Festo CPX-CMAX-C1-1 Mounting, Installation And Diagnostics

CPX terminal

Description
Electronics

CMAX axis
controller

Type
CPX−CMAX−C1−1

System description
CMAX axis
controller

Mounting,
installation
and diagnostics
Positioning system

Description

559 751
en 0908NH
[727 403]

Contents and general safety instructions

Original de. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Edition en 0908NH. . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . .

Designation P.BE−CPX−CMAX−SYS−EN. . . . . . . . . . . . . . . . . .

Orderno. 559 751. . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . .

© (Festo AG&Co. KG, D73726 Esslingen, 2009)
Internet:http://www.festo.com
E−mail: [email protected]

The copying, distribution and utilisation of this document
as well as the communication of its contents to others

with
out expressed authorization is prohibited. Violations will
give rise to compensation. All rights are reserved, in par
ticular the right to carry out patent, registered design or
ornamental design registration.

Festo P.BE−CPX−CMAX−SYS−EN en 0908NH

I

Contents and general safety instructions

Interbus®, DeviceNet®, PROFIBUS®, CC−Link®, EtherNet/IP®, PROFINET®, Adobe

®

Reader

und TORX® are registered trademarks of their respective trademark holders in

certain countries.

II

Festo P.BE−CPX−CMAX−SYS−EN en 0908NH

Contents and general safety instructions

Contents

Intended use VII . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safety note VIII . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Target group X . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Service X . . . . . . . . . . . . . . . . . . .

Required software versions for the CPX

Important user instructions XII . . . . . . . . . . . . . . . .

Notes on this description XIV . . . . . . . . . . . . . . . .

Glossary XVII . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

nodes XI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . .

1. CMAX system overview 1−1 . . .

1.1 CMAX axis controller 1−3 . . . . . . . .

1.1.1 Connection and display components of the CMAX 1−3 . . . . . . . .

1.1.2 CMAX function 1−4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.1.3 CMAX

1.2 Structure of a positioning system 1−6 . . . . . . . . .

1.3 Parameterisation and commissioning options 1−7 . . . . . . . . . . . . . . . . . . . . .

1.3.1 Festo Configuration Tool (FCT) 1−7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.3.2 FHPP communication profile 1−8 . . . . . . . . . . . .

in the CPX terminal 1−5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . .

. . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . .

. . .

Festo P.BE−CPX−CMAX−SYS−EN en 0908N H

III

Contents and general safety instructions

2. Fitting and pneumatic installation 2−1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.1 General notes on mounting and installation 2−3 . . . . . . . . .

2.2 Mounting/dismounting the CMAX 2−4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . .

. . . .

2.3 Installation of the drive and position measuring system 2−6 . . . . . . . . . . . . . . . .

2.3.1 General mechanical requirements 2−7 . . . . . . . . . . . . . . . . . . . .

. . . . . .

2.3.2 Drive, shock absorbers and fixed stops 2−8 . . . . . . . . . . . . . . . . . . . . . .

2.3.3 Position measuring system 2−10 . . . . . . . . . . . . .

2.3.4 Load 2−12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . .

2.4 VPWP proportional directional control valve 2−17 . . . . . . . . . . . . . . . . . . . . . . . . .

2.4.1 Approved

drive/valve combinations 2−17 . . . . . . . . . . . . . . . . . . . . . . . .

2.4.2 Mounting the VPWP proportional directional control valve 2−19 . . . . . .

2.5 Mounting the CASM sensor interface 2−22 . . . . . . .

2.6 Pneumatic installation 2−23 . . . . . . . . . . . . . . . . . . . . . . . .

2.6.1 Compressed air supply 2−23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . .

. . . . . .

2.6.2 Filter regulator 2−24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.6.3 Air reservoir (optional) 2−25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.6.4 VPWP proportional directional control valve 2−25 . . . . . . . .

. . . . . . . . . .

2.6.5 Tubing and fittings 2−29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3. Electrical installation 3−1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.1 Earthing 3−3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.2 Axis interface 3−5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . .

3.2.1 VPWP proportional directional control valve 3−7 . . . . . . . . . . . . . . . . . .

3.2.2 CASM sensor interface 3−9 . . . . . . . . . . . . . . . . . . . . .

3.3 Ensuring protection class IP65 3−11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.4 Power supply 3−12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . .

. . .

. . . . .

3.4.1 Determining the current consumption 3−13 . . . . . . . . . . . . . . . . . . . . . . .

3.4.2 Power supply concept, formation of power zones 3−14 . . . . . . . . . . . .

3.4.3 Disconnecting the load voltage in connection with a brake or

clamping unit 3−18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . .

. .

.

IV

Festo P.BE−CPX−CMAX−SYS−EN en 0908NH

Contents and general safety instructions

4. Commissioning 4−1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.1 Overview/procedure for

4.1.1 Instructions for commissioning 4−4 . . . . . . . . . . . . . . . . . .

commissioning 4−3 . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . .

4.1.2 Installing the Festo Configuration Tool and FCT CMAX plug−in 4−5 . . . .

4.2 Preparations for commissioning 4−8 . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . .

4.2.1 Checking the axis string 4−8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.2.2 Switching on

the power supply, switch−on behaviour 4−8 . . . . . . . . . . .

4.2.3 Establishing a connection to the PC 4−11 . . . . . . . . . . . . . . . . . . . . . . . . .

4.3 Commissioning with the FCT

4.3.1 Overview of commissioning steps 4−12 . . . . . . . . . . . . . . . .

4.4 Operation instructions 4−14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

(overview) 4−12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . .

. . . .

4.4.1 CMAX control 4−14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.4.2 General

4.5 Structure of the cyclical I/O data 4−16 . . . . . . . . . . . . . .

operation instructions 4−14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . .

4.5.1 Defining the operating mode with CCON 4−17 . . . . . . . . . . . . . . . . . . . . .

4.5.2 Controlling the

CMAX in record select operating mode 4−19 . . . . . . . . .

4.5.3 Controlling the CMA X in direct operating mode 4−20 . . . . . . . . . . . . . . .

4.5.4 Execute record (record select mode) 4−22 . . . . . . . . .

4.5.5 Direct mode 4−29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . .

. . . . . . . . . . .

4.5.6 Acknowledge error 4−37 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.6 Flow charts for programming 4−38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.6.1 Establish ready status 4−38 . . . . . .

4.6.2 Start record 4−41 . . . . . . . . . . . . . . . . . . .

4.6.3 Acknowledge malfunction 4−42 . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . .

4.6.4 Switch operating mode 4−43 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Festo P.BE−CPX−CMAX−SYS−EN en 0908N H

V

Contents and general safety instructions

5. Diagnostics and error handling 5−1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.1 Summary of diagnostics options 5−3 . . . . . . . .

5.2 Malfunctions and warnings 5−4 . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . .

5.2.1 Error numbers on the CPX terminal 5−6 . . . . . . . . . . . . . . . . . . . . . . . . .

5.2.2 Malfunction

groups: Classification according to the cause 5−6 . . . . . .

5.2.3 Error level and reset type: Classification according to effect and

acknowledgement 5−7 . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . .

5.2.4 Error numbers and warning numbers 5−8 . . . . . . . . . . . . . . . . . . . . . . .

5.3 Diagnostics via LEDs 5−29 . . . . . . . .

5.3.1 CMAX−specific LEDs 5−30 . . . . . . . . . . . .

5.3.2 Axis−specific LEDs 5−31 . . . . . . . . . . . . . . . . . . . . . . .

5.3.3 LEDs on the VPWP 5−32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . .

. . . . . . . . .

5.3.4 LEDs on the sensor interface 5−33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.3.5 LEDs on the displacement encoder (DGCI only) 5−34

5.4 Diagnostics via the display/7−segment display 5−35 . . . . . . . . . . . . . . . . . . . . . . .

5.4.1 Error status 5−35 . . . . .

5.4.2 Status display 5−36 . . . . . . . . . .

5.5 Diagnostic functions with the CPX−MMI 5−39 . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . .

5.5.1 Error display ([Diagnostics] menu) 5−39 . . . . . . . . . . . . . . . . . . . . . . . . . .

5.5.2 Information on the CMAX ([Module

A. Technical appendix A−1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

A.1 CMAX technical data A−3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

A.2 Replacing components A−6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

data] menu) 5−40 . . . . . . . . . . . . . . .

. . . . . . . . . . . . . .

. . . . . . . . . .

. . . . .

A.3 Additional pneumatic circuits A−7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

A.4 Index A−8 . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . .

VI

Festo P.BE−CPX−CMAX−SYS−EN en 0908NH

Contents and general safety instructions

Intended use

The CPX−CMAX−C1−1 axis controller documented in this
description is intended exclusively for use in Festo CPX
terminals for installation in a machine or an automation
system.

In connection with a CPX terminal with suitable CPX bus
nodes or CPX−FEC, as well as with enabled drives with a
displacement encoder as well as
tional control valve, CMAX serves as a position controller with
position and force control for pneumatic drives.

The CPX terminal may only be used with the CMAX as follows:

As intended for the industrial environment

In its original condition without unauthorised modifica

tions. Only the conversions or modifications described
in the documentation supplied with the product are per
mitted.

a VPWP proportional direc

Festo P.BE−CPX−CMAX−SYS−EN en 0908N H

In perfect technical condition.

 Only in combination with approved components

(valves, drive/displacement encoder combinations,
see section 1.2).

The limit values specified for pressures, temperatures, electri
cal data, torques etc. should be observed.

Please comply with regulations of the trade associations,
the German Technical Control

Board (TÜV), the VDE or the

relevant national regulations.

VII

Contents and general safety instructions

Safety note

Protection against dangerous movements

Warning

High acceleration forces at the connected actuators!
Unexpected motions can cause collisions and severe
injuries.

Dangerous movements can occur due to the faulty control
ling of connected actuators, e.g. due to:

 Dirty or faulty wiring/cabling
 Component operating errors
 Measured value and signal generator errors
 Faulty or non−EMC−compliant components
 Errors in the higher−order control system.
Simply switching off the compressed air supply or load

voltage are not suitable locking procedures. In the event of
a fault, this could lead to unintentional movement of the
drive.

· Before mounting, installation and maintenance work, put

the system into a safe state (e.g. by putting the drive in a
safe position and deactivating the controller).
Always make sure that the compressed air and power
supplies are switched off and locked before working in
the machine area.

· Make sure that no persons are in the operating range of

the drive or any other connected actuators.

· Do not switch on the compressed air until the system is

correctly installed and parameterised.

VIII

Festo P.BE−CPX−CMAX−SYS−EN en 0908NH

Contents and general safety instructions

· The holding brakes controlled by the drive controller are

not appropriate for personal protection by themselves.
Lock vertical axes additionally to keep them from falling
down or sinking when the compressed air and load volt
age are switched off, e.g. by means of:
 mechanical locking of the vertical axis
 external braking/safety
 sufficient counterbalance of the axis.

· If used in safety applications, additional measures are

necessary, e.g. in Europe the standards listed under the
EU machine guidelines must be observed. Without addi
tional measures in accordance with statutory minimum
requirements, the product is not suitable for use in
safety−related sections of control systems.

Protection from pressurised tubing

catch/clamping device

Festo P.BE−CPX−CMAX−SYS−EN en 0908N H

Caution

Danger of injury through inappropriate handling of pres
surised tubing!

Uncontrolled movements of the connected actuators and
uncontrolled movements of loose tubing can cause injury
to human beings or damage to property.

· Do not connect, disconnect or open pressurised lines.

· The lines must always be exhausted before removal

(release compressed air).

· Use suitable protective equipment (e.g. safety goggles,

safety shoes, etc.).

IX

Contents and general safety instructions

Target group

This manual is intended exclusively for technicians trained in
control and automation technology, who have experience in
installing, commissioning, programming and diagnosing posi
tioning systems.

Service

Please consult your local Festo Service agent if you have any
technical problems.

X

Festo P.BE−CPX−CMAX−SYS−EN en 0908NH

Contents and general safety instructions

Required software versions for the CPX nodes

Particular software versions for the CPX node are required for
operating the CMAX (versions as of August 2009):

CPX node

CPX−FEC From Revision 18 (R18) On request  Max. 8 CMAX modules

CPX−FB6 (Interbus) From Revision 22 (R22) On request  Max. 1 CMAX module

CPX−FB11 (DeviceNet) From Revision 20 (R20) Suitable  Max. 8 CMAX modules

CPX−FB13 (PROFIBUS−DP) From Revision 23 (R23) Suitable  Max. 8 CMAX modules

CPX−FB14 (CANopen) From Revision 20 (R20) On request  Max. 3 CMAX modules

CPX−FB23 (CC link) From Revision 19 (R19) On request  Max. 8 CMAX modules

CPX−FB32 (Ethernet/IP) From Revision 14 (R14) On request  Max. 8 CMAX modules

CPX−FB33 (PROFINET, M12) From Revision 7 (R7) On request  Max. 8 CMAX modules

CPX−FB34 (PROFINET, RJ45) From Revision 7 (R7) On request  Max. 8 CMAX modules

CPX−FB38 (EtherCAT) All On request  Max. 8 CMAX modules

CPX−CEC In preparation On request  Max. 8 CMAX modules

1)

Revisions version (Rev...) see name plate. Older revisions are not suitable for use with CMAX and
cannot lead to the intended behaviour.

