Emerson Control Techniques FM-4 User manual

Reference Manual
P/N 400509-01
Revision: A7
Date: March 26, 2009
© Control Techniques Drives, Inc. 2001-2009
FM-4
Programming Module

Information furnished by Control Techniques Americas LLC (Control Techniques) is believed to be accurate and reliable. However,
no responsibility is assumed by Control Techniques for its use. Control Techniques reserves the right to change the design or
operation of the equipment described herein and any associated motion products without notice. Control Techniques also assumes
no responsibility for any errors that may appear in this document. Information in this document is subject to change without notice.
P/N 400509-01
Revision: A7
Date: March 26, 2009
© Control Techniques Americas LLC, 2001-2009
FM-4
Programming Module
Reference Manual

ii
© Control Techniques Americas LLC, 2001-2008 All rights reserved.
Part Number: 400509-01
Revision: A7
Date: March 2009
Printed in United States of America
Information in this document is subject to change without notice. No part of this document may be reproduced or transmitted in any
form or by any means, electronic or mechanical, for any purpose, without the express written permission of Control Techniques.
The following are trademarks of Control Techniques and may not be reproduced in any fashion without written approval of Control
Techniques: EMERSON Motion Control,
EMERSON Motion Control PowerTools, AXIMA, “Motion Made Easy.”
Control Techniques is a division of EMERSON Co.
Control Techniques is not affiliated with Microsoft Corporation, owner of the Microsoft, Windows, and Windows NT trademarks.
This document has been prepared to conform to the current released version of the product. Because of our extensive development
efforts and our desire to further improve and enhance the product, inconsistencies may exist between the product and documentation
in some instances. Call your customer support representative if you encounter an inconsistency.

iii
Customer Support
Control Techniques Americas LLC
12005 Technology Drive
Eden Prairie, Minnesota 55344-3620
U.S.A.
Telephone: [phone] or [phone]
It is Control Techniques’ goal to ensure your greatest possible satisfaction with the operation of our products. We are
dedicated to providing fast, friendly, and accurate assistance. That is why we offer you so many ways to get the support you
need. Whether it’s by phone, fax or modem, you can access Control Techniques support information 24 hours a day, seven
days a week. Our wide range of services include:
FAX [phone]
You can FAX questions and comments to Control Techniques. Just send a FAX to the number listed above.
Website and Email www.emersonct.com
Website: www.emersonct.com
Email: [e-mail]
If you have Internet capabilities, you also have access to technical support using our website. The website includes technical
notes, frequently asked questions, release notes and other technical documentation. This direct technical support connection
lets you request assistance and exchange software files electronically.
Technical Support [phone] or [phone]
Email: [email protected]
Control Techniques’ “Motion Made Easy” products are backed by a team of professionals who will service your installation.
Our technical support center in Eden Prairie, Minnesota is ready to help you solve those occasional problems over the
telephone. Our technical support center is available 24 hours a day for emergency service to help speed any problem solving.
Also, all hardware replacement parts, if needed, are available through our customer service organization.
When you call, please be at your computer, with your documentation easily available, and be prepared to provide the
following information:
• Product version number, found by choosing About from the Help menu
• The type of controller or product you are using
• Exact wording of any messages that appear on your screen
• What you were doing when the problem occurred
• How you tried to solve the problem
Need on-site help? Control Techniques provides service, in most cases, the next day. Just call Control Techniques’ technical
support center when on-site service or maintenance is required.
Training Services [phone] or [phone]
Email: [email protected]
Control Techniques maintains a highly trained staff of instructors to familiarize customers with Control Techniques’ “Motion
Made Easy” products and their applications. A number of courses are offered, many of which can be taught in your plant upon
request.
Application Engineering [phone] or [phone]
Email: [email protected]
An experienced staff of factory application engineers provides complete customer support for tough or complex applications.
Our engineers offer you a broad base of experience and knowledge of electronic motion control applications.

