Emerson FM-3 User manual

P/N 400508-02
Revision: A2
Date: August 23, 2000
© EMERSON Motion Control, Inc.2000
FM-3Programming Module
Installation Manual
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InformationfurnishedbyEMERSONMotionControlisbelievedtobeaccurateandreliable.However,
no responsibility is assumed by EMERSON Motion Control for its use. EMERSON Motion Control
reserves the right to change the design or operation of the equipment described herein and any
associated motion products without notice. EMERSON Motion Control 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 400508-02
Revision: A2
Date: August 23, 2000
© EMERSON Motion Control™, Inc. 2000
FM-3
Programming Module
Installation Manual
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ii
© EMERSON Motion Control, Inc. 2000
Part Number: 400508-02
Revision: A2
Date: August 2000
Printed in United States of America
Information in this document is subject to change without notice. Companies, names, and data used in
examples herein are fictitious unless otherwise noted. 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 EMERSON Motion Control.
The following are trademarks of EMERSON Motion Control and may not be reproduced in any
fashion without written approval of EMERSON Motion Control: EMERSON Motion Control,
EMERSON Motion Control PowerTools.
EMERSON Motion Control, a Division of Emerson Electric Co.
EMERSON Motion Control, Inc.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.
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iii
Customer Service
It is EMERSON Motion Control’s 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 by
phone, fax or modem, you can access EMERSON Motion Control support information 24
hours a day, seven days a week.
EMERSON Motion Control
12005 Technology Drive
Eden Prairie, Minnesota 55344
U.S.A.
FAX [phone]
You can FAX questions and comments to EMERSON Motion Control. Just send a FAX to
the number listed above.
Website: www.emersondrivesolutions.com
If you have Internet capabilities, you also have access to technical support using our Website
at http://www.emersondrivesolutions.com. 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.
Service Support [phone]
EMERSON Motion Control’s products are backed by a team of professionals who will
service your installation wherever it may be. Our customer service center in Eden Prairie,
Minnesota is ready to help you solve those occasional problems over the telephone. Our
customer service center is available 24 hours a day for emergency service to help speed any
problem solving. Also, all hardware replacement parts, should they ever be needed, are
available through our customer service organization.
When you call, please be at your computer, have your documentation in hand, 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.
You can also contact us by email: [e-mail]
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iv
Need on-site help? EMERSON Motion Control provides service, in most cases, the next day.
Just call EMERSON’s customer service center when on-site service or maintenance is
required.
Training Services [phone] or Fax [phone]
EMERSON Motion Control maintains a highly trained staff of instructors to familiarize
customers with EMERSON Motion Control’s products and their applications. A number of
courses are offered, many of which can be taught in your plant upon request.
Application Engineering [phone]
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
knowledgeof electronic motion control applications. Applicationengineers may be contacted
by email at [e-mail] or at the telephone number listed above.
Sales: [phone]
Email: [email protected]
Authorized EMERSON Motion Control distributors may place orders directly with our Order
Processing department by calling the number listed above. For information on your local
distributor, call EMERSON Motion Control.
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v
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®1documentation.
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.
Special nomenclature is provided for people working with these products, as follows:
Warning
For the purpose of this manual and product, “Warning” indicates death, severe personal
injury or substantial property damage CAN result if proper precautions are not taken.
Caution
For the purpose of this manual and product, “Caution” indicates minor personal injury or
property damage CAN result if proper precautions are not taken.
Note
For the purpose of this manual and product, “Note” indicates information about the
product or the respective part of the manual which is essential to highlight.
Throughout this manual, the word “drive” refers to an E Series drive.
1.See page ii of the preface.
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 Place holders 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.
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vi
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 it. 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, 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.
•FM-3 Speed Module Reference Manual (P/N 400508-01)
•Epsilon Eb and E Series EN Drives Reference Manual (P/N 400501-01)
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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
necessarytraining and experience. Read andfollowthis safety information and theinstruction
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.
Warning
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
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viii
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 for Epsilon and 30 seconds for
E Series drives 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.
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.