2)

Depending on the CPX node functions used, the address range and therefore the maximum number
of modules can be further restricted, if necessary.

Required version

1)

Use Special features

 Acyclic services, DPV1

(then max.
7 CMAX modules)

2)

Tab.0/1: Overview CPX nodes

Festo P.BE−CPX−CMAX−SYS−EN en 0908N H

Please also observe the notes on the software version in the
documentation for the CPX node.

To commission the CMAX, you will require the Festo configur
ation tool with a CMAX plug−in. You can find this on the Festo
website at:

è www.festo.com ˛ Downloads ˛ Download Area:
Software,

drivers and firmware ˛ Enter search term: CMAX

XI

Contents and general safety instructions

Important user instructions

Danger categories

This manual contains instructions on the possible dangers
which can occur if the product is not used correctly. These
instructions are marked (Warning, Caution, etc), printed on
a shaded background and marked additionally with a picto
gram. A distinction is made between the following danger
warnings:

Warning

... means that failure to observe this instruction may result
in serious personal injury or material damage.

Caution

... means that failure to observe this instruction may result
in personal injury or material damage.

XII

Note

... means that failure to observe this instruction may result
in material damage.

The following pictogram marks passages in the text which
describe activities with electrostatically sensitive devices:

Electrostatically sensitive devices: Inappropriate handling can
result in damage to components.

Festo P.BE−CPX−CMAX−SYS−EN en 0908NH

Contents and general safety instructions

Identification of specific information

The following pictograms designate texts that contain special
information.

Pictograms

Information:
Recommendations, tips and references to other sources of
information

Accessories:
Information about necessary or useful accessories for the
Festo product.

Environment:
Information on the environmentally friendly use of Festo
products.

Festo P.BE−CPX−CMAX−SYS−EN en 0908N H

Text designations

· Bullet points indicate activities that may be carried out in

any order.

1. Numerals denote activities which must be carried out in
the specified sequence.

 Arrowheads indicate general lists.

XIII

Contents and general safety instructions

Notes on this description

This description refers to the following versions:

 CPX−CMAX−C1−1 axis controller starting from software

version V1.0

This description contains special information on the mode of
operation, mounting, installation and commissioning of the
CMAX axis controller with the modules and components on
the axis string (see Tab.0/2).

Information about the activation, programming and diagnosis
of a CMAX
CMAX communication profile" description.

Special information about the configuration for certain CPX
nodes can be found in the corresponding supplementary
description. See Tab.0/3.

General basic information on the mode of operation, mount
ing, installing and commissioning CPX terminals can be found

CPX system description, type P.BE−CPX−SYS−... .

in the

with the used CPX node can be found in the

XIV

Festo P.BE−CPX−CMAX−SYS−EN en 0908NH

Contents and general safety instructions

This description contains information on the following
modules and components of the positioning system:

Module/component type

CMAX−C1−1 CMAX axis controller with 7−segment display as well as an axis

VPWP−... VPWP proportional directional control valve with connections to the

CASM−S−D2−R3
CASM−S−D3−R7

DGCI−...

DGP(L)−... with
MLO−P OT−...−TLF

DNCI−...

Description

interface to the VPWP.
The CMAX is a CPX module (technology module) in a CPX terminal.

CMAX and to the displacement encoder or sensor interface.
The position measuring system or sensor interface is connected to
the VPWP .
Additional digital output with a load voltage supply for activati n g a
brake or clamping unit.

Sensor interfaces with a connection to the VPWP , for connecting
special position measuring systems to the axis string:
analogue, absolute displacement encoders (potentiometers)
 digital, incremental displacement encoders

Enabled drives with position measuring systems:
 Linear drive with permanently integrated position measuring

system.
(digital, absolute)

 Linear drive with external position measuring system

(potentiometer, absolute)

Standard cylinder with integrated position measuring system

(encoder, incremental)

1)

DNC−... with
MLO−P OT−...−L W G

DNCM−...

DSMI−...

1)

Support for other drives in preparation

Standard cylinder with external position measuring system

(potentiometer, absolute)

Standard cylinder with external position measuring system

(potentiometer, absolute)

 Semi−rotary drive with integrated position measuring system

(potentiometer, absolute)

Tab.0/2: Overview of positioning system modules and components

Festo P.BE−CPX−CMAX−SYS−EN en 0908N H

XV

Contents and general safety instructions

Manual for CMAX axis controller

Type Title Contents

Electronics de
scription

Communica
tion profile de
scription

Online help Help for the Festo configur

Operating in
structions

CMAX axis controller
system description"
P.BE−CPX−CMAX−SYS−...

CMAX communication
profile"
P.BE−CPX−CMAX−CONTROL−...

ation tool with CMAX plug−in

Operating instructions for the used components

Mounting, installation, commissioning and diagnosis
of the CMAX axis controller

Activation, programming and diagnosis of a CMAX
with the used CPX node

Configuration and commissioning of the CMAX axis
controller with the FCT
è www.festo.com ˛ Downloads ˛ Download
Area: Software, drivers and firmware ˛ Enter

search term: CMAX

Tab.0/3: Documentation for the positioning system with CMA X

XVI

Festo P.BE−CPX−CMAX−SYS−EN en 0908NH

Contents and general safety instructions

Glossary

The following product−specific terms and abbreviations are
used in this description:

Term/abbreviation

0xA0 (A0h) Hexadecimal numbers are marked by a prefixed 0x" or by a subscript

Absolute position
measuring system

Adaptation CMAX function to improve non−optimal switch−on behaviour automati

Axis string Totality of all modules and cables which are connected via the axis inter

Bus node Establish the connection to specific fieldbuses. Transmit control signals

Control interface Connection for all modules and cables in the axis string.

CPX modules Collective term for the various modules which can be integrated in a CPX

CPX node Collective term for all CPX bus nodes or the CPX−FEC

CPX terminal Complete system consisting of CPX modules with or without pneumatics.

Drive In this description, the term drive" represents linear drives (DGCI, DGP),

Festo Configuration Tool
(FCT)

Festo Handling and Posi
tioning Profile (F HPP)

Meaning

h.".

A position measuring system with fixed (absolute) assignment of
the measured value (position, angle, etc.) and measured variable,
for digital" or potentiometer" CMAX.

cally during operation

face to the CMAX

to the connected modules and monitor their operation (as CPX module:
CPX bus node).

terminal.

standard cylinders, positioning drives (DNC, DNCI, DNCM) or swivel
modules (DSMI).

Software with standardised project and data management for supported
device types. The special requirements of a device type are supported
with the necessary descriptions and dialogues by means of plug−ins.

Fieldbus data profile for Festo position controllers

Festo Parameter
Channel (FPC)

Festo P.BE−CPX−CMAX−SYS−EN en 0908N H

FHPP−specific parameter access

XVII

Contents and general safety instructions

Term/abbreviation Meaning

Functions Special functions in the different operating modes. e.g.:

 Jog mode
 Homing

Homing By means of homing, the reference position and thereby the origin of the

I Digital input.

I/Os Digital inputs and outputs.

Identification System function where specific characteristics of the connected axis are

Incremental position
measuring system

Jog mode Manual travel in positive or negative direction.

Logic 0 Input or output provides 0 V (also LOW, FALSE or logical 0).

Logic 1 Input or output provides 24 V (also HIGH, TRUE or logical 1).

O Digital output

OB Output byte

Operating mode Type of CMAX control, function or setpoint specification

Parameter Various settings which must be defined for system operation and be

dimension reference system of the axis are defined.

From the point of view of the master controller, the CMAX status outputs
are module input data. See section 4.5.

determined by means of an identification run, e.g. break−away forces,
frictional behaviour, dynamics (maximum accelerations and speeds), etc.

A position measuring system in which the measured variable refers to a
reference point and is determined by counting equally large measure
ment steps (increments) with the CMAX encoder".

Function for setting positions by approaching the target position,
e.g. by teaching records.

From the point of view of the master controller, the CMAX control inputs
are module output data. See section 4.5.

saved in CMAX.

PLC/IPC Programmable logic controller; for short: Controller

PNU Parameter number  each parameter has a number and subindex.

Position control Control mode where a defined position is approached and held with

XVIII

(also IPC: industrial PC).

control.

Festo P.BE−CPX−CMAX−SYS−EN en 0908NH

Contents and general safety instructions

Term/abbreviation Meaning

Pressure/force control Control mode where a defined force is applied via pressure control. In the

Project zero point (PZ) Dimension reference point for all positions in positioning tasks (project

Record Positioning command defined in the position set table, consisting of

Reference point (REF) Point of reference for the incremental displacement encoder.

Software end position Programmable stroke limit (point of reference = axis zero point)

following, the term force control" will be used.

zero point). The project zero point forms the basis for all absolute posi
tion specifications (e.g. in the position set table or in direct mode). The
point of reference for the project zero point is the axis zero point.

target position, positioning mode, speed, acceleration, ...

The reference point defines a known position within the drive’s travel.

Upper software end position

Max. limit position in the positive direction (increasing actual values).

Lower software end position

Min. limit position in negative direction (decreasing actual values).

Tab.0/4: Terms and abbreviations

Festo P.BE−CPX−CMAX−SYS−EN en 0908N H

XIX

Contents and general safety instructions

XX

Festo P.BE−CPX−CMAX−SYS−EN en 0908NH

CMAX system overview

Chapter 1

1−1Festo P.BE−CPX−CMAX−SYS−EN en 0908N H

1. CMAX system overview

Contents

1. CMAX system overview 1−1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.1 CMAX axis controller 1−3 . . .

1.1.1 Connection and display components of the CMAX 1−3 . .

1.1.2 CMAX function 1−4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.1.3 CMAX in the CPX terminal 1−5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.2 Structure of a positioning system 1−6 . . .

1.3 Parameterisation and commissioning options 1−7 . . . . . . . . . . . . . . . .

1.3.1 Festo Configuration Tool (FCT) 1−7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.3.2 FHPP communication profile 1−8 . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . .

. . . .

. . . . . . . .

1−2

Festo P.BE−CPX−CMAX−SYS−EN en 0908NH

1. CMAX system overview

1.1 CMAX axis controller

1.1.1 Connection and display components of the CMAX

The following connection and display components can be
found on the CMAX:

1 Status LED

See section 5.3

5

2 X: Axis interface

(connection for
VPWP)

4

3 Inscription labels

(accessories)

4 3−character display

See section 5.4

5 Name plate

(on side surface)

Fig.1/1: Connection and display components of the CMAX

3

DxDyX

1

Y

2

Festo P.BE−CPX−CMAX−SYS−EN en 0908N H

1−3

1. CMAX system overview

1.1.2 CMAX function

The CMAX axis controller, together with a VPWP proportional
directional control valve and a drive with a position measur
ing system, forms a positioning system for pneumatic axes
(see section 1.2).

The positioning system permits:

 Travel at selectable speed in any positions (position con

trol)

 The approach of a position and applying a defined

(force control).

Mode of operation

CMAX functions The CMAX takes over the following functions:

 Parameter storage (hardware configuration, records, con

troller settings, etc.)

It ascertains system characteristic values of the con

nected components (identification).

 Specifies setpoint values (position or force)

 Tracks setpoint and actual values (position or force con

trol) by appropriately activating the proportional direc
tional control valve.

Mode of

operation The CMAX, valve, drive and displacement encoder are

connected to form a closed−loop control circuit.

force

1−4

Festo P.BE−CPX−CMAX−SYS−EN en 0908NH

1. CMAX system overview

1.1.3 CMAX in the CPX terminal

The CMAX is integrated in a CPX terminal as a CPX module
and is controlled by the CPX node via the internal bus using
8bytes of module output and 8 bytes module input data.
See section 4.5.

Information about the control and parameterisation of the
CMAX via the CPX node can be found

cation profile" description, P.BE−CPX−CMAX−CONTROL−... .

