Festo CMMP-AS-...-M3 Series Description

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Page 1

Motor controller

CMMP-AS-...-M3

Description

Functional description (firmware).

for motor controller CMMP-AS-...-M3 FW: 4.0.1501.1.0

760330

1203NH

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CMMP-AS-...-M3

Translation of the original instructions GDCP-CMMP-M3-FW-EN

Windows PROFIBUS

,PHOENIX®,CiA®,CANopen®, Bec khoff®,Rockwell®, D eviceNET®,EtherCAT®,

, Heidenhain®,EnDat®,HIPERFACE®,Stegmann®,Yaskawa®,CANopen®are registered

trademarks of the respective trademark owners 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.

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CMMP-AS-...-M3

Table of contents – CMMP-AS-...-M3

1 Safety and requirements for product use 8......................................

1.1 Safety 8..................................................................

1.1.1 Safety instructions for commissioning, repair and de-commissioning 8...........

1.1.2 Protection against electric shock through protective extra-low voltage (PELV). 9...

1.1.3 Designated use 9.....................................................

1.2 Prerequisites for use 10.......................................................

1.2.1 Technical requirements 10...............................................

1.2.2 Qualification of the specialists (requirements for the personnel) 10..............

1.2.3 Range of application and certifications 10...................................

2 Operating modes and functions 11..............................................

2.1 Overview 11................................................................

3 Control interfaces 12.........................................................

3.1 Control interfaces 12.........................................................

3.1.1 Overview of interfaces 12................................................

4 Fieldbus options 13..........................................................

4.1 Supported fieldbuses 13......................................................

4.2 Required I/O c onnection for fieldbus control 14....................................

5Service 15.................................................................

5.1 Supported functions 15.......................................................

5.2 Memory card 15.............................................................

5.2.1 Load firmware via memory card 16.........................................

5.2.2 Load parameter set from memory card 16...................................

5.3 Ethernet (TFTP) 17...........................................................

5.3.1 Load firmware via Ethernet 17............................................

5.3.2 Load parameter set via Ethernet 17........................................

5.3.3 Save parameter set via Ethernet 18........................................

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CMMP-AS-...-M3

6Functions 19...............................................................

6.1 Position controller 19.........................................................

6.1.1 Basic principles of the position controller 19.................................

6.1.2 Record selection through I/O 24..........................................

6.1.3 Start of the record selection 24...........................................

6.1.4 Stop of the record selection through “digital halt” 24..........................

6.1.5 Record selection with record continuation 24................................

6.1.6 Modulo positioning 26..................................................

6.2 Homing 28.................................................................

6.2.1 Homing methods 29....................................................

6.2.2 Homing - options 35....................................................

6.2.3 Homing parameters 36..................................................

6.2.4 Secure zero point shift 36................................................

6.2.5 Homing via I/O 37......................................................

6.2.6 Timing diagrams 38.....................................................

6.3 Jog mode 40................................................................

6.3.1 Function 40...........................................................

6.3.2 Process 41............................................................

6.3.3 Jog mode parameters 42................................................

6.4 Teach-in function 44..........................................................

6.5 Setpoint specification 45......................................................

6.5.1 Analogue setpoint 45...................................................

6.5.2 Digital nominal value 47.................................................

6.5.3 Master-slave 51.......................................................

6.5.4 Flying saw 51..........................................................

6.5.5 Scope of functions for cam discs ( C AM) 53..................................

6.6 Second measuring system 53..................................................

6.6.1 Technology 53.........................................................

6.6.2 Example, toothed belt axis 54............................................

6.6.3 Example, spindle axis 54................................................

6.6.4 Function in the controller 54..............................................

6.6.5 Inclusion of a second displacement encoder 55..............................

6.6.6 2nd measuring system at the incremental encoder input [X10] 55................

6.6.7 EGC-...-M at [X10] 56....................................................

6.6.8 2nd measuring system at input [X2A] 57....................................

6.6.9 Commissioning 57......................................................

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CMMP-AS-...-M3

6.7 Additional functions 58.......................................................

6.7.1 Encoder emulation 58...................................................

6.7.2 Brake control and automatic brake 59......................................

6.7.3 Position trigger 61.....................................................

6.7.4 Inputs for option “flying measurement” 62..................................

6.7.5 Software limit switch 62.................................................

6.7.6 Input for digital halt 63..................................................

6.7.7 I/O [X1] 63............................................................

6.7.8 Supported encoder systems 71...........................................

7 Dynamic response 73........................................................

7.1 PFC for increased intermediate circuit voltage 73...................................

7.1.1 Switch-on behaviour: 73.................................................

7.1.2 Behaviour under normal operation and control properties 74...................

7.2 Extended sine modulation for increased output voltage 74...........................

7.3 Variable cycle times, current, speed and position controller 75........................

8 Service functions and diagnostic messages 76....................................

8.1 Protective and service functions 76..............................................

8.1.1 Overview 76..........................................................

8.1.2 Phases and mains failure detection with 3-phase motor controllers 76............

8.1.3 Overload current and short-circuit monitoring 76.............................

8.1.4 Overvoltage monitoring for the intermediate circuit 77.........................

8.1.5 Temperature monitoring for the heat sink 77.................................

8.1.6 Monitoring of the motor 77...............................................

8.1.7 I2t monitoring 77......................................................

8.1.8 Power monitoring for the brake chopper 77.................................

8.1.9 Commissioning status 78................................................

8.1.10 Rapid discharge of the intermediate circuit 78...............................

8.2 Operating mode and error messa ges 78..........................................

8.2.1 Operating mode a nd error display 78.......................................

8.2.2 Seven-segment display 79...............................................

8.2.3 Acknowledgement of error messages 80....................................

8.2.4 Diagnostic messages 80.................................................

A Diagnostic messages 81......................................................

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CMMP-AS-...-M3

Instructions on this description

This documentation is intended to help you safely work with the motor controllers of the series CMMP-AS-…-M3. It includes safety instructions that must be observed. Refer to the documentation for the CMMP-AS product family for further information  Ta b. 1 .

• Unconditionally observe the general safety regulations for the CMMP-AS-...-M3.

The general safety regulations for the CMMP-AS-...-M3 can be found in the description Hardware, GDCP-CMMP-AS-M3-HW-..., see Tab. 1.

Tar g et g rou p

This description is intended exclusively for tec hnicians trained in control and automation technology, who have experience in installation, commissioning, programming and diagnosing of positioning systems.

Service

Please consult your regional Festo contact if you have any technical problems.

Product identification, versions

This description refers to the following v ersions: – Motor controller CMMP-AS-...-M3 from Rev. 01 – Firmware from Version 4.0.1501.1.0 – FCT plug-in CMMP-AS from Version 2.0.x.

This description does not apply to the older variants CMMP-AS-...

Note

With newer firmware versions, check whether there is a newer version of this description available: www.festo.com

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CMMP-AS-...-M3

Documentation

You will find additional information on the motor controller in the following documentation:

User documentation on the motor controller CMMP-AS-...-M3 Name, type Contents

Hardware description, GDCP-CMMP-M3-HW-...

Mounting and installation for all variants/power classes (1-phase, 3-phase), pin assignments, error messages,

maintenance. Function descriptions, GDCP-CMMP-M3-FW-... Description FHPP, GDCP-CMMP-M3-C-HP-...

Instructions on commissioning + functional description

(firmware). Overview of fieldbus, safety engineering.

Control and parameterisation of the motor controller through

the Festo pro file FHPP with the following fieldbuses: CANopen,

PROFIBUS, DeviceNet, EtherCAT, PROFINET, Ethernet/IP. Description CiA 402 (DS 402), GDCP-CMMP-M3-C-CO-...

Control and parametrisation of the motor controller through the

device profile CiA 402 (DS402) with the following fieldbuses:

CANopenand EtherCAT. Description CAM-Editor,

Cam disc function (CAM) of the motor controller. P.BE-CMMP-CAM-SW-... Description safety module, GDCP-CAMC-G-S1-...

Functional safety engineering for the motor controller with the

safety function STO. Help for the FCT plug-in CMMP-AS User interface and functions of the CMMP-AS plug-in for the

Festo Configuration Tool.

 www.festo.com

Tab. 1 Documentation on the motor controller CMMP-AS-...-M3

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1 Safety and requirements for product use

1.1 Safety

1.1.1 Safety instructions for commissioning, repair and de-commissioning

Warning

Danger of electric shock. – When modules or cover plates are not mounted on the slots Ext1 … Ext3. – When cables are not mounted to the plugs [X6] and [ X9] . – When connecting cables are disconnected when powered. Touching live parts causes severe injuries and can lead to death. The product may only be operated in a built-in status and when all protective measures have been initiated. Before touching live parts during maintenance, repair and cleaning work and when there have been long service interruptions:

1. Switch off power to the electrical equipment via the mains switch and secure it against being switched on again.

2. After switch-off, wait at least 5 minutes discharge time and chec k that power is turned off before accessing the controller.

The safety functions do not protect against electric shock but only against dangerous movements!

Note

Danger from unexpected movement of the motor or axis. – Make sure that the movement does not endanger any people. – Perform a risk assessment in accordance with the EC machinery directive. – Based on this risk evaluation, design the safety system for the entire machine, tak-

ing into account all integrated components. This also includes the electric drives.

– Bypassing safety equipment is impe r missible.

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1 Safety and requirements for product use

1.1.2 Protection a gainst electric shock through protective extra-low voltage (PELV).

Warning

• Use for the electrical power supply only PELV circuits in accordance with IEC DIN EN 60204-1 (Protective Extra-Low Voltage, PELV). Also take into account the general requirements for PELV circuits in accordance with IEC/DIN EN 60204-1.

• Use only power sources which guarantee reliable electrical disconnection of the operating voltage as per IEC/DIN EN 60204-1.

Through the use of PELV circuits, protection from electric shock (protection from direct and indirect contact) in accordance with IEC DIN EN 60204-1 is ensured (Electrical equipment of machines. General requirements).

1.1.3 Designated use

The motor controller CMMP-AS-...-M3 is intended for installation in machines or automated systems andistobeusedasfollows: – in a faultless technical condition, – in original status without unauthorised modifications, – within the limits of the product defined by the technical data ( appendix A of the documentation

GDCP-CMMP-AS-M3-HW-...),

– in an industrial environment.

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.

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1 Safety and requirements for product use

1.2 Prerequisites for 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 components and modules.

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

• For emergency stop applications, restart may take place only as intended under the control of a safety switching device.

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 connection and environmental conditions specified in the technical data of the motor controller ( appendix A of the documentation GDCP-CMMP-AS-M3-HW-...) and of all connected components. 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 this documentation.

1.2.2 Qualification of the specialists (requirements for the personnel)

The device may only be set into operation by a qualified electrotechnician who is familiar with: – installation and operation of electrical control systems, – the applicable regulations for operating safety-engineered systems, – the applicable regulations for acc ident protection and occupational safety, and – the documentation for the product.

1.2.3 Range of application and certifications

Standards and test values which the product complies with and fulfils can be found in the “Technical data” section ( appendix A of the documentation GDCP-CMMP-AS-M3-HW-...). 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.

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2 Operating modes and functions

2.1 Overview

The following operating modes are available to support your application.

Operating mode/functions

Profile Positioning Mode (Profile Position Mode)

Speed-controlled operation (Profile Velocity Mode)

Force/torque operation (Profile Force/Torque Mode)

Homing (Homing) Interpolated positioning mode (Interpolated position mode in accordance with CiA 402)

Description

Operating mode for executing a positioning record ( record selection) or a positioning task (direct mode). In addition to operation with speed control, a higher-level position controller (setpoint value generator) is active; it processes deviations between setpoint position and actual position and converts it into corresponding setpoint specifications for the speed controller. For position control, the current settings for speed, acceleration, braking deceleration, etc. are taken into account. Operating mode for executing a positioning record ( direct mode). Regulation in acc ordance with speed setpoint values and profiles. In speed-controller operation, current limitation can be activated through specification of a force/torque limit value. Operating mode for executing a positioning record ( direct mode) with force/torque control (current control). This operating mode permits specification to the controller of an external force/torque setpoint value (relative to the motor current). All specifications on forces/torques refer to the motor nominal torque or the motor nominal current. Since force/torque are proportional to the motor c urrent, only the current regulator is activated in this operating case. In addition, speed limiting can be activated through specification of a limit value. Positioning mode with a sequence established through the homing method for definition of the mechanical reference system (homing point). Positioning mode with a sequence established through the homing method for definition of the mechanical reference system (homing point) – Travelling along trajectory curves – Coupling of axes for multiple axis systems – Axis error compensation. The movement is parameterised for several axes in advance in the shape of data points (position, speed, time) and loaded into the controllers. Between the data points, the various axes interpolate independently and work off the movement profile synchronously in time.

Tab. 2.1 Overview of operating modes

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3 Control interfaces

3.1 Control interfaces

Control interfaces Setpoint s pecification via Signal type

Analogue [X1] (±10 V) Analogue signal Synchronisation [X10] (5 V) A/B – tracking signals (RS422)

CLK/DIR – pulse/direction CW/CCW – pulse

I/O [X1] (24 V) Digital I/O – signals for control of

record selection and jog mode

Fieldbus CANopen (FHPP/CiA DSP 402)

PROFIBUS-DP (FHPP) DeviceNet (FHPP) EtherCAT (FHPP/CiA 402) EtherNet/IP ( FHPP) PROFINET (FHPP)

Tab. 3.1 Control interfaces

3.1.1 Overview of interfaces

Control interface

Analogue Analogue setpoint spe-

Synchronisation – Flying saw

I/O – Record selection

Fieldbus Depending on the field-

Function Operation Mode Reference 

cification

– Synchronisation

(slave)

– Cam disc

–Jogmode – Linked position sets –Homingrun – Cam disc

bus profile

– Speed adjustment – Torque regulation – Chap. 6.5.2

Position c ontrol Chap. 6.1.2

– Speed adjustment – Torque regulation – Position control

Chap. 6.5.1 45 ff

47 ff

24 ff

GDCP-CMMPM3-C-HP-... GDCP-CMMPM3-C-CO-...

Tab. 3.2 In t er fa ce s

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4 Fieldbus options

4.1 Supported fieldbuses

Different fieldbuses c an be used with the CMMP-AS-...-M3. Standard with the CMMP-AS -...-M3 is that the CAN bus is permanently integrated in the motor controller. Optionally, additional fieldbus interfaces or card modules can be used. But only one fieldbus can be active at any given time. For all fieldbuses, the Festo Profile for Handling and Positioning (FHPP) has been implemented as the communication protocol. Additionally, for the CAN bus, the communication protocol based on the CANopen profile in accordance with the CiA DS-301 and the drive profile in accordance with the CiA 402 have been implemented. Independent of the field bus, a factor group can be used so that application data can be transferred into use r-specific units.

Fieldbus

CANopen [X4] — GDCP-CMMP-M3-C-CO-... (CiA 402)

DeviceNet [Ext1] CAMC-DN GDCP-CMMP-M3-C-HP-... (FHPP) DriveBus [X4] — GDCP-CMMP-M3-C-CO-... (CiA 402)

EtherCAT [Ext2] CAMC-EC GDCP-CMMP-M3-C-CO-... (CiA 402)

PROFIBUS DP [Ext2] CAMC-PB GDCP-CMMP-M3-C-HP-... (FHPP) PROFINET [Ext2] CAMC-F-PN GDCP-CMMP-M3-C-HP-... (FHPP) Ethernet/IP [Ext2] CAMC-F-EP GDCP-CMMP-M3-C-HP-... (FHPP)

Tab. 4.1 Fieldbus support

Connection Interface

(type)

Fieldbus support files are included on the CD-ROM in the scope of supply of the motor controller CMMP-AS-...-M3. Update on  www.festo.com/download.

Documentation – type

GDCP-CMMP-M3-C-HP-... (FHPP)

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4 Fieldbus options

4.2 Required I/O connection for fieldbus control

Fieldbus

CMMP-AS-...-M3

24 V DC

Controller enable / DIN5

Output stage enable / DIN4

Limit switch0 / DIN61)

Limit switch1 / DIN71)

Operating status / DOUT0

Default - motion complete / DOUT1

The connection plan shows the switch position in the active operating state.

1) The limit switches are set by default to N/C contact (configuration over FCT)

Fig. 4.1 Connection diagram: required I/O interface

X1/Pin

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5Service

5.1 Supported functions

Firmware Parameter file

Medium

Memory card X – X X Ethernet (TFTP) X – X X FCT (Ethernet/USB) X – X X

Tab. 5.1 Supported functions

5.2 Memory card

Characteristic Description

load save load save

Functions Copying (loading) a parameter set from the memory card to the

CMMP-AS-...-M3. Copying (saving) a parameter set from the CMMP-AS-...-M3 to the memory card. Copying (loading) a firmware from the memory card to the CMMP-AS-...-M3.