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ix
Customer Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii
Reference Materials. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vi
Safety Considerations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii
Introduction 1
Installation 3
Basic Installation Notes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Mechanical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Software Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
PC System Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Preparing for PowerTools FM-3 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Installing PowerTools FM-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Starting and Exiting PowerTools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Accessing Help . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Diagnostics and Troubleshooting 9
Diagnostic Display. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Brake Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Analog Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Diagnostic Analog Output Test Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Drive Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Error Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Programming Error Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Online Status Indicators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Specifications 29
Dimensions and Clearances. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Cable Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Index 45
Table of Contents
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x
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1
Introduction
FM-3 is a compact and rugged function module that attaches to the front of the E Series 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 E Series ENdrive.
Unlikeother function modules, the FM-3 offerscomplexmotion profiling. A complex motion
profile consists of two or more indexes that are executed in sequence such that the final
velocity of each index except the last is non-zero. Logical instructions between index
statements can provide a powerful tool for altering motion profiles ’on the fly’. The FM-3
definescomplex motion by aconfiguration file that includessetups, function assignments and
programs. The configuration file is created using EMERSON Motion Control PowerTools®
FM-3software1. 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. Emerson Motion Control
PowerTools FM-3 is an easy-to-use Microsoft® Windows®2based setup and diagnostics
tool.
Figure 1: E Series ENDrive with FM-3 Function Module
Note that the E Series drive’s firmware is disabled whenever a Function Module such as the
FM-3 is attached. Therefore, if the E Series drive’s hardware is FM compatible, then the E
Series 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
Emerson Motion Control webpage.
1.In this manual, Emerson Motion Control PowerTools FM-3 software will be referred to as
PowerTools FM-3.
2. See page ii of the preface
FM-3 Programming Module Installation Manual
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2
FM-3 Programming Module Installation Manual
The FM-3 stores E Series drive setup parameters within the module itself. This allows you to
transfer the FM-3 to another E Series drive without losing setup parameters.
Figure 2: FM-3 Programming Module Features
485 +
485 -
SHLD
Aligning Tabs
100-Pin Connector
Front Back
Inputs
Outputs
10-30 VDC
1
2
3
4
5
6
7
8
1
2
3
4
+
-
Programming Module
InputsOutputs10-30
VDC
MODEL
FM-3
PART
REV
SER
9820B025
E
x
p
.
I
/
O
S
y
n
c
.
I
n
p
u
t
S
y
n
c
.
O
u
t
p
u
t
Sync. Output
Sync. Intput
Expanded I/O
3 Row by 12
Character Display
Direction Arrow
Keys
Soft Keys
Fastening Latch
960499-01
A5/A3
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3
Installation
Basic Installation Notes
You are required to follow all safety precautions during start-up such as providing proper
equipment grounding, correctly fused power and an effective Emergency Stop circuit which
can immediately remove power in the case of a malfunction. See the “Safety Considerations”
section for more information.
Mechanical Installation
The FM-3 detects and verifies the drive serial number when its attached to an E Series drive.
If an FM-3 is moved from one drive to another, it will detect the difference in serial numbers
and generate an Invalid Configuration fault.
Two aligning tabs, a locking latch and a 100-pin connector are used to attach the FM-3 to an
E Series drive. All electrical connections between the FM-3 and the E Series drive are
accomplished with the single connector located on the rear of the FM-3.
Figure 3: Attaching the FM-3 to an E Series Drive
Caution
Do not attach or detach the FM-3 when power is applied to the drive. It could cause drive
instability.
1
Grip the FM
firmly on
each side.
3
Gently press the
FM against the
drive, aligning the
100-pin connector.
4
Continue pressing the FM
against the drive until the
latch clicks into the slot
on the top of the drive.
2
Insert the
aligning tabs
into the slots
on the drive.
FM-3 Programming Module Installation Manual
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4
FM-3 Programming Module Installation Manual
Figure 4: Detaching the FM-3 from the Drive Connections
Caution
Do not attach or detach the FM-3 when power is applied to the drive It could cause drive
instability.
Modbus Communications
The drive’s serial communication protocol is Modbus RTU slave with a 32 bit data extension.
