

Master Source

Master Source indicates the hardware location of the master encoder input. Select module to use the sync input connector on the FM-3 module; select drive to use the drive 44-pin command connector on the drive.

Master Polarity

Master Polarity defines the direction of the master encoder that correspon ds to a positive master position change.

Master Interpretation

Master Interpretation determines how the incoming pulses are seen to generate the synchronized motion command. This setting allows you to choose the appropriate signal type to match the device generating the master input pulses.

Drive Input Signal

Setting Up Parameters

Drive Input Signal is selected accordingly based on whether the incoming pulses are Differential (default) or Single Ended.

Output Source

Output Source determines which signal will be sent to the Sync Output connector on the FM3 module. If Motor Encoder (default) is selected, then the encoder signals from the motor that the FM-3/drive is controlling will be sent out the FM-3 Sync Output connector. If Drive Encoder Input is selected, then the synchronization signals sent to the Dr ive 44-pin command connector will be sent to the FM-3 Sync Output connector. If Module Encoder Input is selected, then the same signal coming into the FM-3 Sync Input connector will be sent out the Sync Output connector.

Master Position Setup Group

Define Home Position

Define Home Position is the value that the Master Position Feedback will be set to when the MasterAxis.DefineHome destination is activated. After the MasterAxis.DefineHome has been activated, the MasterAxis.AbsolutePosnValid source will activate.

Rotary Rollover Check Box

If checked, the rotary rollover feature for the Master Axis will be enabled.

Rotary Rollover

If enabled, the Master Position will rollover to zero at the value specified here. As the master encoder counts up, the master position feedback will increase until it reaches the Rotary

FM-3 Programming Module Reference Manual

Rollover value and then reset to zero and continue to count up. If rotating in the negative direction, the master position feedback will decrease un til it reaches zero , and then s tart over at the Rotary Rollover value.

Master Distance Units

The parameters in this group are used to establish the scaling of the master axis into user units.

Units Name

This is a text string up to 12 characters that will be used to define the units of distance traveled by the master axis for incoming synchronization signals.

Decimal Places

The number of decimal places set in this parameter determines the number of digits after the decimal point used in all distance and position parameters used in synchronized motion throughout the software. Using a high number of decimal places will improve position resolution, but will also limit the maximum position. You can select from zero to six decimal places of programming resolution.

Scaling

The scaling factor is defined as MasterAxis.CharacteristicDistance / MasterAxis.Counts. The numerator (top value of the scaling fraction) is the Characteristic Distance. The denominator (bottom value of the scaling fraction) is the # of Counts. The Characteristic Distance is the number of Master Distance Units that will be traveled per number of counts in the bo ttom of the fraction. The Counts parameter is the number of incoming pulses it takes to tr avel the characteristic distance.

Master Velocity Units

Decimal Places

Decimal Places determines the number of decimal places to be us ed in the velocity parameter for all synchronized motion.

Master Acceleration Units

Decimal Places The number of decimal places set in this parameter determines the number of digits after the

decimal point used in all real-time accel/decel parameters used for synchronized motion throughout the software. Using a high number of decimal places will improve accel/decel resolution, but will also limit the maximum accel/decel rate. You can select from zero to six decimal places of programming resolution.

Master Position Filter

The master filter is designed for applications where the master encoder inpu t requ ire s smoothing due t o low res olution or hi gh gain. These ap plicatio ns includ e low s peed masters , low resolution master encoders, and large follower to master gear ratios.

Filters inherently introduce phase shift (or delay) in the fol lowers response to the master position, velocity and acceleration. The FM-3 provides Feedforward compens ation to correct for these delays introduced by the filter.

The user may set the number of filter samples to be used to "smooth" the master encoder velocity. The more samples used by the filter, the smoother the master velocity signal, however the more positional delay introduced by the filter. This means that more filtering will cause more position error between master and follower. Feedforward is used in conjunction with the filter to provide accurate positioning performance while still maintaining smooth motion.

The table below can be used to best determine the proper filter settings for your application.

Disabled

# of

Samples

Feedforward OFF Feedforward ON

One update of phase shift

(not velocity dependent)

No Filtering

Small Lag (function of speed),

Low Filtering

Medium Lag (function of speed),

Medium Filtering

Large Lag (function of speed),

High Filtering

No Filtering

Poor at low speed,

Low Filtering

Good at low speed,

Medium Filtering

Best at low speeds,

High Filtering

Reduced Lag

No delay,

Setting Up Parameters

Smoother

Increasing Lag

with FF Off

Filter parameters cannot be changed using the "Update to RAM" feature. Changes must be fully downloaded before taking effect.

The gray box in the table above denotes the default setting for the master filter parameters.

Enable Check Box

The enable check box is used to turn on or tur n off the Mast er Position Filter. If ch ecked, the filter is active and the user must select the number of samples used by the filter. If unchecked, the filter is not used.

Samples

Defines the number of samples used by the fi lter to sm ooth th e master sign al. Incr easing the number of samples increases smoothness, but also increases lag. See Filter table above to select proper setting.

FM-3 Programming Module Reference Manual

Enable Feedforward Check Box

The Enable Feedforward Check Box is used to turn on or turn off feedforward. If checked, feedforward is active. If unchecked, feedforward is not used.

Position View

The Position View allows you to set up and view the parameters related to drive positioning. In Figure 32, Position has been selected in the Hierarchy View. The right side of the view is

divided into groups. An explanation of the groups and their functions is provided below.

Figure 32: Position View

Settings Group

Define Home Position

This is the value to which the position command will be set when the Define Home destination is activated. This is used in applications which do not use a home routine, but require a known reference point. The units are defined on the User Units View.

Setting Up Parameters

In Position

The In Position (InPosn) source will activate at the end of a move if the absolute value of following error is less than or equal to the In Position Window for the In Position Time.

