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FM-3
User Manual
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Emerson FM-3 User Manual

FM-3 Programming Module
Reference Manual
P/N 400508-01
Revision: A8
Date: March 10, 2004
© Control Techniques Drives, Inc. 2000-2004
FM-3
Programming Module
Reference Manual
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 Tech niques.
The following are trademarks of Control Techniques and may not be reproduced in any fashion without written approval of Control Techniques: EMERSON Motion Co ntrol, 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 tr ademarks.
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.
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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 Techniques’ goal to ens ure your g reatest poss ible satisfacti on with the o peration
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 in for mation 2 4 ho urs a day, seve n 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 abov e.
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 direct tec hnical support conn ection lets you reques t 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 problems over the telepho ne. Our technical 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 co mputer, with your documentation easily av ailable, 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
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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 p rovides service, in most cases, the n ext 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 staff of instructors to familiarize customers
with Control Techniques’ “Motion Made Easy” products and t heir applications. 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 f actory 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.
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.
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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 manu al and prod uct, “Note” indicates es sential information about the product or the respective part of the manual.
EN Only
For the purpose of this manu al and product, the “E N” 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 hazardous situation that, if not avoided , could re sult 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.
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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 electr ic 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 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 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 Guide (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)
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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. Sy stem des ign, installation, commission ing and mai ntenance mu st b e carried out by per sonnel wh o have t he necessary training and experience. Read and follow this safety information and the ins truction 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 Main tenan ce

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 los s of life mu st be subject to a risk as sessment, and f urther protection provided where needed.
General warning
Failure to follow safe inst allation guide lines can c ause death or serious in jury. The v oltages used in this unit can cause severe electric shock and/or burns, and could be lethal. Extreme care is necessary at all times when workin g with or adja cent to this equ ipment. The in stallation must comply with all
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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 discon nect before any servicing work is performed, other than adjustments to the settings or parameters specified in the manual. The driv e contain s capacito rs which re main charge d to a p otentially lethal voltage after the supply has been removed. Allow at least 3 minutes after removing the supply before carrying out any work which may in volve contact with electrical connections to the drive.
Products connected by plug and sock et
A special hazard may exist where the drive is incorporated into a product which is connected to the AC supply by a plug and s ocket. When unplugged, the pins of the plug may be connected to t he 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 exte rnal 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
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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 T roubleshooting 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
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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 co nfiguration 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 for firmware up grades 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 Mot io n Control PowerTools Pro software will be referred 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 of th e d rive. The dr ive’s b asic oper ating mod es (Puls e, Velocity and Torque) are not available when a FM-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 multiple 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 diagnostics 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” (shown above) contains expandable 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 displays that View on the righ t side of the computer screen.
To setup a drive the user simply steps through the Hierarchy View from top to bottom. Simple applications can be setup i n a matter of minutes. Man y of the views have Assignment tabs that display the assign ments pertaining to the vi ew (i.e. on the Position view, t he position assignments are displayed).

Keypad Interface

The keypad on the fron t of the FM-3 modul e provides navig ation 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 commands lo cated directly above each key on the LCD. These keys are used to select the operation (e.g. Modify, Ok, C ancel), parameter group, an d/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
Figure 4: FM-3 Display Screen and Keypad
Operation al Overview
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 dr ive parameters to work with. 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 are arran ged into seven groups (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
EN-204 Adr01 MG-316 SECUR
Menu
Screen
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
RAMPS
Group
Stop
MODIF MENU
Security: 0
Stop.Decel
MODIF MENU
Security: 1
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)
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
+ 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
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 co uld 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
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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 affects all motion types by specifying which direction of motor revolution (CW or CCW) is considered motion in the “+” direction.

How Jogging Works

Operation al Overview
Jogging produces rotation of the motor at controlled velocities in a positive or neg a tive direction.
Assignments to jogs are level sensitive such that when the jog input is turn ed 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 Assign ments view, through a pr ogram, or with the Online t ab. A Home or Define Home is required to set the Absolute Position Valid so that any ind e x 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
Figure 6: Basic Home Function, Example
The figure above show a basic home function us ing a ball screw. This example uses most of the setup features in the PowerTools Pro Home tab.

Home Sequence

1. Back off the sensor (if on the sensor. This step is optional).
Operation al Overview
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 mot ion 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 Reference Position is established.
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FM-3 Programming Module Reference Manual
PowerTools Pro allow s selection of on e of three different Hom e References: Sensor, Marker, or Sensor and Marker.
Sensor
Selecting Sensor means the rising edge of the Home Sensor input functi on 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.
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Figure 8: Marker Home Reference Position
Sensor and Marker
Selecting Sensor and Marker means the reference position is established using the firs t 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).
Operation al Overview
Note
The data above assumes the use of a perfectly repeatable home sensor.
In Sensor and Marker applications, the marker mus t be at least 800 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 Travel
Figure 10: Sensor and Ma rker Home Re ference Po si tion Example 2
The Home Sensor must be “On” for at least 800 µsec to guarantee that it will be recognized.
Sensor
On Time

Home Offset

12
800 µsec
Figure 11: Sensor and Ma rker Home Re ference Po si tion Example 3
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.
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.
Operation al 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 Specifi ed Offs et radio butt on. PowerTo ols 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 continue to the precise off set 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.
Figure 14: Specified Home Offset, Greater than Calculated Offset
Specified 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.
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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 distance witho ut finding the reference. Additionally, the Home.CommandComplete function 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.
Operation al Overview
Figure 16: Home to Sensor and Mark er, Example
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 input. It continues
at the same velocity until the motor’s encoder marker channel is sensed. The rising edge of the motor’s encoder marker channel 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 sens or
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
4
Offset Move
2.0 Revs
2
Sensor
+ 100
Sensor
Final Position = End of Home Positio
Marker
1
Back Off Sensor
Home Move
5
Time
16
Offset
Figure 18: Home Move Sequence
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