Festo CMCA series, CMCA-***-CC series, CMCA-***-C series, CMCA-***-CS series Electrical Installation

Control system

CMCA

Description

Electrical installation

8023865

1211a

CMCA

Translation of the original instructions
GDCP-CMCA-INST-EN
CoDeSys

®

is a registered trademark of its respective trademark holder in certain countries.

Identification of hazards and instructions on how to prevent them:

Warning

Hazards that can cause death or serious injuries.

Caution

Hazards that can cause minor injuries or serious material damage.

Other symbols:

Note

Material damage or loss of function.

Recommendations, tips, references to other documentation.

Essential o r useful accessories.

Information on environmentally sound usage.

Text designations:

• Activities that may be carried out in any order.

1. Activities that should be carried out in the order stated.
– General lists.

2 Festo – GDCP-CMCA-INST-EN – 1211a –

CMCA

Table of Contents – CMCA

1 Safety and requirements for product use 5......................................

1.1 Safety 5..................................................................

1.1.1 General safety instructions 5.........................................

1.1.2 Intended use 5.....................................................

1.1.3 Foreseeable misuse 6...............................................

1.2 Requirements for product use 6...............................................

1.2.1 Technical requirements 6............................................

1.2.2 Qualification of trained personnel 6....................................

1.2.3 Range of application and certifications 6................................

2 Transport and storage 7.....................................................

2.1 Transport 7................................................................

2.1.1 Dimensions and weights 7...........................................

2.2 Storage conditions 8........................................................

2.3 Unpacking 8...............................................................

2.3.1 Mounting plate design CMCA-…-C-… 9..................................

2.3.2 Control cabinet versions CMCA-…-CC-…/CMCA-…-CS-… 10...................

2.4 Checking control system and scope of delivery 13..................................

3Overview 14................................................................

3.1 Characteristics 14...........................................................

3.2 Function and application 15....................................................

3.3 Product overview 16.........................................................

3.3.1 Control sections and connections, control cabinet CMCA-…-CC-…/CMCA-…-CS-… 16

3.3.2 Control and signal elements on the control c abinet

CMCA-…-CC-…/CMCA-…-CS-… 17.......................................

3.3.3 Components and connections inside the control cabinet or mounting plate

design 18..........................................................

3.3.4 Overview, terminal strips 19...........................................

3.3.5 Overview, fuses 20..................................................

4 Mounting a nd installation 21..................................................

4.1 Mounting 21................................................................

4.1.1 Mounting plate design CMCA-…-C-… 21..................................

4.1.2 Control cabinet version CMCA-…-CC-… 22.................................

4.1.3 Control cabinet version with base CMCA-…-CS-… 23........................

Festo – GDCP-CMCA-INST-EN – 1211a – English 3

CMCA

4.2 Electrical installation 24.......................................................

4.2.1 Safety instructions 24................................................

4.2.2 Design of the double-stack terminals 26.................................

4.2.3 Connecting supply voltage 26..........................................

4.2.4 Connect power switch (with mounting plate design) 27.....................

4.2.5 Connect emergency stop switch (with mounting plate design) 28..............

4.2.6 Connect emergency stop circuits 29.....................................

4.2.7 Connect protective door switch 29......................................

4.2.8 Connect operating and signal elements (with mounting plate design) 30........

4.2.9 Operating mode selection 31..........................................

4.2.10 Connect kinematic drives 32...........................................

4.2.11 Connect limit switches 32.............................................

4.2.12 Rod loss detection (only for rod kinematic system EXPT) 33..................

4.2.13 Connect axis of rotation reference sensor 33..............................

4.2.14 Connect the camera system supply 33...................................

4.2.15 Connect lighting 33..................................................

4.2.16 Freely usable outputs 34..............................................

4.2.17 Additional peripheral modules for the multi-axis controller 34................

5 Commissioning 35...........................................................

6 Operation and diagnostics 36..................................................

6.1 Operation 36...............................................................

6.2 Maintenance and care 36......................................................

6.2.1 Control cabinet fan 36................................................

7 Module replacement and repair 37.............................................

7.1 Replace module 37..........................................................

7.2 Repair 37..................................................................

7.3 Disposal 37................................................................

A Technical appendix 38........................................................

A.1 Technical data 38............................................................

A.1.1 Safety engineering 38................................................

A.1.2 General 38.........................................................

A.1.3 Electrical data 39....................................................

A.1.4 Operating and environmental conditions 39...............................

4 Festo – GDCP-CMCA-INST-EN – 1211a – English

1 Safety and requirements for product use

1 Safety and requirements for product use

1.1 Safety

1.1.1 General safety instructions

• Observe the general safety instructions in the corresponding chapters.

Specific safety regulations can be found immediately before the task instructions.

Warning
Danger of electric shock even if power switch is shut off.

The control system is only completely voltage-free if all supply lines have been switched
voltage-free.

• Switch off all supply lines (also external voltage) prior to assembly, installation
and/or maintenance work and secure them from being restarted accidentally.

• Switch the voltage back on only after completion of work.

Note

Damage to the product from incorrect handling.

• Never pull the plugs and interfaces when powere d.

• Never plug in plugs and interfaces when powered.