Supported card types MMC1)(version 3)

SD1)(version 1 and 2) SDHC1)(from class 2)

Supported file systems FAT16

FAT32

Format filename 8.3

1) Recommended are industry-suitable cards from the Festo accessories programme.

Tab. 5.2 Characteristics of the memory card

Note

The filenames may only consist of upper case letters. If lower case letters are used when the filename is issued, Windows automatically saves the file in the file format for long filenames!

Filename extension

.mot Firmware file FW_CMMP-AS-M3_4P0_2P0.MOT .dco Parameter file CMMP01.DCO .txt Info file INFO.TXT

Tab. 5.3 Filename extension

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Description Example

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5Service

5.2.1 Load firmware via memory card

Procedure for loading firmware via the memory card:

1. Make sure that the output stage enable is switched off.

2. Shift the switch [S3] onto ON.

3. Insert the memory card with the firmware into the module [ M1].

4. Actuate the reset button

5. The motor controller checks whether a memory c ard is plugged in and includes loadable firmware. Memory card plugged in and valid firmware version  firmware is loaded.

6. The firmware update is signaled through “F.” on the digit representation with 7 segments.

7. The motor controller automatically starts the firmware by triggering a RESET.

8. The motor controller searches for the newest parameter file on the memory c ard and loads it into the motor controller.

9. Shift the switch [S3] to ON.

Errors may occur in firmware download. Possible causes for this are: – Memory card not plugged in – Invalid firmware version – Firmware file includes lower case letters If one of these points is applicable, the firmware update is cancelled and an error reported.

The decimal point in the digit representation with 7 segments is also displayed in case of errors that were detected or triggered through the bootloader.

If no memory card was found or there is no parameter set on the memory card, the parameter set valid before the firmware download is loaded. If no memory card was found or there is no firmware on the memory card: – Error 29-0 is reported – The boot process is stopped (displayed through a decimal point on the digit repres-

entation with 7 segments). It is recommended to have only one firmware file at a time on the SD card. In the case of several files, the newest one is always loaded! If the newest file is already included on the motor controller, no firmware update is carried out.

5.2.2 Load parameter set from memory card

Parameterisation in the FCT can establish whether a parameter set is loaded from the memory c ard when the motor controller is reset. Possible options: – Use the newest parameter file. – Load parameter file with specific name. Loading of the parameter set is shown with a “d” on the digit representation with 7 segments.

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5Service

5.3 Ethernet (TFTP)

5.3.1 Load firmware via Ethernet

Firmware can be loaded via the Ethernet interface [ X18]. For computers that use Windows Vista or Windows 7 as operating system, the TFTP client and ports must be specially activated or opened for the firewall. Procedure with the program TFTP.EXE:

1. Make sure that the output stage enable is switched off.

2. Start the program CMD.EXE

3. Call up the program TFTP.EXE with the following syntax

4. tftp -i <ip-address> PUT <FILENAME.MOT> <ip-address> = IP address of the motor controller <FILENAME.MOT> = Filename of the firmware

5. The PC copies the firmware file locally into the motor controller.

6. The motor controller checks whether the firmware is appropriate.

7. If yes, the firmware version is checked. Firmware version is th e same -> error message “File already exists” Firmware version is different -> Firmware update is started.

8. The firmware update is signaled through “F.” on the digit representation with 7 segments.

9. The motor controller automatically starts the firmware by triggering a RESET.

A firmware download is also possible if the firmware programming has been cancelled and the controller does not have valid firmware. But observe that the controller in this case may have a different IP address (if it procures it through DHCP).

Errors may occur in firmware download. Possible causes for this are: – The firmware to be loaded is unsuitable for the device! (see FW header) – Faulty S record received. – Error when programming the S record in FLASH.

The decimal point in the digit representation with 7 segments is also displayed in case of errors that were detected/triggered through the bootloa der.

5.3.2 Load parameter set via Ethernet

A parameter set can be loaded via the Ethernet interface [X18]. For computers that use Windows Vista or Windows 7 as operating system, the TFTP client and ports must be specially activated or opened for the firewall. Procedure with the program TFTP.EXE:

1. Make sure that the output stage enable is switched off.

2. Start the program CMD.EXE

3. Call up the program TFTP.EXE with the following syntax

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5Service

4. tftp -i <ip-address> PUT <FILENAME.DCO> <ip-address> = IP address of the motor controller <FILENAME.DCO> = Filename of the parameter set

5. The PC copies the firmware file locally into the motor controller.

6. The motor controller checks the parameter set. Parameter set is the same -> Parameter set is not loaded Parameter set is different => Parameter set update is started.

7. The parameter set update is signaled through “d” on the digit representation with 7 segments.

8. The motor controller automatically starts the firmware by triggering a RESET.

During Parameter set download, error 49-0 may occur. Possible causes for this are: – Formatting error in the DCO file – Faulty parameters in the DCO file (invalid value). – Error during parameter access (read or write)

5.3.3 Save parameter set via Ethernet

A parameter set can be stored via the Ethernet interface [ X18]. For computers that use Windows Vista or Windows 7 as operating system, the TFTP client and ports must be specially activated or opened for the firewall. Procedure with the program TFTP.EXE:

1. Make sure that the output stage enable is switched off.

2. Start the program CMD.EXE

3. Call up the program TFTP.EXE with the following syntax

4. tftp -i <ip-address> GET <FILENAME.DCO> <ip-address> = IP address of the motor controller <FILENAME.DCO> = Filename of the parameter set

5. Through the GET command, creation of the DCO file is started.

Creation of the DCO file takes approx. 1-2 seconds. Therefore, the first GET command is answered with the error message “File not found”.

6. Enter the command “tftp -i <ip-address> GET <FILENAME.DCO>” again.

7. The motor controller copies the parameter set into the PC.

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6Functions

6 Functions

6.1 Position controller

6.1.1 Basic principles of the position controller

In t he positioning mode, a certain position is specified to which the motor must move. The current position is obtained from the information gained from the internal encoder analysis. The position deviation is processed in the position controller and passed on to the speed regulator. The integrated position controller allows jerk-limited or time-optimised positioning, either relative to the c urrent position or absolute with respect to a reference point. It provides setpoint values to the position controller and, to improve the dynamic response, also to the speed regulator. With absolute positioning, travel occurs directly to a defined target position. With relative positioning, travel occurs around a parameterised path. The positioning range of 2 relative positioning can occur as often as desired in a given direction. After the positioning range is reached, the actual position runs over it without triggering an error. This overrunning must be taken into account by the controller. The positioning controller is parameterised via a target table. This contains entries for parameterising a target via a communication interface and also target positions that can be access via the digital inputs. The positioning method, travel profile, acceleration and braking times, and maximum speed can be specified for every entry. All targets can be pre-parameterised. Positioning then only requires an entry to be selected and a start command to be issued. In the motor controller CMMP-AS-...-M3, 255 position records can be stored. All position records have the following possible settings: – Mode (relative or absolute positioning) – T arget position – Speed – Acceleration – Braking deceleration – Smoothing – Start Condition – Direction of rotation with modulo positioning – Step criterion – Record at digital input NEXT1 – Record at digital input NEXT2 – Ignore stop input – End speed – Synchronisation – Remaining path message – Torque feed forward – T orque limitation –StartDelay

full rotations ensures that

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6Functions

The positioning records can be addressed via digital inputs, fieldbus or the parameterisation software FCT.

Absolute positioning linear/rotative axis

Here, the positioning target is moved to regardless of the current position. With absolute positioning the target position is a fixed (absolute) position relative to the zero point or reference point.

Absolute positioning, modulo axis

The target position of the positioning record is travelled to with modulo correction. Example: 490°  for modulo 360, the axis is positioned to 130°.

Relative positioning, linear/rotative axis

With relative positioning, the target position is obtained by adding a value to the current position. Referencing is necessary to bring the drive into a defined position. Concatenation of relative positioning can be used to continuously position in the same direction, such as for a trimming unit or conveyor (incremental dimensions). The following options are available: – Relative reference to the last target position – Relative reference to the current position (actual position)

Relative positioning, modulo axis

The target position of the positioning record is not travelled to with modulo correction. Example: 490° , the axis travels positively around 490°.

Positioning with analogue setpoint

The target position is determined through the analogue setpoint specification at AIN0 [X1]. The following options are available: – Absolute reference to the project zero point – Relative reference to the last target position – Relative reference to the current position – Continuous positioning c orresponding to the analogue setpoint specification (joystick function)

Speed

The maximum speed at which movement to the position is to take place.

Acceleration

Setpoint value of acceleration for the positioning record.

Deceleration

Setpoint value of the positioning record deceleration.

Smoothing

With travel profiles, a distinction is made between time-optimised and jerk-limited positioning. With time-optimised positioning, motion occurs with the maximum specified acceleration and braking. The drive moves to the target in the shortest possible time, the speed sequence is trapezoidal and the acceleration sequence square. With jerk-limited positioning, the acceleration is trapezoidal and the speed curve is third-order. Since the acceleration constantly changes, the drive moves in a manner that is especially gentle to the mechanics.

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a(t) a(t) a(t)

123

ttt

v(t) v(t) v(t)

t1 t2 t3

1 Time-optimised = 0 %

3 Jerk-free = 100 %

2 Jerk-limited

Fig. 6.1 Positioning profiles

Start Condition

Start of a new positioning record with ongoing movement – Ignore: Start command is not carried out – Wait: Terminate current record and then start selected record – Interrupt: Cancel current record and immediately start new record.

Direction

Establishment of the direction of rotation when modulo positioning is active in the mode “Direction of rotation from position record” is defined here. The following settings are possible: – Positive: The direction of movement of the axis is always positive – Negative: The direction of movement of the axis is always negative – Auto: The direction of travel is determined automatically from the current position, target position

and additional options (absolute, relative, relative related to last target, etc .).

Command (record continuation)

Record continuation consists of a defined sequence of positioning records. Each positioning re cord can be used as a reco rd sequence through parameterisation of its subsequent position and continuation condition. The number of positions in a record sequence is limited only by the total number of positions available. The continuation condition for the next positioning record is determined through the “Command” column of the positioning record table. The following commands are available:

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Command Function

END No continuation takes place; the record sequence ends with this positioning

record.

GoFP1 Continuation takes place after the current positioning record is completed and is

always to the subsequent positioning record specified in Next1 (without evaluation of the digital input NEXT1).

IgnUTP Continuation only takes place after completion of the current positioning record

and a subsequent rising edge at the digital input NEXT1 or NEXT2 to the associated specified subsequent positioning record Next1 or Next2. Signal edges at NEXT1 and NEXT2 are ignored during the current positioning motion.

GoImm Continuation takes place immediately in the event of a rising edge at the digital

input NEXT1 or NEXT2 to the associated specified subsequent positioning record NEXT1 or NEXT2. Movement is not continued to the target position of the current positioning record.

GoAtp Continuation only takes place after the current positioning record is completed.

During the current positioning movement, the most recently detected rising edge at the digital input NEXT1 or NEXT2 decides the associated subsequent positioning record NEXT1 or NEXT2 to which continuation is made. This decision is made by the first detected edge after th e current positioning

motion is completed. Additional pa rameters: Ign. Stop Ignore STOP input.

The signal of the digital input is ignored for this positioning record. End speed Specifies the end speed of the positioning record. Default = 0 (rest when the

setpoint position is reached). The current positioning record is ended at the

target position with the defined end speed. This enables the drive to execute a

subsequent record with the same positioning speed without reducing the speed.

Tab. 6.1 Commands for record continuation

NEXT1/NEXT2

Subsequent positions of a positioning record for record continuation through positioning record number a nd digital inputs. Execution (travel to the subsequent position) corresponds to the logic operation of the digital inputs NEXT1 and NEX T2 through step enabling condition of the positioning record. The digital inputs N EXT1 and NEXT2 are evaluated only through the step enabling conditions GoImm, IgnUTP, GoATP.

Synchronisation

The “Sync.” (synchronisation) column is only shown when using the “Flying Saw” function. If the “Flying Saw” function is active, synchronisation can be activated or deactivated by starting positioning records. When synchronisation is active, the position of the encoder (master) selected for the synchronisation is locked onto the setpoint position value. The drive thus follows the changes in position of the master drive.

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The following settings are possible:

Command

Function

Sync Synchronisation is activated when positioning is started, if it was not already. If

the master is not stationary when positioning starts, the offset that occurs will be made up in a controlled manner. The positioning speed used for this corresponds t o the speed of the master plus the positioning speed entered in the positioning record as an excessive increase in speed. The entries of the star ted positioning record are likewise used for the accelerations.

Sync Out Synchronisation is deactivated when positioning is started, if it was not already.

Positioning starts with the current synchronous positioning speed ( rotational speed of the master). This results in controlled desynchronisation.

No Sync Synchronisation is deactivated when positioning is started, if it was not already.

Positioning starts with the values for speed and acceleration entered in the positioning record.

Tab. 6.2 Commands for synchronisation

Remaining Distance

Enter the amount for the remaining distance message.

TFF (torque feed forward)

This value is used to permit the motor greater dynamic response during acceleration when large loads are moved. The current required for approaching is increased by the set percentage (related to the nominal current of the motor) after the positioning record is started. The result is a higher starting torque that facilitates greater dynamic response. The value is determined experimentally .

Torque limitation

During standard positioning, the torque is limited only by the set nominal or peak currents. Torque limitation provides another way of further limiting the torque during active positioning. The value should be less than the set nominal current.

Start Delay

Waiting time until positioning starts.

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6.1.2 Record s election through I/O

To address a command record, a record number with up to 8 bits can be agreed and thus the reference travel (record 0) and 255 command records addressed (via F HPP 250). In the default setting without I/O extension and without reconfiguration, the motor controller CMMP-AS-...-M3 allocates 4 digital inputs DIN0 … DIN3 for a maximum of 15 command records. The respective positioning record is selected via the binary code of the record numbers 1 … 15.

Record

Record 0

Bit 3 Bit 2 Bit 1 Bit 0

0 0 0 0 Record 1 0 0 0 1 Record 2 0 0 1 0 … Record 15 1 1 1 1

1) Homing

Tab. 6.3 Bit pattern of the record number

The following I/O expansions are possible: – 4 additional inputs (DIN10 … 13) through corresponding reconfiguration of digital outputs or ana-

logue inputs possible with FCT

– Two extension modules, each with 8 additional digital inputs and out puts (accessories type

CAMC-D-8E8A).

6.1.3 Star t of the rec ord selection

After setting the START signal, the number of the selected positioning record is taken over and the drive carries out the record.

6.1.4 Stop of the record selection through “digital halt”

The digital halt stops in positioning mode with the parameterised ramp of the positioning record. After that, the drive is controlled ( brake is opened).

6.1.5 Record s election with record continuation

Function

Process

The continuation condition for the next positioning record is determined through the “Command” column of the positioning record table. Through the continuation condition of the positioning records, the following record continuation sequences can be set: – Linear sequence with established subsequent position NEXT1 of the positioning record – Conditional branching to the subsequent position NEXT1 or NEXT2 of the current positioning record – cyclical process ( repetition of the sequence, infinite loop...).

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Continuation takes place dependent on: – the continuation c ondition set for the current positioning record, – the logical status of the digital inputs with the assignment NEXT1 or NEXT2.

Starting the process

The start is made through: – a rising edge at the digital input “travel to the STAR T position”

Stopping the process

Record continuation is terminated when – a positioning record is executed with the option END or – a stop signal is present at the STOP input.

The Stop signal at the STOP input is not executed if the continuation condition “StopIgn” has been set for the current positioning record.

Sequence control

DIN

Function

START Set positioning records for the Home or Start position.

HOME

When the START signal is set (0 (1

}

0). The MC signal (Motion Complete) is reset (1}0),; the drive carries out the homing run. When the START signal is reset (1 signal (0 (0

}

1). After completion of the positioning job, the MC signal is set again

1).

}

1), confirmation follows via the ACK signal

}

0), c onfirmation follows via the ACK

NEXT1/2 Subsequent positions of a positioning record for record continuation through posi-

tioning record number and digital inputs. Execution (travel to the subsequent position) corresponds to the logic operation of the digital inputs NEXT1 and NEXT2 through the step enabling condition of the positioning record. The digital inputs NEXT1 and NEXT2 are evaluated only through the step enabling conditions GoImm, IgnUTP, GoATP.