The descriptions are also available as PDF files:
è www.festo.com ˛ Downloads ˛ Manual

in the CMAX communi

Festo P.BE−CPX−CMAX−SYS−EN en 0908N H

1−5

1. CMAX system overview

1.2 Structure of a positioning system

A positioning system typically consists of the following com
ponents (see Fig.1/2):

1 CPX terminal with

CMAX

12 3 4

2 VPWP proportional

directional control
valve

3 A sensor interface

with displacement
encoder cable
(optional, depending
on the displacement
encoder used)

4 Drive with position

measuring system
(in this example a
DNCI)

5 Pneumatic tubing

6 Axis string

Fig.1/2: Structure of positioning system

Specific information on the structure is provided in
chapters 2 and 3.

56

1−6

Festo P.BE−CPX−CMAX−SYS−EN en 0908NH

1. CMAX system overview

1.3 Parameterisation and commissioning options

Tab.1/1 provides an overview of the commissioning,
parameterising and teaching options.

Operated via

FCT CMAX plug−in Easy commissioning thanks to special dialogues

Master controller,
CPX node
(CPX bus node or
CPX−FEC)

Properties For details, see

and functions.

Direct on−site" operation with drive monitoring

is possible

PC must be connected on site with the diagnostic

interface of the CPX terminal.

 Parameterisation of several positioning

systems is possible.

 Commissioning and teaching require additional

measures for the necessary drive monitoring.

 Additional programming required.

Tab.1/1: Commissioning, parameterising and teaching options

1.3.1 Festo Configuration Tool (FCT)

The Festo Configuration Tool (abbreviated as FCT) is the soft
ware platform for configuring and commissioning various
Festo components and devices.

The CMAX plug−in for the FCT helps to carry out all the steps
necessary for commissioning a CMAX.

An overview for commissioning with the FCT can be found in
chapter 4.
The help
operating the Festo Configuration Tool. The device−specific
plug−ins each have their own help files.

for the FCT contains the complete information on

Chapter 4,
help for FCT CMAX
plug−in

CMAX communication
profile" description,
P.BE−CPX−CMAX−CON
TROL−...

Festo P.BE−CPX−CMAX−SYS−EN en 0908N H

1−7

1. CMAX system overview

1.3.2 FHPP communication profile

Festo has developed an optimised data profile, the Festo
Handling and Positioning Profile (FHPP)", tailored to handling
and positioning functions.
The FHPP allows the various Festo fieldbus systems and con
trollers to be uniformly controlled and programmed.

It also uniformly defines the following for the user:

 Operating modes

 I/O data structure

 Parameters

 Sequence control.

1−8

Basic information

can be found in section 4.5.

More detailed information about FHPP can be found in the
CMAX communication profile" description.

Festo P.BE−CPX−CMAX−SYS−EN en 0908NH

Fitting and pneumatic installation

Chapter 2

2−1Festo P.BE−CPX−CMAX−SYS−EN en 0908N H

2. Fitting and pneumatic installation

Contents

2. Fitting and pneumatic installation 2−1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.1 General notes on mounting and installation 2−3 . . . . . . . . .

2.2 Mounting/dismounting the CMAX 2−4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.3 Installation of the drive and position measuring system 2−6 . . . . . . . . . . . . . . . .

2.3.1 General mechanical requirements 2−7 . . . . . . . . . . . . . . . . . . . .

2.3.2 Drive, shock absorbers and fixed stops 2−8 . . . . . . . . . . . . . . . . . . . . . .

2.3.3 Position measuring system 2−10 . . . . . . . . . . . . .

2.3.4 Load 2−12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.4 VPWP proportional directional control valve 2−17 . . . . . . . . . . . . . . . . . . . . . . . . .

2.4.1 Approved

2.4.2 Mounting the VPWP proportional directional control valve 2−19 . . . . . .

2.5 Mounting the CASM sensor interface 2−22 . . . . . . .

2.6 Pneumatic installation 2−23 . . . . . . . . . . . . . . . . . . . . . . . .

2.6.1 Compressed air supply 2−23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.6.2 Filter regulator 2−24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.6.3 Air reservoir (optional) 2−25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.6.4 VPWP proportional directional control valve 2−25 . . . . . . . .

2.6.5 Tubing and fittings 2−29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

drive/valve combinations 2−17 . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . .

. . . .

. . . . . .

. . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . .

. . . . . .

. . . . . . . . . .

. .

2−2

Festo P.BE−CPX−CMAX−SYS−EN en 0908NH

2. Fitting and pneumatic installation

2.1 General notes on mounting and installation

Information about mounting the CPX terminal can be found in
the CPX system description (P.BE−CPX−SYS−..).

Note

Using components that have not been approved for oper
ation with the CMAX may lead to malfunctions.

Use only the special matching components from Festo for
setting up and wiring the system.

When mounting the components, also observe the mounting
instructions in the operating instructions supplied and the
instructions in this chapter.
Only then

can you guarantee trouble−free operation.

Section 2.6.3

Section 2.4

Section 2.6.2

Section 2.6.5

Section 2.6.1

Section 2.3

Section 2.3.4

Fig.2/1: Overview of mounting and pneumatic installation

Festo P.BE−CPX−CMAX−SYS−EN en 0908N H

Section 2.2

Section 2.6.4

Section 2.5

2−3

2. Fitting and pneumatic installation

2.2 Mounting/dismounting the CMAX

The CMAX is mounted in an interlinking block (see also
section 3.4) of the CPX terminal. See Fig.2/2.

Note

· Always switch off the power supply before mounting/

dismounting CPX modules.

Note

The CMAX contains electrostatically sensitive devices.

· Therefore, do not touch any of the components.

· Observe the handling specifications for electrostatically

sensitive devices.

Removal Remove the CMAX as follows:

1. Loosen the four screws of the CMAX with a T10 Torx
screwdriver.

2. Pull the CMAX carefully and without tilting away from the
contact rails of the interlinking block.

1 CMAX

4

2 Interlinking block

3 Contact rails

4 Torx T10 screws

3

Fig.2/2: Mounting/dismounting the CMAX

2−4

1

2

Festo P.BE−CPX−CMAX−SYS−EN en 0908NH

2. Fitting and pneumatic installation

Mounting Mount the CMAX as follows:

1. Place the CMAX in the interlinking block. Make sure that
the grooves with the power contact terminals on the bot
tom of the CMAX lie above the contact rails.

2. Push the CMAX carefully and without tilting as far as
possible into the interlinking block.

3. Tighten the screws only by

hand. Place the screws so that

the self−cutting threads can be used.

4. Tighten the screws with a size T10 Torx screwdriver with a
torque of 0.9 to 1.1 Nm.

The parameterisation is saved in the CMAX. Therefore, after
replacing a CMAX, check the parameters and, if necessary,
repeat the commissioning process. See chapter

4.

Observe the instructions in section A.2.

Festo P.BE−CPX−CMAX−SYS−EN en 0908N H

2−5

2. Fitting and pneumatic installation

2.3 Installation of the drive and position measuring system

Use only the drive/displacement encoder combinations
approved by Festo for the CMAX.

Note

In order to avoid damage due to uncushioned movement
into the end positions:

· Use appropriate shock absorbers.

· Define the software end positions.

To avoid damage to the displacement encoder when the
displacement encoder is shorter than the drive stroke:

· Limit the travel range with additional end stops.

Tab.2/1 shows the approved drive/displacement encoder
combinations:

Drive

Design Type Design, function Type

Linear drive

Cylinder

Semi−rotary drive DSMI Potentiometer (absolute) Integrated CASM−S−D2−R3

DGCI Digital (absolute) Integrated 

DGP(L) Potentiometer (absolute) MLO−POT−TLF−... CASM−S−D2−R3

DNCI Encoder (incremental) Integrated CASM−S−D3−R7

DNC Potentiometer (absolute) MLO−POT−LWG−... CASM−S−D2−R3

DNCM Potentiometer (absolute) Integrated CASM−S−D2−R3

Displacement encoder Sensor

interface

Tab.2/1:Drive overview (as of August 2009)

Further drives are in preparation.

2−6

Festo P.BE−CPX−CMA X−SYS−EN en 0908N H

2. Fitting and pneumatic installation

2.3.1 General mechanical requirements

Note

Connect the drive, guide, displacement encoder and load
with as little backlash as possible and align them flush
with each other.

Mechanical backlash, e.g. between the cylinder piston
and the mass to be moved, leads to poor movement be
haviour (the backlash presents the controller with con
stantly changing mass").

Important for positioning accuracy:

rod

The c

ylinder, guide, position measuring system and load
must be rigid in the direction of movement, have very
little backlash and must be connected flush with each
other.

The backlash between the drive, guide, mass and position

measuring system must be smaller by a factor of 10 than
the required tolerance (max. 0.1 mm).

Note

Transverse loads falsify the measuring results and could
damage the displacement encoder.

· Use an external guide for the effective load in order to

prevent transverse loads on the drive.

· Use mounting attachments which will withstand the

acceleration forces long−term.

· If necessary, provide a sufficiently large energy chain in

order to minimise the effects of bending forces on the
positioning behaviour.

Festo P.BE−CPX−CMA X−SYS−EN en 0908NH

2−7

2. Fitting and pneumatic installation

Note

Please observe the notes in the operating instructions for
the drive used. Make sure that the following are complied
with:

the permitted lateral force
the p

ermitted longitudinal force
the permitted mass moment of inertia
the maximum permitted speeds and swivel frequencies.

2.3.2 Drive, shock absorbers and fixed stops

Drive

Note

With all work, be sure to follow the mounting instructions
in the operating instructions.

Use only the permitted drives with suitable guide listed in
Tab.2/1

(as of August 2009).

Consult Festo if you wish to use other drives.

Drive

DGP(L) · Completely unscrew the adjusting screws for the end−position cushioning (PPV) on

DNC Note

Notes

both sides.

The following DNC variants are not permitted for use with the CMAX:
 Slow speed variant S10
Low friction variant S11
Temperature−resistant variant S6 (only on request).
Use only:
 DNC variants with permitted maximum piston speed Vmax > 1 m/s.
For standard cylinders with end−position cushioning PPV:

· Completely unscrew the adjusting screws for the end−position cushioning (PPV) on

both sides.

Tab.2/2: Instructions for the drives DGP(L) and DNC

2−8

Festo P.BE−CPX−CMA X−SYS−EN en 0908N H

2. Fitting and pneumatic installation

Shock absorbers / fixed stops

Shock absorbers or fixed stops are recommended, depending

on the specific application and the drive used. These fulfil the
following functions:

 Protection of the drive or position

measuring system

 Definition or setting of the end positions, as needed

Note

Damage due to uncushioned travel into the end positions.

· Carry out commissioning again after adjusting the fixed

stops or when components and tubing have been re
placed.

Use suitable external stops or shock absorber

s / fixed stops

from Festo.

Information on mounting the Festo shock absorbers / fixed
stops is provided in the operating instructions for the drive or
the assembly instruc

tions for the shock absorbers / fixed

stops.

Festo P.BE−CPX−CMA X−SYS−EN en 0908NH

2−9

2. Fitting and pneumatic installation

2.3.3 Position measuring system

Tab.2/3 provides instructions on mounting the displacement
encoder.

Drive

DGCI Permanently integrated position

DGP(L) External position measuring

DNCI Integrated position measuring

DNC External position measuring

Position measuring system Mounting instructions

measuring system.

system of type MLO−POT−...−TLF.

system.

system of type MLO−POT−...−LWG.



· Only use a displacement encoder and drive

with the same stroke length. The displacement
encoder must be longer than the drive stroke
used. An electric reserve ţ 0.3% of the nominal
length must be available.

· For safe and quick mounting of the displace

ment encoder: Use the BB−TLF−DGPL−...
mounting kit.

· Mount the displacement encoder electrically

isolated on the mounting surface using the

clamps provided.

When used under difficult environmental condi

tions (dusty environment):

· Mount the displacement encoder with the

actuator slide facing downwards. The draining
edge on both sides prevents excessive dirt

from accumulating on the bearing surface.



· Use only a displacement encoder and standard

cylinder with the same stroke length.

· Mount the displacement encoder and standard

cylinder symmetrically (middle of the displace
ment encoder stroke must be aligned with the
middle of the entire cylinder stroke).

DNCM External position measuring

system already mounted on
delivery

DSMI Integrated position measuring

system.

· Always leave the displacement encoder

mounted on the standard cylinder.

· Observe the instructions in the operating

instructions.



Tab.2/3: Instructions for mounting the position measuring systems

2−10

Festo P.BE−CPX−CMA X−SYS−EN en 0908N H

2. Fitting and pneumatic installation

Note

If the positioning range of the drive is longer than the
effective stroke of the displacement encoder:

· Limit the positioning range using shock absorbers or

stops, so that the position measuring system covers the
complete possible positioning range. In thi

protect the displacement encoder from damage.

External potentiometer position measuring system

If analogue displacement encoders are used (e.g. type
MLO−POT−...), the following applies:
In combination with the CMAX, an electric reserve of ţ 0.3%
of the nomina
not apply for the integrated system in the case of DSMI).