• Observe the handling specifications for electrostatically sensitive devices.

1.1.2 Intended use

The control system CMCA serves to operate a kinematics system in the environment of a machine or
automated systems and must be used as follows:
– in excellent technical condition
– in original status, without unauthorised modifications
– within the limits of the product defined by the technical data ( appendix A.1)
– in an industrial environment
The safety circuit of the CMCA control solution is only one part of the the safety concept for a machine,
whereby the safety concept m ust be based on a risk assessment of the entire machine to be performed
by the machine manufacturer.

Note

In the event of damage caused by unauthorised manipulation or other than intended
use, the guarantee is invalidated and the manufacturer is not liable for damages.

Festo – GDCP-CMCA-INST-EN – 1211a – English 5

1 Safety and requirements for product use

1.1.3 Foreseeable misuse

– The safety circuit of the CMCA control solution is changed in its function.
– Safety functions are thus implemented that are not specified in this description.
– An adequate risk assessment is not performed for the machine.
– There is no safety concept of the machine available.
– Suitability of this safety circuit for the application is not established.
– No verification and no validation of the switch is performed in the machine.

1.2 Re quirements for product use

• Make this documentation available to the design engineer, installer and personnel responsible for
commissioning the machine or system in which this product is used.

• Make sure that the specifications of the documentation are always complied with. Also consider the
documentation for the other c omponents and modules.

• Take into consideration the legal regulations applicable for the destination, as well as:
– regulations and standards
– regulations of the testing organizations and insurers
– national specifications

1.2.1 Technical requirements

General conditions for the correct and safe use of the product, which must be observed at all times:

• Comply with the c onnection and environmental conditions of the product ( appendix A.1) and all
connected components specified in the technical data.
Only compliance with the limit values or load limits permits operation of the product in accordance
with the relevant safety regulations.

• Observe the instructions and warnings in t his documentation.

1.2.2 Qualification of tr ained pe rsonnel

The product should only be installed by properly trained personnel in accordance with these instruc­tions. The trained personnel must be familiar with:
– installation and operation of electrical control systems
– the applicable regulations for operating safety-engineered systems
– the applicable regulations for accident protection and industrial safety
– the documentation for the product

1.2.3 Range of application and certific ations

Standards and test values which the product complies with and fulfils can be found in the technical
data ( appendix A.1). The product-relevant EU directives can be found in the declaration of conform­ity.

Certificates and the declaration of conformity for this product can be found at
www.festo.com.

6 Festo – GDCP-CMCA-INST-EN – 1211a – English

2Transportandstorage

2 T ransport and storage

2.1 Transport

The control system is delivered on a pallet and is protected with a cover of plates. The mounting plate
design CMCA -…-C-… is also screwed to the pallet.

2.1.1 Dimensions and weights

CMCA-…-

Dimensions [mm]

H 565 868 1018
L 1010 1140 1140
B 640 510 510

Weight [kg]

Control system 41 79 89
Overall weight

1) With max. accessories

Tab. 2. 1

1. Transport the pallet with the control system to the installation/storage location.

2. Set down the pallet on a firm and flat base at the installation/storage location.

1)

Note

• For transport, observe the marking on the upper side of the transport box.

C-… CC-… CS-…

85 125 142

Festo – GDCP-CMCA-INST-EN – 1211a – English 7

2 Transport and storage

2.2 Storage conditions

For safe la ter use, the following storage conditions must be complied with.

Storage conditions

Storage temperature [°C] –20 … +60
Relative air humidity [%] 10 … 95, non-condensing or protected against condensation
Max. storage time 60 months
Requirements of storage location dry, solid and flat base

Tab. 2. 2

2.3 Unpacking

Note

Damage to the product from incorrect removal of the transport box.

• Use the correct tool to loosen the screws.

• Make sure that no packaging parts can fall onto the control system.

• Observe the product weight ( chapter 2.1.1).

• Keep the packaging for later use or dispose of it in accordance with the instructions
( chapter 7.3).

8 Festo – GDCP-CMCA-INST-EN – 1211a – English

2Transportandstorage

2.3.1 Mounting plate design CMCA-…-C-…

Removing transport packaging

1. Loosen and remove the lower screws of the
cover.

2. Lift the cover up and off.

Remove the packaging foil

3. Cut the foil parallel to the c ontour of the
product with an appro priate tool. Whe n cut­ting, make sure that you do not damage or
scratch the components of the control system.

4. Pull the foil up and off. Carefully remove the
bag with desiccant and dispose of it in accord­ance with the instructions ( chapter 7.3).

Loosen mounting plate

5. Loosen and remove the screws with which the
mounting plate is screwed to the pallet.

6. With two people, lift the control system off the
pallet and bring it to the installation site.

Fig. 2.1

Festo – GDCP-CMCA-INST-EN – 1211a – English 9

2 Transport and storage

2.3.2 Control cabinet versions CMCA-…-CC-…/CMCA-…-CS-…

Warning
Danger of injury/damage due to falling loads.

The device to lift the control cabinet out of the transport packaging must be sufficiently
dimensioned for the weight of the control cabinet.

• Observe the product weight ( chapter 2.1.1).