STOP Stop record continuation

}

1: Record c ontinuation is stopped. The ongoing positioning is still ended in any case. Note: If the positioning record has the setting “StopIgn”, despite the set STOP input the positioning record of the subsequent position is started.

Combined START/STOP

The MC signal (Motion Complete) is set (0 0}1: START position of the record continuation is approached. 1

}

0: activates Stop function of record continuation

}

1), the READY signal is reset (1}0).

Tab. 6.4 Sequence control via I/O

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Example

For positioning record “4”, the following are established as subsequent positions: – NEXT1 := “19” (Z DIN0 – NEXT2 := “20” (Z DIN1

}

1) Through the I/O configuration, the subsequent positions are logically linked to the digital inputs DIN0 and DIN1. Corresponding to the established continuation condition, the following positioning behaviour results:

Command

Continuation c ondition (example)

END After position 4 is reached, record continuation is ended. GoFP1 Signal edges 0}1 at input DIN0 or DIN1 are not evaluated. After position 4 is reached,

position 19 is travelled to immediately.

IgnUTP As long as position 4 has not been reached yet, edge changes at DIN0 and DIN1 are

ignored. If position 4 is reached, a rising edge at input –NEXT1(DIN00 –NEXT2(DIN10

}

1) c auses approach of the target position 19

}

1) an approach of the target position 20.

GoImm Signal edges 0}1 at input DIN0 or DIN1 are evaluated during the positioning pro cess.

With an active positioning edge at input NEXT1 or NEXT2, the ongoing positioning is cancelled and –NEXT1(DIN00 –NEXT2(DIN10

}

1) c auses approach of the target position 19

}

1) causes the target position 20 to be approached.

GoATP – As long as position 4 has not been reached yet, edge changes at DIN0 and DIN1 are

recorded; positioning is not interrupted. During the ongoing positioning, first a signal edge appears at DIN0 0

}

1, after that an edge at DIN1 0}1. After target posi-

tion 4 is reached, positioning is started to Pos. 20.

– If position 4 is reached before an edge oc c urs, a rising edge at input:

–NEXT1(DIN00 –NEXT2(DIN10

}

1) c auses approach of the target position 19

}

1) an approach of the target position 20.

Tab. 6.5 Continuation condition (example)

6.1.6 Modulo positioning

“Modulo” positioning can be performed for timed endless movements (e.g. conveyor belts, rotary indexing tables). This enables endless movements to be implemented without losing the position reference to the zero point of the measuring reference system. Selection for the modulo positioning is possible for the following axis configurations: – Rotative axis with unlimited positioning range – User-defined linear axis - type “conveyor belt”

Direction of movement

For modulo positioning, the direction of movement of the positioning motion is specified through the following selection: In the case of the “Direction of rotation always positive/negative” mode, the setting also applies to setpoints outside the interval (i.e. position specification prefixes are ignored in the position record table). The “Shortest Patch” se tting only applies for absolute positioning within the

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specified interval. Outside the interval and for relative positioning, the direction of movement is taken from the positioning record table.

Observe that with an unlimited drive that always mov es in the same direction, it is possible for the actual position to be overrun. There is no limitation of the range of values. The actual position is incremented up to overflow.

Option

Shortest path (for absolute positioning within the interval)

Direction of rotation from positioning record

Direction of rotation always positive (Absolute and relative positioning) Direction of rotation always negative (Absolute and relative positioning) Range limit positive/negative (interval)

Function

Both directions of movement are permitted. Positioning takes place by the shortest path, optimised for direction. Example: The positioning interval is defined from 0 R … 5 R. The current actual position is 4.5 R. The new setpoint position is 0.5 R. => The motor controller does not travel four revolutions in the negative direction but instead one revolution in the positive direction as this is the shortest path to reach its destination. The direction of rotation is not universally defined, but can be individually defined for each positioning record. The following settings are possible in the positioning record: positive The direction of movement of the axis is always posit-

ive. (Absolute and relative positioning)

negative The direction of movement of the axis is always negat-

ive. (Absolute and relative positioning)

auto The direction of travel is determined automatically

from the current position, target position and additional options (absolute, relative, relative related to last target, etc.).

The direction of movement of the axis is always positive.

The direction of movement of the axis is always negative.

By specifying an interval, the actual value only runs through values within the specified limits. The position range is not influenced by specifying the interval (unlimited, software limit switch not active).

Tab. 6.6 Options modulo positioning

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If the actual value exceeds the lower limit of the interval, it assumes the upper limit value. If the actual value reaches the upper limit of the interval, it displays the lower limit value. The lower limit of the interval is contained in the range of values; the upper limit does not belong to this, i.e. the highest value is never shown, as it is physically at the same position as the lowest value. Example: An interval of precisely one revolution is to be defined: Incorrect: 0 R … 0.99999 R Correct: 0 R … 1 R.

Note

setpoints outside the interval (incl. the upper interval limit) are always approached again, even if the drive is already at the position.

Note

When the cam disc function is activated, modulo positioning can only be used for the master.

6.2 Homing

No homing is required for speed-controlled operation or force/torque operation. For absolute positioning, homing must be executed and the dimensional reference system defined at initial commissioning. If the drive does not use a multi-turn absolute encoder, homing must be repeated at each switch-on or reset.

To be able to travel to an absolute, unique position in the positioning range, the drive must be referenced to a measuring reference system. Homing of the drive comprises: –Homing – Establishment of the axis zero point – Definition of the dimensional reference system. With homing, t he correct zero position is determined by means of a reference signal. The reference signal trigger defines the reference point of the dimensional reference system. The reference point is the absolute point of reference for the axis zero point. In the factory setting, the axis zero point = project zero point. The reference signal supplies, for example, a switch that is triggered at a known, unique position on the travel path. Also, dependent on the motor encoder, additional signals (e.g. encoder zero track) can be evaluated to increase accuracy. You establish the used signals via the homing method.

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6.2.1 Homing methods

The homing methods are oriented on CiA 402.

With some motors (those with absolute encoders, single- or multi-turn), the drive may be permanently referenced. In such cases, methods involving homing to an index pulse (= zero pulse) might not cause homing to be carried out; rather the drive will move directly to the axis zero point (if it has been entered in the parameters).

The drive homes against a stop, a limit switch or a reference switch. The motor current increases when the drive reaches a stop. Since the drive must not continuously home against the stop, it must move at least one millimetre back in to the stroke range.

Procedure:

1. Search for the homing point corresponding to the configured method.

2. Run relative to the reference point around the “Offset axis zero point”.

3. Set at the axis zero point: Current position = 0 – offset project zero point.

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Homing methods

hex dec Desc riptio n

01h 1 Negative limit switch with index pulse

1. If negative limit switch inactive: Run at search speed in negative direction to the negative limit switch.

2. Travel at creep speed in a positive direction until the limit switch becomes inactive, then continue to the first index pulse. This position is taken as the homing point.

3. If this is parameterised: travel at positioning speed to the axis zero point.

02h 2 Positive limit switch with index pulse

1. If positive limit switch inactive: Run a t search speed in positive direction to the positive limit switch.

2. Travel at creep speed in negative direction until the limit switch becomes inactive, then continue to the first index pulse. This position is taken as the homing point.

3. If this is parameterised: travel at positioning speed to the axis zero point

07h 7 Reference switch in positive direction with index

pulse

1. If reference switch inactive: Travel at search speed in positive direction to the reference switch. If the stop or limit switch is approached: Travel at search speed in positive direction to the reference switch.

2. Travel at creep speed in negative direction until the homing switch becomes inactive, then continue to the first index pulse. This position is taken as the homing point.

3. If this is parameterised: travel at positioning speed to the axis zero point.

Index pulse

Negative limit switch

Index pulse

Positive limit switch

Index pulse

Homing Switch

1) Only possible for motors with encoder/resolver with index pulse.

2) Limit switches are ignored during travel to the stop.

3) Since the axis is not to remain at the stop, the travel to the axis zero point must be parameterised and the axis zero point offset

mustbe≠0.

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Homing methods

hex Descriptiondec

0B 11 Reference switch in negative direction with index

pulse

1. If reference switch inactive: Travel at search speed in negative direction to the reference switch. If the stop or limit switch is approached: Travel at search speed in positive direction to the reference switch.

2. Travel at creep speed in positive direction until the homing switch becomes inactive, then continue to the first index pulse. This position is taken as the homing point.

3. If this is parameterised: travel at positioning speed to the axis zero point.

11h 17 Negative limit switch

1. If negative limit switch inactive: Run at search speed in negative direction to the negative limit switch.

2. Travel at creep speed in positive direction until the limit switch becomes inactive. This position is taken as the homing point.

3. If this is parameterised: travel at positioning speed to the axis zero point.

12h 18 Positive limit switch

1. If positive limit switch inactive: Run a t search speed in positive direction to the positive limit switch.

2. Travel at creep speed in negative direction until the limit switch becomes inactive. This position is taken as the homing point.

3. If this is parameterised: travel at positioning speed to the axis zero point.

Index pulse

Homing Switch

Negative limit switch

Positive limit switch

1) Only possible for motors with encoder/resolver with index pulse.

2) Limit switches are ignored during travel to the stop.

3) Since the axis is not to remain at the stop, the travel to the axis zero point must be parameterised and the axis zero point offset

mustbe≠0.

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Homing methods

hex Descriptiondec

17h 23 Reference switch in positive direction

2. Travel at creep speed in negative direction until the homing switch becomes inactive. This position is taken as the homing point.

3. If this is parameterised: travel at positioning speed to the axis zero point.

1Bh 27 Referenceswitchinnegativedirection

2. Travel at creep speed in positive direction until the homing switch becomes inactive. This position is taken as the homing point.

3. If this is parameterised: travel at positioning speed to the axis zero point.

21h 33 Index pulse in negative direction

1. Travel at creep speed in negative direction until the index pulse. This position is taken as the homing point.

2. If this is parameterised: travel at positioning speed to the axis zero point.

Homing Switch

Index pulse

1) Only possible for motors with encoder/resolver with index pulse.

2) Limit switches are ignored during travel to the stop.

3) Since the axis is not to remain at the stop, the travel to the axis zero point must be parameterised and the axis zero point offset

mustbe≠0.

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Homing methods

hex Descriptiondec

22h 34 Index pulse in positive direction

1. Travel at creep speed in positive direction until the index pulse. This position is taken as the homing point.

2. If this is parameterised: travel at positioning speed to the axis zero point.

23h 35 Cur rent position

1. The current position is taken as the reference position.

2. If this is parameterised: travel at positioning speed to the axis zero point.

Note: Through shifting of the reference system, travel to the limit switch or fixed stop is possible. For that reason this method is mostly used for axes of rotation.

FFh -1 Negative stop with index pulse

1. Travel at search speed in negative direction to the stop.

2. Travel at creep speed in positive direction until the next index pulse. This position is taken as the homing point.

3. If this is parameterised: travel at positioning speed to the axis zero point.

FEh -2 Positive stop with index pulse

1. Travel at search speed in positive direction to the stop.

2. Travel at creep speed in negative direction until the next index pulse. This position is taken as the homing point.

3. If this is parameterised: travel at positioning speed to the axis zero point.

EFh -17 Negative stop

1)2)3)

1. Travel at search speed in negative direction to the stop. This position is taken as the homing point.

2. If this is parameterised: travel at positioning speed to the axis zero point.

Index pulse

1)2)

Index pulse

1)2)

Index pulse

1) Only possible for motors with encoder/resolver with index pulse.

2) Limit switches are ignored during travel to the stop.

3) Since the axis is not to remain at the stop, the travel to the axis zero point must be parameterised and the axis zero point offset

mustbe≠0.

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Homing methods

hex Descriptiondec

EEh -18 Positive stop

1)2)3)

1. Travel at search speed in positive direction to the stop. This position is taken as the homing point.

2. If this is parameterised: travel at positioning speed to the axis zero point.

E9h -23 Reference switch in positive direction with travel

to stop or limit switch.

1. Run at search speed in positive direction to stop or limit switch.

2. Travel at search speed in negative direction to the reference switch.

3. Travel at creep speed in negative direction until the homing switch becomes inactive. This position is taken as the homing point.

4. If the axis zero point ≠ 0: Travel at positioning speed to the axis zero point.

E5h -27 Reference switch in negative direction with

travel to stop or limit switch

1. Run at search speed in negative direction to stop or limit switch.

2. Travel at search speed in positive direction to the reference switch.

3. Run at crawl speed in positive direction until reference switch becomes active. This position is taken as the homing point.

4. If this is parameterised: travel at positioning speed to the axis zero point.

Homing Switch

1) Only possible for motors with encoder/resolver with index pulse.

2) Limit switches are ignored during travel to the stop.

3) Since the axis is not to remain at the stop, the travel to the axis zero point must be parameterised and the axis zero point offset

mustbe≠0.

Tab. 6.7 Overview of homing methods

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6.2.2 Homing - options

Option

Travel to axis zero point after homing Homing with output stage and controller enable

Function

After finding the reference point, the drive runs automatically to the axis zero point. Automatic execution of homing with a positive edge at the digital input c ontroller enable if output stage and controller enable were previously off. For permanently referenced absolute value encoders, homing is not restarted in I/O operation if it has taken place once and the output stage enable has not been removed.

No homing after commutation Suppresses automatic homing after determination of the commut-

ation position. This option is only effective for a drive without commutation signals (e.g. motor type ELGL). In the basis setting, homing is automatically started after successful definition of the c ommutation

position. This option must be marked to suppress this. No synchronisation during homing No encoder emulation during

Suppresses switching off of the synchronised position during hom-

ing [X10].

During homing, no encoder signals are output at [X11]. Homing Reference switch at index pulse of [ X2B]

Evaluation of a reference pulse of the shaft encoder at [X2B] for

determination of the reference point. If this option is activated, an

index pulse from [X2B] is evaluated as a reference signal. Timeout monitoring If the parameterised maximum time for homing is reached without

the homing point being found, homing is terminated with an error

message: “Time-out in homing”. Limit se arch distance Path monitoring of homing: If the specified search distance

(e.g. effective stroke) is run without the homing point being found,

homing is terminated with an error message:

“Homing: End of search path reached” Torque threshold Requirement: Homing method “Stop”

Optional specification of a torque for identification of the stop in

the homing method.

Tab. 6.8 Homing – options

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6.2.3 Homing parameters

The following parameters must be set for homing:

Parameter

Description

Speed The parameter setting applies for:

Acceleration/ deceleration

– Searching travel to the primary destination – Crawl travel for identification of the switching point in the homing method

“Limit switch” or “reference switch”

Smoothing

– Travel to the axis zero point.

Axis zero point Definition of the axis zero point

Default values as a function of the set search direction Linear axes ±3.00 mm (±0.100 in) Axis of rotation ±10° (±0.030 R)

Tab. 6.9 Homing parameters

– Select the speed so that the reference mark can be detected by the controller. This

sometimes requires very low travel speeds.

– Set braking sufficiently high so that the motor c ontroller does not overrun the targets

too much during search travel.

6.2.4 Secur e zero point shift

Single-turn encoders that are set to permanently homed are already permanently homed on delivery. The absolute zero point is stored by the manufacturer in the EEPROM of the encoder.

Note

Incorrect positioning of the axis. Drives with absolute value encoders are always homed at switch-on to the absolute encoder zero point stored in the encoder. For comparison between the homing point of the c urrent measuring reference system and the mounting-related absolute zero point of the motor encoder, the resulting offset in the EEPROM of the encoder must be stored. The value is used for conversion of the actual position measured by the encoder.

• Carry out homing first

• Observe the subsequent special features for saving the zero offset.

Multi-turn

Absolute value e nc oders supply directly after switch-on an absolute position that is unique throughout the entire travel distance of an axis. Such an encoder is calibrated on the measuring reference system one time through homing and through a position offset stored in the EE PROM of the encoder (saving the zero point offset).

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Single-turn

Single-turn encoders supply a unique position only within one motor revolution (partial-absolute encoder). At commissioning, the encoder is calibrated on the measuring reference system through homing and through zero point offset. Despite this, the absolute position is undefined after a RESET in most cases (> 1 revolution), that is, homing is fundamentally required after each switch-on. You can permanently home the drive for specific applications (e.g. for modulo positioning 0 … 1 R), so that the status “referenced” is automatically set at switch-on. Homing at switch-on can then be optionally eliminated, as with the multi-turn encoder.

6.2.5 Homing via I/O

Homing via I/O can be started through the following methods. A requirement in both cases is an act ive output stage and controller enable. – Activation t hrough the assigned digital input “reference start” – Selection of the positioning record 0 and activation of the assigned digital input “position selector -

start”.