In Position Window

The absolute value of the Following Error must be less than or equal to this value at the end of an index in order for the InPosn source to activate. This window is set in units specified in the User Units View.

For example: The In Position window is set to .0025 revs. At the end of an index, the following error

is calculated to be .0012 revolutions. Therefore, the InPosn source will activate. In Position window is set to .001 inches. If at the end of an index, the following error is

calculated to be .0015 inches, then the InPosn source will not activate.

In Position Time

This is the amount of time in seconds that commanded motion must be complete and the absolute value of the following error must be less than the In Position Window for the InPosn source to activate. If set to zero (default), then InPosn will activate as soon as motio n stops and the following error is less than the In Position Window param eter.

Limits Group

Enable Following Error Check Box

Check this box to enable (or disable if not checked) the Following Error Limit. If enabled, a fault will be generated if the absolute value of the following error ever exceeds the value in the following error parameter. If disabled, a fault will never be generated.

Following Error

Following Error is the difference between the Position Command and the Position Feedback. It is positive when the Position Command is greater than the Position Feedback. If the absolute value of the following error exceeds the value you enter here, the drive will generate a Following Error Fault (F). All accumulated Following Error will be cleared when the drive is disabled.

The Following Error Limit is defined in user units.

Enable Software Travel Limits Check Box

Check this box to enable (or disable if not checked) th e software travel limits. If uncheck ed, the software travel limits are not monitored.

FM-3 Programming Module Reference Manual

Software Travel Limits

Software Travel limits can be used to limit machine travel. They are often setup inside the hardware travel limits to add another level of security or protection from exceeding the machines travel limits. The FM-3 module constantly monitors the feedback position, and if this position exceeds the values entered for Software Travel Limit + or -, then the drive will decel to a stop. Software Travel Limits are not functional unless the AbsolutePosnValid source is active. AbsolutePosnValid is active upon successful completion of a home or the DefineHome destination is activated.

To recover from a software travel limit, a jog may be commanded in the opposite direction of travel. For example, if a software travel limit - is hit, then the axis can be jogged in the + direction.

Software Travel Limit +

If the absolute position is greater than or equal to this value the Software Travel Limit Plus Active source shall activate.

A rising edge occurs when the absolute position is greater than or equal to the parameter Software Travel Limit +. A falling edge will be generated as soon as the above is not true.

Software Travel Limit -

If the absolute position is less than or equal to this value the Software Travel Limi t Minus Activate shall activate.

A rising edge occurs when the absolute position is less than or equal to the parameter Software Travel Limit -. A falling edge will be generated as soon as the above is not true.

Rotary Group

Rotary Rollover Check Box

Check this box to enable (or disable if not checked) the rotary rollover feature.

Rotary Rollover

This parameter is used in rotary applications and determines the position at which the internal position counter will be reset to zero.

Example:

The user has a rotary table application with dis tance user units of degrees, 360.00 degrees/1 rev. The Rotary Rollover would be set to a value of 360°.

The motor is traveling in the positive direction. As the feedback position reaches 359.999 and continues on, the feedback position will reset (or roll-over) to zero. If the motor changes direction and travels in the negative direction, the position will rollover at 0 to 359.999 degrees and count down. The resolution of the rotary rollover point is determined by the

Distance Units Decimal Places parameter on the Setup\User Units View in the PowerTools Pro software.

If an absolute index is used with a non-zero rotary rollover point, the FM-3 module will calculate the shortest path to its destination and move in the required direction .

To force the motor to run a certain direction, use the Rotary Plus or Rotary Minus type of indexes.

Online Tab (not shown)

While online, the following real-time data will be dis played.

Motor Position Group

Position Command

This is the commanded position in user units generated by the FM-3 module.

Position Feedback

Setting Up Parameters

This is the feedback position of the motor in user units.

Following Error

The Following Error is the difference (in user units) between the Position Command and the Position Feedback. It is positive when the Position Comm a nd is g reater than the Position Feedback.

Encoder Position

The motor position in en coder cou nts s ince p ower up when the v alue was s et to zero. This is a signed 32-bit value.

FM-3 Programming Module Reference Manual

Velocity View

The Velocity View allows the setup of feedrate override details. By selecting Velocity in the Hierarchy View, the Velocity View will appear on the right (see

Figure 33).

Figure 33: Velocity View

Settings Group

FeedRate Override

This parameter is used to scale all motion. It can be described as scaling in real time. The default setting of 100% will allow all motion to occur in real time. A setting of 50% will scale time so that all moves run half as fast as they do at 100%. A setting of 200% will scale time so that all moves run twice as fast as they would at 10 0%. FeedRate Override is always active and affects all motion, including accels, decels, dwells, and synchronized motion. This parameter may be modified via Modbus or in a program.

Setting Up Parameters

FeedRate Decel/Acc el

The FeedRate Decel/Accel parameter specifies the ramp used when velocity changes due to a change in the FeedRate Override value. The units of FeedRate Decel/Accel are Seconds/ 100% of Feed Rate. Therefore, the user must specify the amount of time (in seconds) to accelerate or decelerate 100% of FeedRate.

Examples:

FeedRate Override is set to 100% (default). The user wishes to slow down motion to 50% of programmed velocity. If FeedRate Decel/Accel is set to 1 Sec/100%, when the FeedRate Override parameter is changed to 50%, it will take 0.5 seconds to decelerate to 50% velocity.

Decel/Accel Time = FeedRate Decel/Accel * % Change in Feedrate

= (1 Sec/100%) * (100% - 50%) = 0.5 Seconds

A user wishes to accelerate from 100% programmed velocity to 175% in 0.5 Seconds. Therefore, the value they need to enter for FeedRate Decel/Accel is calculated as follows:

FeedRate Decel/Accel = Decel Time/ % Change in Feedrate

Online Tab (not shown)

If online, this view will show the limits group and the velocity group.