Removing transport packaging

1. Loosen and remove all screws of the cover.

2. Remove the cover up and off the transport
box.

Fig. 2.2

3. Loosen and remove all screws of the side wall
near the control cabinet doors.

4. Pull the side wall forward and off.

Fig. 2.3

10 Festo – GDCP-CMCA-INST-EN – 1211a – English

2Transportandstorage

5. Mount an appropriate lifting device to the
transport lugs of the control cabinet.

Fig. 2.4

6. Lift the control cabinet out of the transport
packaging.

Fig. 2.5

Festo – GDCP-CMCA-INST-EN – 1211a – English 11

2 Transport and storage

Unpack filter mats

Caution
Fire danger from overheating.

At delivery, the filter mats for control cabinet fans and outlet filters are packed in plastic
and placed in the filter cassettes.
Operation of the control system with packaged filter mats results in overheating and
related consequential damage.

• Remove the plastic packaging from both filter mats as described below.

1. Pull the covers of the filter housing off to the
front.

2. Take out the packaged filter mats.

3. Remove the packaging.

Fig. 2.6

4. Place the unpackaged filter mats in the filter
housing.

5. Put the covers back on.

Fig. 2.7

Remove drying agent

The control cabinet includes several bags with drying agent to protect against damage
due to moisture. Before installation of the control system, carefully remove the desiccant
and dispose of it in accordance with the instructions ( chapter 7.3)

12 Festo – GDCP-CMCA-INST-EN – 1211a – English

2Transportandstorage

2.4 Checking control system and scope of delivery

1. After unpacking, check whether the product corresponds to the version you ordered.

2. After unpacking, check the following parts:

Check

Possible malfunction Remedy

Fuses Open Close
Ethernet cable Unplugged Plug in
CMXR memory card Not completely plugged in Plug in completely
Component Damaged Replace

1)  www.festo.com/spareparts

2)  Chapter 7

1) 2)

Tab. 2. 3

3. Check that the delivery is complete.

Documentation

Number

Electrical installation CMCA control system 1
Circuit diagram, CMCA c ontrol system 1
Controller CMXR-C1 1 (for c haracteristic C1)
Controller CMXR-C2 1 (for c haracteristic C2)
Motor controller CMMP-AS + CD-ROM 1
I/O module CECX-D-8E8A-NP-2 1
Power supply SVG-1 1
Subcon cable interface 1
Ethernet switch SFNB 1
Controller PNOZ S7 + supplement 1
Controller PNOZmulti Mini + DVD 1
Buffer module 1 (for characteristic S2)
Terminals with filter 1, 21108-2EN-04 1

Tab. 2. 4

Accessories (for characteristic CC and CS)

Keyforkeyswitch 2 eac h
Key for control cabinet doors 1
Inscription labels for control elements, German 6

Tab. 2. 5

Festo – GDCP-CMCA-INST-EN – 1211a – English 13

Number

3Overview

3Overview

3.1 Characteristics

The control system CMCA can be equipped with the following characteristics:

Characteristic

Kinematics -K1 – For parallel kinematic robot EXPT

Multi-axis
controller

Motor
controller

Code Brief description

-K2 – For H-gantry or surface gantry

-K3 – For T-gantry or linear gantry

-C1 – Multi-axis controller CMXR-C1

-C2 – Multi-axis controller CMXR-C2 with integrated PLC

-A1 – 2 motor controllers CMMP-AS-C5-3A for 2 main axes

-A2 – 2 motor controllers CMMP-AS-C5-3A for 2 main axes
– 1 motor controller CMMP-AS-C2-3A for 1 supplemental axis

-A3 – 2 motor controllers CMMP-AS-C5-3A for 2 main axes
– 2 motor controllers CMMP-AS-C2-3A for 2 supplemental axes

-A4 – 3 motor controllers CMMP-AS-C5-3A for 3 main axes

-A5 – 3 motor controllers CMMP-AS-C5-3A for 3 main axes
– 1 motor controller CMMP-AS-C2-3A for 1 supplemental axis

-A6 – 2 motor controllers CMMP-AS-C5-11A for 2 main axes

-A7 – 2 motor controllers CMMP-AS-C5-11A for 2 main axes
– 1 motor controller CMMP-AS-C2-3A for 1 supplemental axis

-A8 – 2 motor controllers CMMP-AS-C5-11A for 2 main axes
– 2 motor controllers CMMP-AS-C2-3A for 2 supplemental axes

14 Festo – GDCP-CMCA-INST-EN – 1211a – English

3Overview

Characteristic Brief descriptionCode

Design -C Mounting plate design

– For integration into a customer-provided control cabinet
– Various operator control elements and safety equipment must

themselves be connected

–CC Control c abinet version

– Operator control elements and safety equipment specific to the

control cabinet are connected

– Additional safety equipment must be connected or deactivated

through bridges

-CS Control cabinet version with base
– Operator control elements and safety equipment specific to the

control cabinet are connected

– Additional safety equipment must be connected or deactivated

through bridges

– The control cabinet is mounted on a base

Safety
engineering

-S1 – Integrated safety switching device

-S2 – Integrated safety switching device with power failure detection

Tab. 3. 1

3.2 Function and application

The control system CMCA serves to control and monitor a connected kinematics system with several
axes
Each axis of the kinematics system is controlled by a motor controller.
For characteristic C1 and C2, a higher-order multi-axis controller coordinates the movement of the indi­vidual axes through the corresponding motor c ontroller.