iv
Customer Service (Sales) [phone] or [phone]
Email: customer.ser[email protected]
Authorized Control Techniques distributors may place orders directly with our Customer Service department. Contact the
Customer Service department at this number for the distributor nearest you.
Document Conventions
Manual conventions have been established to help you learn to use this manual quickly and easily. As much as possible, these
conventions correspond to those found in other Microsoft® Windows® compatible software documentation.
Menu names and options are printed in bold type: the File menu.
Dialog box names begin with uppercase letters: the Axis Limits dialog box.
Dialog box field names are in quotes: “Field Name.”
Button names are in italic: OK button.
Source code is printed in Courier font: Case ERMS.
In addition, you will find the following typographic conventions throughout this manual.
Note
For the purpose of this manual and product, “Note” indicates essential information about the product or the respective part
of the manual.
E Series Only
E
N
For the purpose of this manual and product, the “EN” symbol indicates information about the EN drive specifically.
Throughout this manual, the word “drive” refers to an MDS or EN drive.
“Warning” indicates a potentially hazardous situation that, if not avoided, could result in death or serious injury.
“Caution” indicates a potentially hazardous situation that, if not avoided, may result in minor or moderate injury.
“Caution” used without the safety alert symbol indicates a potentially hazardous situation that, if not avoided, may result
in property damage.
This Represents
bold Characters that you must type exactly as they appear. For example, if you are directed to type
a:setup, you should type all the bold characters exactly as they are printed.
italic Placeholders for information you must provide. For example, if you are directed to type
filename, you should type the actual name for a file instead of the word shown in italic type.
ALL CAPITALS Directory names, file names, key names, and acronyms.
SMALL CAPS Non-printable ASCII control characters.
KEY1+KEY2
example: (Alt+F)
A plus sign (+) between key names means to press and hold down the first key while you press
the second key.
KEY1,KEY2
example: (Alt,F) A comma (,) between key names means to press and release the keys one after the other.

v
Safety Instructions
General Warning
Failure to follow safe installation guidelines can cause death or serious injury. The voltages used in the product can cause
severe electric shock and/or burns and could be lethal. Extreme care is necessary at all times when working with or adjacent
to the product. The installation must comply with all relevant safety legislation in the country of use.
Qualified Person
For the purpose of this manual and product, a “qualified person” is one who is familiar with the installation, construction and
operation of the equipment and the hazards involved. In addition, this individual has the following qualifications:
• Is trained and authorized to energize, de-energize, clear and ground and tag circuits and equipment in accordance with
established safety practices.
• Is trained in the proper care and use of protective equipment in accordance with established safety practices.
• Is trained in rendering first aid.
Reference Materials
The following related reference and installation manuals may be useful with your particular system.
•Function Module Installation Manual (P/N 400506-03)
•Epsilon Eb and EN Drives Reference Manual (P/N 400501-01)
•Modular Drive System (MDS) Reference Manual (P/N 400525-01)
•FM-4 and FM-4 Connectivity Reference Manual (P/N 400508-04)