Velocity Group

Velocity Command

The Velocity Command is the actual command generated by the FM-3 module to the moto r in user units.

Velocity Feedback

This parameter is the actual feedback motor velocity in user units.

= (0.5 Sec) / (175% - 100%) = 0.5 Sec / 75% = (0.5 Sec) / (100% * 75%) = 0.66 Sec / 100%

FM-3 Programming Module Reference Manual

Ramps View

The Ramps View contains all setup information for the global acceleration and deceleration profiles.

By selecting Ramps in the Hierarchy View, the Ramps View will appear on the right (see Figure 34).

Figure 34: Ramps View

Settings Group

The Settings Group contains the Acceleration Type List Box.

Acceleration Type

Press the arrow by the Acceleration Type list box. It will display the various acceleration types: 5/8 S-Curve, 1/4 S-Curve, Linear, and S-Curve.

This is used to select the acceleration/deceleration type for all motion (homes, jogs and indexes). The “S-Curve” ramps offer the smoothest motion, but lead to higher peak acceleration/deceleration rates. “Linear” ramps have the lowest peak acceleration/ deceleration rates but they are the least smooth ramp type. “5/8 S-Curve” ramps and “1/4 SCurve” ramps use smooth ing at the b eginn ing and end of th e ramp but hav e consta nt (lin ear) acceleration rates in the middle of their profiles. The “5/8 S-Curve” is less smooth than the “S-Curve” but smoother than the “1/4 S-Curve”.

S-Curve accelerations are very useful o n machines where product slip is a problem. They are also useful when smooth machine operation is critical. Linear ramps are useful in applications where low peak torque is critical. Below is a comparison of the 4 ramp types:

S-Curve: Peak Acceleration = 2 x Average Acceleration 5/8 S-Curve: Peak Acceleration = 1.4545 x Average 1/4 S-Curve: Peak Acceleration = 1.142857 x Average Acceleration Linear: Peak Acceleration = Average Acceleration

Ramps Group

Setting Up Parameters

Stop Deceleration

The value you enter here defines the deceleration rate which is used when the Stop destination is activated. The default is 100 RPM/second.

The Stop destination is found in the Ramps Group in the Assignments view.

Feedhold Decel/Accel

When the Feedhold destination is activated, the motor will d ecelerate to a sto p in the time specified by the FeedholdDecelTime parameter. When feedhold is cleared, the motor will accelerate back to speed in the same specified period of time.

Feedhold is a means to halt the motor within a velocity profile and then return to the profile later at the exact same place in the profile. Feedhold does not ramp and does not decelerate in terms of velocity. Instead, it stops by decelerating time. For example, if the motor is running at 50 revs/second and feedhold is activated with 2 seconds specified in the FeedholdDecelTime parameter, then the motor will actually slow and stop in 2 seconds as measured time (on a time/velocity profile) goes from 100% to 0%.

Travel Limit Decel

The value entered here is the deceleration ramp that is used when a software or hardware travel limit is hit.

FM-3 Programming Module Reference Manual

Torque View

The Torque View allows you to edit torque level and limit parameters as well as view realtime torque values when online.

By selecting Torque in the Hierarchy View, the Torque View will appear on the right (see Figure 35). The right part of the screen is divided into groups. An explanation of the groups and their functions is provided below.

Figure 35: Torque View

Settings Group

Torque Level

This parameter sets the activation point for the Torque Level Active source. If set to 100%, the Torque Level Active source will activate any time the Torque Command reaches or exceeds 100% continuous. This parameter is specified in Torque User Units.

Limits Group

Torque Limit

This parameter sets the value to which the Torque Command will be limited when the Torque Limit Enable destination is active. To make the Torque Limit always active, assign the Torque Limit Enable destination to the Initially Active source on the Assignments view.

Peak Torque

Displays the Peak Torque for the motor drive combination setup in th e Setup View.

Online Status Tab

If online, this view will show the Torque Command, Limited Torque, Foldback RMS, and Shunt Power RMS.

Setting Up Parameters

FM-3 Programming Module Reference Manual

Tuning View

The Tuning View allows you to modify tuning parameters based on specific application information.

By selecting Tuning in the Hierarchy View, the Tuning View will appear on the right (see Figure 36). The right part of the screen is divided into groups. An explanation of the groups and their functions is provided below.

For help on calculating tuning parameters and more in-depth tuning inform ation, turn to “Tuning Procedures” on page 213.

Figure 36: Tuning View

Load Group

Inertia Ratio

Inertia Ratio specifies the load to motor inertia ratio and has a range of 0.0 to 50. 0. If the exact inertia is unknown, a conservative approximate value should be used. If you enter an inertia

value higher than the actual inertia, the resultant motor response will tend to be more oscillatory.

Friction

This parameter is characterized in terms of the rate of friction increase per 100 motor RPM. If estimated, always use a conservative (less than or equal to actual) estimate. If the friction is completely unknown, a value of zero should be used. A typical value used here is less than one percent.

Low Pass Filter Group

The Low Pass Filter will reduce machine resonance due to mechanical coupling and other flexible drive/load components by filtering the command generated by the velocity loop.

Low Pass Filter Enable Checkbox

When selected it enables a Low Pass Filter to be applied to the output of the velocity command before the torque compensator.

Setting Up Parameters

Low Pass Frequency

This parameter defines the Low Pass Filter cut-off frequency. Signals exceeding this frequency will be filtered at a rate of 40 dB per decade. The default value is 600Hz.

Tuning Group

Response

The Response adjusts t he velocity loop bandw idth with a range of 1 to 500 Hertz. In general , it affects how quickly the drive will respond to commands, load disturbances and velocity corrections. A good value to start with (the default) is 50 Hz. The maximum value recommended is 80 Hz.

