Emerson 400508-02 User Manual

FM-3 Programming Module

Installation Manual

P/N 400508-02

Revision: A2

Date: August 23, 2000

© EMERSON Motion Control, Inc. 2000

FM-3

Programming Module

Installation Manual

Information furnished by EMERSON Motion Control is believed to be accurate and reliable. However,
no responsibility is assumed by EMERSON Motion Control for its use. EMERSON Motion Control
reserves the right to change the design or operation of the equipment described herein and any
associated motion products without notice. EMERSON Motion Control 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 400508-02

Revision: A2

Date: August 23, 2000

© EMERSON Motion Control™, Inc. 2000

© EMERSON Motion Control, Inc. 2000
Part Number: 400508-02
Revision: A2
Date: August 2000
Printed in United States of America
Information in this document is subject to change without notice. Companies, names, and data used in

examples herein are fictitious unless otherwise noted. 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 EMERSON Motion Control.

The following are trademarks of EMERSON Motion Control and may not be reproduced in any
fashion without written approval of EMERSON Motion Control: EMERSON Motion Control,
EMERSON Motion Control PowerTools.

EMERSON Motion Control, a Division of Emerson Electric Co.
EMERSON Motion Control, Inc. is not affiliated with Microsoft Corporation, owner of the MicroSoft,

Windows, and Windows NT trademarks.

This document has been prepared to conform to the current released version of the 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 Service

It is EMERSON Motion Control’s goal to ensure your greatest possible satisfaction 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 by
phone, fax or modem, you can access EMERSON Motion Control support information 24
hours a day, seven days a week.

EMERSON Motion Control
12005 Technology Drive
Eden Prairie, Minnesota 55344
U.S.A.

FAX [phone]

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

Website: www.emersondrivesolutions.com

If you have Internet capabilities, you also have access to technical support using our Website
at http://www.emersondrivesolutions.com. The Website includes technical notes, frequently
asked questions, release notes and other technical documentation. This direct technical
support connection lets you request assistance and exchange software files electronically.

Service Support [phone]

EMERSON Motion Control’s products are backed by a team of professionals who will
service your installation wherever it may be. Our customer service center in Eden Prairie,
Minnesota is ready to help you solve those occasional problems over the telephone. Our
customer service center is available 24 hours a day for emergency service to help speed any
problem solving. Also, all hardware replacement parts, should they ever be needed, are
available through our customer service organization.

When you call, please be at your computer, have your documentation in hand, and be
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.
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.
You can also contact us by email: [e-mail]

iii

Need on-site help? EMERSON Motion Control provides service, in most cases, the next day.
Just call EMERSON’s customer service center when on-site service or maintenance is
required.

Training Services [phone] or Fax [phone]

EMERSON Motion Control maintains a highly trained staff of instructors to familiarize
customers with EMERSON Motion Control’s products and their applications. A number of
courses are offered, many of which can be taught in your plant upon request.

Application Engineering [phone]

An experienced staff of factory application engineers provides complete customer support for
tough or complex applications. Our engineers offer you a broad base of experience and
knowledge of electronic motion control applications. Application engineers may be contacted
by email at [e-mail] or at the telephone number listed above.

Sales: [phone]

Email: [e-mail]
Authorized EMERSON Motion Control distributors may place orders directly with our Order
Processing department by calling the number listed above. For information on your local
distributor, call EMERSON Motion Control.

iv

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®1 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.

Place holders 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.

Special nomenclature is provided for people working with these products, as follows:

Warning

For the purpose of this manual and product, “Warning” indicates death, severe personal
injury or substantial property damage CAN result if proper precautions are not taken.

Caution

For the purpose of this manual and product, “Caution” indicates minor personal injury or
property damage CAN result if proper precautions are not taken.

Note

For the purpose of this manual and product, “Note” indicates information about the
product or the respective part of the manual which is essential to highlight.

Throughout this manual, the word “drive” refers to an E Series drive.

1.See page ii of the preface.