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6.2.6 Timing diagrams

Start(DIN)

Speed <> 0

E0/E1

HA: HOMING_ACTIVE MC: MOTION COMPLETE E0: Limit switch 0 E1: Limit switch 1

Fig. 6.2 Timing diagram: homing without error

3 4 5

1 0…10ms 2 20 ms 3 Dependent on braking ramp 4 Dependent on braking ramp 5 20 ms

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Start(DIN)

Error

Speed <> 0

ERR

HA: HOMING_ACTIVE MC: MOTION COMPLETE ERR: Error

Fig. 6.3 Timing diagram: homing with error

1 0…10ms 2 20 ms 3 Dependent on braking ramp 4 50 ms + x (x=delay until brake locked) 5 0…10ms

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DIN8 (Start)

Speed <> 0

DIG. HOLD

HA: HOMING_ACTIVE MC: MOTION COMPLETE

1 0…10ms 2 20 ms 3 Dependent on braking ramp 4 0…10ms

Fig. 6.4 Timing diagram: homing with digital halt

6.3 Jog mode

6.3.1 Function

In the “Operation enabled” status, the drive can be travelled through jogging in a positive or negative direction. This f unc tion is usually used for: – Moving to teach positions – Drive free running (e.g. after a system malfunction) – Manual travel as a normal operating mode (manually operated feed). The jog mode can be controlled as follows: – Fieldbus/FHPP (jog mode) – I/O interface through the parameterised digital inputs

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6.3.2 Process

When one of the signals Jog positive/Jog negative is set, the drive star ts to move slowly. Due to the slow speed (creep speed), a position can be defined very accurately. If the signal remains set for longer than the configured “creeping period” the speed is increased until the c onfigured maximum speed is reached. In this way large strokes can be traversed quickly. If the signal changes to 0, the drive is braked with the pre-set maximum deceleration. To protect the mechanics, smoothing can also be parameterised. All parameters can be set separately for positive and negative travel direction. If the drive is referenced: The drive stops automatically if it reaches a software end position. The software end position is not over-travelled; the path for stopping is taken into account according to the ramp set. The jog mode can also only be exited here again after Jogging = 0.

1 Low speed phase 1

t(s)

(slow travel).

2 Maximum speed for

phase 2

3 Acceleration 4 Dec eleration

Speed

v(t)

5 Time period phase 1

(creeping duration)

Jog

positive/negative

Tab. 6.10 Sequence chart for jog mode

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6.3.3 Jog mode parameters

The following parameters must be set for jog mode:

Parameter

Function

Crawling speed Speed during the crawl period. Acceleration takes place with the ramp defined

under “Acceleration” and “Smoothing”.  Tab. 6.10 1

Slow moving time Durat ion of crawling - until th e shift to maximum speed.

 Tab. 6.10 5

Max. speed Maximum speed during jog mode. Acceleration takes place with the ramp

defined under “Acceleration” and “Smoothing”.  Tab. 6.10 2

Acceleration Setpoint for acceleration of the drive during jog movements.

 Tab. 6.10 3

Deceleration Setpoint for deceleration of the drive during jog movements.

 Tab. 6.10 4

Smoothing Smoothing in acceleration value in % (default = 0 %).

– 0 % no smoothing – 100 % jerk-free approach or jerk-free braking

Tab. 6.11 Parameters for jog mode

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Negative

Positive

Speed > 0

Speed < 0

MC: MOTION COMPLETE 1 0…10ms

2 Dependent on braking ramp

Fig. 6.5 Timing diagram. Jog positive/negative

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Negative

Positive

Speed > 0

Speed < 0

MC: MOTION COMPLETE 1 0…10ms

2 Dependent on braking ramp

Fig. 6.6 Timing diagram: Jog positive/negative (simultaneously)

6.4 Teach-in function

The teach procedure is started with the rising edge at the parameterised teach input. With the falling edge, the actual position is temporarily stored in the position record selected via digital inputs. To accept all temporarily saved position data, a positive edge at the parameterised “Save position” input is required. The parameterised output “Saving process is running” goes to High at the start of the saving process. Completion of the saving process is signaled through a Low signal at the “Saving process is running” output.

Data are temporarily stored in the volatile main memory of the controller and are immediately effective in the controller. These data are lost when the power supply is switched off or in the event of a power failure. Data are stored permanently in the permanent memory of the controller and remain available even after a power failure or switch-off.

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Teach (DIN)

Digital position selector (bit

0…3,4…7optional)

Position saved

TA: TEACH_ACKNOWLEDGE 1 0…10ms

2 0…10ms

Fig. 6.7 Timing diagram: Teach

6.5 Setpoint specification

6.5.1 Analogue s etpoint

Through the analogue inputs, setpoint values can be specified as controller input data via a correspondingly scaled input signal. The setting of the function is dependent on the number of inputs used, the selected control interface and the selected operating mode/function.

Setpoint value

Torque/force x x x Speed x x x Position x – –

Tab. 6.12 Setpoint value via analogue inputs

Scaling

Specify in the FCT which value of the respective input variables corresponds to an input voltage of 10 V. The scaled range c orresponds to a linear c haracteristic curve symmetric to the zero point (e.g. –1000 R/min … +1000 R/min).

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Zero balancing

With an externally specified voltage 0 volt, an undesired setpoint value can still be generated due to voltage differences. For zero balancing, you can manually enter an offset in the FCT or execute synchronisation automatically (recommendation). Through zero balancing, the scaled range is divided asymmetrically ( example Fig. 6.8: –750 … +1250 R/min).

Safe Z ero

Threshold value of the input voltage, up to which the setpoint value = 0 is set to achieve a defined rest of the drive, for example in the speed control mode, independently of offset fluctuations, noise, etc.

• Enter the threshold value U0 > 0 V an. If the input v oltage UIN is in the range +U0 … –U0, the setpoint v alue = 0 is output. The offset set for zero balancing is taken into consideration.

Note that specifying the threshold value means that an appropriate setpoint range is no longer available for the application.

Filter time constant

AIN0 is a 16-bit input. Due to the high resolution, a digital filter is activated.

• Specify the time constant to be used to filter the input voltage.

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1250

1000

500

-1

17.5510-10 -7.5 -5 -2.5

-500

-750

-1000

1 Safe Zero = 1 V 2 S afe zero = 1 V and Offset = 2.5 V Fig. 6.8 Analogue setpoint value processing

6.5.2 Digital nominal value

Through the input [X10], the motor controller receives the signals of a transmitter, e.g. a second controller of type CMMx as synchronous setpoint value. The interpretation of the setpoint value corresponds to the setting of the operating mode of the CMMP-AS-...-M3. The switch takes place automatically in positioning mode, and through setpoint value selector in the speed-controlled mode and force/torque mode.

Deactivate

Through a configured input (DIN) or FHPP, synchronisation can be switched on and off.

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Function Description

Position-synchronous operation with speed pilot control

Signal at [X10] (= synchronous position) is taken over directly as setpoint value (special case: control interface = synchronisation) or added to the setpoint value Applications: – Flying saw

– CAM (cam disc) Speed-synchronous operation with torque limitation

Signal at [X10] = synchronous speed. Switch-on takes

place via setpoint selector:

Selector A <synchronous speed>

Selector B <torque limiting> Force-/torque-controlled operation with synchronous speed limiting

Signal at [X10] = speed limiting.

Switch-on takes place via setpoint selector:

Selector B <speed limiting>

Tab. 6.13 Synchronisation CMMP-slave (function)

Fundamentally, speed pilot control of the speed controller takes place in position-synchronous operation. The motor controller CMMP-AS-...-M3 can calculate the speed pilot control itself.

Position-synchronous with setpoint value addition

In the position-synchronous mode, the signal of the encoder interface [X10] is automatically added to the setpoint value.

Position-synchronous without setpoint value addition

The synchronous value is taken over directly from the input [X10] as setpoint value. Setpoint value input through record selection, direct mode or analogue input is blocked. No setpoint value addition takes place.

Instructions on further position-synchronous applicatio ns with special settings can be found in the subsequent chapters under: – Flying saw ( chapter 6.5.4) – CAM (cam disc) ( chapter 6.5.5)

In applications, it may occur that the sensor that gives the trigger signal (that is, registers the master position which should be travelled to position-synchronously) lies outside the possible travel range of the slave. The slave should then wait until the synchronous position of the master is in the travel range of the slave. For this, the section between the sensor and the start of the travel path of the slave should be known. This is entered as position lead. The S tart can already exist before the travel range of the master position is reached. In this case, the drive does not start until positioning when the position lead has been covered.

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Accidental positioning may occur here. If a start command is generated without a prior trigger signal, the diagnostic event 41-0 is triggered: (Record c ontinuation: Start of synchronisation without prior sampling pulse: Check parameterisation of the pre-stop section)

Through the input SAMPLE, the current actual position of t he master system can be recorded (trigger event). At each trigger event, the current master position of the input [X10] is saved. After that, synchronisation can be started through the digital input START. A new synchronisation is not initiated until a new start command, whereby the destination is calculated using the stored syn chronous position. The advantage of this procedure is a more exact determination of the synchronisation destination, since jitters at the start of synchronisation are reduced.

Speed-synchronous torque limitation

The setpoint speed is transferred to the slave by the master via the encoder interface [ X10] and added as synchronous speed via setpoint selector A. You can optionally activate a torque limitation via selector B.

Synchronous speed limiting in torque-controlled operation

Torque-controlled operation with speed limitation via the encoder interface [X10]. The speed is transferred to the slave by the master via the encoder interface [X10] and activated as speed limitation via setpoint selector B.

Required parameters

Parameter

Description

Electronic gear unit Through parameterisation of the gear ratios, exact translation

ratios between a master and slave drive are achievable. The default setting is 1 (number of lines of the slave : number of lines of the master). A transmission ra tio > 1 is a “reduction” r atio. The drive speed (master) would therefore be bigger than the output speed (slave).

Speed filter Filter time c onstant of the synchronous speed

This describes the scanning rate (time slot pattern) used to refresh the incoming signals at the synchronous input [X10].

Input tracks Depending on the encoder design, there are various signal inputs

available at [X10]. Alternatively, the following signals can be c onnected in accordance with RS422 specification: – Differential inputs with TTL level A-B-(N), – Differential inputs for SSI pulse/direction encoder (CLK/DIR) or

upward/downward counter (CW/CWW).

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Parameter Description

Number of lines The line c ount corresponds to the number of full periods in a track

per revolution. (Value must be between 1 and 2

). The incremental input always uses four-fold evaluation. Accordingly the resolution is higher than the line count itself by a factor of 4.

Tab. 6.14 Increment generator input parameter

The line count can normally be found in a data sheet or the name plate for the shaft encoder. Observe that specification of the line count is dependent on the track signals. A/B-(N): – A/B (quadrature evaluation): The line count of the master is entered with reference to

one revolution.

– Index track: If the index track is used, the specified line count must correspond to the

number of lines between index pulses. CLK/DIR (pulse/direction): – The number of increments for the master referred to 90° must be entered here due to

the c ontroller's four-fold evaluation method. CW/CCW (upwa rd/downward counter): – The number of increments for the master referred to 90° must be entered here due to

the c ontroller's four-fold evaluation method.

After a change of the encoder data, you must save the data following download and perform a restart with interruption of the power supply.

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Tracking sig-

nals

A/B-(N) Quadrature evaluation

Description Option

Standard incremental signals. Two rectangular track signals whose phases are offset by 90° are evaluated. A defined pulse is output once per revolution (=zero index). The zero index can be used for definition of a switching point, for counting revolutions or for synchronisation of a following counter.

CLK/DIR Pulse-direction interface.

The controller can also be controlled from stepper motor controller cards through these signal inputs.

CW/CCW Clockwise/counterclockwise counters

Two signals each separately supply the change in position for a direction of rotation. This means that when there is a pulse train on one signal line, the other signal line should be quiet.

– A/B track switch-off:

The incremental signals A/B are ignored (“encoders standing still”).

– Zero track switch-off (ignore zero

pulse): The zero pulse generates a position jump if necessary if individual incrementsoftheA/Btrackarenotcorrectly detected during operation. If the index pulse results in malfunctions, the signal can be suppressed.

– Counting signals switch-off:

The signals CLK/DIR are ignored (“encoders standing still”).

– Counting signals switch-off:

The signals CLK/CCW are ignored (“encoders standing still”).

1) In accordance with RS 422 specification, specifications must be taken from the data sheet of the encoder.

Tab. 6.15 Track signals ( slave, input [X10])

6.5.3 Master-slave

The motor controller CMMP-AS-...-M3 permits a master-slave mode, which hereafter is designated synchronisation. The motor controller can function both as master and as slave. If the motor controller CMMP-AS-...-M3 operates as master, it can provide a slave with the current rotor position at the incremental encoder output [ X11] . If the motor controller CMMP-AS-...-M3 is to operate as a slave, the [X10] input is available for synchronisation. The motor controller CMMP-AS-...-M3 c an calculate the speed pre-control values itself. All inputs c an be activated/deactivated. The internal encoder can be switched off if desired if another input is used as the actual value encoder. This also applies in the speed adjustment operating mode. The external inputs can be weighted with gear ratios. The various inputs can be used individually and also simultaneously.

6.5.4 Flying s aw

“Flying saw” designates position-synchronous applications in which synchronisation is activated or deactivated, dependent on the positioning record. The setpoint value at the synchronisation input is added to the setpoint position value in the selected record only.

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Prerequisites

The following settings must be parameterised:

1. Control interface I/O or fieldbus

2. Selection of the following operating modes/functions – Positioning mode – Synchronisation ([X10]/slave) – Flying saw

3. Set the parameters of the encoder interface [X10].

Function

– Synchronous positioning records for synchronisation with the rotation of the master – Non-synchronous positioning records for travel to the rest position/wait position – Upward and downward synchronisation so that not jerking movements are generated.

Activate

If the “Flying Saw” function is set, synchronisation can be activated or deactivated by starting c ommand records.

• Set synchronisation for the respective positioning record via the “Positioning record” dialog:

Synchronisation activated (Sync):

With synchronisation active, the current position of the master drive is switched onto the position setpoint value of the motor controller via the encoder at connection [ X10] . The drive thus follows the changes in position of the master drive. Synchronisation is activated when positioning is started, if it was not already. If the master is not stationary when positioning star ts, the offset that occurs will be made up in a controlled manner. The positioning speed used for this corresponds to t he speed of the master plus the positioning speed entered in the positioning record as an excessive increase in speed. The entries of the started positioning record are likewise used for the accelerations.

Synchronisation deactivated (No Sync):

Synchronisation is deactivated when positioning is started, if it was not already. Positioning starts with the current setpoint speed, that is, with the speed of the master. This results in controlled desynchronisation.

Synchronisation deactivated (Sync Out):

Synchronisation is deactivated when positioning is started, if it was not already. Positioning starts with the c urrent synchronous positioning speed (rotational speed of the master). This results in controlled desynchronisation.

Note

Observe the following: When positioning with synchronisation is activated, the digital halt only stops the positioning record, but not necessarily the movement of the drive, since synchronisation remains active! Synchronisation must be explicitly terminated by starting a new positioning record without synchronisation or by using the digital input “Disconnect sync.”.

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6.5.5 Scope of functions for cam discs (CAM)

The term “electro nic cam disc” designates applications in which an input angle or an input position is depicted through a function as an angle setpoint value or a setpoint position. These applications are typically master-slave applications. The CMMP-AS-...-M3 has the option of processing 16 cam discs each with 4 assigned cam tracks. The CMMP-AS-...-M3 provides the following functionality for this purpose via F HPP: – Slave with synchronisation operation onto external input with cam disc – Virtual master (internal) with cam disc. A requirement is the positioning mode operating mode (record selection or direct mode). Additional information on parameterisation can be found in the Help for the CMMP-AS plug-in. For complete in-

formation on the cam disc function, see the special cam disc manual P.BE-CMMP-CAM-SW-....

6.6 Second measuring system

6.6.1 Technology

Purpose

A second measuring system is used if the displacement measurement integrated into the motor is not sufficient. There are 2 main reasons for this: – double safety (for instance, at safely reduced speed)

Inclusion of a displacement encoder for secure applications is not described further here.

– The accuracy is not sufficient

For instance, if the resolution of the motor encoder is not sufficiently large. But more frequently, it is the mechanics between the motor and positioned unit (for instance, slide of a toothed belt axis) that is not precise enough.