Enable Feedforwards Check Box

When feedforwards are enabled, the accuracy of the Inertia and Friction parameters is very important. If the Inertia parameter is larger than the actual inertia, the result could be a significant overshoot during ramping. If the Inertia parameter is smaller than the actual inertia, following error during ramping will be reduced but not eliminated. If the Friction parameter is greater than the actual friction, it may result in velocity error or instability. If the Friction parameter is less than the actual friction, velocity er ror will be reduced but not eliminated.

Position Error Integr al Group

Time Constant Check Box

This enables the Time Constant parameter.

FM-3 Programming Module Reference Manual

Time Constant

Position Error Integral is a control term, which can be used to compensate for the continuou s torque required to hold a vertical load against gravity. It is also useful in low speed applications, which have high frict ion.

The user configures this control term using the “Position Error Integral Time Constant” parameter. This parameter determines how quickly the drive will correct for in-position following error. The time constant is in milliseconds and define s how long it will take to decrease the following error to 37 percent of the original value. In certain circumstances the value actually used by the drive will be greater than the value specified here.

Min Time Constant = 1000/Response

For example, with “Response” set to 50, the minimum time constant val ue is 1000/50 = 20 msec.

Faults View

The Faults View displays any active faults. Figure 37 below shows th e Faults view.

Setting Up Parameters

Figure 37: Faults View

Active Faults Group

The Active Faults group contains the Active Faults window.

Active Faults Window

This window displays any active faults in the system. Those faults which do not require a reboot can be cleared by clicking on the Reset button. For more detailed fault information, refer to “Diagnostics and Troubleshooting” on page 225.

FM-3 Programming Module Reference Manual

Power Up Group

These parameters will be active when online with the drive.

Power Up Count

This parameter shows the numbers of times the drive that the FM-3 is attached to has been powered up since the last reset be the factory.

Power Up Time

This parameter shows the time, in hours, since the drive was last powered up.

Total Power Up

This parameter shows the total time that the drive has been powered up since reset b y the factory.

PLS View

The PLS View allows users to define Programmable Limit Switches (PLS) for advanced machine operation.

By selecting PLS in the Hierarchy View, the PLS View will appear on the right (see Figure

38).

Setting Up Parameters

Figure 38: PLS View

A PLS can be used to turn on or off a bit based on feedback position, commanded position, or master feedback position. Eight global PLS’s are available for a single application. To operate a PLS, first it must be enabled (see the PLS enable destinations in the assignments view) and then the Absolute Position Valid source must be active. Each PLS has its own OnPoint and Off Point, as well as a Rollover Point.

The terms OnPoint and Off Point assume movement in the positive direction. Those labels should be reversed if traveling in the negative direction.

FM-3 Programming Module Reference Manual

Number of PLS Points

This parameter d eter mines the number of PLS Points that will be us ed. Count always begins with 0, so 5 points will be 0 to 4. Up to eight PLS points may be used simultaneously.

Source

The source of a PLS can be assigned to the motor axis (MotorPosnFeedback, MotorPosnCommand) o r a mas ter s ynch ron ization sig nal (MasterPos nFeedback ). Th e term motor axis refers to the motor being controlled by the FM-3/drive combination. The source list box is used to select the source for the individual PLS.

On Point

PLS.#.Status will be active when the selected source position is between the PLS.#.OnPosn and the PLS.#.OffPosn. Assume that the PLS.#.Direction is set to "Both". When traveling in the positive direction and the feedback position executes the OnPosn, the PLS.#.Status will activate. As the motor continues in the same direction, the PLS.#.Status will deactivate when feedback position reaches or exceeds the OffPosn. If motor travel changes to the negative direction, the PLS.#.Status will activate when the feedback position reaches the OffPosn, and will deactivate when it continues past the OnPosn. All on/off positions are defined in user units.

PLS.#.Status will be act i ve if:PLS.#.OnPosn < Feedback Posi tion £ PLS.#.OffPosn

Off Point

PLS.#.Status will be active when the selected source position is between the PLS.#.OnPosn and the PLS.#.OffPosn. Assume that the PLS.#.Direction is set to "Both". When traveling in the positive direction and the feedback position reaches the OnPosn, the PLS.#.Status will activate. As the motor continues in the same direction, the PLS.#.Status will deactivate when feedback position reaches or exceeds the OffPosn. If motor travel changes to the negative direction, the PLS.#.Status will activate when feedback position reaches the OffPosn, and will deactivate when it continues past the OnPosn.

PLS.#.Status will be act i ve if:PLS.#.OnPosn < Feedback Posi tion £ PLS.#.OffPosn If using negativ e val u es for your OnPosn and OffPosn, the most negative value should go in

the OnPosn parameter, and the least negative value should go in the OffPosn. If the PLS has a rollover point, and the OnPosn is greater than the OffPosn, the PLS will b e

active whenever the position feedback is not between the On an d Off positions, and in-active whenever the position feedback is between the two positions. However, the PLS.#.Status will not turn on until it reaches the OnPosn the first time.All on/off positions are defined in user units.

Direction

This parameter specifies the direction of motion that a particular PLS output will function. If set to Both, the PLS will activate regardless of whether the motor (or master motor) is moving in the positive or negative direction. If set to Plus, the PLS will activate only when the motor

Setting Up Parameters

is moving in the positive direction. If set to Minus, the PLS will activate only when the motor is moving in the negative direction.

For example: A flying cutoff or flying shear application may use this feature to activate

the PLS to fire the knife only when the axis is moving in the positive direction.

If accessing this parameter fro m a network, the following table displays value s for this 16- bit integer.

0N/A 1 Both 2Plus 3 Minus

Rotary Enable

This parameter is used to enable the RotaryRolloverPosn for this PLS.

Rollover Point

This parameter is the absolute position of the first repeat position for this PLS. When enabled it causes the PLS to repeat every time this distance is passed. The repeating range begins at an absolute position of zero and ends at the RotaryRolloverPosn.