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 severe electric shock and/or burns, and could be
lethal.Extreme care is necessary at all times when working with or adjacent to it. The
installation must comply with all relevant safety legislation in the country of use.

Qualified Person

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 qualifications:

• Is trained and authorized to energize, de-energize, clear, 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.

• FM-3 Speed Module Reference Manual (P/N 400508-01)

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

vi

Safety Considerations

Safety Precautions

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

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

Enclosure

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

Setup, Commissioning and Maintenance

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

Safety of Machinery

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

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

Warning

General warning

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

vii

relevant safety legislation in the country of use.

AC supply isolation 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 drive contains capacitors which remain charged to a potentially lethal
voltage after the supply has been removed. Allow at least 3 minutes for Epsilon and 30 seconds for
E Series drives after removing the supply before carrying out any work which 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 pins of the plug may be connected to the
drive input, which is only separated from the charge stored in the bus capacitor by semiconductor
devices. To avoid any possibility of electric shock from the pins, if they are accessible, a means
must be provided for automatically disconnecting the plug from the drive (that is, a latching
contactor).

Grounding (Earthing, 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 the 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

Customer Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii

Reference Materials. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vi

Safety Considerations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii

Introduction 1
Installation 3

Basic Installation Notes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Mechanical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Software Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

PC System Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Preparing for PowerTools FM-3 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Installing PowerTools FM-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Starting and Exiting PowerTools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Accessing Help . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Diagnostics and Troubleshooting 9

Diagnostic Display. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Brake Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Analog Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Diagnostic Analog Output Test Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Drive Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Error Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Programming Error Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Online Status Indicators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Specifications 29

Dimensions and Clearances. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Cable Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Index 45

ix

x

FM-3 Programming Module Installation Manual

Introduction

FM-3 is a compact and rugged function module that attaches to the front of the E Series 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 E Series EN drive.

Unlike other function modules, the FM-3 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
defines complex motion by a configuration file that includes setups, function assignments and
programs. The configuration file is created using EMERSON Motion Control PowerTools®

FM-3 software1. Setup views have the same look and feel as dialog boxes. The wiring of input
and output functions is done through assignments in the software. Emerson Motion Control

PowerTools FM-3 is an easy-to-use Microsoft® Windows®2 based setup and diagnostics
tool.

Figure 1: E Series EN Drive with FM-3 Function Module

Note that the E Series drive’s firmware is disabled whenever a Function Module such as the
FM-3 is attached. Therefore, if the E Series drive’s hardware is FM compatible, then the E
Series drive’s firmware can be any version because the programming features reside in the
function module’s flash memory. Flash files used for firmware upgrades are available on the
Emerson Motion Control webpage.

1.In this manual, Emerson Motion Control PowerTools FM-3 software will be referred to as
PowerTools FM-3.

2. See page ii of the preface

1

FM-3 Programming Module Installation Manual

Inputs

Outputs

10-30 VDC

MODEL

9820B025

E
x

p
.

I

/

O

S
y

n

c

.

I

n
p
u
t

S
y

n
c

.

O
u
t

p
u
t

Character Display

Soft Keys

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

Fastening Latch

Expanded I/O

Sync. Intput

Sync. Output

Programming Module

Inputs Outputs

485 +
485 -
SHLD

10-30

VDC

3 Row by 12

Direction Arrow
Keys

1
2
3
4
5
6
7
8

1
2
3
4
+

-

100-Pin Connector

Aligning Tabs

Front

Figure 2: FM-3 Programming Module Features

PART
REV
SER

FM-3

960499-01

A5/A3

Back

2

FM-3 Programming Module Installation Manual

Installation

Basic Installation Notes

You are required to follow all safety precautions during start-up such as providing proper
equipment grounding, correctly fused power and an effective Emergency Stop circuit which
can immediately remove power in the case of a malfunction. See the “Safety Considerations”
section for more information.

Mechanical Installation

The FM-3 detects and verifies the drive serial number when its attached to an E Series drive.
If an FM-3 is moved from one drive to another, it will detect the difference in serial numbers
and generate an Invalid Configuration fault.