Absolute positioning accuracy

Most frequently, a second displacement encoder is used to improve the absolute positioning accuracy. Here, an absolute reference is used directly for the moving mass. The second measuring system corrects inaccuracies between the motor encoder and the moving mass. The relative positioning accuracy results from the system of all components (motor, gear unit, coupling, axis,…) and is used, for example, when teaching positions. For most applications, a high relative positioning accuracy, also called repetition accuracy, is sufficient. Since a second displacement encoder means expense, both mechanically and in parameterisation, the accuracies of common systems are compared in the following:

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6.6.2 Example, toothed belt axis

Component

Type

Motor EMMS-AS-70-M-Rx Gear unit EMGA-60-P-G3-SAS-70 Axis EGC-80-2000-TB-KF-0H-GK (real feed constant 90.2 mm/R)

Tab. 6.16 Toothed belt axis components

Parameterisation

Repetition accuracy Approx. absolute accuracy

Standard parameterisation [mm] 0.08 4.44 Parameters with real feed

[mm] 0.08 0.44 constant External displacement encoder [mm] < 0.08

1) Depending on the system used (possible loose gears or gear backlash are compensated with the 2nd measuring system and thus

improve the absolute accuracy.)

< 0.10

Tab. 6.17 Repetition accuracy of toothed belt axis

6.6.3 Example, spindle axis

Component

Type

Motor EMMS-AS-70-M-Rx Axis EGC-80-2000-BS10-KF-0H-Mx-GK-S (Feed constant = 10 mm/R)

Tab. 6.18 Spindle axis components

Parameterisation

Repetition accuracy Approx. absolute accuracy

Standard parameterisation [mm] 0.02 0.05 External displacement encoder [mm] < 0.02 < 0.05

Tab. 6.19 Repetition accuracy of spindle axis

6.6.4 Function in the controller

In the controller, the position actual value of the external displacement encoder is evaluated instead of that of the motor encoder. Both commutation and speed adjustment continue to be made through the encoder in the motor. Through encoder difference monitoring, an adjustable offset between the motor encoder and external measuring system is detected and reported. Errors, for instance mechanical offset, failure of external encoders or torn toothed belt, result in stopping with a corresponding error message.

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6.6.5 Inclusion of a second displacement encoder

At the CMMP-AS-...-M3, position actual values can be read in through 3 interfaces. Observe here that the motor encoder already occupies one interface:

Motor with encoder

Used interface Free interfaces

type

Encoder [X2B] [X2A], [X10] Resolver [X2A] [X2B], [X10]

Tab. 6.20 Interface assignments

The second displacement encoder must first be parameterised in the FCT software, independently of the motor and encoder type.

6.6.6 2nd measuring system at the incremental encoder input [X10]

The incremental encoder input [X10] can be used both for motors with encoder and for motors with resolver. After switch-on (24V voltage off or reset), homing must be executed first. The interface [X10] supports all commonly available incremental encoders with 5 volt level. The A/B tracks are thereby evaluated fourfold through edge detection.

1 Tr a ck A 2 Tr a ck B

4 Increment distance/signal period 5 Resolution through fourfold evaluation

3 Zero track

Fig. 6.9 Timing diagram: evaluation of incremental encoder

Alternatively, pulse-direction signals or upward-downward counters can be evaluated at [X10], likewise with 5 volt level.

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For the cable, a screened line that twists together the data pairs A and A#, B and B#, N and N# (twisted pairs) must be used. The outer screening must always be connected on both sides, at the controller to the plug housing. Only with the recommended line can reliable transmission with higher frequencies be ensured.

The 2nd displacement encoder must be activated in the FCT. In parameterisation, differentiation is made between linear and rotative incremental encoders. With linear measuring systems, the signal period, that is, the increme nt distance, is entered. The real line count for rotative encoders or the real resolution ( signal period) for linear encoders must be parameterised; this corresponds to the value before the quadrature evaluation. For linear systems, in addition to the signal period, the reference signal (distance between two adjacent zero-pulse signals) must be parameterised. Through the selection of reversal of direction, the counting direction of the 2nd displacement encoder can be turned. With activated encoder difference monitoring, the permissible encoder difference is specified in °. The error E 171 (deviation between position actual value and commutation encoder too large) is output if the actual position of the motor deviates by x° from the actual position of the external displacement encoder. In particular for toothed belt axes, the value must not be selected too small, since an offset always occurs due to expansion of the toothed belt under load. In the case of rotative incremental encoders, it is not the signal period, but the line count per revolution of the external encoder that is specified. In addition, a transmission ratio (standard 1:1) can be configured. The line count always refers to one revolution of the motor. With the values to be entered here for an “electronic gear unit”, the transmission ratio between the commutation encoder (in the motor) and the 2nd encoder as position encoder is compensated for. Enter here the inverse of the multiplicative product of the gear unit present between the two encoders. All o ther parameters must be set as with the linear system.

6.6.7 EGC-...-M at [X10]

For EGC axes with type code –M, an incremental displacement encoder is already attached. The sensor of the 2nd displacement encoder of an EGC-…-M axis has the following technical data:

Axis

Signal period Reference signal

EGC-...-M1 [mm] 0.01 5 EGC-...-M2 [mm] 0.04 5

Tab. 6.21 Signal period EGC

As par t of the normal parameterisation, the 2nd displacement encoder must be activated. Through the selection of reversal of direction, the counting direction of the 2nd displacement encoder can be turned. Parameters to be set: – Signal period ( Tab. 6.21) – Encoder difference – Reference signal

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The encoder difference of 60° represents a start value that is operational in most cases. But it must be adjusted, depending on the application.

6.6.8 2nd measuring system at input [X2 A]

The input [ X2A] can only be used for motors with encoder. After switch-on (24 V voltage off or reset), homing must be executed first. The interface [X2A] supports all commonly available incremental resolvers, single-pole or multipolar.

6.6.9 Commissioning

After parameterisation, the system is commissioned. Before the first enable, the counting direction of the motor and of the external encoder must be checked. To do this, shift the moving mass by hand and observe the change in the FCT (online area – operate). The actual position is recorded by the external encoder, and the speed is calculated from the encoder in the motor. Both values change as a result of shifting by hand. The direction of the system c an be selected freely and is usually simply selected corresponding to the application. After selection of a suitable zero point, shift the axis by hand in a positive direction. If the actual position becomes smaller rather than larger, the direction of the 2nd measuring system must be changed. If the speed is negative, the direction of rotation of the motor must be reversed. After each change, download, save and restar t must be done. For motors with integrated brake, the brake can be manually opened with the button R elease brake.

Note

For vertical axes, the moving masses must be secured against falling.

After that, the c ustomary commissioning is c ontinued. Usually, the controller data must be adjusted manually to achieve a good positioning. For longer toothed belt axes, reinforcement of the position controller must not be too large, since the system would otherwise swing up.

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6.7 Additional functions

6.7.1 Encoder emulation

The output [X11] of the motor controller can simulate an encoder that can be used by another device as an input signal.

The output [X11] is active even if the function has not been activated in the FCT.

In the FCT, the following configurations can be made.

Option

Description

Encoder Data Number of lines Number or lines (increments) per revolution.

Track A and track B are offset by 90°. As a result, the connected incremental input can increase the resolution with a fourfold evaluation. The result is, the number of increments per revolution is increased by the factor 4.

Offset Angle Additive c orrection value in the range from -180° to +180° for

electronic adjustment of the zero position. Options Disable track A,B The incremental signals are n ot output (“encoders standing still”). Suppress zero pulse The emulated incremental encoder does not output a zero pulse. Inverse rotation polarity The phase position of tracks A and B is rotated by 180° (right rotation

field -> left rotation field) Encoder output Position virtual master Only for activated cam disc function with virtual master. Actual position – With cam disc function: actual value of slave position.

– Without cam disc function: actual position of the motor controller. Setpoint value position – With cam disc function: setpoint position of the slave.

– Without cam disc function: setpoint position of the motor

controller.

Tab. 6.22 Configuration of the encoder emulation

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6.7.2 Brake control and automatic brake

Function

The motor controller CMMP-AS-...-M3 can directly control a 24V holding brake integrated into the motor

Caution

If the maximum permissible connected loads are not complied with: – The controller can be destroyed – The functioning of the holding brake is not reliable.

• For correct connection and reliable control of the brake (safe stop, emergency stop), observe the instructions in the hardware description

• In th e case of h igher current needs, the brake must be switched via a coupling relay, if necessary with interference suppression.

Note

The holding brake must not be used to brake moving masses. Braking masses in movement leads to increased wear and the functional failure of the holding brake: – The brake must be opened before a new positioning motion begins. – The drive must stand still before the brake is closed.

• Pay attention to the required time delays (brake delay time), in particular for holding brakes with high mechanical inertia.

With lo nger time delays between command records, the automatic function of the holding brake closes the brake and switches off the controller output stage (less temperature rise).

Note

In cer tain applications (e.g in synchronous mode), the automatic function can damage the brake and/or the system. In the case of parameterisation via the FCT software, the automatic brake can therefore not be activated for synchronous operation.

• Check the operating conditions in your application before you activate the automatic brake.

If no command record is executed in the specified time, for axes under load: – The current setpoint value is set to zero – The brake is engaged – The controller end stage is switched off.

Example

In this example, the activation time of the automatic brake starts to run after the completion of a positioning record (MC). After the activation time has expired, the brake is closed and the switch-off delay runs simultaneously. After the switch-off delay has expired, the controller end stage is switched off (less warming).

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After the start of a new positioning record, the drive moves only after the switch-on delay has expired.

Drive is mov ing

START

Open brake

Automatic

Switch-on delay

Switch-off delay

Controller energised

Record completed

Start of new positioning record

Fig. 6.10 Pulse-time diagram - holding brake with automatic function

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Parameters

Parameter

Function

Switch-on delay Requiredtimetocompleteopeningofthebrakewith:

– Setting of the controller enable (DIN5 0

}

– START signal (if the automatic brake is activated) and the start

of a positioning motion. The configured brake output is set immediat ely; the brake opens. Correct setting ensures that the drive does not run against the closed brake. With a STA RT signal before the switch-on delay expires, the motor controller starts the positioning motion only after the switch-on delay has expired completely.

Switch-off delay Required time until complete closing of the brake with:

– Removal of controller enable (DIN5 1

}

0) – Expiration of the activation time of the automatic brake. Correct setting ensures that the drive is maintained in the current position until the holding brake has achieved its full holding torque. The controller is only switched off after the switch-off delay has expired.

Activation time of the automatic brake

Time in [ms] between the completion of a positioning motion (“Motion complete”) and the resetting of the brake output (providing in this period of time there is no new START signal). The switch-off delay follows after the activation time. Value = 0 deactivates the automatic brake.

Tab. 6.23 Parameter safe brake control

6.7.3 Position trigger

The position triggers can be used to pass on information about the logical statuses of position switches, rotor position switches and cam controller units (only when the cam disc function is activated) to digital outputs. Four position triggers can be configured to this end. With specified trigger levels, the position triggers can: – implement the actual position of the commutation encoder corresponding to the value pair (switch)

in binary signals (1/0) – output the binary signals logically linked with OR to the assigned digital outputs. A maximum of four value pairs for positions or four value pairs for rotor locations must be assigned to each position trigger. To depict the information on a digital output, the function of a digital output must be set to “position trigger 1” … “4”.

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Example Position trigger

Trigger signal switch 1: – Position 1 = 400 mm – Position 2 = 700 mm

Trigger signal switch 2: – Position 1 = 100 mm – Position 2 = 900 mm – Signal inverted

Position trigger 1/DOUT: – Logical OR operation

of the trigger signals

Tab. 6.24 Position trigger

100 400 700 900

6.7.4 Inputs for option “flying measurement”

The local digital inputs can be used as quick sampling inputs. Setting of the digital input takes place in the FCT. The inputs DIN8 or DIN9 can be selected. With every rising and falling edge at the configured sample input, the current position value is written into a register of the controller and can afterwards be read out through the higher-order controller (PLC/IPC). Additional information on the available parameters can be found in the documentation for FHPP (GDCP-CMMP-M3-C-HP-...) or CANopen (GDCP-CMMP-M3-C-CO-...).

6.7.5 Software limit switch

The permissible positioning range (effective stroke) is limited by setting the software end positions. The software end positions refer to the axis zero point. If the target position of a positioning command lies outside of the software limits, the positioning command will not be processed and an error status will be set.

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6Functions

6.7.6 Input for digital halt

The control port “Digital halt” is high active (default). It immediately stops all movements. Other star t signals do not work as long as this input is active. The following delay ramp is run, dependent on the active operating mode:

Operating mode

Deceleration ramp

Positioning mode Ramp of the positioning record Speed regulation Set speed ramp Torque regulation Set torque ramp

Tab. 6.25 Delay ramp dependent on the operating mode

All available digital inputs can be assigned. After a “Halt”, there must always be a “Start”. The polarity of the input can be switched via FCT.

Note

Note the following when using the “Flying Saw” function in combination with “Digital I/O” as the control interface: – When positioning with synchronisation is activated, the digital halt only stops the

positioning record, but not necessarily the movement of the drive, since synchronisation remains active!

– Synchronisation must be explicitly terminated by starting a new positioning record

without synchronisation or by using the digital input “Disable sync”.

6.7.7 I/O [X1]

Standard assignment and extension of the digital I/Os

The motor controller CMMP-AS-...-M3 has standard 10 digital inputs (DI N0 … DIN9) and 4 digital outputs (DOUT0 … 3). The existing digital inputs DIN0 … 9 are already assigned for typical applications through basic logic functions: – The inputs DIN0 … DIN3 are pre-assigned for selection of the positioning records (position selector)

and the inputs DIN8 and DIN9 for start and sample functions.

The factory setting can be changed, if needed, to correspond to the application. – Fixed functions are assigned to the inputs DIN4 … D IN7 and the output DOUT0. This assignment is

not configurable. The following I/O expansions are possible: – Four additional inputs (DIN10 … 13) are possible through corresponding reconfiguration of digital

outputs or analogue inputs with FCT – Two extension modules, each with 8 additional digital inputs and out puts (accessories type

CAMC-D-8E8A).

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Digital I/O Function

Standard DIN DIN0 … DIN3 Position selector, selection of the positioning records (0 … 15)

configurable DIN 4 Fix: Output stage enable (POWER ENABLE) DIN 5 Fix: Controller enable (CONTROLLER E NABLE) DIN 6 Fix: Limit switch negative (LIMIT 0) DIN 7 Fix: Limit switch positive (LIMIT 1) DIN 8 Configurable DIN 9 Configurable high-speed input

(Sample input/reference switch) Standard DOUT DOUT0 Fix: Controller operational (READY) DOUT1 Configurable DOUT2 Configurable (optional: DIN10) DOUT3 Configurable (optional: DIN11) Additional DIN DIN10 (DOUT2) Configurable DIN11 (DOUT3) Configurable DIN12 (AIN1) Configurable – trigger level at 8 V DIN13 (AIN2) Configurable – trigger level at 8 V

Tab. 6.26 Assignment DIN/DOUT

Activated signal inputs require calculation time of the motor controller. Therefore, do not deactivate required signal inputs.

Functions of the digital inputs

Note

Multiple assignments of digital in puts are tolerated by the firmware. Execution of the function with multiple assignment depends on the respectively set operating mode.

• Check carefully whether your combination of input signals makes sense.

Function assignment is dependent on: – the control interface used – the selected operating mode – the number of freely usable inputs.

To control additional functions via digital inputs, you can change the factory-set assignment of the digital inputs present at the basic unit.

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Function Description Polarity

General Detecting the actual position (sampling)

Setup mode By setting the input, the maximum speed is limited dir-

The current actual position is saved in the internal memory with rising or falling flank of the input in order to transfer it to an external controller over fieldbus (see also “Flying measurement”).

Positive and negative edge Low active

ectly to the setup speed set.

Release brake Input for releasing the holding brake with deactivated

High active

controller enable.

Switch off synchronisation With this, a previously activated synchronisation (e.g.:

Low active Flying saw) must be switched off. Synchronisation is switched off with a falling edge at the parameterised input.

Record selection/positioning Record selection (position selector)

Selection of the positioning records 1 … 255 Selection of the reference travel (positioning record 0)

High active

The signals must be securely applied if the START edge is set.

Start record After setting the START signal, the number of the active

High active positioning record is taken over and the drive carries out the record.

Digital halt In positioning mode, the drive brakes with the ramp of

the active positioning record. After that, the drive is controlled (brake is opened).

Can be

paramet-

erised

Homing Homing Switch Input that supplies the reference signal. Can be

paramet-

erised

Start homing After setting the START signal (0}1), the drive carries

High active out homing. After completion of homing, positioning procedures can be carried out.

Jog mode Negative travel direction Jog mode enables manual travel of the drive. In the “Op-

Positive t ravel direction High active

eration enabled” status, the drive can be travelled over the positive/negative inputs.

