Control Techniques FM-3 Reference Manual

FM-3
Programming Module

Reference Manual

P/N 400508-01

Revision: A8

Date: March 10, 2004

© Control Techniques Drives, I nc. 2000-2004

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

© 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.

ii

Customer Support

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

Telephone: [phone] or [phone]
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 [phone]

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: [e-mail]
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 [phone] or [phone]

Email: [e-mail]
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

iii

• 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 [phone] or [phone]

Email: [e-mail]
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 [phone] or [phone]

Email: [e-mail]
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) [phone] or [phone]

Email: [e-mail]
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.

iv

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

EN

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.

v

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)

vi

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

vii

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.

viii

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

ix

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

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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

xi

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.

1

.

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.

1

FM-3 Programming Module Reference Manual

Figure 2: FM-3 Programming Module Features

2

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

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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.

4

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)

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FM-3 Programming Module Reference Manual

Security: 1

Screen

EN-204 Adr01
MG-316
SECUR

Menu

PBus-

Group

Slave Address

MODIF MENU

Security: 1

Baud Rate

MENU

Security: 0

Network Sts

MENU

Security: 0

Module Sts

MODIF MENU

Security: 0

MasterAddr

MENU

Security: 0

MsgProcessed

MENU

Security: 0

DVNET+

Group

MacID

MODIF MENU

Security: 1

Baud Rate

MODIF MENU

Security: 1

Security: 1

Network Sts

MENUMODIF

Security: 0

Module Sts

MENU

Security: 0

Net OK

MENU

Security: 0

Conn Type

MENU

Security: 0

Mster MacID

MENU

Security: 0

Transmit Cntr

MENU

Security: 0

Receive Cntr

MENU

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?

OK

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

MENU

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

MENU

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

MENU

Security: 0

ModuleInput

MENU

Security: 0

DriveOutput

MENU

Security: 0

ModuleOutput

MENU

Security: 0

Fault Sts 1

MENU

Security: 3

Fault Sts 2

MENU

Security: 0

Clear Fault?

OK MENU

Security: 0

Module Rev

MENU

Security: 0

Boot Rev

MENU

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

6

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.

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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.

8

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.

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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

10

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.

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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.

12

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

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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.

14

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.

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FM-3 Programming Module Reference Manual

n

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

2

Marker

Sensor

Sensor

+ 100

Time

Marker

1

Back Off Sensor

Home Move

4

Offset Move

2.0 Revs

Offset

Figure 18: Home Move Sequence

16

5

Final Position = End of Home Positio