Example:
Nominal length of the displacement encoder:
Electric effective length: Approx. 1006 mm

} Permissible effective path: 0 ... 1000 mm

s way you can

l length is required at both end positions (does

1000 mm

Festo P.BE−CPX−CMA X−SYS−EN en 0908NH

If the slide of the displacement encoder leaves the
permissible e

ffective path, the CMAX will generate a
corresponding error message. To avoid these error messages,
limit the positioning range so that the slide of the displace
ment encoder

is always within the permissible effective path.

2−11

2. Fitting and pneumatic installation

2.3.4 Load

For good positioning behaviour, the CMAX must be adjusted
to the load. Here, the load represents the total mass to be
moved with the positioning drive, includ
piston and the slide. It consists of the mass of the workpiece
 which generally changes during the process  and all other
parts of the

slides, workpiece grippers or gripper units, etc. which are
defined during the design engineering, and generally do not
change:

Load = workpiece mass

There is a maximum and a minimum permissible load. The
permissible load depends

the type of drive used

ing the weight of the

drive with mass, such as pistons, piston rods,

+ total moving mass without workpiece

on:

2−12

the diameter of the drive used

the selected mounting position

the operating pressure.

Make sure that in all load situations the e

ffective load:

is at least equal to the minimum permissible load.

This especially applies when there is no workpiece.
If necessary, fasten an additional

mass / load to the slide.

The maximum permissible load must not be exceeded.

See Tab.2/4 and Tab.2/6.

Festo P.BE−CPX−CMA X−SYS−EN en 0908N H

2. Fitting and pneumatic installation

Note

Minimum load.
A pneumatic positioning axis always requires a minimum

load. You can find these values in tables Tab.2/4 and
Tab.2/6.
If necessary, this min
the use of an additional weight.

For every positioning job, you have the option of specifying
the respectively existing load,
troller setting of the CMAX to the various loads.

Note

If the load varies from positioning job to positioning job
(e.g. due to changing workpieces) by more than 30%, the
load in the positioning job must be
parameters.

imum load must be ensured through

thereby adjusting the con

adjusted to the actual

Load for linear drives and piston rod cylinders

Determine the permissible load using Tab.2/4:

Mounting position

horizontal (á = 0°) m

vertical (á = 90°) 0.33 * m

diagonal (0° < á < 90°) (1  2/3 sin á) * m

á = mounting position in [°]

m
d= cylinder diameter [mm]

p

sys

= d³ * p

max

= supply pressure [bar]

* 0.008 (maximum load for horizontal mounting position [kg] )

sys

Tab.2/4: Maximum and minimum load

Festo P.BE−CPX−CMA X−SYS−EN en 0908NH

Maximum load Minimum load

max

max

Example:
Load for DNCI−32 with p = 6 bar.

max

0.1 * m

0.1 * m

0.1 * m

max

max

max

2−13

2. Fitting and pneumatic installation

Mounting position Maximum load Minimum load

horizontal (á = 0°) m

vertical (á = 90°) 0.33 * m

diagonal (45°) (1  2/3 sin 45°) * m

= 322 * 6 * 0.008 = 49.15 kg 0.1 * m

max

= 16.22 kg 0.1 * m

max

Tab.2/5: Load example

Instructions for coupling (piston rod drives)

If a coupling is required between the piston rod and the
guide:

· Check the backlash of the coupling.

The following applies here: Coupling backlash Ţ 0.05 mm

· Adjust the coupling backlash accordingly, if necessary.

If there is too much coupling backlash, this may cause:

 Noise due to knocking on the coupling

Increased coupling wear

Worsened operating behaviour.



Make sure that the coupling backlash does not exceed

0.05 mm.

= 25.98 kg 0.1 * m

max

= 4.92 kg

max

= 4.92 kg

max

= 4.92 kg

max

2−14

Mounting instructions

· Mount the load backlash−free, if necessary with a guide.

Festo P.BE−CPX−CMA X−SYS−EN en 0908N H

2. Fitting and pneumatic installation

Mass moment of inertia for semi−rotary drives

Permissible mass moments of inertia for the DSMI swivel
module in electronically regulated operation with the CMAX
are shown in the following table:

Swivel module

DSMI−25−... 15 ... 300

DSMI−40−... 60 ... 1200

Permissible mass moment of inertia

2

[kgm

* 10−4]

Tab.2/6:Permissible mass moment of inertia

Festo will support you in calculating the mass moment
of inertia with software for calculating 2nd−degree mass
moments of ine

rtia for various basic bodies and standard

parts from Festo (e.g. DSMI push−on flange).

è www.festo.com ˛ Downloads ˛ Download Area:
Software, drivers

and firmware ˛ Enter search term: mass

moment of inertia

Note

Natural vibrations of the load can lead to malfunctions.

· Fasten the load so that vibration is kept to a minimum.

· Avoid masses on long, flexible lever arms.

Festo P.BE−CPX−CMA X−SYS−EN en 0908NH

2−15

2. Fitting and pneumatic installation

1 Favourable natural

vibration behaviour

12

2 Unfavourable natural

vibration behaviour

Fig.2/3: Example: Favourable and unfavourable natural vibration behaviour of the mass

Mass moment of inertia for semi−rotary drives

The mass moment of inertia must not change during the
m

ovement. For this reason, the following applies for the

mounting position, depending on the load:

Centre of gravity in the axis of rotation

Mass is rotationally symmetri
} any mounting position permissible.

Centre of gravity in the axis of rotation

Mass is rotationally asymmetrical:

} only vertical mounting position
shaft points upward or downward (see example Fig.2/3).

cal:

permissible, drive

2−16

Centre of gravity outside of the axis of rotation

(not recommended):

nly vertical mounting position permissible, drive

} o

shaft points upward or downward.

Festo P.BE−CPX−CMA X−SYS−EN en 0908N H

2. Fitting and pneumatic installation

2.4 VPWP proportional directional control valve

2.4.1 Approved drive/valve combinations

Tab.2/7 contains the approved drive/valve combinations
(as of August 2009).

Use the specified fittings and tubing or appropriate tubes
with the corresponding flow rates.

VPWP sizes 2 and 10 are in preparation.
Depending on the application, you can also use sizes 4 or 8
after consulting with Festo.

Drive

Type Size Length Valve Drive

DGCI 18

25

32

40

63

100 ... 300 VPWP−2−... QSM−M5−6 QSM−M5−6 PUN−6x1

360 ... 2000 VPWP−4−... QS−1/8−6 QSM−M5−6 PUN−6x1

100 ... 160 VPWP−2−... QSM−M5−6 QS−1/8−6 PUN−6x1

225 ... 750 VPWP−4−... QS−1/8−8 QS−1/8−8 PUN−8x1.25

850 ... 2000 VPWP−6−... QS−1/8−8 QS−1/8−8 PUN−8x1.25

100 VPWP−2−... QSM−M5−6 QS−1/8−6 PUN−6x1

160 ... 360 VPWP−4−... QS−1/8−8 QS−1/8−8 PUN−8x1.25

450 ... 2000 VPWP−6−... QS−1/8−8 QS−1/8−8 PUN−8x1.25

100 ... 300 VPWP−4−... QS−1/8−8 QS−1/4−8 PUN−8x1.25

360 ... 750 VPWP−6−... QS−1/8−8 QS−1/4−8 PUN−8x1.25

850 ... 2000 VPWP−8−... QS−1/4−10 QS−1/4−10 PUN−10x1.5

100 ... 160 VPWP−4−... QS−1/8−8 QS−3/8−8 PUN−8x1.25

225 ... 300 VPWP−6−... QS−1/8−8 QS−3/8−8 PUN−8x1.25

360 ... 450 VPWP−8−... QS−1/4−10 QS−3/8−10 PUN−10x1.5

500 ... 2000 VPWP−10−... QS−3/8−12 QS−3/8−12 PUN−12x2

Valve Fitting Tubing

Festo P.BE−CPX−CMAX−SYS−EN en 0908N H

2−17

2. Fitting and pneumatic installation

DNCM

Drive TubingFittingValve

Type

DGP(I)(L) 25

32

40

50

63

DNCI,
DNC,
DNCM

DSMI

32

40

50

63

25  (270°) VPWP−2−... QSM−M5−6 QSM−M5−6 PUN−6x1

40  (270°) VPWP−4−... QS−1/8−8 QS−1/8−8 PUN−8x1.25

LengthSize

225 ... 750 VPWP−4−... QS−1/8−8 QS−1/8−8 PUN−8x1.25

1000 ... 2000 VPWP−6−... QS−1/8−8 QS−1/8−8 PUN−8x1.25

225 ... 300 VPWP−4−... QS−1/8−8 QS−1/8−8 PUN−8x1.25

360 ... 2000 VPWP−6−... QS−1/8−8 QS−1/8−8 PUN−8x1.25

225 VPWP−4−... QS−1/8−8 QS−1/4−8 PUN−8x1.25

300 ... 750 VPWP−6−... QS−1/8−8 QS−1/4−8 PUN−8x1.25

1000 ... 2000 VPWP−8−... QS−1/4−10 QS−1/4−10 PUN−10x1.5

225 ... 500 VPWP−6−... QS−1/8−8 QS−1/4−8 PUN−8x1.25

600 ... 2000 VPWP−8−... QS−1/4−10 QS−1/4−10 PUN−10x1.5

225 ... 1000 VPWP−8−... QS−1/4−10 QS−3/8−10 PUN−10x1.5

1250 ... 2000 VPWP−10−... QS−3/8−12 QS−3/8−12 PUN−12x2

50 ... 150 VPWP−2−... QSM−M5−6 QS−1/8−6 PUN−6x1

150 ... 400 VPWP−4−... QS−1/8−8 QS−1/8−8 PUN−8x1.25

> 400 VPWP−6−... QS−1/8−8 QS−1/8−8 PUN−8x1.25

50 ... 300 VPWP−4−... QS−1/8−8 QS−1/4−8 PUN−8x1.25

> 300 VPWP−6−... QS−1/8−8 QS−1/4−8 PUN−8x1.25

50 ... 200 VPWP−4−... QS−1/8−8 QS−1/4−8 PUN−8x1.25

200 ... 900 VPWP−6−... QS−1/8−8 QS−1/4−8 PUN−8x1.25

> 900 VPWP−8−... QS−1/4−10 QS−1/4−10 PUN−10x1.5

50 ... 300 VPWP−6−... QS−1/8−8 QS−3/8−8 PUN−8x1.25

300 ... 1000 VPWP−8−... QS−1/4−10 QS−3/8−10 PUN−10x1.5

> 1000 VPWP−10−... QS−1/4−10 QS−3/8−10 PUN−10x1.5

Valve

Tubing

DriveValve

Tab.2/7: Drive/valve combinations

2−18

Festo P.BE−CPX−CMAX−SYS−EN en 0908NH

2. Fitting and pneumatic installation

2.4.2 Mounting the VPWP proportional directional control valve

Mount the VPWP proportional directional control valve on an
even surface with two M3 screws and one retaining washer
each. See Fig.2/4.
Tightening torque: 1.5 Nm ±10%

1 M3 screws with

retaining washers

2 Earth terminal

(see section 3.1)

1

2

Fig.2/4: Mounting the VPWP

When mounting on moving parts:

· Attach the VPWP perpendicular to the direction of move

1 Mounting at right

angles to the direc
tion of movement

2 Impermissible:

Mounting in the
direction of move
ment

3 VPWP proportional

directional control
valve

1

ment. Acceleration forces then have no influence on the
valve slide setting.

12

3

Fig.2/5: Mounting the VPWP on moving parts

Festo P.BE−CPX−CMAX−SYS−EN en 0908N H

2−19

2. Fitting and pneumatic installation

H−rail mounting

You will require the following mounting kit to mount the
VPWP on H−rails.

Valve

VPWP−2, ...−4, ...−6 527392 CPASC1−BG−NRH

VPWP−8, ...−10 123491 CPV10−VI−BG−NRH

Mounting

P. No. Type

Tab.2/8: VPWP H−rail mounting set

Mounting onto an H−rail:

1. Ensure that the mounting surface can carry the weight of
the VPWP.

2. Mount the H−rail (DIN mounting rail EN 60715−TH35).
Be sure to leave sufficient space for connecting the
supply cables and tubes.

3. Screw the 2 clips from the mounting kit to the VPWP using

screws provided (see Fig.2/6).

the
Tightening torque: 1.5 Nm.
Make sure that the fixing bolts of the clip engage in the
recess of the VPWP.