For example, in a rotary ap plication a PLS coul d be setup wi th an OnPos n of 90 degrees and an OffPosn of 100 degrees. If the RotaryRolloverPosn is set to 360 degrees the PLS would come on at 90, go off at 100, go on at 450 (360+90), go off at 460 (360+100), go on at 810 (2*360+90), go off at 820 (2*360+100), and continue repeating every 360 degrees forever.

FM-3 Programming Module Reference Manual

Setup NVM View

At power-down, parameters can be saved to Non-Volatile Memory (NVM). See the "How Communications Work" section of the "Operational Overview" chapter for more details. In PowerTools Pro, you can customize which parameters will be saved in non-volatile memory.

Figure 39: Setup NVM View

NVM Warning: Assi gning p arameters to NVM could shorte n the l ife of your F M-3 or FM-4 ! The Non-Volatile memory list displays the parameters that will be saved after power down. A command to store these parameters into the NVM is given to the module whenever a parameter on the li st chan ges va lue (vi a a prog ram or a commun icatio ns networ k). Cu rrently the NVM in the FM-3 will accept at a minimum, 1 million writes before the FM-3 ceases operation.

Therefore, do not add parameters to the NVM list if these parameters will be changing more than an average of 1 time every 30 seconds.

User Variables View

User variables allow the user to store data related to their system into a parameter, which the user can name. The user must define each user variable by giving it a name, resolution (number of decimal places), and in itial value. All user variables are signed 32-bit parameters . Setup for the User Variables is done on the User Variables view located under the Setup group in the hierarchy. The User Variables view is shown in Figure 40 below.

Setting Up Parameters

Figure 40: User Variables Vie w

The following parameters are part of the User Variable definition:

Name

This is a twelve-character string that allows the user to assign a descriptive name to the parameter. Spaces are not allowed in the name of a user variable.

Decimal

This parameter defines the number of digits (up to 6) to be used after the decimal point for the specific variable. This is the maximum resolution that the parameter will have.

FM-3 Programming Module Reference Manual

Initial Value

This is the initial value of the user variable that will be used on power up. If the user variable has been configured as a Save to NVM parameter, then the value in NVM will overwrite the initial value on power up.

Adding and Deleting Variables

The default number of variables is ten. To add more user varia bles, click o n the up arrow n ext to the “Number of User Variables” window on the User Variables view. The maximum number of user variables is 500.

Only the last variable in the list can be deleted. To delete the last variable, simple click on the down arrow next to the “Number of User Variables” window.

User variables are all of a Global type, meaning that they can be accessed from any program.

Online Tab (not shown)

While online with the FM-3, an online tab will be shown on the lower half of the User Variables view. This online tab will show the current value of each of the user variables.

Using Variables in a Program

Once setup, user variables can be used inside a program in calculations, motion profile setup, or any other user-desired function. To access user variables, click on the Drag in Variables icon in the user progr am toolbar. User Variabl es is a branch in the Drag In Variables selection box.

User Bits View

User Bits act just like User Variables except that they allow the user to store bit level parameters rather than 32-bit param eters. The user may customize each User Bit by giving it a Name and an Initial Value.

The Name for each bit may be up to 12 characters in length, and must start in an alph a character (non-numeric character). Spaces are not available in the Name for a User Bit, however the underscore character ("_") may be used.

The Initial Value for each us er bit is configured using a checkbox for the specific bit. To make the Initial Value "On" or "Active", simply enable the checkbox for that bit. The default value for each User Bit will be "Off" or "Inactive".

User Bits are configured on the User Bits view as shown in Figure below.

User Bits may be accessed in the User Program. Several examples of this are shown below. Bit.Raise_Table = ON

Setting Up Parameters

Wait For Bit.Vacuum_ON = OFF Wait For Bit.RunPart_A OR Bit.RunPart_B OR Bit.RunPart_C If (Bit.RunPart_A = ON AND Bit.Vacuum_ON = OFF) Then Call Program.1 Endif Bits are turned on by setting them equal to ON, TRUE, YES, SET, or ENABLE (not case

sensitive), and can be deactivated by setting them equal to OFF, FALSE, NO, CLEAR, or DISABLE. Setting an individual bit equal to 1 or 0 in a user program will cause a red dot error. The Boolean values listed above must be used.

FM-3 Programming Module Reference Manual

Figure 41: User Bits View

Adding and Deleting User Bits

User bits can be added or dele ted in groups of 32-bi ts. Individual bits cannot be added or deleted. The default number of User Bits available is 32. To add an additional 32 bits, simply click on the “Up Arrow” on the spinner box at the top of the User Bits view (see Figure 41). To decrease the number of User Bits by 32, click the “Down Arrow” on the spinner box. When decreasing the number of User Bits, it is always the last 32 bits in the list that will be eliminated.

Setting Up Parameters

000

01000011110000111111101010110

00000010100001101011101010100

User 32-bit Bit Register and User Bit Masking

When using different communications protocols (i.e. DeviceNet, Profibus, Modbus), it is often desirable to access groups of User Bits in a single parameter, rather than having to access them individually. In the FM-3 module it is possible to access 32 User Bits in a single parameter. This parameter is named BitRegister.#.Value. Because some of the 32 User Bits may be used by the program, and should not be modified from the network communications, it is possible to “Mask Off” certain bits. Masking bits prevents them from being modified in the program when the 32-bit parameter is written to.

When a User Bit Register (group of 32 User Bits) is written to, the value is then logic-AND’ed with the mask to determine the resulting state of each of the 32 individual bits. If the individual bit value of the 32 -bit mask is “1”, then the correspo nding bit fr om the written 32bit parameter is passed through, and the resulting value stored in the s pecific b it will be the written bit value. If the bit value of the 32-bit mask is “0”, then that particular bit is blocked (or masked), and the resulting bit value does not change, (Original Value AND NOT 32-Bit Mask) or (Value Written over Network AND 32-Bit Mask). An example of this is shown below.