vi

vii
Safety Considerations
Safety Precautions
This product is intended for professional integration into a complete system. If you install the product incorrectly, it may
present a safety hazard. The product and system may use high voltages and currents, carry a high level of stored electrical
energy, or control mechanical equipment that can cause injury.
You should give close attention to the electrical installation and system design to avoid hazards either in normal operation or
in the event of equipment malfunction. System design, installation, commissioning and maintenance must be carried out by
personnel who have the necessary training and experience. Read and follow this safety information and the instruction manual
carefully.
Enclosure
This product is intended to be mounted in an enclosure which prevents access except by trained and authorized personnel,
and which prevents the ingress of contamination. This product is designed for use in an environment classified as pollution
degree 2 in accordance with IEC664-1. This means that only dry, non-conducting contamination is acceptable.
Setup, Commissioning and Maintenance
It is essential that you give careful consideration to changes to drive settings. Depending on the application, a change could
have an impact on safety. You must take appropriate precautions against inadvertent changes or tampering. Restoring default
parameters in certain applications may cause unpredictable or hazardous operation.
Safety of Machinery
Within the European Union all machinery with which this product is used must comply with Directive 89/392/EEC, Safety
of Machinery.
The product has been designed and tested to a high standard, and failures are very unlikely. However the level of integrity
offered by the product’s control function – for example stop/start, forward/reverse and maximum speed – is not sufficient for
use in safety-critical applications without additional independent channels of protection. All applications where malfunction
could cause injury or loss of life must be subject to a risk assessment, and further protection provided where needed.
General warning
Failure to follow safe installation guidelines can cause death or serious injury. The voltages used in this unit can cause
severe electric shock and/or burns, and could be lethal. Extreme care is necessary at all times when working with or
adjacent to this equipment. The installation must comply with all relevant safety legislation in the country of use.
AC supply isolation device
The AC supply must be removed from the drive using an approved isolation device or disconnect before any servicing
work is performed, other than adjustments to the settings or parameters specified in the manual. The drive contains
capacitors which remain charged to a potentially lethal voltage after the supply has been removed. Allow at least 3
minutes after removing the supply before carrying out any work which may involve contact with electrical connections
to the drive.
Products connected by plug and socket
A special hazard may exist where the drive is incorporated into a product which is connected to the AC supply by a plug
and socket. When unplugged, the pins of the plug may be connected to the drive input, which is only separated from the
charge stored in the bus capacitor by semiconductor devices. To avoid any possibility of electric shock from the pins, if
they are accessible, a means must be provided for automatically disconnecting the plug from the drive (that is, a latching
contactor).
Grounding (Earthing, equipotential bonding)
The drive must be grounded by a conductor sufficient to carry all possible fault current in the event of a fault. The ground
connections shown in the manual must be followed.
Fuses
Fuses or over-current protection must be provided at the input in accordance with the instructions in the manual.

viii
Isolation of control circuits
The installer must ensure that the external control circuits are isolated from human contact by at least one layer of
insulation rated for use at the applied AC supply voltage.

ix
Customer Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii
Document Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iv
Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .v
Reference Materials. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .v
Safety Considerations vii
Introduction 1
Operational Overview 3
Software Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
PowerTools Pro Setup Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Keypad Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
How Motion Works . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
How Jogging Works . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
How Home Works . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
How Indexes Work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
How Communications Work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Secure Downloading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Brake Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
How Data Capture Works . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
Setting Up Parameters 29
Status View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Status Online Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Information Tab. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
Graph View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
Setup View. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
Motor View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
User Units View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
Master Units View. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
Virtual Master View - FM-4E Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
Position View. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
Velocity View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53
Ramps View. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54
Torque View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58
Distance Recovery View - FM-4E Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59
Tuning View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59
Faults View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61
Setup NVM View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64
Devices / Vars Group. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65
PLS View. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65
Capture View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67
Timers View - FM-4E Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74
Variables View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .83
Bits View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85
Packed Bits - FM-4E Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88
I/O Setup Group. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95
Assignments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95
Assignments View. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95
Selector View. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .98
Table of Contents

x
Input Lines View. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Output Lines View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Analog Inputs View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Analog Outputs View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Jog View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Home View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Index View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Gearing View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Camming View - FM-4E Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Torque Mode View - FM-4E Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Multiple Profiles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Stopping Motion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Network Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Modbus View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Modbus Master View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
DeviceNet View - FM-4DN Only. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
Profibus View - FM-4PB Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
Ethernet View - FM-4E Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
Programming 141
Programs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
Program Toolbar Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
Cyclic Program View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
User Program View. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
Real Time Program View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
Program Multi-Tasking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
Program Instruction Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
Adding and Deleting Programs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
Run Anytime Programs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
Example Programs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
Parameter Descriptions 173
Installation 205
Basic Installation Notes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
Mechanical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
Electrical Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
Software Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
Starting and Exiting PowerTools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
Accessing Help . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
Quick Start 211
Basic Setup Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
Example Application Start Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
Tuning Procedures 229
PID vs. State-Space . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
Tuning Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
Tuning Parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
Determining Tuning Parameter Values. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
Diagnostics and Troubleshooting 237
Diagnostic Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
Drive Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242