The Modbus protocol is available on most operator interface panels and PLC’s.
EMERSON Motion Control’s Motion Interface panels are supplied with a Modbus master
communications driver.
Serial Communications Specifications
Max baud rate 19.2k (default)
Start bit 1
Stop bit 2
Parity none
Data 8
1
Grip the FM
on each side
of the LCD.
4
Continue pulling the top
of the FM away from the
drive until the connector
clears the drive. Lift the
FM out of the aligning
tab slot and away from
the drive.
3
Gently pull the FM away from
the drive. A slight rocking
motion may be used to loosen
the FM's connector.
2
Press down on the
latch located on
the top of the FM.
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5
Installation
Software Installation
Emerson Motion Control PowerTools® FM-3 software was designed for users who need
access to all setup options and diagnostic information for the drive. The software provides
access to all commonly used drive parameters.
PC System Configuration
Required:
•Microsoft®Windows®95/98 or Microsoft Windows NT®4.0 (service pack 3)
•Serial port
•Mouse
•3.5" floppy drive for installation
Recommended:
•16 MB or more RAM for Windows 95/98, and 32 MB or more for Windows NT.
•Up to 45 MB of hard disk space required for a full installation; 15 MB for minimum
installation.
Optional:
•Windows-compatible printer
•Modem and Internet access
Preparing for PowerTools FM-3 Installation
•Close all programs and turn off virus protection software to prevent installation conflicts.
•If you have another version of PowerTools on your computer and do not want to overwrite
that version, change the default installation folder for PowerTools during installation
setup.
•To avoid overwriting programs you have customized or created, place them into a
separate folder before you install.
Installing PowerTools FM-3
You must be running Microsoft Windows 95/98 or Microsoft Windows NT 4.0 to install M-3.
To install PowerTools:
1. Insert the PowerTools disk 1 into the floppy drive.
2. From the Start menu, choose Run.
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6
FM-3 Programming Module Installation Manual
3. In the Run dialog box, type a:/setup, where ais the letter assigned to your 3.5" floppy
drive.
4. Click the OK button, then follow the instructions on your screen.
Installation will take about five minutes. The install program automatically:
•Creates the directory on your hard drive named:
C:\EMERSON\PT-FM3
•Creates a new Windows group called "EMERSON Motion Control-FM3".
•Loads the required DLL’s into your Windows system directory.
•Loads PowerTools into the EMERSON\PT-FM3 directory.
•Loads drive setup files into the EMERSON\APPS directory.
Note
To complete the installation for Windows 98 and NT, you may be required to restart
Windows.
Refer to the readme.txt file located on the installation floppy for more information.
If You Need Help with Installation
If you encounter problems while installing PowerTools, call Technical Support at (952)995-
8033 (24 hour assistance).
Starting and Exiting PowerTools
Starting the Software
1. Click the Start button on the taskbar at the bottom left of the screen.
2. Click on the Programs selection. The Programs menu appears.
3. Click on the “EMERSON Motion Control” folder icon.
4. Click on the “PowerTools” folder icon.
5. Click on the PowerTools program icon.
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7
Installation
Exiting the Software
Choose File from the menubar, then click Exit. If you are using the keyboard, press the
shortcut key combination Alt+F, X.
If you made changes, PowerTools displays an Alert dialog box asking whether you want to
save your current work. Click theYes button or press Enter to save your work, or click theNo
button to quit without saving.
Accessing Help
All PowerTools tabs and dialog boxes provide a Help button. This retrieves help for that
particular subject and provides details to assist you in the use of each tab or dialog box. Also,
provided is a index-based help system. There is the ability to search the online help using a
keyword. Lastly, PowerTools has context sensitive help capability.
Online Help displays detailed procedural and reference information. It contains some
information that does not appear in this manual.
To display Help in PowerTools, do one of the following:
•Press F1.
•Choose a command from the Help menu.
•Click the Help button on a dialog box or tab.
•Click the Help icon on the toolbar.
•Click the Context Sensitive Help button on the toolbar and then the field on the tab.
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8
FM-3 Programming Module Installation Manual
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