Original Value

Value written over network

32-bit Mask

Result stored in each bit

Bit #31

100000010100000010000010000000

011

010101010101010101010101010101

110

Figure 42: Writing to the User Bit Register

The Mask is only used when WRITING to the 32-bit parameter, BitRegister.#.Value. When reading the 32-bit value, all bits are read regardless of the mask.

FM-3 Programming Module Reference Manual

Value

Write

Network

Master

Written data is AND’ed with the Mask and then written into 32-bit Value.

Read

FM-3/4

AND

Mask

Read data is read directly from the 32-bit Value and bypasses the Mask.

Figure 43: User Bits Read/Write Process

Configuring the User Bit Mask Register

The User Bit Mask is a 32 -bi t p aramet er t hat can be configured through Power Tools Pr o, in the User Program, or over the communications network. The default value for the Mask register is 0xFFFFFFFF (HEX), or all bits ON. To change the Mask value using PowerTools Pro, navigate to the Mask tab on the User Bits view. See Figure below).

In the User Bits Mask view, each bit of the Mask can be set to 0 or 1 indi vidually. ON (o r 1 ) is indicated by a shaded square, and OFF (or 0 ) is indicated b y an empty s quare. B it 31 is the most significant bit in the word, and bit 0 is the least significant bit. If the bit is shaded, it means that particular bit will be passed through when written.

Each additional group of 32 User Bits that are added, a new Mask parameter will appear for that group. Mask 0 wi ll co ntro l the mas k for User Bits 0 through 31. Mask 1 wil l cont ro l the mask for Bits 32 through 63. This sequence repeats for each additional 32 bits that is added.

Setting Up Parameters

Figure 44: User Bits Mask View

To configure the mask i n a user p rogram, the parameter named BitRegisiter.#.ValueMask is written to. The mask can be written to using Hexadecimal based values or decimal based values. To write a hexadecimal value to the parameter, the hex value must be preceded with the characters "0x". To write a decimal value to the parameter, normal notation is used. For examples of writing the Mask to a value in a program, see below.

For example: BitRegister.0.ValueMask = 0xFFFF0000 This example writes a 1 into all bits of the upper sixteen bits, and 0 into each of the lower

sixteen bits using hexadecimal value. To write the same value using decimal notation, the following instruction would be used.

For example: BitRegister.0.ValueMask = 4294901760 This instruction would also write a 1 into each of the upper sixteen bits, and a 0 into each of

the lower sixteen bits.

FM-3 Programming Module Reference Manual

I/O Setup Group

The I/O Setup group contains four views that control input and output functions as well as other drive functions. These views are as follows: Selecto r, Assignm ents, Input Lines and Output Lines. These can be viewed by expanding I/O Setup by simply clicking on any one of the setup views underneath the I/O Setup.

Assignments

External control capability is provided through the use of assignments to the sou rces (D rive Inputs and Module Inputs) or the destinations (Drive Outputs and Module Outputs). Assignments provide a mechanism for the user to define the internal and external dynamic control structure to separate complex motion profiles. These functions directly correspond to any input or output line on th e drive or the FM-3 module. External co ntrollers, such as a PLC or other motion controllers, may be connected to affect or monitor the device’s operation.

The drives are equipped with five optically isolated input lines (one dedicated to a Drive Enable function) and three optically isolated output lines. The FM-3 mo dule has an additional eight input and four output lines.

The drive’s input and output lines can be accessed through the removable 10-pin I/O connector (J6), or through the 44-pin command connector (J5). The FM-3 input and output lines are located on the front of the FM-3 module.

All inputs and outputs are configured as sourcing and are designed to operate from a +10 to 30 VDC power source. You are responsible for limiting the output current to less than 200 mA for each digital output.

Assignments View

The Assignments Vi ew not only displays information but als o makes ass ignmen t s regar di ng the source and the destination.

Setting Up Parameters

Figure 45: Assignments View

The Assignments View is used to tie a source to a destination. Destinations are functions that need to be triggered, such as Index Initiates, Program Initiates, Jog Initiates and so on.

Sources are located on the left side of the Assignment View and reflect events that occur in the drive. These events are based on drive activ ity. By expan ding indiv idual group s, you w ill see more detailed parameters. For example, if you expand the Inputs source group, you will see DriveInput.1 thro ugh ModuleInpu t.8, as show n in Figure 45. You can use these even ts to trigger certain actions (or destinations) on the right side of the view.

To make an assignment in the FM-3 module occur, you must tie a source to a destination. Any source can be tied to any destination to create the desired system operation.

Creating An Assignment:

Various methods can be used to tie a source (such as DriveInput.1) to a destination, such as Index.0.Initiate:

FM-3 Programming Module Reference Manual

Drag and Drop Method

First, position y our pointer over the sour ce on the left that you wis h to assign to the destinatio n on the right. Press the left mouse button while over the source, and hold the button down. While holding the left button down, drag the source over until your pointer is positioned over the desired destination and release the left mouse button.

Destinations can also be dragged over to sources.

Assign Button Method

Click on both the source and destination you wish to assign to each other. Once both are highlighted, the Assign button in the lower left corner of the view will become enabled. Click on the Assign button to complete the assignment. Figure 4 6 shows the sour ce and destination highlighted, and the Assign button has just been clicked.

Once an assignment has been made, you will see the “Assigned to..” and the “Set From” columns be filled in for the specific sources and destinations. This indicates what destination(s) an individual source has been assigned to, and what source(s) an individual destination is assigned to.

Any source can be assigned to up to ten different desti nations maximum. Any destination can have as many sources as desired assigned to it.

Deleting An Assignment

Delete Button Method

Click on both the source and destination your wish to delete. Once both are highlighted, the Delete button will become available. Click on the Delete button to remove the assignment.