Festo – GDCP-CMCA-INST-EN – 1211a – English 15

3Overview

3.3 Product overview

3.3.1 Control sections and connections, control cabinet CMCA-…-CC-…/CMCA-…-CS-…

8

7

6

5

4

3

2

1

9

aJ

aA

1 Base (only for characteristic CS)
2 Control cabinet door, left
3 Control cabinet fan cover
4 Power switch
5 Connection for handheld terminal CDSA
6 Operating and signal elements
7 Emergency stop switches
8 Transport lugs
9 Outlet filter c over
aJ Control cabinet doors interlock
aA Control cabinet door right

Fig. 3.1

16 Festo – GDCP-CMCA-INST-EN – 1211a – English

3Overview

3.3.2 Control and signal elements on the control cabinet CMCA-…-CC-…/CMCA-…-CS-…

562341

1 Illuminated push-button (S20/P20) “quit emergency stop”: Confirms unlocking of the emergency

stop circuit

2 Indicator light (P21) “external emergency stop”: External emergency stop circuit triggered
3 Indicator light (P4) “automatic control”: automatic operation active
4 Key switch (S2) “automatic/manual”: Switch between automatic and manual override

The switch is only active when the “local” operating mode has been se le cted by means of link
plug operating mode selection ( Tab. 4.17). In case of “external” operating mode, the switch is
without effect.

5 Indicator light (P5) “manual control”: manual operation active
6 Key switch (S3) “brake release”: releases the motor brakes (only possible in manual override and

in combination with the enabling button on the handheld terminal)

Fig. 3.2

Note

The labels for marking the control elements in German are also included in the control
cabinet.

Festo – GDCP-CMCA-INST-EN – 1211a – English 17

3Overview

3.3.3 Components and connect ions inside the control cabinet or mounting plate design

This controller’s equipment can deviate from that of the illustration.

7 8 9aJaA aB aC aD aE

6

5

4

3

2

1

1 Terminal strips X0 … X6
2 Fuses F1 … F20
3 Protective contact socket type F (230 V AC, max. 10 A) for PC
4 Controller, safety control circuit
5 Controller, safety control circuit expansion
6 Multi-axis controller
7 Control module for mains failure detection (only for characteristic S2)
8 Ethernet switch
9 Connection for CDSA (with control cabinet design on the left door)
aJ Buffer module 24 V DC (only for characteristic S2)
aA Power supply unit 24 V DC
aB Motor controller for axis 1
aC Motor controller for axis 2
aD Motor controller for axis 3 (only for characteristic A2, A3, A4, A5, A7, A8)
aE Motor controller for axis 4 (only for characteristic A3, A5, A8)

Fig. 3.3

18 Festo – GDCP-CMCA-INST-EN – 1211a – English

3Overview

3.3.4 Overview, terminal strips

23

1 X0: Feed upstream of power switch
2 X1: Feed downstream of power switch
3 X2: Control c ircuit 24 V DC
4 X3: Emergency stop
5 X4: External emergency stop
6 X6: Control and signal elements

Fig. 3.4

41

56

Festo – GDCP-CMCA-INST-EN – 1211a – English 19

3Overview

3.3.5 Overview, fuses

562341 78

1 F1 ( B 10 A):

power supply 230 V AC, power supply unit 24 V DC

2 F2 ( B 10 A):

power supply 230 V AC, load circuit motor controller axis 1
(for c haracteristic A6, A7 and A8, three-phase)

3 F3 ( B 10 A):

power supply 230 V AC, load circuit motor controller axis 2
(for c haracteristic A6, A7 and A8, three-phase)

4 F4 (B 10 A):

power supply 230 V AC, load circuit motor controller axis 3
(only for characteristic A2, A3, A4, A5, A7, A8)

5 F5 ( B 10 A):

power supply 230 V AC, load circuit motor controller axis 4
(only for characteristic A3, A5, A8)

6 F6 ( B 10 A):

power supply 230 V AC, plug

7 F20 ( B 10 A):

voltage supply 24 V DC

8 F10 ( 2 A):

power supply 230 V AC, control cabinet fan

9 F11 ( 2 A):

power supply, control cabinet lighting

aJ F12 (6.3 A):

external emergency stop

aA F13 (6.3 A):

external emergency stop

Fig. 3.5

9

aJ

aA

20 Festo – GDCP-CMCA-INST-EN – 1211a – English

4 Mounting and installation

4 Mounting and installation

4.1 Mounting

Warning
Danger of injury/damage due to falling loads.

If incorrectly mounted, the control system c an become loose and fall.

• Observe the product weight ( chapter 2.1.1) in selection of the mounting surface
and mounting material (screws, mounting bracket, …).

4.1.1 Mounting plate design CMCA-…-C-…

The control system on the mounting plate must be mounted to the 6 mounting points on a vertical and
sufficiently st able surface.