4. Hang the VPWP on the H−rail. Secure against tipping or
slipping on both sides by using the H−rail clamping.

2−20

Festo P.BE−CPX−CMAX−SYS−EN en 0908NH

2. Fitting and pneumatic installation

1 Fixing bolts

(underneath
the VPWP−8/10)

2 M4x10 screw

3 H−rail

4 H−rail clamping

Fig.2/6: Mounting the VPWP on an H−rail

1

2

3

4

Festo P.BE−CPX−CMAX−SYS−EN en 0908N H

2−21

2. Fitting and pneumatic installation

2.5 Mounting the CASM sensor interface

Mount the CASM−... sensor interface on an even surface with
two M4 screws and one retaining washer each. See Fig.2/7.
The

symbol marks the position of the mounting screws.
The outer mounting screw also serves for earthing (
Tightening torque: 2 Nm.

1 ).

1 Mounting screw

(connect
earthing)

1

Approx. 30 mm

Fig.2/7: Mounting the CASM

Mounting on H−rails as per EN 60715 is possible with
mounting kit CP−TS−HS35. See Fig.2/8.

1 H−rail

Fig.2/8: Mounting the CASM on H−rail

Approx. 126 mm

S1

S2

1

2−22

Festo P.BE−CPX−CMAX−SYS−EN en 0908NH

2. Fitting and pneumatic installation

2.6 Pneumatic installation

Note

Observe the following instructions for installing the pneu
matic components. Only then can you guarantee trouble−
free operation.

Section 2.6.3

Section 2.6.2

Section 2.6.5

Section 2.6.1

Fig.2/9: Overview of pneumatic installation

2.6.1 Compressed air supply

Requirements of the compressed air supply:

· Use only dry, unlubricated, 5 m filtered compressed air.

· Permissible pressure range: 3 ... 8 bar.

Festo P.BE−CPX−CMAX−SYS−EN en 0908N H

Section 2.6.4

2−23

2. Fitting and pneumatic installation

2.6.2 Filter regulator

· Use a filter regulator consisting of a compressed air filter

and a regulating valve (e.g. LFR−...−D−... with 5ìm filter
cartridge) in conjunction with a soft−start valve (e.g. HEL):

without lubricator

with a 5 m filter

with sufficiently large standard nominal flow rate

correspon di n g to the air requirement of the connected
drive during

positioning. Reference value: twice the stan

dard nominal flow rate of the valve (type VPWP), e.g.:

Valve (fitting)

VPWP−2−... (M5) LFR−1/8−D−5M−MINI or

VPWP−4−... (1/8) LFR−1/8−D−5M−MINI or

VPWP−6−... (1/8) LFR−1/4−D−5M−MINI or

VPWP−8−... (1/4) LFR−3/8−D−5M−MIDI or

VPWP−10−... (3/8) LFR−3/4−D−5M−MAXI or

Filter regulator

MS4−LFR−1/4−D7−CRM−AS

MS4−LFR−1/4−D7−CRM−AS

MS4−LFR−1/4−D7−CRM−AS

MS6−LFR−1/4−D7−CRM−AS

MS6−LFR−3/8−D7−CRM−AS

Tab.2/9: Selection of filter regulator

· Use a fine filter or micro filter if you cannot avoid slight oil

mist from the compressed air supply.

2−24

Festo P.BE−CPX−CMAX−SYS−EN en 0908NH

2. Fitting and pneumatic installation

2.6.3 Air reservoir (optional)

If the positioning behaviour does not conform to your require
ments, and if you ascertain fluctuations in pressure of over
1 bar at the measuring point, then proceed as follows:

· Install an air reservoir (e.g. type VZS−...−B) between the

filter regulator and the proportional directional control
valve.

This way, you can reduce pressure fluctuations during posi
tioning. You can compensate for slight excesses in the per
missible pressure fluctuation by using supply tubing with a
larger cross section.

Reservoir volume The reservoir volume should be

as the volume of the drive used.

= 4 * V

V

P

Z

VP = buffer volume
V

= cylinder volume

Z

(Linear drives: V

= cylinder stroke length

L

Z

r = 1/2 * cylinder diameter

2.6.4 VPWP proportional directional control valve

Arrange the tubing between the valve (VPWP) and the drive
symmetrically.

Recommendation for linear drives and drives with piston rod:
tubing length = cylinder length

Fig.2/10 shows a schematic diagram of the tubing of a cylin
der (example) with the VPWP.

at least four times as large

= r2 * ð* LZ)

Z

Festo P.BE−CPX−CMAX−SYS−EN en 0908N H

2−25

2. Fitting and pneumatic installation

y

1 Working line 2

(blue releasing ring):
} Drive moves in a
positive direction

2 Working line 4

2

(black releasing ring):
} Drive moves in
negative direction

3 VPWP proportional

directional control
valve

4 Filter regulator with

5m filter, without
lubricator

Fig.2/10: Pneumatic circuit diagram

Drive with dis
placement encoder

DGCI

DGP(L) with
MLO−POT−...−TLF

DNCI

Direction of movement

Negative () Positive (+)

Towards the dis
placement encoder
connection

Away from the dis
placement encoder
connection

+

Block circuit diagram

2

2

1

3

4

4

4

DNC with
MLO−POT−...−LWG

DNCM

DSMI Clockwise (view of

Tab.2/10: Direction of movement and tubing

Retracted piston
rod

stop lever)

2−26

Extended piston rod

Anticlockwise (view
of stop lever)

4

4

42

4

Festo P.BE−CPX−CMAX−SYS−EN en 0908NH

2

2

2

2. Fitting and pneumatic installation

Tubing aid for DGCI and DSMI−...−B

When ordering the DGCI with fittings  standard (no modular
system feature) or modular system feature QD" or QR", as
well as for DSMI−...−B:
The fittings on the valve and drive have colour−coded releas
ing rings.

· Connect the fittings with the respective blue and black

releasing rings.

Note

Check the tubing connection with the movement test.

Silencer

The VPWP is available with an integrated flat plate silencer.

When using the VPWP without an integrated flat plate si
lencer:

Festo P.BE−CPX−CMAX−SYS−EN en 0908N H

· Install silencers with a large nominal flow rate, e.g. UC−

M5, U−1/8, U−1/4 or U−3/8 (depending on valve type)

· Conduct the collected exhaust air into a small air reservoir

and exhaust this with a large silencer. Make sure that
the fittings and tubing provide sufficient flow (shortest
possible tube length).

A correct layout can reduce the exhaust noise.

2−27

2. Fitting and pneumatic installation

Instructions on converting systems

When converting systems you should still use the existing
drives. Often, only drives with a unilateral air connection are
available here and the cushioning path (PPV) is used as the
drive stroke.

In some cases the specified positioning times cannot be fully
achieved.

The specified positioning times and optimum system
behaviour can only be
described in the previous section are observed.

Drives with unilateral compressed air supply

Please observe the following when using drives with unilat
eral air supply connections:

A unilateral air supply connection may only be used with

cylinders or drives with a stroke length Ţ 600 mm.

achieved if the installation instructions

2−28

If compressed air

is applied to port 4 of the proportional
directional control valve then the drive must move in a
negative direction. If compressed air is applied to port 2
then the drive must move in a positive direction. In some
cases, arrows on the drive indicate the direction of mo
tion.

 The resulting positioning

times may vary according to the

direction of the stroke.

Festo P.BE−CPX−CMAX−SYS−EN en 0908NH

2. Fitting and pneumatic installation

2.6.5 Tubing and fittings

· Use only straight fittings. If elbow connectors cannot be

avoided, use push−in fittings from the Quick Star series.

· Size the tubing and tubing connectors as specified in sec

tion 2.4.1.

· Arrange the tubing between the valve (VPWP) and the

drive symmetrically.

· Use only clean tubing and fittings.

· Do not use flow control valves or non−return valves in the

supply lines.

· Arrange the tubing so that it does not project into the

positioning range.

For good positioning behaviour during operation, pressure
fluctuations of max. 1 bar are permissible in front of the pro
portional directional control valve. In order to check the sta
bility of the supply pressure, you can fit a pressure measur
ing

point directly in front of the proportional directional

control valve.

Festo P.BE−CPX−CMAX−SYS−EN en 0908N H

If necessary, select a sufficiently large energy chain in order
to minimise the effects of bending forces on the positioning
behaviour.

2−29

2. Fitting and pneumatic installation

2−30

Festo P.BE−CPX−CMAX−SYS−EN en 0908NH

Electrical installation

Chapter 3

3−1Festo P.BE−CPX−CMAX−SYS−EN en 0908N H

3. Electrical installation

Contents

3. Electrical installation 3−1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.1 Earthing 3−3 . . . . .

3.2 Axis interface 3−5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.2.1 VPWP proportional directional control valve 3−7 . . . . . . . . . . . . . . . . . .

3.2.2 CASM sensor interface 3−9 . . . . . . . . . . . . . . . . . . . . . . .

3.3 Ensuring protection class IP65 3−11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.4 Power supply 3−12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.4.1 Determining the current consumption 3−13 . . . . . . . . . . . . . . . . . . . . . . .

3.4.2 Power supply concept, formation of power zones 3−14 . . . . . . . . . . . . .

3.4.3 Disconnecting

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . .

the load voltage in connection with a brake or

clamping unit 3−18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . .

. . . .

.

3−2

Festo P.BE−CPX−CMAX−SYS−EN en 0908NH

3. Electrical installation

3.1 Earthing

The CMAX power is supplied via the CPX terminal.
See section 3.4.

The CMAX is earthed via the CPX terminal. See the CPX
system description.

Observe the additional earthing measures described below,
depending on the components used.

Note

Operative malfunctions can occur due to incorrect or no
earthing.

· Make the specified connections at low impedance (short

cable with large cross−section) to the earth potential.

Festo P.BE−CPX−CMAX−SYS−EN en 0908N H

Unless otherwise specified, the earthing conductors must
have:

a cable cross−section of at least 2.5 mm

2

a cable length as short as possible (typically 20 ... 30 cm)

VPWP earthing

· Connect the earth terminal of the VPWP to the earth po

tential of the CPX terminal. See also sections 2.4, Fig.2/4.
Use the tapping screw provided.

Sensor interface earthing

When using a sensor interface:

· Make a low−impedance connection between the earth

terminal of the sensor interface and the earth potential of
the CPX terminal.

3−3

3. Electrical installation

Earthing the drives/displacement encoders...

Depending on the drive or displacement encoder used, these
must be earthed. See Tab.3/1.

Drive

DGCI Linear drive with permanently

Description Earthing instructions

integrated position measuring
system.

· Make a low−impedance connection (earthing

strap) between the flat pin of the position
measuring system and the earth potential!
 Flat pin (DIN 46246−2, width: 4.8 mm)

DGP(L) Linear drive with external position

measuring system MLO−POT−...−TLF.

DNCI Standard cylinder with integrated

position measuring system.

· Mount the position measuring system so that it

is electrically isolated.

· Make a low−impedance connection (short

cable with large cross section) between the
earth terminal on the cylinder and the earth

potential.
A self−tapping screw for mounting an earth strap
is supplied with the displacement encoder.

DNC Standard cylinder with external

position measuring system
MLO−POT−...−LWG.

· Make a low−impedance connection (earthing

strap supplied) between the flat pin of the

position measuring system and the earth

potential!

DNCM Standard cylinder with external

No earthing is required.

position measuring system already
mounted on delivery.

DSMI Semi−rotary drive with integrated

position measuring system.

· Make a low−impedance connection (earthing

strap) between the earth terminal of the DSMI

and the earth potential.

1)

Alternatively: Mount the drive on an earthed machine frame.

1)

1)

Tab.3/1: Instructions for earthing the drive and position measuring systems

3−4

Festo P.BE−CPX−CMAX−SYS−EN en 0908NH

3. Electrical installation

3.2 Axis interface

The VPWP proportional directional control valve is connected
to axis interface ’X’ of the CMAX. The position measuring sys
tem or a sensor interface (depending on the displacement
encoder) is connected to the VPWP.

This forms an axis string.

The axis interface pin allocation for the CMAX, VPWP and sen
sor interface are shown

in Tab.3/2.

Pin

1 + 24 V operating voltage

2 + 24 V load voltage

3 0 V

4 CAN_H

5 CAN_L

Housing Cable shield

1)

Allocation CMAX: X

VPWP: Out

1)

Connect each VPWP cable shield to the earth terminal

VPWP: In
CASM: S1

Tab.3/2: Pin allocation of the axis interfaces

Line length

The maximum permissible line length (total) of the
KVI−CP−3−... connecting cables of the axis string is 30m
(total length CMAX  VPWP  sensor interface or displace
ment encoder).

Tab.3/3 shows the recommended connecting cables.