Two aligning tabs, a locking latch and a 100-pin connector are used to attach the FM-3 to an
E Series drive. All electrical connections between the FM-3 and the E Series drive are
accomplished with the single connector located on the rear of the FM-3.

Continue pressing the FM
against the drive until the
latch clicks into the slot
on the top of the drive.

4

1

Grip the FM
firmly on
each side.

Gently press the
FM against the
drive, aligning the
100-pin connector.

3

Insert the
aligning tabs
into the slots
on the drive.

2

Figure 3: Attaching the FM-3 to an E Series Drive

Caution

Do not attach or detach the FM-3 when power is applied to the drive. It could cause drive
instability.

3

FM-3 Programming Module Installation Manual

Press down on the
latch located on
the top of the FM.

Grip the FM
on each side
of the LCD.

Continue pulling the top
of the FM away from the
drive until the connector
clears the drive. Lift the
FM out of the aligning
tab slot and away from
the drive.

1

Gently pull the FM away from
the drive. A slight rocking
motion may be used to loosen
the FM's connector.

2

4

3

Figure 4: Detaching the FM-3 from the Drive Connections

Caution

Do not attach or detach the FM-3 when power is applied to the drive It could cause drive
instability.

Modbus Communications

The drive’s serial communication protocol is Modbus RTU slave with a 32 bit data extension.
The Modbus protocol is available on most operator interface panels and PLC’s.

Max baud rate 19.2k (default)
Start bit 1
Stop bit 2
Parity none
Data 8

EMERSON Motion Control’s Motion Interface panels are supplied with a Modbus master
communications driver.

4

Serial Communications Specifications

Software Installation

Emerson Motion Control PowerTools® FM-3 software was designed for users who need
access to all setup options and diagnostic information for the drive. The software provides
access to all commonly used drive parameters.

PC System Configuration

Required:

• Microsoft® Windows® 95/98 or Microsoft Windows NT® 4.0 (service pack 3)

• Serial port

• Mouse

• 3.5" floppy drive for installation

Recommended:

• 16 MB or more RAM for Windows 95/98, and 32 MB or more for Windows NT.

• Up to 45 MB of hard disk space required for a full installation; 15 MB for minimum
installation.

Optional:

• Windows-compatible printer

Installation

• Modem and Internet access

Preparing for PowerTools FM-3 Installation

• Close all programs and turn off virus protection software to prevent installation conflicts.

• If you have another version of PowerTools on your computer and do not want to overwrite
that version, change the default installation folder for PowerTools during installation
setup.

• To avoid overwriting programs you have customized or created, place them into a
separate folder before you install.

Installing PowerTools FM-3

You must be running Microsoft Windows 95/98 or Microsoft Windows NT 4.0 to install M-3.

To install PowerTools:

1. Insert the PowerTools disk 1 into the floppy drive.

2. From the Start menu, choose Run.

5

FM-3 Programming Module Installation Manual

3. In the Run dialog box, type a:/setup, where a is the letter assigned to your 3.5" floppy
drive.

4. Click the OK button, then follow the instructions on your screen.
Installation will take about five minutes. The install program automatically:

• Creates the directory on your hard drive named:
C:\EMERSON\PT-FM3

• Creates a new Windows group called "EMERSON Motion Control-FM3".

• Loads the required DLL’s into your Windows system directory.

• Loads PowerTools into the EMERSON\PT-FM3 directory.

• Loads drive setup files into the EMERSON\APPS directory.

Note

To complete the installation for Windows 98 and NT, you may be required to restart
Windows.

Refer to the readme.txt file located on the installation floppy for more information.

If You Need Help with Installation

If you encounter problems while installing PowerTools, call Technical Support at (952)995­8033 (24 hour assistance).

Starting and Exiting PowerTools

Starting the Software

1. Click the Start button on the taskbar at the bottom left of the screen.

2. Click on the Programs selection. The Programs menu appears.

3. Click on the “EMERSON Motion Control” folder icon.

4. Click on the “PowerTools” folder icon.

5. Click on the PowerTools program icon.

6