Mounting points

Fig. 4.1

Dimensions [mm]

L1 925
L2 530
L3 462.5

Tab. 4. 1

L2

L3

L1

Festo – GDCP-CMCA-INST-EN – 1211a – English 21

4 Mounting and installation

4.1.2 Control cabinet version CMCA-…-CC-…

The control system with its own control cabinet must be mounted as follows:
– upright on a sufficiently strong wall bracket
– upright on horizontal cross braces in a frame with sufficient bearing capacity
– with a free space below the control cabinet of at least 200 mm for the cable throughfeed

Note

A wall bracket is not included in the scope of delivery.

Mounting points, control cabinet bottom for mounting on wall bracket

Fig. 4.2

Dimensions [mm]

L1 940
L2 239.4
D1 ∅ 9

Tab. 4. 2

22 Festo – GDCP-CMCA-INST-EN – 1211a – English

4 Mounting and installation

4.1.3 Control cabinet version with base CMCA-…-CS-…

The control system with its own control cabinet and base must be mounted as follows:
– Fastened with 4 screws through the 4 holes in the base on a sufficiently stable base.

Note

The screws etc. are not included in the scope of delivery.

Mounting points

Fig. 4.3

Dimensions [mm]

L1 850
L2 260
D1 ∅ 14

Tab. 4. 3

Festo – GDCP-CMCA-INST-EN – 1211a – English 23

4 Mounting and installation

4.2 Electrical i nstallation

4.2.1 Safety instructions

Warning
Danger of electric shock from voltage sources.

• Attach the control system directly to the mains switch. Do not use a plug.

• Install strain relief for the connecting cable of the supply voltage and for the motor
cables.

• Make sure that the supply voltage is switched off during the entire installation
(switch voltage-free) and secure it against unintended restart.
Only disconnection of the supply voltage in the supply line (fuse or separate switch)
switches voltage off in the connected control system.

• Wait at least one minute after switching off the supply voltage before starting work
on plugs and interfaces so that the residual voltage can drop below 60 V.

• Due to the high leakage current, use a protective earth c onductor with a minimum
cross section of 10 mm² (copper) or 16 mm² (aluminium).

• Only use power sources which guarantee reliable electrical isolation of the operating
voltage in accordance with EN 60204-1.

• For reasons of safety, always connect all PE protective earth c onductors prior to
commissioning.

• Observe the regulations of EN 50178 and EN 60204-1 for protective grounding dur­ing installation.

Warning
Danger of electric shock even if mains switch is shut off.

The control system is only completely voltage-free if all supply lines have been switched
voltage-free.

• Switch off all supply lines (also external voltage) prior to assembly, installation
and/or maintenance work and secure them from being restarted accidentally.

• Switch the voltage back on only after c ompletion of work.

Note

The power supply must be secured at the mains with a maximum of 20 A (slow-blow).

24 Festo – GDCP-CMCA-INST-EN – 1211a – English

4 Mounting and installation

Note

The description of the electric installation in this chapter requires c ompletely mounted
and installed kinematics ( Description of mechanical installation).
For operation of the control system, the following measures must be taken:
– Use of screened motor connection cables ( motor controller description).
– The high leakage current can cause problems if a residual c urrent protective device

is used.

Note

Damage to the product from incorrect handling.

• Never pull the plugs and interfaces when powere d.

• Never plug in plugs and interfaces when powered.
ESD (electrostatic discharge) c an cause damage to the device or other system parts at
plug connectors that are not used.

• Observe the handling specifications for electrostatically sensitive devices.

Note

Unplugging the connection cover or handheld terminal triggers an emergency stop.

• Put the system at rest before you plug in or unplug the connection cover or handheld
terminal.

Either a handheld terminal or the connection cover must be mounted. Otherwise, the
emergency stop circuit is opened (emergency stop active).

Warning
Danger of injury/damage due to ineffective emergency stop.

A not-connected handheld terminal in reach of the user can result in ineffective use of
the emergency stop switch.

• Keep a not-connected handheld terminal outside the reach of the user.

Caution

An active emergency stop only has an effect on the electric drives. Any pneumatic com­ponents that may be on hand are not affected.

• If necessary, plan corresponding safety equipment for the pneumatic components of
the system. The connection for external emergency stop circuits c an be used for
control ( chapter 4.2.6).

Festo – GDCP-CMCA-INST-EN – 1211a – English 25

4 Mounting and installation

4.2.2 Design of the double-stack terminals

The double-stack terminals of the terminal strips X2 … X6 and the right part of X1 have the following
design.

Connection number with the labelling on top

The terminals on top correspond to the terminal
numbers also attached somewhat further on top
(here 610 … 618).
Both connections of a terminal are bridged intern­ally.

Fig. 4.4

Connection number with the labelling underneath

The terminals below correspond to the terminal
numbers also attached somewhat further under­neath (here 600 … 608).
Both connections of a terminal are bridged intern­ally.

Fig. 4.5

4.2.3 Connecting supply voltage

Note

In the control cabinet design, guide the supply lines of the supply voltage through the
left one of the two cut-outs on the bottom of the control cabinet.

Guide the supply line of the supply voltage (230/400 V AC / 3-phase, 50 … 60 Hz) in the cable duct to
the terminal strip X0. Attach the conductors to the lower c lamping contacts of the terminals.