High active

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Function PolarityDescription

Teach/save position Teach position Theteachprocedureisstartedwiththerisingedgeatthe

parameterised teach input. With the falling edge, the

Start teach

high active actual position is temporarily stored in the position record selected via digital in puts.

Tar ge t

transfer

low active

Save position To permanently accept all temporarily saved position

High active data, a positive edge at the parameterised “Save position” input is required.

Start/stop record sequence Run to HOME position The input starts the positioning record “HOME-Position”. High active Run to the Star t position The input starts the positioning record “START position”. High active Stop If the digital input is activated, the path program is

Low active stopped. The ongoing positioning is still ended in any case. In the position records, it can still be specified whether the path program may or may not be stopped at the end of this record. In this case, despite setting of the Stop input, the subsequent chained positioning is started.

Combined star t/stop Through this function, starting and stopping of a path

program can be controlled through a unique digital input.

Start

high active The general S TART position of the path program is thereby approached on the rising edge of the digital input. On the falling edge, the already described Stop func-

Stop

low active tion of the path program is activated.

Sequence control Digital input NEXT1 Subsequent positions of a positioning record for record

High active continuation through positioning record number and digital inputs. Execution (travel to the subsequent position) corresponds to the logic operation of the digital inputs

Digital input NEXT2 High active

NEXT1 and NEXT2 through step enabling condition of the positioning record. The digital inputs NEX T1 and NEXT2 are evaluated only through the step enabling conditions GoImm, IgnUTP, GoATP.

Tab. 6.27 Function overview of the digital inputs

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Function of the digital outputs

The function can be determined for the available outputs DOUT1, DOUT2 and DOUT3 as follows:

Function

Description Polarity

Off The output is always low. – On The output is always high. – Group “Enabled” Brake vented The output is active as soon as the brake is released. High active Output stage active The output is active if the output stage enable has been

High active

granted (power enable present, motor energised).

Setpoint lock active The output is active as soon as one or both setpoint locks

High active

is triggered by a limit switch.

Linear motor identified This output is active if the commutation position has

High active been found. For angle encoders without c ommutation signals, the commutation position is determined by means of an automatic function. Starting a positioning movement, for example, only makes sense once this process is complete.

Reference position v alid The output is active if the drive is homed. High active Collective status Ready for controller enable Output stage release level Returns the level of the output stage enable digital input

Signals the status that no error is present and the controller is ready for controller enable.

High active

High active DIN4. The condition is fulfilled if the level at DIN4 = HIGH.

Group “Movement” Position Xsetpoint = Xdest The setpoint position is within the tolerance window of

High active the target position.

Position Xact = Xdest The actual position is within the tolerance window of the

High active target position.

Remaining Distance The output is ac tive if the deviation between the target

High active and actual position has fallen below the set value for the remaining distance message.

Reference run active The output is active as long as homing is active. High active Reference speed reached The actual speed corresponds to the parameterised com-

High active parison spe ed in the “Speed reached” message, taking into consideration the specified tolerance window .

Following error The deviation between the nominal and actual position

High active exceeds the set value.

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6Functions

Function PolarityDescription

Alternative target reached This output is active if a positioning movement has been

High active terminated, for example by reaching a comparison torque. The co ndition Xact = Xdest is then not satisfied.

Comparison torque reached

The actual torque corresponds to the comparison torque parameterised in the “Torque reached” message, taking

High active

into consideration the specified tolerance window .

Acknowledge for start posi-

Start-Ack (low active) High active

tioning Destination reached with handshake Speed 0 The output is active if the actual speed is equal to 0. The

Destination reached with handshake for the dig. start. The output is not set as long as START is on HIGH level.

High active

High active tolerance window is the message window for the message “Speed 0”.

=0: Positioning job active

High active =1: Positioning job completed, possibly with error

Active when positioning record running

Signals that a positioning record is currently being executed.

High active

Cam disc (CAM) Cam disc active The output is active as soon as a cam disc has been activ-

High active ated.

CAM-IN movement in operation

The output is active as soon as a CAM-IN movement is executed.

High active

CAM-CHANGE Like CAM-IN, but fo r a change between 2 cam discs. High active CAM-OUT movement in operation Cam disc start point reached

The output is active from deactivation of a cam disc until the final standstill of the drive. The output is active if the start position of the selected cam disc is reached. The tolerance window is the mes-

High active

sage window for the message “Target reached”.

Error I2t motor monitoring active Undervoltage intermediate circuit

The output is active as soon as the motor or output stage workload is in the critical range. The output is active if an undervoltage occurs in the intermediate circuit.

High active

Common error active Signals that one or more errors are active. High active

1) When a cam disc is active, the MC signal always relates to the movement of the master (physical or virtual), i.e. to the setpoint

for the active cam disc.

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6Functions

Function PolarityDescription

Position t rigger Position t rigger 1 … 4 The position triggers can be used to pass on information

High active about the logical status of position triggers, rotor position triggers and cam controller units to the digital outputs.

Teach Acknowledge teac h The signal goes to Low with the rising edge at the Teach

Low active input and back to High with the falling edge at the Teach input.

Saving process in operation The signal goes to High as soon as a saving procedure is

High active started and is extinguished automatically after the saving process has been completed.

Functional safety module STO active Signals that safe status STO ( S afe torque off ) is active. High active STO requested Signals that safe status STO (Safe torque off ) has been

High active requested.

Tab. 6.28 Function overview of the digital outputs

The digital outputs “STO active” and “STO requested” must not be used in a safety-directed manner.

Analogue inputs

Analogue inputs — configuration

Input

AIN0 16 bit, high resolution, differential

Resolution Level

+10 VDC … –10 VDC

(Digital filter)

AIN1 10 bit, single-ended

(optional: DIN12)

AIN2 10 bit, single-ended

(optional: DIN13)

Tab. 6.29 Analogue inputs

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6Functions

The specified value defines how the relevant input signal is converted into a torque, a speed or a positioning setpoint value. Input voltages in the value range from –10 V … +10 V are processed.

• Specify in the respective registers in the FCT which value of the respective input variables corresponds to an input voltage of 10 V. The scaled range corresponds to a linear characteristic curve symmetric to the zero point (e.g. –1000 R/min … +1000 R/min).

Correction

1. Connect the input with the potential corresponding to the setpoint value = 0.

2. Now carry out the “Automatic offset calibration” via FCT.

Analogue outputs

To configure the analogue outputs (AOUT):

• Select the respective desired output signal, e.g. setpoint or actual value of the controlled variable in the FCT.

• Adjust the required settings and values (scaling, numerical overflow limitation) of the outputs used.

Analogue monitor

The motor controller has two analogue outputs AOUT 0 and AOUT 1 for output, e.g. of controlled variables, which can be represented with an external oscilloscope. The output voltage lies in the range of

-10 V to +10 V.

• Select the output variable that should be output through the analogue monitor.

• For output variable “Fixed clamping value”: In the “spanning value” field, set the voltage that should remain constant at the output.

• For other output variables: In the “Scaling” field, set which value of the selected size corresponds to an output voltage of 10 V.

Output variables (AOUT0, AOUT1)

Axis variables – Speed setpoint value

– Speed ac tual value – Position setpoint – Position actual value

Values for current – Effective current setpoint

– Effective current ac tual value – Reactive current setpoint value – Reactive current actual value – Phase Current

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6Functions

Output variables (AOUT0, AOUT1)

Additional signals – Rotor Position

– Intermediate circuit voltage – Fixed voltage level

Tab. 6.30 Output variables

Overflow limitation activated

The numerical overflow limitation limits the voltage values U calculated corresponding to the scaling to the range +10 V … -10 V.

Overflow limitation not activated

In case of overflow of the range limit + 10 V, the output voltage jumps to (–10 V +ΔU). In case of overflow of the range limit -10 V, the output voltage jumps ( + 10 V -Δ U).

6.7.8 Supported encoder systems

The following encoder systems are supported by the motor controller CMMP-AS-...-M3:

Type

Remark Protocol Interface

Heidenhain Endat encoder ROC 400 ECI 1100/1300

Single-turn absolute encoder

with/without analogue signal ECN 100/400/1100/1300 ROQ 400 EQI 1100/1300

Multi-turn absolute encoder

with/without analogue signal EQN 100/400/1100/1300 LC 100/400 Absolute length measurement

equipment Stegmann HIPERFACE Encoder SCS60/70 S CM60/70 Single- / multi-turn encoder with

analogue incremental signal.

Line count 512 (fixed). Number

of multi-turn revolutions: +/-

2048 R. SRS50/60/64 SCKxx

SRM50/60/64 SCLxx

Single- / multi-turn encoder with

analogue incremental signal.

Line count 1024 (fixed). Number

of multi-turn revolutions: +/-

2048Uxx=25/35/40/45/

50 / 53

EnDat 2.1 (01/21)

[X2B]

EnDat 2.2 (22)

EnDat 2.1 (01/21)

[X2B]

EnDat 2.2 (22)

EnDat 2.1 (01)

[X2B]

EnDat 2.2 (22)

HIPERFACE [X2B]

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6Functions

Type InterfaceProtocolRemark

SKS36 SKM36 Single- / multi-turn encoder with

analogue incremental signal. Line count 128 (fixed). Number of multi-turn revolutions: +/- 2048 R

SEK37/52 SEL37/52 Single- / multi-turn encoder with

analogue incremental signal. Li n e count 16 (fixed). Number of multiturn revolutions: +/- 2048 R

L230 Absolute length measuring sys-

tem with analogue incremental signal. Resolution: 156.25 μm. Measuring length max. approx.

40 m Yaskawa ∑-ENCODER ∑(sigma1) Digital incremental encoder with

zero-pulse Analogue incremental encoders ROD 400 ERO 1200/1300/1400

Heidenhain, encoder with zero

and reference pulse ERN 100/400/1100/1300 Digital incremental encoders CDD50 Stegmann encoder with Hall

sensors Resolver Standard Transmission ratio type 0.5 +-

10 %, Input supply type 7 Vrms

HIPERFACE [X2B]

Yaskawa OEM protocol [X2B]

– [X2B]

– [X2A]

Tab. 6.31 Supported encoder systems

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7 Dynamic response

7.1 PFC for increased i ntermediate circuit voltage

The motor controllers CMMP-AS-C2-3A-M3 and CMMP-AS-C5-3A-M3 with single-phase supply are intended for connection to the 230 VAC mains grid and are equipped with an active PFC step (Power Factor Control). The PFC stage is an active mains power converter that is required for conformance to the relevant standards for limiting mains grid harmonics. The PFC stage also performs ac tive regulation of the intermediate c ircuit voltage. The PFC step operates using the boost chopper principle and provides a regulated nominal intermediate voltage of 380 VDC. This voltage is independent of the quality of the mains voltage, also when the mains voltage fluctuates or with mains grid undervoltage. This is a significant advantage when selecting the servo motor because, compared to a device with passive mains feed, higher speeds are achievable or a higher torque c onstant can be selected. Further, due to the ac tive PFC step, the device is also appropriate for wide-range operation down to 100 VAC mains voltage; but the limitation of the effective power consumption due to the permissible maximum c urrent of the PFC step must be observed.

Note

The PFC step of all motor controllers connected to the intermediate circuit must be disabled if motor controllers are coupled via the intermediate circuit.

Note

It must be ensured that the reference potential (N) is switched before or simultaneously with the phase (L1). This c an be achieved through: – unswitched reference potential (N) – use of fuses with leading N when switching of the reference potential is not spe-

cified.

7.1.1 Switch-on behaviour:

As soon as the motor controller is provided with mains voltage, the intermediate circuit is charged (< 1 s) via the braking resistors, with the intermediate circuit relay deactivated. The PFC stage is not switched on at this point. After the intermediate circuit has been successfully pre-charged, the relay engages and the intermediate circuit is "hard" connected to the mains supply. The PFC stage is then activated and the intermediate stage is loaded with the full voltage. If the intermediate c ircuit voltage is too low after successful charging, because the mains input voltage lies below the permitted level for PFC operation, the PFC stage remains blocked and a warning is displayed on the sever-segment display. If the motor controller is supplied with less than the nominal voltage of 230 VAC, after pre-loading is completed, a power reduction for the PFC step is calculated based on the achieved intermediate circuit voltage.

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7 Dynamic response

7.1.2 Behaviour under normal operation and control properties

In operation, the power consumption of the motor controller from the mains network is monitored via the PFC step. The mains current is regulated by an analogue control circuit so that the shape of the curve reflects that of the mains voltage sinewave and the phase shift is 0°. The amplitude is adjusted according to the specified effective power. A higher-level digital controller regulates the in termediate circuit voltage to an average v alue of approx. 360 VDC. To relieve the relatively sluggish voltage regulation under load changes (acc eleration/braking of the drive), the effective power delivered to the motor from the motor controller is measured and used to pre-control the PFC step.

100 V … 230 V AC

±10

U_in I_in U_ZK i_u i_v Angle encoder

IC for Power

Factor Control

PWM

Voltage

regulator

u_q

i_q

Microcontroller

Drive

regulator

Fig. 7.1 Schematic structure of the PFC stage

Control e ncompasses the following variables: – Digital control of the intermediate circuit voltage to an average of approx. 380 VDC – Analogue control of the mains input current – Maintenance of a sinewave mains current under stationary load c onditions – Operation with cosü > 0.97 at rated operation (at the rated power of the PFC step) The parameterisation program can be used to switch the PFC control on or off. When the PFC is deactivated, the intermediate circuit behaves like a normal intermediate circuit with an upstream bridge rectifier. The intermediate circuit voltage is usua lly regulated t o a constant average value that, under stationary load conditions, is independent of the specified effective power of the motor.

7.2 Extended sine modulation for increased output voltage

With the CMMP-AS-...-M3 motor c ontroller, the cycle rate in the current regulator circuit is set to a cycle time of 125 μs or 62.5 μs. To minimise switching losses, the pulse width modulation clock frequency can be set to half that of the current regulator clock frequency.

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7 Dynamic response

The motor controller CMMP-AS-...-M3 also has a sine-wave modulation or, alternatively, an extended sine-wave modulation (with third harmonic wave). This increases the effective converter output voltage. The modulation type can be selected using the parameterising software. The standard setting is extended sine-wave modulation.

7.3 Variable cycle times, current, speed and position controller

The motor controllers of the CMMP-AS-...-M3 series permit a switchable current control c ycle time. From these settings are derived the cycle times for the speed and position controller as well as the interpolation time. Faster cycle times permit lower reaction times and an improved control dynamic (depending on the application, higher possible closed-loop gain or lower “overshooting” of the position actual values). The following table includes the pulse-width modulation frequencies supported by the CMMP-AS-...-M3 and their related cycle times:

PWM frequency

Scanning frequency of current control

Cycletimeof current control

Cycle time of speed adjustment

Cycletimeof position control

Interpolation time

4kHz 8kHz 125 μs 250 μs 500 μs 1000 μs 8kHz 8kHz 125 μs 250 μs 500 μs 1000 μs 8kHz 16 kHz 62.5 μs 125 μs 250 μs 500 μs 16 kHz 16 kHz 62.5 μs 125 μs 250 μs 500 μs

Tab. 7.1 PWM frequencies and cycle times

The PWM frequency can be set in the parameterisation software FCT with the option “Half output stage frequency”.

With higher PWM frequencies, the result is reduced nominal/peak currents of the power

sections. Derating tables  Technical data GDCP-CMMP-M3-HW-....

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8 Service functions and diagnostic messages

8.1 Protective and service functions

8.1.1 Over view

The motor controller CMMP-AS-...-M3 has a complex array of sensors that monitor the controller section, power output stage, motor and external communication to ensure that they function excellently. All diagnostic events which occur are saved in th e internal diagnostic memory. The diagnostic memory in the motor controller has a two-tier architecture: – All messages since the motor controller was last switched on are saved in the temporary memory

(these are lost in the event of a power failure).

– The messages are permanently saved in the permanent memory of the family CMMP-AS-...-M3 (se-

cure in the event of a power failure). This memory consists of 2 segments that are filled one after the other. When both segments are full, the older segment is automatically cleared. This means that

a sort o f ring memory is available for the permanently saved messages. Most errors cause the controller section to switch off the motor c ontroller and the power end stage. The motor controller can only be switched on again when the error has been eliminated and then acknowledged. For some of the diagnostic messages, t he behaviour of the motor controller can be parameterised. Possible reactions: – PS off Switch off power section immediately – MCStop Stop with maximum peak current – QStop Quick stop with the deceleration specified on the “Axis” ( FCT) page – Warn Output of a warning – Ignore Ignore diagnostic message A complex system of sensors and numerous monitoring functions ensure operational reliability: – Measurement of the motor temperature – Measurement of th e power output stage temperature – Earth fault detection (PE) – Detection of short-circuits between two motor phases – Detection of overvoltages in the intermediate circuit – Detection of faults in the internal voltage supply – Collapse of supply voltage

8.1.2 Phases and mains failure detection with 3-phase motor controllers

The motor controller CMMP-AS-...-M3 detects a phase failure in three-phase operation (phase failure detection) or fa ilure of several phases (network failure detection) of the mains supply at the device.