xi
Error Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .242
Online Status Indicators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .244
Diagnostic Analog Output Test Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .247
Specifications 249
Dimensions and Clearances. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .249
Cable Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .251
Glossary 265
Index 271

xii

1
Introduction
The FM-4 module is a compact and rugged function module that attaches to the front of the drive. It provides eight digital
input lines and four digital output lines, in addition to the four input and three output lines available on the drive.
Unlike other function modules, the FM-4 module offers complex motion profiling, along with multi-tasking user programs.
A complex motion profile consists of two or more indexes that are executed in sequence such that the final velocity of each
index except the last is non-zero. Logical instructions between index statements can provide a powerful tool for altering
motion profiles ’on the fly’. The FM-4 module defines complex motion by a configuration file that includes setups, function
assignments and programs. The configuration file is created using EMERSON Control Techniques PowerTools Pro software
on a PC running Windows® 98, 2000, 2003, 2008, XP (SP2) (32-bit) or Vista (32-bit) operating system. Setup views have
the same look and feel as dialog boxes. The wiring of input and output functions is done through assignments in the software.
Complete diagnostics are provided for quick troubleshooting. A diagnostic display on the front of the drive as well as the
display on the module inform the user of the operational or fault status. The last 10 faults are stored in non-volatile memory
along with a time stamp for easy recall.
Figure 1: EN Drive with FM-4 Function Module
Note that the drive’s firmware is disabled whenever a Function Module, such as the FM-4 module is attached. Therefore, if
the drive’s hardware is FM compatible, then the drive’s firmware can be any version because the programming features reside
in the function module’s flash memory. Flash files used for firmware upgrades are available on the Control Techniques
webpage.
The FM-4 module stores drive setup parameters within the module itself. This allows you to transfer the FM-4 module to
another drive without losing setup parameters.
FM-4 Programming Module Reference Manual

2
FM-4 Programming Module Reference Manual
Figure 2: FM-4 Programming Module Features
MODEL FM-4
PART 960498-01
REV
SER 0120B025
A1/A1
485 +
485 -
SHLD
1
2
3
4
5
6
7
8
1
2
3
4
+
-
Inputs Outputs 10-30
VDC
Exp. I/O
Sync.
Input
Sync.
Output
Programming Module
Fastening Latch
Soft Keys
Keys
Direction Arrow
Character Display
3 Row by 12
(not used at this time)
Expanded I/O
Sync. Input
Sync. Output +10 to 30 VDC
Outputs
Inputs
100-Pin Connector
Aligning Tabs
Front
Back

3
Operational Overview
This section provides a complete functional description of the FM-4 module. It is intended to provide you, the user, with a
thorough understanding of all operations. The description includes references to many FM-4 module and drive parameters
which can be displayed and/or edited using PowerTools Pro software, or through any Modbus interface.
The FM-4 module augments the drive by providing the ability to implement programs written using PowerTools Pro. When
a FM-4 module is attached to a drive, it overrides the operation and user accessible features of the drive. The drive’s basic
operating modes (Pulse, Velocity and Torque) are not available when a FM-4 module is attached.
The FM-4 module stores drive setup parameters within the module itself. This allows the user to transfer the FM-4 module
to another drive without losing setup parameters.
The FM-4 module allows the user to set up 55 different Indexes, Jog functions and a Home. It also provides eight digital input
lines and four digital output lines in addition to the four input and three output lines available on the drive.
Software Interface
The FM-4 module is set up using PowerTools Pro software. PowerTools Pro is an easy-to-use Windows® based setup and
diagnostics tool. It provides the user with the ability to create, edit and maintain the drive’s setup. You can download or
upload the setup data to or from a device. The setup data can also be save to a file on the PC or printed for review or permanent
storage.
PowerTools Pro Setup Software
PowerTools Pro is designed to be the easiest-to-use software available for single axis motion controllers.
Features
• “Hierarchy Tree” for quick navigation to any setup view
• Simple I/O function assignments
• Powerful online diagnostic capabilities
• Programming
Figure 3: Hierarchy Tree
The “Hierarchy Tree” (shown above on the left side) contains expandable groups of parameters. The groups can be expanded
and contracted just like folders in Windows® Explorer. Left click on a view name in the Hierarchy Tree will display that view
on the right side of the computer screen.
To setup a drive the user simply steps through the Hierarchy Tree from top to bottom starting with the Setup view. Simple
applications can be setup in a matter of minutes.
FM-4 Programming Module Reference Manual