26 Festo – GDCP-CMCA-INST-EN – 1211a – English

4 Mounting and installation

Terminal strip Ter mina l Description

X0 L1 Phase 1

L2 Phase 2
L3 Phase 3
N Neutral conductor
PE Protective earth conductor (connected to the mounting plate)

Tab. 4. 4

4.2.4 Connect power switch (with mounting plate design)

The power switch is connected from above to the terminal strip X0 and from below to the terminal strip
X1.

Caution
Danger of damage to the motor controller.

Switching on one or more phases before switching on the neutral conductor can result
in damage to the motor controller.

• Use a 4-pin switching power switch with a leading contact at switch-on for the neut­ral conductor to prevent damage to the motor controllers when switched on.

Terminal strip

Ter mina l Connections, power switch

X0 L1 L1

L2 L2
L3 L3
N N

X1 1L1 T1

1L2 T2
1L3 T3
N1 N

Tab. 4. 5

Festo – GDCP-CMCA-INST-EN – 1211a – English 27

4 Mounting and installation

4.2.5 Connect emergency stop switch (with mounting plate design)

The switches for triggering the emergency stop function are c onnected to the terminal strip X3.
To confirm the unlocking of an emergency stop switch, the illuminated push-button “Acknowledge
emergency stop” must be actuated.

Connect emergency stop control cabinet door (with mounting plate design)

Note

This emergency stop switch is already c onnected with the control cabinet design.
In the mounting plate design, a corresponding switch must be connected by the in­staller.

Terminal strip

Ter mina l Description

X3 302 Switch 1 pin 11

310 Switch 1 pin 12
303 Switch 2 pin 21
311 Switch 2 pin 22

Tab. 4. 6

Connect emergency stop expansion

Connection option for an additional emergency stop switch.

Note

If not used, the terminals (300 with 310 and 301 with 311) must be bridged.

Terminal strip

Ter mina l Description

X3 300 Switch 1 pin 11

310 Switch 1 pin 12
301 Switch 2 pin 21
311 Switch 2 pin 22

Tab. 4. 7

28 Festo – GDCP-CMCA-INST-EN – 1211a – English

4 Mounting and installation

Connect external emergency stop contacts

Connection option for external potential-free contacts for triggering the emergency stop function
(e.g. from other control areas of the same complete system).

Note

If not used, the terminals (304 with 307 and 305 with 317) must be bridged. An auto­matic restart must be prevented through a higher-order safety circuit.

Terminal strip

Ter mina l Description

X3 304 + 307 External emergency stop, channel 1

305 + 317 External emergency stop, channel 2

Tab. 4. 8

4.2.6 Connect emergency stop circuits

Connections for signalling an emergency stop to other control areas of the complete system. Two float­ing relay contacts are made available for this purpose and are opened when emergency stop is
triggered.

Note

The maximum current on contact is 6 A.

Terminal strip

X4 409 + 439 External emergency stop, channel 1

1) Protected through fuse F12

2) Protected through fuse F13

Ter mina l Description

410 + 440 External emergency stop, channel 2

1)

2)

Tab. 4. 9

4.2.7 Connect protective door switch

Connections for the contact switches of the protective doors.
The protective door signal can also be generated from another control circuit of the complete system.

Note

If not used, the terminals (308 with 312 and 318 with 313) must be bridged. An auto­matic restart must be prevented through a higher-order safety circuit.

Terminal strip

Ter mina l Description

X3 308 + 312 Protective door switch, channel 1

318 + 313 Protective door switch, c hannel 2

Tab. 4. 10

Festo – GDCP-CMCA-INST-EN – 1211a – English 29

4 Mounting and installation

4.2.8 Connect operating and signal elements (with mounting plate design)

Note

These components are already connected in the control switch design.
In t he mounting plate design, th ese components must be connected by the installer.

Illuminated button “quit emergency stop” (S20/P20)

Terminal strip

Ter mina l Description

X3 306 Connection 13 (S20)
X6 600 Connection 14 (S20)
X6 601 +24 V DC, (P20)
X2 207 0 V DC, (P20)

Tab. 4. 11

Indicator light “external emergency stop” (P21)

Terminal strip

Ter mina l Description

X6 602 +24 V DC, (P21)
X2 205 0 V DC, (P21)

Tab. 4. 12

Indicator light “automatic control” (P4)

Terminal strip

Ter mina l Description

X2 210 0 V DC, (P4)
X6 616 +24 V DC, (P4)

Tab. 4. 13

Key actuator “automatic/manual” (S2)

Terminal strip

Ter mina l Description

X6 615 Pin 12, (S2)
X2 224 Pin 11, (S2) (connect via S2:13)

X6 612 Pin 14, (S2)

Tab. 4. 14

Indicator light “manual control” (P5)

Terminal strip

Ter mina l Description

X2 210 0 V DC, (P5) (connect via P4:X2)
X6 617 +24 V DC, (P5)

Tab. 4. 15

30 Festo – GDCP-CMCA-INST-EN – 1211a – English

Pin 13, (S2)

4 Mounting and installation

Key actuator “brake release”(S3)

Terminal strip

Ter mina l Description

X2 225 Pin 13, (S3)
X6 618 Pin 14, (S3)

Tab. 4. 16

4.2.9 Operating mode selection

Terminal strip

Ter mina l Ter mina l Description

X6 611 612 With the key ac tuator (S2), you can select locally

614 615

between the manual operation and automatic opera­tion modes (status on delivery)

611 610 With the external higher-order c ontroller, you can

614 613

select locally between the manual operation and
automatic operation modes

Tab. 4. 17

Fig. 4.6 Operating mode selection, external Fig. 4.7 Operating mode selection, local

Operating mode selection by means of higher-order controller

If the operating mode selection is made through a higher-order controller, you must make two poten­tial-free relay contacts available there.