8.1.3 Overload current and short-circuit monitoring

Overload current and short-circuit monitoring detects shor t circuits between two motor phases and short circuits at the motor output terminals against the positive and negative reference potential of the intermediate circuit and against PE. If the error control detects overload current, the power output stage shuts down immediately, guaranteeing protection against short circuits.

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8 Service functions and diagnostic messages

8.1.4 Overvoltage monitoring for the intermediate circuit

The overvoltage monitoring for the intermediate circuit takes effect as soon as the intermediate circuit voltage exceeds the operating voltage range. The power output stage is then deactivated.

8.1.5 Temperature monitoring for the heat sink

The heat sink temperature of the output end stage is measured with a linear temperature sensor. The temperature limit varies from device to device. A temperature warning is triggered at about 5°C below the limit value.

8.1.6 Monitoring of the motor

The motor controller CMMP-AS-...-M3 has the following protective functions for monitoring the motor and the connected shaft encoder:

Protective func-

Description

tion

Monitoring the shaft encoder

An error of the shaft encoder causes the power output stage to be switched off. For the resolver, for example, the tracking signal is monitored. For increment generators, the commutator signals are checked. Generally true for intelligent encoders is that their various error messages are evaluated and reported to the

CMMP-AS-...-M3 as common error E 08-8. Measurement and monitoring of the motor temperature

The motor controller CMMP-AS-...-M3 has a digital and an analogue input for

recording and monitoring the motor temperature. The following temperature

sensors can be selected:

– [X6]: Digital input for PTCs, N/C contacts and N/O contacts.

– [X2A] and [X2B]: N/C contact and KTY series analogue sensors. ( Only for

parameterisation of user-defined motors)

Tab. 8.1 Protective functions of the motor

8.1.7 I

The motor controller CMMP-AS-...-M3 has I

t monitoring

t monitoring to limit the average power loss in the power end stage and in the motor. Since the power loss that occurs in the power electronics and the motor can, in the worst case , grow at a rate equal to the square of the flowing current, the squared current value is taken as a measure for the power loss.

8.1.8 Power monitoring for the brake chopper

The braking resistors are monitored on the firmware side through the function I the output monitoring reaches “I²t brake chopper” of 100 %, the output of the internal braking resistor is switched back to rated output. As a result of this switch back, the error “E 07-0” “Overvoltage in the intermediate c ircuit” is generated if the braking process is not yet finished and (too much) energy is fed back to the controller. In a ddition, the brake choppe r is protected by means of overcurrent detection. If a shor t circuit is detected via the braking resistor, the brake chopper controller is switched off.

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8 Service functions and diagnostic messages

8.1.9 Commissioning status

Motor controllers sent to Festo for servicing are loaded with other firmware and parameters for testing purposes. Before it is commissioned again at the location of the final customer, the motor controller CMMP-AS-...-M3 must be parametrised. The parametrisation software queries the commissioning status and prompts the user to parameterise the motor controller. At the same time, the device signals that it is ready for operation but has not yet been parametrised by displaying “A” on the seven-segment display.

8.1.10 Rapid discharge of the intermediate circuit

When a mains supply failure is detected, the intermediate circuit is quickly discharged within the safety time specified in EN 60204-1. Delayed connection of the brake chopper by power class in parallel operation and when a mains failure occurs ensures that the main energy during rapid discharge of the intermediate circuit is taken over through the braking resistors of the higher power classes.

But the rapid discharge can be ineffective in certain device constellations, especially when several motor controllers are connected in parallel in the intermediate circuit or a brake resistance is not connected. The motor controllers may carry dangerous voltage for up to 5 minutes after being switched off (capacitor residual charge).

8.2 Operating mode and error messages

8.2.1 Operating mode and error display

The motor controller CMMP-AS-...-M3 has three LEDs and one seven-segment display on the front for showing the operating statuses.

Element

Seven-segment display – Displays the operating mode and a coded error number in

LED1 Green Operating status

LED2 Green Controller enable LED3 Yellow CAN bus status display RESET button – Hardware reset for the processor

Tab. 8.2 Display components and RESET pushbutton

LED col-

Function

our

case of error.

Red Error

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8 Service functions and diagnostic messages

8.2.2 Seven-segment display

The display and the meaning of the symbols shown are illustrated in the following table:

Display

Significance

The outer segments “rotate” on the display in the speed control operating mode. The display depends on the current actual position or speed.

With active controller enable, the centre bar is also active.

The motor controller CMMP-AS-...-M3 must still be parameterised. (Seven-segment display = “A”)

Controlled t orque mode. (Seven-segment display = “I”)

“H”: The motor controller is in the “safe status”. This does not mean the same as the information about the status of the safety function STO (Safe Torque Off ). This can only be read at the LED of the safety module. For the “unsafe status”, no special display is intended; the standard status displays of the motor controller are depicted. “F.”: Signals that firmware is currently being loaded into the flash.

“.”: Bootloader active

“d”: Signals that a parameter record is currently being loaded from the SD card to the controller.

P xxx Positioning (“xxx” is the position number)

The numerals are shown in succession

PH x Homing. “x” stands for the respective phase of the homing:

x = 0: search phase x = 1: crawl phase x=2:runtozeroposition The numerals are shown in succession

E xxy Error message with main index “xx” and sub-index “y”

-xxy- Warning message with main index “xx” and sub-index “y”. Warnings are shown at least twice on the seven-segment display.

Tab. 8.3 Operating mode and error display

Festo – GDCP-CMMP-M3-FW-EN – 1203NH 79

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8 Service functions and diagnostic messages

8.2.3 Acknowledgement of error messages

Error messages can be acknowledged through: – the parametrisation interface – the fieldbus (control word) – a decreasing edge at DIN5 [X1]

Controller enable DIN5 [X1]

“Error active”

1L80 ms

Fig. 8.1 Timing diagram: acknowledge error

Diagnostic events which are parametrised as warnings are automatically acknowledged when the cause is no longer on hand.

8.2.4 Diagnostic messages

The significance and their measures for diagnostic messages are summarised in the following chapter: ( chapter A Diagnostic messages).

80 Festo – GDCP-CMMP-M3-FW-EN – 1203NH

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A Diagnostic messages

If an error occurs, the motor c ontroller CMMP-AS -...-M3 shows a diagnostic message cyclically in the seven-segment display of the motor c ontroller CMMP-AS-...-M3. An error message consists of an E (for Error), a main index and sub-index, e.g.: E 0 1 0. Warnings have the same number as an error message. In contrast to error messages, however, warnings are preceded and followed by hyphens, e.g. -170-. The following table summarises the significance of the diagnostic messages and the actions to be takeninresponsetothem:

Column

Code The Code column includes the error code (Hex) via CiA 301 No. Main index and sub-index of the diagnostic message.

Message Message that is displayed in the F CT. Cause Possible causes for the message. Action Action by the user. Reaction The Reaction column includes the error response (default setting, partially

Tab. A.1 Explanations on the table “Diagnostic messages of the CMMP-AS-...-M3”

The following table includes the error messages corresponding to the firmware versions at the time this document was printed.

Significance

Display in the indicator, in FCT or diagnostic memory via FHPP.

configurable): – PS off (switch off output stage), – MCStop (fast stop with maximum current), – QStop ( fast stop with parametrised ramp), –Warn(Warning), – Entry (Entry in diagnostic memory), –Ignore(Ignore).

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A Diagnostic messages

Diagnostic messages of the CMMP-AS-...-M3

No. Code Message Causes Actions Reac tion

00-0 – Inv alid error Information: An in valid er-

ror entry (corrupted) was found in the diagnostic memory marked with this error number. Thesystemtimeentryis set to “0”.

00-1 – Inv alid error de-

tected and corrected

Information: An invalid error entry (corrupted) was found in the diagnostic memory and corrected. The additional information contains the original error number. Thesystemtimeentry contains the address of the corrupted error number.

00-2 – Error cleared Information: Active errors

were acknowledged.

01-0 6180hStack overflow Incorrect firmware?

Sporadic high processor load due to cycle time being too short and special compute-bound processes (save parameter set, etc.).

– Entry

• Load an approved

PS off

firmware.

• Reduce the processor load.

• Contact Technical Support.

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A Diagnostic messages

Diagnostic messages of the CMMP-AS-...-M3

No. ReactionActionsCausesMessageCode

02-0 3220hUndervoltage in

intermediate circuit

03-0 4310hAnalogue motor

overtemperature

03-1 4310hDigital motor

overtemperature

03-2 4310hAnalogue motor

overtemperature: broken wire

Intermediate circuit voltage falls below the parametrised threshold. Error priority set too high?

Motor overloaded, temperature too high. – Suitable sensor or

sensor characteristics parametrised?

– Sensor defective?

Motor overloaded, temperature too high. – Suitable sensor or

sensor characteristics parametrised?

– Sensor defective?

The measured resistance value is above the threshold for wire break detection.

• Quick discharge due to switched-off mains

supply.

• Check power supply.

• Couple intermediate circuits if technically permissible.

• Check intermediate circuit voltage (measure).

If there is overloading:

• Check parameters (current regulator, current limits).

• Check the parametrisation of the sensor or the sensor characteristics.

If the error persists when the sensor is bypassed: device defective.

If there is overloading:

• Check parameters (current regulator, current limits).

• Check the parametrisation of the sensor or the sensor characteristics.

If the error persists when the sensor is bypassed: device defective.

• Check the connecting cables of the temperature sensor for wire breaks.

• Check the parametrisation (threshold value) for wire break detection.

Configurable

QStop

Configurable

1) Supplemental information in PNU 203/213:

To p 16 bits: Status number o f internal state machine

Bottom 16 bits: Intermediate circuit voltage (internal scaling approx. 17.1 digit/V).

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A Diagnostic messages

Diagnostic messages of the CMMP-AS-...-M3

No. ReactionActionsCausesMessageCode

03-3 4310hAnalogue motor

overtemperature: short circuit

04-0 4210hPower end stage

overtemperature

04-1 4280hIntermediate cir-

cuit overtemperature

05-5 – Voltage failure in-

terface Ext1/Ext2

05-6 – Voltage failure

[X10], [X11]

05-7 – Safety module in-

ternal voltage failure

05-8 – Failure of internal

voltage 3

The measured resistance value is below the threshold for short circuit detection.

Device is overheated – Temperature display

plausible? – Device fan defective? – Device overloaded?

Device is overheated – Temperature display

plausible? – Device fan defective? – Device overloaded?

Defect on the plugged-in interface

Overloading through connected peripherals

Defect on the safety module

Defect in the motor controller

• Check the connecting cables of the temperature sensor for wire breaks.

• Check the parametrisation (threshold value) for short circuit detection.

• Check installation conditions; are the control cabinet fan filters dirty?

• Check the drive layout (due to possible overloading in continuous duty).

• Check installation conditions; are the control cabinet fan filters dirty?

• Check the drive layout (due to possible overloading in continuous duty).

Interface replacement  R epair by the manufacturer.

• Check pin allocation of the connected peripherals.

• Short circuit?

Interface replacement  R epair by the manufacturer.

Internal defect  Repair by the manufacturer.

Configurable

PS off

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A Diagnostic messages

Diagnostic messages of the CMMP-AS-...-M3

No. ReactionActionsCausesMessageCode

05-9 – Encoder supply

defective

05-0 5114hFailure of internal

voltage 1

05-1 5115hFailure of internal

voltage 2

05-2 5116hFailure of driver

supply

05-3 5410hUndervoltage dig.

I/O

Back measurement of the encoder voltage not OK.

Monitoring of the internal power supply has recognised undervoltage. This is either due to an internal defect or an overload/ short circuit caused by connected peripherals.

Defective peripheral device?

Internal defect  Repair by the manufacturer.

• Separate device from theentireperipheral equipment and check whether the error is still present after reset. If yes, then there is an internal defect  R epair by the manufacturer.

• Check connected peripherals for short circuit / rated loads.

• Check connection of the brake (connected incorrectly?).

PS off

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A Diagnostic messages

Diagnostic messages of the CMMP-AS-...-M3

No. ReactionActionsCausesMessageCode

05-4 5410hOverload current

dig. I/O

06-0 2320hShort circuit in

output stage

Defective peripheral device?

– Faulty motor, e.g.

winding short circuit due to motor overheating or short to PE inside motor.

– Short circuit in the

cable or the connecting plugs, i.e. short circuit between motor phases or to the screening/PE.

– Output stage defect-

ive (short circuit).

– Incorrect paramet-

erisation of the current regulator.

• Check connected peripherals for short circuit / rated loads.

• Check connection of the brake (connected incorrectly?).

Dependent on the status of the system  footnote

cases a) … f)

PS off

2) Actions:

Case a) Error only with active brake chopper: Check external braking resistor for short circuit or insufficient resistance value.

Check circuitry of the brake chopper output at the motor controller (bridge, etc.).

Case b) Error message immediately when the power supply is connected: internal short circuit in the output stage (short circuit

of a complete half-bridge). The motor controller can no longer be connected to the power supply; the internal (and possibly

external) fuses are tripped. Repair by the manufacturer is necessary.

Case c) Short circuit error message only when the output stage or controller enable is issued.

Case d) Disconnection of motor plug [X6] directly on the motor controller. If the error still occurs, there is a fault in the motor

controller. Repair by the manufacturer is necessary.

Case e) If the error only occurs when the motor cable is connected: check the motor and cable for short circuits, e.g. with a

multimeter.

Case f) Check parametrisation of the current regulator. Oscillations in an incorrectly parametrised current regulator can generate

currents up to the short circuit threshold, usually clearly audible as a high-frequency whistling. Verification, if necessary, with the

trace in the FCT (actual active current value).

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A Diagnostic messages

Diagnostic messages of the CMMP-AS-...-M3

No. ReactionActionsCausesMessageCode

06-1 2320hOverload current

brake chopper

Overload current at the brake chopper out put.

07-0 3210hOvervoltage Braking resistor is over-

loaded; too much braking energy which cannot be dissipated quickly enough. – Resistor capacity is in-

correct?

– Resistor not connec-

ted correctly?

08-1 – Sense of rotation

of the serial and incremental position evaluation is not identical

Only encoder with serial position transmission combined with an analogue SIN/COS signal track: The direction of rotation of encoder-internal position determination and incremental evaluation of the analogue track system in the motor controller are the wrong way around.  Footnote

• Check external braking resistor for short circuit or insufficient resistance value.

• Check circuitry of the brake chopper output at the motor controller (bridge, etc.).

•Checkthedesignof the braking resistor; resistance value may be too great.

• Check the connection to the braking resistor (internal/external).

• Swap the following signals on the [X2B] angle encoder interface (the wires in the connecting plug must be changed around), observing the technical data for the angle encoder where applicable:

–SwapSIN/COStrack. – Swap the SI N+/SIN-

or COS+/COS- signals, as applicable.

PS off

Configurable

3) The encoder counts internally, for example positively in clockwise rotation wh ile the incremental evaluation counts in negative

direction with the same mechanical rotation. The interchange of the direction of rotation is detected mechanically at the first

movement of over 30° and the error is triggered.

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A Diagnostic messages

Diagnostic messages of the CMMP-AS-...-M3

No. ReactionActionsCausesMessageCode

08-0 7380hResolver angular

encoder error

08-2 7380hError in increment

generator tracking signal Z0

08-3 7383hError in increment

generator tracking signal Z1

Resolver signal amplitude is faulty

Signal amplitude of the Z0 track at [X2B] is faulty. –Angleencodercon-

nected?

– Angle encoder c able

defective?

– Angle encoder defect-

ive?

Signal amplitude of the Z1 track on X2B is faulty. –Angleencodercon-

nected?

– Angle encoder c able

defective?

– Angle encoder defect-

ive?

Step-by-step approach  footnote

,a)…c):

Check configuration of angle encoder interface: a) Z0 evaluation activ-

ated, but no track signals connected or on

hand.

b) Encoder signals

faulty?

c) Test with another en-

coder.

 Tab. A.3, Page 128.

Check configuration of angle encoder interface: a) Z1 evaluation activ-

ated but not connected.

b) Encoder signals

faulty?

c) Test with another en-

coder.

 Tab. A.3, Page 128.