4
FM-4 Programming Module Reference Manual
Keypad Interface
The keypad and character display on the front of the FM-4 module provides navigation through a menu of common
parameters and displays current functions. Navigation through the menu is accomplished with the six keys located below the
display. The top two keys are called the “soft keys” because they relate to the commands located directly above each key on
the display. These keys are used to select the operation (e.g. Modify, Ok, Cancel), parameter group, and/or to validate
information. The four arrow keys are used to navigate through parameter groups, select a specific parameter to be modified,
and to modify digital and numeric data.
The operation of the arrow keys is dependent upon the type of parameter which is being modified.
Figure 4: FM-4 Display and Keypad
On the Menu screen, the drive type and axis address are always shown on the top line of the display. The second line shows
the motor type. If a user defined motor is selected, the user defined motor name will appear. The third line shows two
parameter group names, one above each of the soft keys.
From the Menu screen, the user selects a group of drive parameters to work with. The group names are scrolled using the left/
right direction keys. The groups correspond roughly to the views used by the PowerTools Pro software. The groups are shown
cyclically and wrap around.
The drive parameters available with the FM-4 module keypad are arranged into seven groups (see list below). Upon power-
up the FM-4 module will display the default parameter groups “SECUR” (left soft key) and “QUICK” (right soft key).
• QUICK (Quick)
• PROG (Program)
• INDEX (Index)
• HOME (Home)
• JOG (Jog)
• RAMPS (Ramps)
• SECUR (Security)