Terminal strip

Ter mina l Description

X2 224 +24 V DC
X6 610 Manual operation

613 Automatic operation

Tab. 4. 18

Note

As supply voltage for these contacts, the supply for terminal X2-224 must be used

Festo – GDCP-CMCA-INST-EN – 1211a – English 31

4 Mounting and installation

4.2.10 Connect kinematic drives

Note

In the control cabinet design, the motor and encoder cables are guided through the
right one of the two cut-outs on the bottom of the control cabinet.

• Connect the axis drives to the motor controller corresponding to the accompanying
motor controller description.

4.2.11 Connect limit switches

Terminal strip

Ter mina l Description Limit switch Axis

X4 411 +24 V DC 1 1

441 0VDC
416 Signal output
412 +24 V DC 2
442 0VDC
417 Signal output

413 +24 V DC 1 2
443 0VDC
418 Signal output
414 +24 V DC 2
444 0VDC
419 Signal output

411 +24 V DC 1 3
441 0VDC
446 Signal output
412 +24 V DC 2
442 0VDC
447 Signal output

Only with
characteristic
A2, A3, A4,
A5, A7, A8

413 +24 V DC 1 4
443 0VDC
448 Signal output
414 +24 V DC 2
444 0VDC
449 Signal output

Tab. 4. 19

32 Festo – GDCP-CMCA-INST-EN – 1211a – English

Only with
characteristic
A3, A5, A8

4 Mounting and installation

4.2.12 Rod loss detection (only for rod kinematic system EXPT)

The pressure switch SDE5 for rod loss detection is connected to the terminal strip X2.
Setting and adjustment of the rod loss detection ( Commissioning description).

Terminal strip

Ter mina l Description

X2 208 Supply voltage 0 V DC

228 Supply voltage +24 V DC
211 Signal from the pressure switch for rod loss detection

Tab. 4. 20

4.2.13 Connect axis of rotation reference sensor

An optional axis of rotation reference sensor can be connected as follows.

Terminal strip

Ter mina l Description

X4 455 Reference sensor signal (at DIN9 motor controller of the last axis)
X2 206 Supply voltage 0 V DC

225 Supply voltage +24 V DC

Tab. 4. 21

4.2.14 Connect the camera system supply

The following connections are reserved for the power supply of a camera system ( 24 V DC).

Terminal strip

Ter mina l Description

X2 201 0VDC

221 +24 V DC

Tab. 4. 22

4.2.15 Connect lighting

The following connections are reserved for the power supply of an illumination device (230 V AC), e.g.
for the camera system.

Terminal strip

X1 101 230 V AC

Ter mina l Description

1)

N3 0VAC

1) Protected through fuse F11

Tab. 4. 23

Festo – GDCP-CMCA-INST-EN – 1211a – English 33

4 Mounting and installation

4.2.16 Freely usable outputs

The unused inputs and outputs of the I/O module CECX-D-8E8A-NP-2 at th e CMXR controller can be
used for their own expansions. The following connections are available for this.

Outputs

Terminal strip

Ter mina l CECX Description

X4 401 DOX+1 Output

431 0VDC
402 DOX+4 Output
432 0VDC
403 DOX+5 Output
433 0VDC
404 DOX+6 Output
434 0VDC
405 DOC+7 Output
435 0VDC

Tab. 4. 24

Detailed information and technical data on the I/O module CECX-D-8E8A-NP-2 can be
obtained from the accompanying documentation.

4.2.17 Additional peripheral modules for the multi-axis controller

There is the possibility to install additional peripheral modules. These can be connected to the internal
power supply.

Terminal strip

Ter mina l Description

X2 201 0VDC

221 +24 V DC

Tab. 4. 25

If the additional power requirement exceeds the value of 1.5 A, the additional modules
must be supplied with 24 V externally.

Please take the available modules from the sales documentation of the respective multi-axis controller.
Installation instructions accompany the modules. Please observe that additional modules have to be
received in the respective machine documentation and are not in the scope of delivery.

34 Festo – GDCP-CMCA-INST-EN – 1211a – English

5 Commissioning

5 Commissioning

Note

Commissioning must always be carried out by a specially trained technician (a robotics
specialist). The following knowledge is required:
– Specialist knowledge of robotics and CoDeSys
– Knowledge of the handling of the Festo components CMMP and CMXR
– Knowledge of handling and operation of the kinematics to be operated.
Commissioning is described in separate documents.
For support in commissioning:

• Please contact your Festo contact person or on the internet (  www.festo.com).

Festo – GDCP-CMCA-INST-EN – 1211a – English 35

6 Operation and diagnostics

6 Operation and diagnostics

6.1 Operation

Note

The instructions for operation must be provided by the system manufacturer. The oper­ator must be instructed in handling the system in a ccordance with the description and
must have access to it at all times.