Configurable

4) a) If possible, test with a different (error-free) resolver (replace the connecting cable too). If the error still occurs, there is a fault

in the motor controller. Repair by manufacturer required.

b) If the error occurs only with a special resolver and its connecting cable: Check resolver signals (carrier and SIN/COS signal),

see specification. If the signal specification is not maintained, the resolver must be replaced.

c) If the error recurs sporadically, check the screening connection or check wh ether the resolver simply h as an insufficient

transmission ratio (standard resolver: A = 0.5).

5) e.g. EnDat 2.2 or EnDat 2.1 without analogue track.

Heidenhain encoder: order codes EnDat 22 and EnDat 21. With these encoders there are no incremental signals, even when the

cables are connected.

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A Diagnostic messages

Diagnostic messages of the CMMP-AS-...-M3

No. ReactionActionsCausesMessageCode

08-4 7384hDigital increment-

al encoder track signals error [X2B]

08-5 7385hError in increment

generator of Halleffect encoder signals

08-6 7386hAngle encoder

communication fault

08-7 7387hSignal amplitude

of incremental tracks faulty [X10]

Faulty A, B, or N track signals at [X2B]. –Angleencodercon-

nected?

– Angle encoder cable

defective?

–Angleencoder

defective?

Hall encoder signals of a dig. inc. at [X2B] faulty. –Angleencodercon-

nected?

– Angle encoder cable

defective?

– Angle encoder defect-

ive?

Communication to serial angle encoders is disrupted (EnDat encoders, HIPERFACE encoders, BiSS encoders). –Angleencodercon-

nected?

– Angle encoder cable

defective?

– Angle encoder defect-

ive?

Faulty A, B, or N track signals at [X10]. –Angleencodercon-

nected?

– Angle encoder cable

defective?

– Angle encoder defect-

ive?

Check the configuration of the angle encoder interface. Proceed according to a) and b): a) Encoder signals

faulty?

b) Test with another en-

coder.

 Tab. A.3, Page 128. Check the configuration

of the angle encoder interface. Proceed according to a) and b): a) Encoder signals

faulty?

b) Test with another en-

coder.

 Tab. A.3, Page 128.

Check configuration of the angle generator interface: procedure corresponding to a) … c): a) Serial encoder para-

metrised but not connected? Incorrect serial protocol selected?

b) Encoder signals

faulty?

c) Test with another en-

coder.

 Tab. A.3, Page 128. Check the configuration

of the angle encoder interface. Proceed according to a) and b): a) Encoder signals

faulty?

b) Test with another en-

coder.

 Tab. A.3, Page 128.

Configurable

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A Diagnostic messages

Diagnostic messages of the CMMP-AS-...-M3

No. ReactionActionsCausesMessageCode

08-8 7388hInternal angle en-

coder error

Internal monitoring of the angle encoder [X2B] has detected an error and forwarded it via serial communication to the c ontroller. – Declining illumination

intensity with visual encoders

– Excess rotational

speed

–Angleencoder

defective?

If the error occurs repeatedly, the encoder is defective.  Replace encoder.

Configurable

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A Diagnostic messages

Diagnostic messages of the CMMP-AS-...-M3

No. ReactionActionsCausesMessageCode

08-9 7389hAngle encoder at

[X2B] is not supported

Angle encoder type read at [X2B], which is not supported or cannot be used in the desired operating mode. – Incorrect or inappro-

priate protocol type selected?

– Firmware does not

support the connected encoder model?

Depending on the additional information of the error message  footnote

• Load appropriate firmware.

• Check/correct the configuration for encoder evaluation.

• Connect an appropriate encoder type.

Configurable

6) Additional information (PNU 203/213):

0001: H I PE RFACE: encoder type is not supported by the firmware -> connect another encoder type or load more recent firmware,

if applicable.

0002: EnDat: The address space in which the encoder parameters would have to lie does not exist with the connected EnDat

encoder -> check the encoder type.

0003: EnDat: encoder type is not supported by the firmware -> connect another encoder type or load more recent firmware, if

applicable.

0004: EnDat: Encoder rating plate cannot be read from the connected encoder. -> Change encoder or load more recent firmware,

if applicable.

0005: EnDat: EnDat 2.2 interface parametrised, connected encoder supported but only EnDat2.1. -> Replace encoder type or

reparameterise to EnDat 2.1.

0006: EnDat: EnDat2.1 interface with analogue track evaluation parametrised, but according to rating plate the connected

encoder does not support track signals. -> Replace encoder or switch off Z0 track signal evaluation.

0007: Code length measuring system with EnDat2.1 connected, but parametrised as a purely serial encoder. Purely serial evalu-

ation is not possible due to the long response times of this encoder system. Encoder must be operated with analogue track

signal evaluation -> connect to analogue Z0 track signal evaluation.

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A Diagnostic messages

Diagnostic messages of the CMMP-AS-...-M3

No. ReactionActionsCausesMessageCode

09-4 – EEPROM data: Er-

roneous custom specific configuration

09-0 73A1hOld angle en-

coder parameter set

09-1 73A2hAngle encoder

parameter record cannot be decoded

Only for special motors: The plausibility check returns an error, e.g. because the motor was repaired or exchanged.

Warning: An encoder parameter set in an old format was found in the EEPROMof the c onnected encoder. This has been converted and saved in the new format.

Data in the EEPROM of the angle encoder could not be read completely, or access to it was partly refused.

• If motor repaired: Carry out homing again and save in the angle encoder, after that ( !) save in the motor controller.

• If motor exchanged: Parameterise the controller again, then carry out homing again and save in the angle encoder, after that ( !) save in the motor controller.

No action necessary at this point. The warning should not re-appear when the 24 V supply is switched back on.

The EEPROM of the encoder contains data (communication objects) which is not supported by the loaded firmware. The data in question is then discarded.

• The parameter record can be adapted to the current firmware by writing the encoder data to the encoder.

• Alternatively, load appropriate (more recent) firmware.

Configurable

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A Diagnostic messages

Diagnostic messages of the CMMP-AS-...-M3

No. ReactionActionsCausesMessageCode

09-2 73A3hUnknown version

of angle encoder parameter record

09-3 73A4hDefective data

structure in angle encoder parameter record

09-7 73A5hWrite-protected

angle encoder EEPROM

Thedatasavedin EEPROM are not compatible with the current version. A data structure was found whichisunabletodecode the loaded firmware.

Data in EEPROM do not match the stored data structure. The data structure was identified as valid but may be corrupted.

Data cannot be saved in the EEPROM of the angle encoder. Occurs with Hiperface encoders.

• Save the encoder parameters again in order to delete the parameter record in the encoder and replace it with a readable record (this will, however, delete the data in the encoder irreversibly).

• Alternatively, load appropriate (more recent) firmware.

• Save the encoder parameters again in order to delete the parameter record in the encoder and replace it with a readable record. If the error still occurs after that, the encoder may be faulty.

• Replace the encoder as a test.

A data field in the encoder EEPROM is readonly (e.g. after operation on a motor controller of another manufacturer). No solution possible, encoder memory must be unlocked with an appropriate parametrisation tool (from manufacturer).

Configurable

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A Diagnostic messages

Diagnostic messages of the CMMP-AS-...-M3

No. ReactionActionsCausesMessageCode

09-9 73A6hAngle encoder's

EEPROM too small

10-0 – Overspeed (spin

protection)

11-7 – Homing: error in

encoder difference monitoring

11-0 8A80hError when hom-

ing is started

11-1 8A81hError during hom-

ing

It is not possible to save all the data in the EEPROM of the angle encoder.

• Reduce the number of data records to be saved. Please read the documentation or contact Technical Support.

– Motor racing (“spin-

ning”) because the commutation angle offset is incorrect.

– Motor is parametrised

• Check the commutation angle offset.

• Check the limit value setting in the parameters.

correctly but the limit for spinning protection is set too low.

Deviation between the actual position value and commutation position is too great. External angle encoder not connected or faulty?

• Deviation fluctuates, e.g. due to gear backlash; cut-off threshold may need to be increased.

• Check connection of the actual value encoder.

Controller enable missing. Homing can only be star-

ted when closed-loop controller enable is active.

• Check the condition or sequence.

Homing was interrupted, e.g. by: – Withdrawal of control-

ler enable.

– Reference switch is

beyond the limit switch.

– External stop signal (a

• Check homing sequence.

• Check arrangement of the switches.

• If applicable, lock the stop input during homing if it is not desired.

phase was aborted during homing).

Configurable

94 Festo – GDCP-CMMP-M3-FW-EN – 1203NH

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A Diagnostic messages

Diagnostic messages of the CMMP-AS-...-M3

No. ReactionActionsCausesMessageCode

11-3 8A83hHoming: timeout The parametrised maxim-

um time for the homing run was exceeded before the homing run was completed.

11-4 8A84hHoming: wrong /

invalid limit switch

– Relevant limit switch

not connected.

– Limit switches

swapped?

– No reference switch

found between the two limit switches.

– Reference switch is at

the limit switch.

– Method “current posi-

tion with zero impulse”: limit switch active in the area of the zero pulse (not permissible).

– Both limit switches

active at the same time.

11-5 8A85hHoming: I@t/fol-

lowing error

– Acceleration ramps

not suitably parametrised.

– Reversing due to pre-

mature triggering of following error; check parametrisation of following error.

– No reference switch

reached between the end stops.

– Zero pulse method:

end stop reached (here not permissible).

• Check the time setting in the parameters.

• Check whether the limit switches are connected in the correct direction of travel or whether the limit switches have an effect on the intended inputs.

• Reference switch connected?

• Check configuration of the reference switches.

• Move limit switch so that it is not in the zero pulse area.

• Check limit switch parametrisation (N/C contact/N/O contact).

• Parameterise the acceleration ramps so they are flatter.

• Check connection of a reference switch.

• Method appropriate for the application?

Configurable

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A Diagnostic messages

Diagnostic messages of the CMMP-AS-...-M3

No. ReactionActionsCausesMessageCode

11-6 8A86hHoming: End of

search path

12-4 – CAN: node guard-

ing

12-5 – CAN: RPDO too

short

12-9 – CAN: Protocol er-

ror

12-1 8120hCAN: Communic-

ation error, bus OFF

The maximum permissible path for the homing run has been travelled

Fault in switch detection.

• Switch for homing is defective?

without reaching the reference point or the homing run target.

Node Guarding telegram not received within the parametrised time. Signals corrupted?

•Comparethecycle time of the remote frames with that of the c ontroller

• Check: failure of the controller?

A rec eived RPDO does not contain the parametrised number of bytes.

The number of parametrised bytes does not match the number of bytes received.

• Check the parametrisation and correct.

Faulty bus protocol. • Check the paramet-

risation of the selected C AN bus protocol.

The CAN chip has switched off communication due to communication errors (BUS OFF).

• Check cabling: cable specification adhered to, cable break, maximum cable length exceeded, correct terminating resistors, cable screening earthed, all signals connected?

• Replace device on a test basis. If a different device works without errors with thesamecabling, sendthedevicetothe manufacturer for checking.

Configurable

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A Diagnostic messages

Diagnostic messages of the CMMP-AS-...-M3

No. ReactionActionsCausesMessageCode

12-0 8180hCAN: double

node number

12-2 8181hCAN: communica-

tion error during transmission

12-3 8182hCAN: communica-

tion error during reception

Node number assigned twice.

The signals are corrupted when transmitting messages. Device is run up so fast that no other nodes on the bus have yet been detected when the boot-up message is sent.

The signals are corrupted when receiving messages.

• Check the configuration of the CAN bus stations

• Check cabling: cable specification adhered to, cable break, maximum cable length exceeded, correct terminating resistors, cable screening earthed, all signals connected?

• Replace device on a test basis. If a different device works without errors with thesamecabling, sendthedevicetothe manufacturer for checking.

• Check the start sequence of the application.

• Check cabling: cable specification adhered to, cable break, maximum cable length exceeded, correct terminating resistors, cable screening earthed, all signals connected?

• Replace device on a test basis. If a different device works without errors with thesamecabling, sendthedevicetothe manufacturer for checking.

Configurable

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A Diagnostic messages

Diagnostic messages of the CMMP-AS-...-M3

No. ReactionActionsCausesMessageCode

13-0 – CAN bus timeout Error message from man-

ufacturer-specific protocol.

14-0 – Insufficient

power supply for identification

Current regulator parameters cannot be determined (because of insufficient supply).

14-1 – Identification of

current regulator: measurement cycle insufficient

14-2 – Automatic para-

meter identifica-

Toofewortoomany measurement cycles required for the connected motor.

The output stage has not

been enabled. tion: Timeout during waiting

14-3 – Automatic para-

meter identification: Cancel

14-5 – Automatic angle

encoder parameter identification: Missing index pulse

Power stage enable was

switched off while identi-

fication was in progress.

The index pulse could not

be found following execu-

tion of the maximum per-

missible number of elec-

trical revolutions.

•ChecktheCANparametrisation

Theavailableintermediate circuit voltage is too low to carry out the measurement.

Automatic determination of parameters has supplied a time constant outside the parameterisable value range.

• The parameters must be manually optimised.

• Check the connection of DIN4.

• Check the sequence control.

• Check the index pulse signal.

• Angle encoder parametrised correctly?

Configurable

PS off

14-6 – Automatic angle

encoder parameter identification: Faulty Hall signals

98 Festo – GDCP-CMMP-M3-FW-EN – 1203NH

Hall signals faulty or invalid. The pulse train or segmenting of the Hall signals is inappropriate.

• Check connection. Refer to the technical data to check whether the encoder shows three Hall signals with 120° or 60° segments; if necessary, contact Technical Support.

PS off

Page 99

A Diagnostic messages

Diagnostic messages of the CMMP-AS-...-M3

No. ReactionActionsCausesMessageCode

14-7 – Identification not

possible

14-8 – Invalid number of

pairs of poles

Angle encoder at a standstill.

The calculated number of pole pairs lies outside the parameterisable range.

15-2 – Counter underrun Internal firmware error.

Internal correction factors could not be calculated.

15-0 6185hDivision by 0 Internal firmware error.

Division by 0 when using the Math Library.

15-1 6186hMathematical

overflow during division

16-0 6181hError in program

execution

Internal firmware error. Overflow when using the Math Library.

Internal firmware error. Error during program execution. Illegal CPU command found in the program sequence.

• Ensure sufficient intermediate circuit voltage.

• Encoder cable connected to the right motor?

• Motor blocked, e.g. holding brake does not release?

• Compare result with the tec hnical data specifications for the motor.

• Check the parametrised number of lines.

• Check the setting of the fac tor group for extreme values and change if necessary.

• Load factory settings.

• Checkthefirmwareto make sure that released firmware has been loaded.

• Load factory settings.

• Checkthefirmwareto make sure that released firmware has been loaded.

• In case of repetition, load firmware again. If the error occurs repeatedly, the hardware is defective.

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16-1 6182hIllegal interrupt Error during program exe-

Festo – GDCP-CMMP-M3-FW-EN – 1203NH 99

cution. An unused I RQ vector was used by the CPU.

• In case of repetition, load firmware again. If the error occurs repeatedly, the hardware is defective.

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Page 100

A Diagnostic messages

Diagnostic messages of the CMMP-AS-...-M3

No. ReactionActionsCausesMessageCode

16-3 6183hUnexpected state Error during periphery ac-

cess within the CPU or error in the program sequence (illegal branching in case structures).

• In case of repetition, load firmware again. If the error occurs repeatedly, the hardware is defective.

16-2 6187hInitialisation error Internal firmware error. • In case of repetition,

load firmware again. If the error occurs repeatedly, the hardware is defective.

17-0 8611hContouring error

limit value exceeded

Comparison threshold for the limit value of the contouring error exceeded.

• Enlarge error window.

• Acceleration parameter too large.

• Motor overloaded (current limitation from i@t monitoring is active?).

17-1 8611hDifference

between actual position and commutation encoder exceeds limit

Deviation between the actual position value and commutation position is too great. External angle encoder not connected or defective?

• Deviation fluctuates, e.g. due to gear backlash; cut-off threshold may need to be increased.

• Check connection of the actual value encoder.

18-0 – Analogue motor

temperature

Motor temperature (analogue) greater than 5° below T_max.

•Checkparametrisation of current regulator and/or speed regulator.

• Motor permanently overloaded?

21-0 5280hError 1 current

measurement U

Offset for current measurement 1 phase U is too great. The closed-loop

If the error occurs repeatedly, the hardware is

defective. controller carries out offset compensation of the current measurement every time its controller enable is issued. Tolerances that are too large result in an error.

PS off

Configurable

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100 Festo – GDCP-CMMP-M3-FW-EN – 1203NH