Festo P.BE−CPX−CMAX−SYS−EN en 0908N H

3−5

3. Electrical installation

Connecting cables for the axis string Length Type

Connecting cable WS−WD
angled plug/angled socket

Connecting cable GS−GD
straight plug/straight socket

Connecting piece
for control cabinet feedthrough

0.25 m KVI−CP−3−WS−WD−0.25

0.5 m KVI−CP−3−WS−WD−0.5

2 m KVI−CP−3−WS−WD−2

5 m KVI−CP−3−WS−WD−5

8 m KVI−CP−3−WS−WD−8

2 m KVI−CP−3−GS−GD−2

5 m KVI−CP−3−GS−GD−5

8 m KVI−CP−3−GS−GD−8

 KVI−CP−3−SSD

Tab.3/3: Overview of cables between CMAX, VPWP, sensor interface, displacement

encoder

3−6

Festo P.BE−CPX−CMAX−SYS−EN en 0908NH

3. Electrical installation

3.2.1 VPWP proportional directional control valve

The VPWP has one incoming (In) and one outgoing (Out) axis
interface. See Tab.3/2.

Digital output DO (brake) A digital output (DO) at pin 2 is also available for controlling

a valve for a brake or clamping unit. This is controlled via the
CMAX I/O data (see section 4.5).

Note

For the control via CMAX to function correctly, it is compul
sory that the clamping unit or brake be connected with the
following logic (see also section 3.4.3, Fig.3/4):

 Pin 2: 0 V = clamping unit/brake closed
 Pin 2: 24 V = clamping unit/brake open

Voltage output
(load voltage)

Festo P.BE−CPX−CMAX−SYS−EN en 0908N H

The load supply voltage

provided at pin 4 can also be used
for switching a valve when the load supply voltage V
for example. See section 3.4.3.

Pin

1 n.c. = (not connected)

2 Digital output (brake)

3 0 V

4 + 24 V voltage output

Allocation DO

3

(load voltage)

Tab.3/4: Pin allocation DO connection of the VPWP,

M8 4−pin, socket

VAL

fails,

4

21

3−7

3. Electrical installation

Technical data Value

Digital output (pin 2)

 Activation
 Supply
 Max. current
 Fuse protection
 Version
 Galvanic isolation

Via I/O data
from 24 V
500 mA

VAL

protected against short circuits
in acc. with IEC 61131−2, positive logic (PNP)
no

Voltage output
(load voltage, pin 4)

 Supply
 Max. current
 Fuse protection

1)

Temperature switch−off: Maximum short−circuit current (short

from 24 V
500 mA

VAL

protected against short circuits

term) is defined only by the cable and connection resistances

Tab.3/5: Technical data of connection DO

1)

1)

3−8

Festo P.BE−CPX−CMAX−SYS−EN en 0908NH

3. Electrical installation

NEBC−P1W4−K−0,3−N−M12G5

3.2.2 CASM sensor interface

The CASM sensor interface has an incoming (S1) axis inter
face. See section 3.2.

A corresponding input (S2) for connecting the specific posi
tion measuring system is also available. See Tab.3/6.

Drive

Position measuring
system

DGCI Permanently

DNCI Integrated CASM−S−D3−R7 Permanently connected to DNCI.

DNC External,

DSMI Integrated

DGP(L) External,

DNCM External, mounted on

integrated

MLO−POT−...−LWG

MLO−POT−...−TLF

delivery

Sensor interface Connecting cable to the

displacement encoder

 (no sensor interface
required)

CASM−S−D2−R3

KVI−CP−3−...

NEBC−P1W4−K−0,3−N−M12G5

NEBC−A1W3−K−0,3−N−M12G5

Tab.3/6: Overview of sensor interfaces and displacement encoder cables

Festo P.BE−CPX−CMAX−SYS−EN en 0908N H

3−9

3. Electrical installation

CASM−S−D3−R7 Sensor interface for digital, incremental displacement encoders

with M12 displacement encoder connection (socket, 8 pin).

Pin

1 + Ub sensor (5 V)

Allocation S2

7

6

1

2 0 V

3 Sine signal +

4 Sine signal 

5 Cosine signal 

5

4

2

3

6 Cosine signal +

7 Screen

8 n.c. (not connected)

Housing Earth terminal (FE)

The cable screening is connected to the earth terminal of the sensor
interface.

Tab.3/ 7 : Pin allocation of connection S2 for the CASM−S−D3−R7

CASM−S−D2−R3 Sensor interface for analogue, absolute displacement encoders

(potentiometer), with M12 displacement encoder connection
(socket, 5 pin).

Pin

1 Displacement encoder housing

2 n.c. (not connected)

3 Analogue GND (AGND)

4 Reference voltage 5 V (REF 5V)

5 Analogue input 0 ... 5 V (INPUT)

Housing Earth terminal (FE)

The cable screening is connected to the earth terminal of the sensor
interface.

Allocation S2

3

2

4

1

5

8

3−10

Tab.3/ 8 : Pin assignment of connection S2 for the

CASM−S−D2−R3

Festo P.BE−CPX−CMAX−SYS−EN en 0908NH

3. Electrical installation

3.3 Ensuring protection class IP65

With a completely installed axis string (all plug connectors
inserted), the CMAX in the CPX terminal complies with protec
tion class IP65.

Note

To comply with protection class IP65:

· Seal unused connections with the corresponding protec

tive caps.

If the axis interface is not used, then seal this using a FLANGE
RECEPTACLE, S712 protective cap. You will then comply with
protection class IP65.

For the VPWP, a protective cap of type ISK−M8 for the output
(DO, brake) is included in the scope of

delivery.

Festo P.BE−CPX−CMAX−SYS−EN en 0908N H

3−11

3. Electrical installation

3.4 Power supply

The power for the positioning system with the CMAX is
supplied via the following connections on the CPX terminal
(interlinking blocks with voltage input):

Interlinking block
CPX−EV−S... or
CPX−M−EV−S... (U

EL/SEN

)

Interlinking block
CPX−EV−V..., CPX−M−EV−V...,
CPX−EV−S... or
CPX−M−EV−S... (U

VAL

)

The following is supplied with power via the operating
voltage supply for the electronics/sensors (U

EL/SEN

) of the

CPX terminal:

 Internal electronics of the CMAX

 Internal electronics of the VPWP

 Connected sensor interface (optional)

 Connected position measuring system.

Power is supplied to the following via the valve load supply
(U

) of the CPX terminal:

VAL

24 V load supply of the VPWP

 Brake output (digital output) of the VPWP.

Note

Operative malfunctions due to power supply outside the
tolerance.

The module with the lowest tolerance always determines
the permissible voltage tolerances.

· If the CMAX is used, special tolerances according to

Tab.3/9 must be observed for the valve load supply
(U

) of the CMAX.

VAL

3−12

Valve load supply (U

CMAX 20 ... 30 V

1)

If midi/maxi pneumatics are also supplied via the valve load sup
ply: 21,6 ... 26.4 V

) Range

VAL

1)

Tab.3/9: Permissible voltage tolerance

Festo P.BE−CPX−CMAX−SYS−EN en 0908NH

3. Electrical installation

3.4.1 Determining the current consumption

The current consumption of a CMAX system depends on the
number and type of the modules connected to the axis inter
face.

Recommendation:

· Use a closed−loop regulated power supply.

· When selecting the power supply unit, check that it pro

vides a sufficient output. Calculate the total current con
sumption, if necessary.

Calculations Tab.3/10 and Tab.3/11 show the current consumption for a

positioning system.

Observe the instructions on selecting the power supply unit
in the CPX system description.

Festo P.BE−CPX−CMAX−SYS−EN en 0908N H

CMAX current consumption from U

EL/SEN

of the

CPX terminal

Typical current consumption 200 mA

Maximum current consumption 300 mA

Tab.3/10: Current consumption via U

EL/SEN

of the

CPX terminal

Current consumption from U

Typical current consumption for the VPWP valve 1 A

Maximum current consumption for the VPWP voltage
output

Max. current consumption for the digital VPWP output
(clamping unit/brake)

Maximum total current consumption 2.5 A

Tab.3/11: Current consumption from U

of the CPX terminal

VAL

of the

VAL

0.5 A

0.5 A

CPX terminal

3−13

3. Electrical installation

3.4.2 Power supply concept, formation of power zones

The modular power supply concept of the CPX terminal allows
power zones to be formed.

Observe the following:

 The internal electronics of the VPWP and the digital posi

tion measuring system and, if present, the sensor inter
face are supplied with power by the electronics/sensors
operating voltage supply (U
The VPWP load supply and the VPWP outputs are sup
plied with power by the valve load supply (U

EL/SEN

).

).

VAL

 The CMAX internally connects the contact rails 0 V

to 0 V

of the CPX terminal.

VAL

EL/SEN

 This means that the operating power supply for the

electronics/sensors (U
the CMAX load supply for the valves (U

) of the CPX terminal and

EL/SEN

VAL

) are no

longer electrically isolated.

 Complete electrical isolation (all poles) of the valve

supply of the VPWP is therefore not possible, even in
conjunction with a CPX valve supply of type CPX−EV−V.

Note

Damage to components and operative malfunctions!

· The CMAX must be supplied via the same potential

(common power supply unit) as the operating power
supply for the electronics/sensors (U

EL/SEN

) of the

CPX terminal (see also Fig.3/3).

The CMAX always connects the 0 V supply for the elec
tronics with the 0 V supply for the valves. This must be
observed when a CPX−GE−EV−V interlinking block is located
to the left of the CMAX because this can remove any inten
tional electrical

isolation.

3−14

Festo P.BE−CPX−CMAX−SYS−EN en 0908NH

3. Electrical installation

1

Basic information on the power supply concept of the
CPX terminal can be found in the CPX system description.

A few examples can be found in Fig.3/1, Fig.3/2 and
Fig.3/3.

A central (shared) power supply (Fig.3/1)

In the example, the entire CPX terminal and the CMAX
positioning system are provided with power via the system
supply.

8DI

CMAX

12 34

8DI4DO

MPA

8 A8 A

Schematic representation:

24V

EL/SEN

0V

EL/SEN

24V

OUT

0V

OUT

24V

VAL

0V

VAL

1 Interlinking block with system supply (supplies the CMAX and the MPA

pneumatics)

Fig.3/1: Common power supply (example)

Festo P.BE−CPX−CMAX−SYS−EN en 0908N H

3−15

3. Electrical installation

1

2

Valve load voltage supply can be disconnected
separately (Fig.3/2)

In the example, CMAX, and therefore the positioning system,
are supplied via the system supply 1.

The MPA pneumatics are supplied via the valve supply 2
(only permitted with MPA electronic modules of type
VMPA..−FB−EMG−...). The MPA pneumatics can be switched
off at all poles (galvanically isolated).

8DI

CMAX

12 34 12 3 4

8DI4DO

MPA

8 A8 A

Schematic representation:

24V

EL/SEN

0V

EL/SEN

24V

OUT

0V

OUT

24V

VAL

0V

VAL

1 Interlinking block with system supply (supplied the CMAX)

2 Interlinking block with additional supply for valves (supplies MPA pneumatics)

Fig.3/2: Separate power supply for MPA pneumatics (example)

3−16

Festo P.BE−CPX−CMAX−SYS−EN en 0908NH

3. Electrical installation

1

2 3

Load voltage supply of the CMAX and the valves can
each be disconnected separately (Fig.3/3)

In the example, CMAX, and therefore the positioning system,
are supplied via the valve supply 2.
Only one pole of the VPWP load voltage can be disconnected.

The MPA pneumatics are supplied via the valve supply 3
(only permitted with MPA electronic modules of type
VMPA..−FB−EMG−...). The MPA pneumatics can be discon
nected at all poles.

8DI

12 34 12 3 4

12 34

8DI4DO

MPA

8 A8 A

CMAX

Schematic representation:

24V

EL/SEN

0V

EL/SEN

24V

OUT

0V

OUT

24V

VAL

0V

VAL

1 Interlinking block with system supply

2 Interlinking block with additional supply for valves (supplies the CMAX)

3 Interlinking block with additional supply for valves (supplies MPA pneumatics)

Fig.3/3: Separate power supply for the CMAX and MPA pneumatics (example)

Festo P.BE−CPX−CMAX−SYS−EN en 0908N H

3−17

3. Electrical installation

3.4.3 Disconnecting the load voltage in connection with a brake or clamping unit

In the example, circuitry for a brake or clamping unit is con
nected to the brake output. When switching off, or when the
CMAX valve load supply drops out, the brake or clamping unit
is activated.