6.2 Maintenance and care

6.2.1 Control cabinet fan

Caution
Fire danger from overheating.

• Regularly check the filter mats of the control cabinet fan and the outlet filter for
contamination (daily in dusty environments) and replace them if necessary.

Procurement of filter mats  Rübsamen & Herr company.
Type AM 435P (216 x 216 mm, filter class G3)

1. Pull the covers of the filter housing off to the
front.

2. Remove the dirty filter mats and dispose of
them in accordance with the instructions in
chapter 7.3

3. Remove the packaging of the new filter mats.

4. Place the new filter mats in the filter housing
and put the covers back on.

Fig. 6.1

36 Festo – GDCP-CMCA-INST-EN – 1211a – English

7 Module replacement and repair

7 Module replacement and repair

Caution

Squeezing of body parts and damage to the system.
Unintended starting can trigger unexpected movements.

• Before any conversion or maintenance work or inspections of the system, ensure
that the system is safely brought to a standstill and is secured to prevent restarting.

Detached parts c ould fall or execute unexpected movements.

• Secure the parts so that they cannot move unexpectedly or bring them into a secure
end position.

7.1 Replace module

Note

Replacement work may only be performed by trained personnel with the corresponding
qualifications and knowledge in handling Festo components.

Note

Replacement of control components (robotics control and/or motor controller) results
in loss of parameterisation and thus operating status. After replacement of these com­ponents, they must be newly parameterised.

7.2 Repair

The control system does not include any repairable components. Defective components must be re­placed ( www.festo.com/spareparts).

7.3 Disposal

• When dismounting parts, observe the instructions ( chapter 7.1).

• Observe the local regulations for environmentally friendly disposal of modules and
packaging materials.
The product is RoHS-compliant.

Festo – GDCP-CMCA-INST-EN – 1211a – English 37

A Technical appendix

A Technical append ix

A.1 Technical data

Note

For the individual components, t he technical data specified in the corresponding
accompanying documentation apply.

A.1.1 Safety engineering

Safety reference data

Safety function SS1 Safe stop 1 in accordance with EN 61800-5-2
Category 3 Classification in accordance with EN ISO 13849-1
Performance level PL d in accordance with EN ISO 13849-1

Tab. A.1 Technical data: safety reference data

A.1.2 General

Mechanical

CMCA-…-C-… CMCA-…-CC-… CMCA-…-CS-…

Width [mm] 962 1000 1000
Height [mm] 548 600 800
Depth [mm] 275 … 310

1)

350 350
Weight [kg] 41 79 89
Note on materials RoHS-compliant, contains PWIS2)materials

1) Dependent on the version

2) Paint-wetting impairment substances

Tab. A.2 Technical data: mechanical

Approvals

CMCA-…-C-… CMCA-…-CC-…

CMCA-…-CS-…

CE marking
(see declaration of conformity)

No CE marking –EUEMCDirective

– EU Low Voltage Directive

1)

( www.festo.com)

1) The device is intended for use in an industrial environment. Measures for interference suppression may need to be implemented in

residential areas.

Tab. A.3 Technical data: certifications

38 Festo – GDCP-CMCA-INST-EN – 1211a – English

A Technical appendix

A.1.3 Electrical data

Voltage supply

Nominal voltage [V AC] 230/400 / 3-phase, 50 … 60 Hz
Fuse protection, connecting

[A] 20
cable
Fuse protection characteristics Slow-blow

Tab. A.4 Technical data: voltage supply and fuse protection

A.1.4 Operating and environmental conditions

Storage

Storage temperature [°C] –20 … +60
Relative air humidity [%] 10 … 95, non-condensing or protected against condensation

Tab. A.5 Technical data: storage

Ambient conditions

CMCA-…-C-… CMCA-…-CC-…

CMCA-…-CS-…

Ambient temperature [°C] +5 … +40 (outside the housing)
Permissible setup altitude Up to 1000 m above sea level

1000 … 4000 m above sea level with performance reduction
of 10%/1000 m

Cooling About the ambient atmo-

sphere.
If installed in a control cabin-

About the ambient atmo­sphere and control cabinet

fan
et, ventilation must be
planned.

Protection class IP20 IP54
Relative air humidity [%] 10 … 95, non-condensing or protected against condensation
Degree of contamination in

1)

2

2

accordance with EN 61800-5-1

1) The integrated safety equipment requires compliance with degree of contamination 2 and thus a protected fitting space. This must

be ensured through corresponding measures, e.g. through installation in an appropriate control cabinet.

Tab. A.6 Technical data: ambient conditions

Festo – GDCP-CMCA-INST-EN – 1211a – English 39

Copyright:
Festo AG & Co. KG
Postfach
D-73726 Esslingen

Phone:
[phone]

Fax:
[phone]

e-mail:
[e-mail]

Reproduction, distribution or sale of this doc ument or
communication of its c ontents to others without express
authorization is prohibited. Offenders will be liable for damages.
All rights reserved in the event that a patent, utility model or
design patent is registered.

Internet:
www.festo.com

Original: de
Version: 1211a