Right Click Method

Position the pointer over the specific assignment you with to delete and click the right mouse button. A selection box will appear. From this selection box, choose Delete.

After either of these procedures, the assignment will disappear.

Setting Up Parameters

Figure 46: Tying a Source to a Destination

Assignment Polarity

The active state of an assignment can be programmed to be Active Off, Active On, or Custom using PowerTools Pro. Making an assignment “Active On” means that the destination will be active when the source it is assigned to becomes active, and is inactive when the source is inactive. Making an assignment “Active Off” means that the destination will be active when the source it is assigned to is inactive, and will be inactive when the source is active.

The polarity of the assignment can also be changed to Custom when required. Custom polarity allows you to make a destination activate and deactivate based on two different sources.

FM-3 Programming Module Reference Manual

Note

Destination functions which initiate motion (Jog.P lus Initiate, Jog.MinusInitiate, Index.#.Initiate, and Home.#.Initiate) cannot be set “Active Off”.

Default polarity for a new assignment is Active On. Two methods will change the polarity of an assignment.

Polarity Button Method

Click on both the source and the destination to be changed. Once highlighted, the Polarity button will become available in the lower left corner of the view. Click on the Polarity button and change the settings as desired in the Polarity edit box. Click OK to apply the changes.

Right Click Method

Position the pointer over the specific assignment you with to change polarity for and click the right mouse butt on. A s e lectio n b ox will appear. From this selection box, choose Polarity. A Polarity edit box will appear. Change the Polarity settings as desired and click OK to apply the changes.

User Level

The User Level filters the available assignments. The User Level is changed on the Options menu at the top of the PowerTools toolbar. Choose Options/Preferences/ User Levels . Easy mode filters out all but the most commonly used sources and destinations. Detailed mode filters out less, expanding the list of sources and destinations for more comp lex configurations. Too Much mode do es not filter at all and provides all sources and destinations.

Only Show Assigned

This checkbox removes the unassigned s ources and destinations fro m this view. It allows the user to quickly see how many sources and destinations have been assigned.

Assignments that Automatically Use Position Capture

Certain assignments (Sources or Destinations) automatically generate position capture data internally for greater performance and accuracy. This captured data is used by the FM-3 module, but is not directly available to the user. Following is a list of assignments that automatically generate or use captured data.

Sources that generate capture data

Module Inputs – The FM-3 Module Inputs (not base drive inputs) are const antly mon itored by the processor, and when activated will automatically capture related data. The processor controls all resetting requirements. The capture only occurs on the rising edge of an input. When the input is activated, the captured data will automatically be passed to the destination

Setting Up Parameters

that it is assigned to. The destination may then use the captured data to accurately initiate motion (if it is a motion-related destination).

Motor Encoder Marker – The rising edge of the motor encoder marker pulse will automatically capture data. This will allow the user to accurately initiate motion on the rising edge of the motor encoder marker pulse. The falling edge of the marker pulse does not capture data.

Master Encoder Marker – The rising edge of the master encoder marker pulse will automatically capture data. This allows the user to accurately initiate motion on the rising edge of the master encoder marker pulse. The falling edge of the marker pulse does not capture data.

Index/Jog Command Complete – Activation of the command complete signal at the end of indexes and jogs will automatically capture data. A subsequent index, jog, or dwell can then use the captured data to start itself extremely accurately at the end of the previous motion.

Index/Jog At Velocity – Activation of the command complete signal at the end of indexes and jogs will automatically capture data. A subsequent index, jog, or dwell can then use the captured data to start itself extremely accurately at the end of the previous motion.

PLS Status – A rising or a falling edge of a Global PLS will automatically capture data for use in initiating motion. In order to accurately initiate motion from a Global PLS, an assignment can be made from PLS.#.Status to the initiate destination.

Destinations that use captured data:

Index/Jog Initiates – When one of the sources listed above is assigned to an Index or Jog Initiate, the captured information is automatically applied to the index starting poi nt. This offers extremely high accuracy for initiation of motion, which is beneficial especially in synchronized applications.

Index.#.SensorTrigger – The sensor tri gger des tinati on us ed in regi strati on indexes can us e captured data to accurately calculate the ending position of the index based on the Registration Offset parameter. The Offset distance is added to the captured position to get the accurate stopping position fo r the registration index.

Selector View

The Selector View is located under I/O Setup in the Hierarchy on the left of the view.

FM-3 Programming Module Reference Manual

Figure 47: Selector View

The selector allows conservation of the number of input lines by using a binary input conversion to decimal. The binary select lines are set up by assigning sources to the selector.select destinations on the Assignments view. In most cases, hardware inputs are assigned to the selector.select functions (see Figure 47).

Based on the status of the binary select lines, a selector.selection source will be active when the Selector.SelectorInitiate destination is activated.

At the top of the Selector view, the Selector Input Destinations field defines how many binary select lines will be used. The number of Selector.Selections is a direct result of the number of select lines. The formula is as follows:

# of selections = 2

where n is the number of select lines.

The maximum number of select lines is eight.

Once you have determined how many select lines you want, the assignments to these Selector.Select lines must then be made in the Assignments View.

Setting Up Parameters

Figure 48: Assignment View

For example, if we entered 2 for the number of Selector Inpu t Destinations , we would ha ve 4 selection lines (Selector.Selection0 through Selector.Selection3). The Selector.Selection number that is activated is determined by the status of the Selector.Select lines when the Selector.Selector Initiate bit is activated. Each select line has a specific binary value.

The binary value is determined as follows:

x 2nwhere Sn = Status of Selector.Select line n

Sn = 0 if Selector.Select line n is inactive, and Sn = 1 if Selector.Select line n is active The sum of all the binary values determines which Selector.Selection line will be active.