CMAX

8DI

Schematic representation:

24V

EL/SEN

0V

EL/SEN

24V

OUT

0V

OUT

24V

VAL

0V

VAL

8DI4DO

MPA

8 A8 A

3

2

1

1 Brake output of the VPWP proportional directional control valve

2 Activation/deactivation of the brake/clamping unit by the CMAX

3 Activation of the brake/clamping unit by switching off the load voltage

Fig.3/4: Switching off the load voltage supply of the brake output at the VPWP together

with the valve load supply (example)

3−18

Festo P.BE−CPX−CMAX−SYS−EN en 0908NH

Commissioning

Chapter 4

4−1Festo P.BE−CPX−CMAX−SYS−EN en 0908NH

4. Commissioning

Contents

4. Commissioning 4−1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.1 Overview/procedure for

4.1.1 Instructions for commissioning 4−4 . . . . . . . . . . . . . . . . . .

4.1.2 Installing the Festo Configuration Tool and FCT CMAX plug−in 4−5 . . . .

4.2 Preparations for commissioning 4−8 . . . . . . . . . . . . . . . . . . . . . . . . .

4.2.1 Checking the axis string 4−8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.2.2 Switching on

4.2.3 Establishing a connection to the PC 4−11 . . . . . . . . . . . . . . . . . . . . . . . . .

4.3 Commissioning with the FCT

4.3.1 Overview of commissioning steps 4−12 . . . . . . . . . . . . . . . .

4.4 Operation instructions 4−14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.4.1 CMAX control 4−14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.4.2 General

4.5 Structure of the cyclical I/O data 4−16 . . . . . . . . . . . . . .

4.5.1 Defining the operating mode with CCON 4−17 . . . . . . . . . . . . . . . . . . . . .

4.5.2 Controlling the

4.5.3 Controlling the CMA X in direct operating mode 4−20 . . . . . . . . . . . . . . .

4.5.4 Execute record (record select mode) 4−22 . . . . . . . . .

4.5.5 Direct mode 4−29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.5.6 Acknowledge error 4−37 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.6 Flow charts for programming 4−38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.6.1 Establish ready status 4−38 . . . . . .

4.6.2 Start record 4−41 . . . . . . . . . . . . . . . . . . .

4.6.3 Acknowledge malfunction 4−42 . . . . . . . . . . . . . . . . . . . . . . .

4.6.4 Switch operating mode 4−43 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

commissioning 4−3 . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . .

. . . . . . . . . .

the power supply, switch−on behaviour 4−8 . . . . . . . . . . .

(overview) 4−12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . .

. . . .

operation instructions 4−14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . .

CMAX in record select operating mode 4−19 . . . . . . . . .

. . . . . . . . . . . . . . .

. . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . .

4−2

Festo P.BE−CPX−CMAX−SYS−EN en 0908NH

4. Commissioning

4.1 Overview/procedure for commissioning

This chapter provides an overview for commissioning
the positioning system with the CMAX using the Festo
Configuration Tool with the CMAX plug−in.

Information about the configuration of the CMAX with specific
CPX nodes, as well as the description for commissioning via
the CPX node, can be found in the CMAX communication
profile" description,

Note

Incorrectly set parameters can damage the fixed stops and
the drive.

Be very careful when setting the parameters.

Note

It is recommended to configure the CMAX and to put it into
operation with the respectively newest FCT CMAX plug−in.

Only the newest FCT plug−in offers you the most extensive
support and the use of all CMAX features.

P.BE−CPX−CMAX−CONTROL−... .

Festo P.BE−CPX−CMAX−SYS−EN en 0908N H

4−3

4. Commissioning

4.1.1 Instructions for commissioning

System structure

Note

Errors in the system structure and incorrectly set parameters
can cause the drive to move to an end position uncushioned.
This can damage the drive.
You must observe the following instructions in order to pre
vent such collisions.

 The CMAX must be set to certain configuration and

application data. Before applying compressed
must adapt these settings to your application and to the
axes which you are using.

 During the movement test, the CMAX can recognize faulty

drive tubing connections. Therefore, the movement test
should be carried out again when components are ex
changed or the tubing connection has been disconnected
and reconnected.

air, you

4−4

 Ensure that the

during operation.

Recommendation:
Place appropriate warning signs on your system.

maximum permissible load is obser ved

CPX node

Recommendation:
When commissioning with the Festo Configuration Tool:

· To avoid the influence of I/O signals etc., commission the

positioning system without a bus by removing the bus
cable or switching the CPX−FEC to Stop"!

Festo P.BE−CPX−CMAX−SYS−EN en 0908NH

4. Commissioning

4.1.2 Installing the Festo Configuration Tool and FCT CMAX plug−in

The Festo Configuration Tool (FCT) is the software platform for
configuring and commissioning different components and
devices from Festo.

The FCT consists of the following components:

A framework as program start and entry point with uni

form project and data management for all supported
types of devices.

A plug−in for each of the special

type (e.g. CMAX) with the necessary descriptions and
dialogs. The plug−ins are managed and started from the
framework.

The CMAX plug−in for the Festo Configuration Tool helps to
carry out all the steps necessary for commissioning a CMAX.
With the CMAX plug−in CMAX for the Festo Configuration Tool,
you can
the CMAX having to be connected to the PC, e.g. for prepar
ing the actual commissioning while the system is being de
signed.

carry out most parameterisations offline, i.e. without

demands of each device

Installing the FCT

The FCT is installed using an installation program on your PC
under Windows 2000, XP or Vista. The CMAX plug−in is in
stalled on your PC together with the installation program of
the FCT.

Note

Administrator rights are required for installing the FCT.

Festo P.BE−CPX−CMAX−SYS−EN en 0908N H

4−5

4. Commissioning

The current installation files for the FCT with CMAX plug−in
can be found on Festo’s website at:

è www.festo.com ˛ Downloads ˛ Download Area:
Software, drivers and firmware ˛ Enter search term: CMAX

1. Download the installation program from the website.

2. Close all programs.

3. Start the installation program
(e.g. Setup_FCT_CMAX.exe").

4. Follow the instructions

on the screen.

Starting the FCT

1. Connect the CPX terminal with the CMAX to your PC via
the NEFC−M12G5−0.3−U1G5 adapter as well as a commer
cially available USB connecting cable with a mini USB
plug. Observe the instructions in section 4.2.3 here.

2. Start the FCT:

· Double click on the FCT icon on the desktop

· Switch to the Windows Start menu and select the

entry [Festo Software] [Festo Configuration Tool].

4−6

Festo P.BE−CPX−CMAX−SYS−EN en 0908NH

4. Commissioning

Additional information about the FCT

Additional information can be found in the general help for
the Festo Configuration Tool.

FCT help with the menu command [Help] [Contents FCT General] e.g.

for working with projects

for working with components, e.g. for inserting a component

(of a device) in a project.

Plug−in help with the menu command [Help] [Contents of installed

PlugIns] [Festo

 for describing the dialogs of the CMAX component"

 for describing the work steps for commissioning

 about the basic functions, e.g. linkage, device names,

device control, etc.

(manufacturer name)] [CMAX], e.g.:

Printed information In order to be able to use the complete Help or parts of it

independently of a PC, you can select one

of the following

options:

· Use the Print" button in the Help window to print individ

ual pages of the Help or all the pages of a book directly
from the table of contents for the help.

· Print a prepared version of the help in Adobe PDF format:

Help

FCT Help ...(FCT installation folder)Help FCT_en.pdf

Plug−in Help
(CMAX)

Folder File

..(FCT installation folder)HardwareFamiliesFestoCMAXV...Help CMAX_en.pdf

In order to use the printed version in Adobe PDF format,
you will require Adobe Reader.

Festo P.BE−CPX−CMAX−SYS−EN en 0908N H

4−7

4. Commissioning

4.2 Preparations for commissioning

4.2.1 Checking the axis string

Prior to commissioning:

· Check the complete system structure, especially the drive

tubing connections and the electrical installation (see
chapters 2 and 3).

It is possible to pre−parameterize the CMAX even without the
components on the axis interface.

4.2.2 Switching on the power supply, switch−on behaviour

4−8

Warning

High acceleration forces on the connected actuators! Unex
pected motions can cause collisions and severe injuries.

· Switching on:

Always first switch on the valve load voltage supply and
then the compressed air supply.

· Switching off:

Before mounting, installation and maintenance work, put
the system into a safe state (e.g. by putting the drive in a
safe position and deactivating the controller).
Always make sure that the compressed air and valve load
voltage supplies are switched off and locked before
working in the machine area.

Festo P.BE−CPX−CMAX−SYS−EN en 0908NH

4. Commissioning

Delivery status
(first switch−on or after data reset)

 The connected components (valve and displacement en

coder/sensor interface) are automatically looked for at
the axis interface. The contained information is read out.

 The recognised components are not automatically ac

cepted as the target state.

 The controller cannot be activated until the axis data is

1)

completely parameterised

. Actual values are then not

updated.

1)

The target configuration (of the mechanics data) must
have been compared with the actual configuration.

Normal start−up

 The connected components (valve and displacement en

coder/sensor interface) are automatically looked for at
the axis interface. The contained information is read out.

 The found actual configuration is compared with the

target configuration. If there is a deviation, this leads to
an error and the controller is not activated.
This error can only
target and actual configurations.

Recognisable parameters The CMAX automatically acquires all parameter values

which are stored in the drive, sensor (displacement encoder)
or valve. The FCT plug−in can read these values out of the
CMAX. They do not have to be entered in the FCT project.
The acquired data cannot

be acknowledged after comparing the

be overwritten.

Festo P.BE−CPX−CMAX−SYS−EN en 0908N H

4−9

4. Commissioning

Valve and displacement

Axis found Axis not found

encoder OK

Power on

Search for axis at

axis interface

PNU 1192:02 = 0

Valve and displacement

encoder missing

Target configuration

present

Controller

ready

Target configuration not

present

Wait for

configuration

123

1 Initial start−up is complete, CMAX is

ready for operation

2 For malfunctions, see chapter 5

Fig.4/1: Switch−on behaviour

Display

C00 Wait for the parameterisation of the system of

C01 Wait for drive type parameterisation.

C02 Wait for axis data parameterisation.

C03 Wait for movement test to be carried out.

Tab.4/1: Display during commissioning

An overview of status displays can be found in section 5.4.2.

Target configuration

present

Malfunction

3 Status when switched on for first time

(delivery status or after data reset):
Wait for initial start−up. For display, see
Tab.4/1

Description

measurement units.

4−10

Festo P.BE−CPX−CMAX−SYS−EN en 0908NH

4. Commissioning

4.2.3 Establishing a connection to the PC

To connect the service interface on the CPX node with the PC,
use the NEFC−M12G5−0.3−U1G5 adapter as well as an addi
tional commercially−available USB cable with mini USB plug.
Information on how to install the adapter as well as the used
COMx interface can be found in the adapter documentation.

1 Adapter

2 USB cable

Fig.4/2: Adapter for connecting with the PC

Note

The ser vice interface (V.24) of the CPX terminal is not
designed to be galvanically isolated. It is not intended for
permanent connection to PC systems or as a controller
interface.

· Remove the adapter during continuous operation.

Observe the instructions for operating and installing the re
quired drivers on the CD−ROM included in delivery, or on the
Internet:

è www.festo.com ˛ Downloads ˛ Download Area:
Software, drivers and firmware ˛ Enter search term: FMT

After commissioning, seal the service interface of the
node with the protective cap supplied.

1

2

CPX

Festo P.BE−CPX−CMAX−SYS−EN en 0908N H

4−11

4. Commissioning

4.3 Commissioning with the FCT (overview)

Detailed information about commissioning with the FCT can
be found in the Help for the FCT CMAX plug−in.

Information for specialists concerning commissioning via the
CPX node can be found in the CMAX communication profile"
description.

4.3.1 Overview of commissioning steps

The following steps are typically carried out during commis
sioning:

1. If necessary, check the structure of the positioning
system with the components used on the axis string
(see section 4.2.1).

4−12

2. Check the power supply of the CPX terminal and switch on
the power supply (see section 4.2.2).

Caution: Leave the compressed air supply
the moment.

3. Create or open a project in the FCT. Add a new component
with the CMAX plug−in.

4. Establish a connection (online) between the PC and CMAX
via the FCT toolbar.

5. When CMAX is in its delivery status (display: C00), the
configuration wizard is started automatically when the
device connection is being

The CMAX can be configured with and without connected
components (in the office"). If the valve and sensor inter
face have been connected, the CMAX automatically de
tects the hardware after being switched on. The data de
tected here is accepted by the FCT. If commissioning is
done without components, all data

established.

Festo P.BE−CPX−CMAX−SYS−EN en 0908NH

switched off for

must be entered.

4. Commissioning

6. Parameterise application data and download it to the
CMAX:

 Mass

 Supply pressure

 Mounting position

This application data is the basis for configuring the con
troller.

7. Set the other parameters (e.g. software end positions,
record list, ...) and download them to the CMAX.

8. Switch on the compressed air supply.

9. Carry out the movement test:

Festo P.BE−CPX−CMAX−SYS−EN en 0908N H

10. Only with incremental position

measuring system: Carry

out homing.