5
Operational Overview
Parameter Screens
After selecting a group using one of the soft keys, the FM-4 module will display a Parameter screen for that group. This screen
could be either the first screen in the group or the last screen that was used in that group. The FM-4 module keeps track of
the last Parameter screen viewed in each group and returns to that screen when returning come back to that group. This is
reset on power-up and the FM-4 module displays the first Parameter screen in the group.
In this screen, the parameter name is shown on the first line of the display. The up/down arrow keys are used to scroll through
the parameters available in the selected group. The second line displays the condition or value of parameters. The third line
displays the soft key actions.
The left/right arrow keys are used to scroll through the parameters when the “<“ and “>” symbols are shown.
Auto Log Out
MODIF MENU
SECUR
Group
Password 2
MODIF MENU
<Jog.0.Vel>
MODIF MENU
JOG*
Group
<Jog.0.Accl>
MODIF MENU
<Jog.0.Decl>
MODIF MENU
<Jog.0.Plus>
MODIF MENU
<Jog.0.Mius>
MODIF MENU
Select Offst
MODIF MENU
Home.0.Accl
MODIF MENU
HOME
Group
Home.0.Decl
MODIF MENU
Home.0.Vel
MODIF MENU
Home.0.Init
MODIF MENU
Posn Fdbk
GRAPH MENU
QUICK
Group
Vel Fdbk
GRAPH MENU
Following Er
GRAPH MENU
Axis Address
MODIF MENU
<Ind.0.Vel>
MODIF MENU
INDEX*
Group
<Ind.0.Accl>
MODIF MENU
<Ind.0.Decl>
MODIF MENU
<Ind.0.Init>
MODIF MENU
<Ind.0.Dist>
MODIF MENU
MacID
MODIF MENU
DVNET+
Group
Baud Rate
MODIF MENU
Network Sts
MENUMODIF
Module Sts
Transmit Cntr
Receive Cntr
Mster MacID
Net OK
Conn Type
EN-204 Adr01
MG-316
SECUR
Stop
MODIF MENU
RAMPS
Group
Stop.Decel
MODIF MENU
Menu
Screen
<Prg.0.Init>
MODIF MENU
PROG*
Group
Security: 0
Security: 1
Security: 1
Security: 1
Security: 1
Security: 0
Security: 0
Security: 0
Security: 0
Security: 0
Security: 0
Security: 0
Security: 3
Security: 1
Security: 3
Security: 1
Security: 1
Security: 1
Security: 1
Security: 1
Security: 1
Security: 1
Security: 1
Security: 1
Security: 1
Security: 0
Security: 0
Security: 0
Security: 0
Security: 0
Security: 0
Security: 0
Security: 0
Security: 1
Security: 1
Security: 1
Security: 1
Security: 1
Log Out Now?
OK
Security: 0
Password 1
MODIF MENU
Security: 3
Posn Fdbk Ct
MENU
Security: 0
ModuleOutput
MENU
Security: 3
Security: 0
Fault Sts 1
MENU
Security: 0
Fault Sts 2
MENU
Security: 0
Baud Rate
MODIF MENU
Security: 3
DriveInput
MENU
ModuleInput
MENU
DriveOutput
MENU
Clear Fault?
OK MENU
Module Rev
MENU
Security: 1
Security: 1
Calc Offset
MENU
Spec Offset
MODIF MENU
Boot Rev
MENU
Security: 0
* Jog Group contains 2 Jogs (Jog.0 and Jog.1)
Index Group contains 7 Indexes (Index.0 to Index.7)
Prog Group contains 4 Programs (Prog.0 to Prog.3)
+ DeviceNet Group is only available on FM-3DN and FM-4DN modules
- Profibus Group is only available on FM-3PB and FM-4PB modules
On all screens with < > symbols, scroll left and right to select the specific Instance
Slave Address
MODIF MENU
PBus-
Group
Baud Rate
MENU
Network Sts
MENU
Module Sts
MODIF MENU
MasterAddr
MsgProcessed
Security: 1
Security: 0
Security: 0
Security: 0
Security: 0
Security: 0
MENU
MENU
MENU
MENU
MENU
MENU
MENU
MENU

6
FM-4 Programming Module Reference Manual
Numeric parameter units are sometimes shown before the actual value, because the parameter value and the units cannot be
displayed on one line. The unit of measure will appear on the second line for about one second. Then the actual parameter
value will appear. The parameter value is updated about five times a second.
How Motion Works
The FM-4 module provides four types of motion: jogging, homing, indexing and gearing. Only one index, jog, home or gear
may be in process at any given moment (exclusionary motion types). Through assignments and programs, the FM-4 module
can sequentially run various motion routines. The Positive direction parameter affects all motion types by specifying which
direction of motor revolution (CW or CCW) is considered motion in the “+” direction.
How Jogging Works
Jogging produces rotation of the motor at controlled velocities in a positive or negative direction.
Assignments to jogs are level sensitive such that when the jog input is turned on, jogging begins and continues jogging until
the jog input is removed.
Each jog has its own acceleration and deceleration ramp along with a specified velocity. Jogging has no distance parameter
associated with it. If trying to move a specific distance or to a known position, then an index is used.
Figure 5: Jog View
How Home Works
The Home is used in applications in which the axis must be precisely aligned with some part of the machine. The Home is
initiated in one of three ways: with the Initiate Destination function found in the Assignments view, through a program, or
with the Online tab. A Home or Define Home is required to set the Absolute Position Valid so that any index to absolute
position can work.
The FM-4 module can home the motor to an external sensor, the motor’s encoder marker pulse, or to a sensor and then to the
encoder marker pulse.