FM-3 Programming Module Reference Manual

The following examples demonstrate how to determine which Selector.Selection will activate based on the Selector.Select lines.

Example 1:

If Selector.Select2 is active, Selector.Select1 is inactive, and Selector.Select0 is active, then the total binary value is as follows:

= 1, S1 = 0, and S0 = 1. Therefore,

Total Binary Value = (1 x 2

) + (0 x 21) + (1 x 20) Total Binary Value = 4 + 0 + 1 Total Binary Value = 5 Therefore, when Selector.SelectorInitiate activates, then Selector.Selection5 will activate.

Example 2:

If Selector.Select2 is inactive, Selector.Select1 is active, and Selector.Select0 is active, then the total binary value would be as follows:

= 0, S1 = 1, and S0 = 1. Therefore,

Total Binary Value = (0 x 2

) + (1 x 21) + (1 x 20) Total Binary Value = 0 + 2 + 1 Total Binary Value = 3 Therefore, Selector.Selection3 would activate. The Selector.Select lines can change without any action until the Selector.SelectorInitiate

destination is activated.

Selector.Selection sour ces can be tied to any destinat ion in the Assig nments view . Figure 48 shows the four selection lines bein g tied to Index 0 through Index 3 initiates. By doin g this, we could initiate up to four indexes with only two select lines and a selector initiate. This can help minimize the number of inputs required to initiate a large number of indexes o r programs.

Input Lines View

The Input Lines View dis pla ys any fu ncti ons that h ave b een as sig ned to the dr ive or mod ule hardware inputs. See Figure 49.

Note

No assignments can be m ade using th e Input Lines Vi ew, assignment s are only dis played in the Input Lines View.

Setting Up Parameters

Figure 49: Input Lines View

Two functions can be performed on the Input Lines vi ew.

Name

You can assign a descriptive name to each input and make the setup easier to follow. The length of the text string is limited by the column width with a maximum of 12 characters. Simply double click on the Name field of any input line to assign a name to it.

Debounce

You can program a “Debounce Time” to any input line, which means the motion profile will need to be steady for at least the debounce time before it is recognized. This feature helps prevent false triggering in applications in noisy electrical environments. At the end of the debounce time, the next action can occur.

FM-3 Programming Module Reference Manual

Figure 50: Input Line Diagram

If the Input Line attached to the home sens or is debounced, the actual rising edge of th e Home Sensor is used to determine the Home Reference Position (the debounce time ensures a minimum pulse width).

Output Lines View

The Output Lines View display s any functions that have been assigned t o the drive or module hardware outputs. See Figu re 51.

Figure 51: Output Lines View

Names

Descriptive text names can be assigned to individual output lines to make the setup easier to follow.

Analog Inputs View

The FM-3 module is able to use the analog input circuitry located on the drive. The analog input accepts a +10 to –10 Volt signal. The analog input can be setup on the Analog view, which is located underneath the I/O Setup group in the PowerTools Pro hierarchy.

Setting Up Parameters

Figure 52: Analog Inputs View

The drive has a 14-bit analog to digital converter (A/D) which is used to transform the analog voltage to a usable parameter in the FM-3 module. The analog input is scanned every 100 microseconds.

User Units

This parameter allows the user to enter a 12 character string to be used as units for the analog input parameter.

Decimal

This parameter defines how many digits (up to six) are used after the decimal place for the user unit scaled analog input parameter. This defines the maximum resolution of the analog input parameter.

FM-3 Programming Module Reference Manual

Bandwidth

This parameter sets the low-pass filter cutoff frequency applied to the analog input. Signals exceeding this frequency will be filtered at a rate of 20 dB per decade.

Maximum Value

This parameter is used for user unit scaling. Enter the maximum value in analog user units to which the maximum analog voltage should correspond.

Maximum Voltage

Enter the maximum voltage that will be seen on the analog input terminals. The user can enter the value in this field by hand, or set the analog source to it’s maximum value, and click on the “Set Max Voltage to Measured” button next to the edit box. This will read the current value on the analog channel and enter it into the Maximum Voltage edit box.

Minimum Value

Enter the minimum value in analog user units that the minimum analog voltage should correspond to.

Minimum Voltage

Enter the minimum voltage that will be s een on the analog input ter minals. The user can enter the value in this field by hand, or set the analog source to it’s minimum value, and click on the “Set Min Voltage to Measured” button next to the edit box. This will read the current value on the analog channel and enter it into the Minimum Voltage edit box.

Raw Value

This parameter is visible while Online. It is the raw analog input in Volts.

Value

This parameter is visible while Online. This is the results of the analog value scaled to the user unit value.

Read Max/Min Voltage Settings

This button is not funtional for the FM-3 module.

Motion Group

All motion parameters related to Jogs, Homes, Indexes and Gearing are located in the Motion hierarchy group.

Motion views will use units that correspond to Realtime or Synchronized motion. This choice is made on each motion view. The un its are customized in the Setup Group: Realtime units are defined on the User Units View, and Synchronized units are defined on both the User Units View and the Master Units View.

Each of the motion views, when online, hav e an Online tab that displays feedback information and provides buttons to initiate motion.

Setting Up Parameters

FM-3 Programming Module Reference Manual

Jog View

Jogging produces rotation of the motor at controlled velocities in a positive or negative direction. The jog is initiated with the Jog.#.Initiate destination or from a program.

Jog Number

Jog Name

Time Base

Figure 53: Jog View

This scroll box allows you to select between Jog0 and Jog1 setup views.

This is a descriptive character string which can be assign ed to the specific jog. Giving a n ame to a jog can make the motion setup easier to follow.

This list box allows the user to select between a jog that is based on time (Realtime) as defined by user units, normally in s econds, or a time based on Master position via an external encoder (Synchronized) set in the Master Units View.

Control Techniques FM-3 Reference Manual

Specifications and Main Features

Frequently Asked Questions

User Manual