11. Carry out identification run.

12. Carry out a test run.

After commissioning the positioning system (see supple
mental CMAX communication profile" description):

13. Configure the CPX bus node or CPX−FEC.

14. Check the control of the positioning system with the
CMAX.

4−13

4. Commissioning

4.4 Operation instructions

4.4.1 CMAX control

An overview of the I/O signals for controlling the CMAX can
be found in section 4.5.

More detailed information can be found in the CMAX com
munication profile" description.

4.4.2 General operation instructions

Warning

High acceleration forces on the connected actuators!
Unexpected motions can cause collisions and severe
injuries.

· Switching on:

Always first switch on the power supply and then the
compressed air supply.

· Switching off:

Before mounting, installation and maintenance work, put
the system into a safe state (e.g. by putting the drive in a
safe position and deactivating the controller).
Always make sure that the compressed air and power
supplies are switched off and locked before working in
the machine area.

4−14

Note

Damage may occur if maximum limits, such as loads, mass
moments of inertia, swivel frequencies etc. are exceeded.

· Make sure that the maximum specified limits of the drive

used are observed (see operating instructions for the
relevant drive).

Festo P.BE−CPX−CMAX−SYS−EN en 0908NH

4. Commissioning

Positioning jobs After switching on the operating voltage, it must be waited

until the CMAX is completely installed, signals no error
(see Fig.4/1) and delivers the inputs SCON.ENABLED and
SCON.OPEN logic 1. Afterwards, the corresponding position
ing job can be executed via the control bytes (module out
put data) (see section 4.5 and the

CMAX communication

profile" description).

Homing after POWER ON Only with incremental position measuring systems:

After the CMAX operating voltage is switched on again, the
relationship between measured variable and current position
is lost. For that reason, homing must always be carried out
after switching on again.

After switching on the power supply, only the positioning
commands homing (CPOS.HOM), jog (CPOS.JOGx) and the
movement test are permissible for incremental displacement
encoders. Other positioning commands lead to error E10
(Drive is not referenced").

Festo P.BE−CPX−CMAX−SYS−EN en 0908N H

4−15

4. Commissioning

4.5 Structure of the cyclical I/O data

Data Byte 1 Byte 2 Byte 3 Byte 4 Byte 5 Byte 6 Byte 7 Byte 8

O data Bytes 1 and 2 (fixed)

I data

are retained in every
operating mode
(except for byte 2
during parameter
isation).
They contain control
and status bytes
(e.g. CCON,
SCON, ...) for enab
ling the CMAX and
setting the operat
ing modes

Bytes 3 to 8 depend on the selected operating mode (record select
mode) and transmit further control and status bytes (e.g. CDIR,
SDIR,...), as well as setpoint and actual values:
 Record number or setpoint position in the output data
 Feedback of actual position and record number in the input data
 Other operating mode and control mode−dependent setpoint

and actual values.

Procedure

First define the operating mode in the control byte CCON. See
section 4.5.1.

This results in the allocation of the other control and status
bytes:

 Record select mode, see section 4.5.2.

 Direct mode, see section 4.5.3.

For commissioning and parameterisation, see the CMAX

communication profile" description.

4−16

Recommendation: Set the control bit CCON.LOCK during oper

This way, the PLC can make sure that the programmed

ation.
sequence cannot be disturbed by FCT access.
Or evaluate the status bit SCON.FCT_MMI and take the mis
sing control access into account in the program sequence of
the PLC.

Festo P.BE−CPX−CMAX−SYS−EN en 0908NH

4. Commissioning

4.5.1 Defining the operating mode with CCON

Operating mode Description

Record select operating mode
 Record select mode
(OPM1 = 0; OPM2 = 0)

Direct operating mode
 Direct mode
(OPM1 = 1; OPM2 = 0)

Commissioning operating
mode
(OPM1 = 0; OPM2 = 1)

Parametrising operating
mode
(OPM1 = 1; OPM2 = 1)

The PLC selects a record from a record list stored in the CMAX.
A record contains all the parameters which are specified for a posi
tioning job. The record number is transferred to the cyclical I/O data
as the setpoint or actual value.

The positioning job is transferred directly into the cyclical I/O data.
The most important setpoint values (position, speed, force) are
transferred here. Supplementary parameters (e.g. acceleration) are
defined via parameterisation.

Commissioning functions (e.g. identification) can be executed and
parameters read or written. Positioning jobs are not possible.

A parameter is transferred into the I/O data according to the FPC
protocol. Positioning jobs are not possible.

Tab.4/2: Overview of CMAX operating modes

CCON All the statuses which must be available in all operating

modes are controlled with control byte 1 (CCON).

Allocation of the control byte CCON (byte 1)

CCON

B7
OPM2B6OPM1B5LOCK

Operating mode
selection

Software
access
blocked

B4


 Acknow−

B3
RESETB2BRAKEB1STOPB0ENABLE

ledge
malfunc
tion

Release
brake

Stop Enable

drive

SCON Status byte 1 (SCON) signals the status of the CMAX in all

operating modes.

Allocation of the status byte SCON (byte 1)

SCON

Festo P.BE−CPX−CMAX−SYS−EN en 0908N H

B7
OPM2B6OPM1B5FCT_MMIB424VL

Acknowledgement of
operating mode

Device
control
software

Load
voltage
applied

B3
FAULTB2WARNB1OPENB0ENABLED

Malfunc
tion

Warning Oper

ation
enabled

Drive en
abled

4−17

4. Commissioning

The operating mode is defined with CCON.OPM1 and OPM2
and is signalled back in SCON.OPM1 and OPM2.

CCON/SCON

OPM2 (B7) OPM1 (B6)

0 0 Record select operating mode  Record

0 1 Direct operating mode  Direct mode

1 0 Commissioning operating mode

1 1 Parametrising operating mode

Operating mode

select mode

Tab.4/3: Defining the operating mode

4−18

Festo P.BE−CPX−CMAX−SYS−EN en 0908NH

4. Commissioning

y

y

Byte 1

Byte 2

Byte 4

4.5.2 Controlling the CMAX in record select operating mode

I/O data: Record select mode

Data Byte 1 Byte 2 Byte 3 Byte 4 Byte 5 Byte 6 Byte 7 Byte 8

O data CCON CPOS Record no. Reserved Reserved

I data SCON SPOS Record no. RSB Primary actual value (actual position, actual

Allocation of the control bytes (overview)

CCON

Byte 1

CPOS

Byte 2

Record no. Byte 3: Record number of the record to be started.

B7
OPM2B6OPM1B5LOCK

To select the operat
ing mode, see
Tab.  4 / 3

B7


  Teach

B6
CLEARB5TEACHB4JOGNB3JOGP

Software
access
blocked

value

B4


 Acknow−

Jog,
negative

force)

B3
RESETB2BRAKEB1STOP

ledge mal
function

Jog, posi
tive

Release
brake

B2
HOM

Start
homing

Stop Enable

B1
STARTB0HOLD

Start
position
ing job

B0
ENABL E

drive



Allocation of the status bytes (overview)

SCON

Byte 1

SPOS

Byte 2

Record no. Byte 3: Acknowledgement of last started record.
RSB

Byte 4

Primary
actual
value

Festo P.BE−CPX−CMAX−SYS−EN en 0908N H

B7
OPM2B6OPM1B5FCT_MMIB424VL

For operating mode
acknowledgem en t,
see Ta b.4/3

B7
REF

Drive ref
erenced

B7


  Stroke

Byte 5 ... 8: Dependent on the parameterisation: Actual position or actual force in the
configu r ed system of units.

B6
STILL

Shut
down
warning

B6


Device
control
software

B5
DEV

Following
error

B5
XLIM

limit
reached

Load volt
age ap
plied

B4
MOV

Axis mov
ing

B4
VLIM

Speed
limit
reached

B3
FAULTB2WARNB1OPENB0ENABL ED

Malfunc
tion

B3
TEACHB2MC

T each
acknow−
ledgment

B3
RCE

Error
switching
to next
record

Warning Operation

Motion
complete

B2
COM1

Control
mode
acknow−
ledgement

enabled

B1
ACK

Acknow−
ledge
start

B1
RCC

All record
switching
executed

Drive
enabled

B0
HOLD



B0
RC1

1. record
switch
executed

4−19

4. Commissioning

y
y

y

4.5.3 Controlling the CMA X in direct operating mode

I/O data: Direct mode

Data Byte 1 Byte 2 Byte 3 Byte 4 Byte 5 Byte 6 Byte 7 Byte 8

O data CCON CPOS CDIR Secondary

I data SCON SPOS SDIR Secondary

setpoint

actual
value

Allocation of the control bytes (overview)

CCON

Byte 1

CPOS

Byte 2

CDIR

Byte 3

Second
ary set
point

Primary
setpoint

B7
OPM2B6OPM1B5LOCK

To select the operat
ing mode, see
Tab.4/3

B7


  Teach

B7


 Exact

Byte 4: Setpoint value, depending on the control mode and FHPP setting (PNU 523)
 Speed in percentage of the set value (PNU 540)
 Force ramp in percentage of the set value (PNU 550)
 Mass in percentage of the set value (PNU 544 or PNU 551).

Byte 5 ... 8: Setpoint value of the position or force in the configured system of units,
depending on the control mode.

B6
CLEARB5TEACHB4JOGN

B6
FAST

stop, fast
stop

Software
access
blocked

value

B5
XLIM

Deacti
vate
stroke
limit

B4


 Acknow

Jog,
negative

B4
VLIM

Speed
limit re
ached

Primary setpoint
(position, force)

Primary actual value
(actual position, actual force)

B3
RESETB2BRAKEB1STOPB0ENABLE

ledge
malfunc
tion

B3
JOGPB2HOM

Jog, posi
tive

B3
CONTB2COM2B1COM1B0ABS

Tracking
mode

Release
brake

Start
homing

Control
mode 2
(profile)

Stop Enable

B1
STARTB0HOLD

Start
position
ing job

Control
mode 1
(position,
force)

drive



Absolute
/relative

4−20

Festo P.BE−CPX−CMAX−SYS−EN en 0908NH

4. Commissioning

y

y

y

Allocation of the status bytes (overview)

SCON

Byte 1

SPOS

Byte 2

B7
OPM2B6OPM1B5FCT_MMIB424VL

For operating mode
acknowledgement,
see Tab.4/3

B7
REF

Drive ref
erenced

B6
STILL

Shut
down

Device
control
software

B5
DEV

Following
error

Load
voltage
applied

B4
MOV

Axis mov
ing

warning

SDIR

Byte 3

B7


 Exact

B6

1)

FAST

stop /
fast stop

B5
XLIM

Stroke
limit re
ached

B4
VLIM

Speed
limit re
ached

active

Second
ary actual

Byte 4: Acknowledgement of the actual value of the speed in percentage of the set value
(PNU540).

value
Primary

actual

Byte 5 ... 8: Acknowledgement of the actual value of the position or force in the configured
system of units, depending on the operating status and the FHPP setting (PNU 523).

value

1)

The status bit only changes when the job is accepted (starting edge). All other status bits in the
SDIR and RSB are cyclically updated.

B3
FAULTB2WARNB1OPENB0ENABL ED

Malfunc
tion

Warning Oper

ation
enabled

B3
TEACHB2MC

Teach
acknow

Motion
complete

ledgment

B1
ACK

Acknow
ledge
start

B3
CONTB2COM2B1COM1B0ABS

Tracking
mode

Acknow−
ledge
ment
control
mode 2

Acknow−
ledge−
ment
control
mode 1

Drive
enabled

B0
HOLD



1)

Absolute
/relative

Festo P.BE−CPX−CMAX−SYS−EN en 0908N H

4−21

4. Commissioning

4.5.4 Execute record (record select mode)

I/O diagram

Requested record no
Output data

Start
CPOS.START

Acknowledge start
SPOS.ACK

Motion complete
SPOS.MC

Actual record no
Input data

1

N − 1

0

1

0

1

0

1

0

1

N − 1

0

1234 567

t

min

t

At least 1 bus cycle waiting time Recommendation: 1 PLC cycle

min:

Not required if consistent data transmission is used

Fig.4/3: Record start sequence

1 Set the desired record number in the PLC’s output data. Until

N N + 1

N

the start, the CMAX responds with the number of the record
last executed.

4−22

2 If SPOS.ACK (Acknowledge start) = 0, the PLC can intitiate

execution of the record with a rising edge at CPOS.START.

3 The CMAX accepts the record

number and starts positioning.
The actual record number is set to the new record in the PLC
input data and SPOS.MC is reset.

Festo P.BE−CPX−CMAX−SYS−EN en 0908NH