Festo CMCA series User manual

Description
Electrical installation
8023865
1211a
Control system
CMCA

CMCA
2 Festo – GDCP-CMCA-INST-EN – 1211a –
Translation of the original instructions
GDCP-CMCA-INST-EN
CoDeSys
®
is a registered trademark of its respective trademark holder in certain countries.
Identification of hazards and instructions on how to prevent them:
Warning
Hazards that can cause death or serious injuries.
Caution
Hazards that can cause minor injuries or serious material damage.
Other symbols:
Note
Material damage or loss of function.
Recommendations, tips, references to other documentation.
Essential or useful accessories.
Information on environmentally sound usage.
Text designations:
• Activities that may be carried out in any order.
1. Activities that should be carried out in the order stated.
– General lists.

CMCA
Festo – GDCP-CMCA-INST-EN – 1211a – English 3
Table of Contents – CMCA
1 Safety and requirements for product use 5......................................
1.1 Safety 5..................................................................
1.1.1 General safety instructions 5.........................................
1.1.2 Intended use 5.....................................................
1.1.3 Foreseeable misuse 6...............................................
1.2 Requirements for product use 6...............................................
1.2.1 Technical requirements 6............................................
1.2.2 Qualification of trained personnel 6....................................
1.2.3 Range of application and certifications 6................................
2 Transport and storage 7.....................................................
2.1 Transport 7................................................................
2.1.1 Dimensions and weights 7...........................................
2.2 Storage conditions 8........................................................
2.3 Unpacking 8...............................................................
2.3.1 Mounting plate design CMCA-…-C-… 9..................................
2.3.2 Control cabinet versions CMCA-…-CC-…/CMCA-…-CS-… 10...................
2.4 Checking control system and scope of delivery 13..................................
3Overview 14................................................................
3.1 Characteristics 14...........................................................
3.2 Function and application 15....................................................
3.3 Product overview 16.........................................................
3.3.1 Control sections and connections, control cabinet CMCA-…-CC-…/CMCA-…-CS-… 16
3.3.2 Control and signal elements on the control cabinet
CMCA-…-CC-…/CMCA-…-CS-… 17.......................................
3.3.3 Components and connections inside the control cabinet or mounting plate
design 18..........................................................
3.3.4 Overview, terminal strips 19...........................................
3.3.5 Overview, fuses 20..................................................
4 Mounting and installation 21..................................................
4.1 Mounting 21................................................................
4.1.1 Mounting plate design CMCA-…-C-… 21..................................
4.1.2 Control cabinet version CMCA-…-CC-… 22.................................
4.1.3 Control cabinet version with base CMCA-…-CS-… 23........................

CMCA
4 Festo – GDCP-CMCA-INST-EN – 1211a – English
4.2 Electrical installation 24.......................................................
4.2.1 Safety instructions 24................................................
4.2.2 Design of the double-stack terminals 26.................................
4.2.3 Connecting supply voltage 26..........................................
4.2.4 Connect power switch (with mounting plate design) 27.....................
4.2.5 Connect emergency stop switch (with mounting plate design) 28..............
4.2.6 Connect emergency stop circuits 29.....................................
4.2.7 Connect protective door switch 29......................................
4.2.8 Connect operating and signal elements (with mounting plate design) 30........
4.2.9 Operating mode selection 31..........................................
4.2.10 Connect kinematic drives 32...........................................
4.2.11 Connect limit switches 32.............................................
4.2.12 Rod loss detection (only for rod kinematic system EXPT) 33..................
4.2.13 Connect axis of rotation reference sensor 33..............................
4.2.14 Connect the camera system supply 33...................................
4.2.15 Connect lighting 33..................................................
4.2.16 Freely usable outputs 34..............................................
4.2.17 Additional peripheral modules for the multi-axis controller 34................
5 Commissioning 35...........................................................
6 Operation and diagnostics 36..................................................
6.1 Operation 36...............................................................
6.2 Maintenance and care 36......................................................
6.2.1 Control cabinet fan 36................................................
7 Module replacement and repair 37.............................................
7.1 Replace module 37..........................................................
7.2 Repair 37..................................................................
7.3 Disposal 37................................................................
A Technical appendix 38........................................................
A.1 Technical data 38............................................................
A.1.1 Safety engineering 38................................................
A.1.2 General 38.........................................................
A.1.3 Electrical data 39....................................................
A.1.4 Operating and environmental conditions 39...............................

1 Safety and requirements for product use
Festo – GDCP-CMCA-INST-EN – 1211a – English 5
1 Safety and requirements for product use
1.1 Safety
1.1.1 General safety instructions
• Observe the general safety instructions in the corresponding chapters.
Specific safety regulations can be found immediately before the task instructions.
Warning
Danger of electric shock even if power switch is shut off.
The control system is only completely voltage-free if all supply lines have been switched
voltage-free.
• Switch off all supply lines (also external voltage) prior to assembly, installation
and/or maintenance work and secure them from being restarted accidentally.
• Switch the voltage back on only after completion of work.
Note
Damage to the product from incorrect handling.
• Never pull the plugs and interfaces when powered.
• Never plug in plugs and interfaces when powered.
• Observe the handling specifications for electrostatically sensitive devices.
1.1.2 Intended use
The control system CMCA serves to operate a kinematics system in the environment of a machine or
automated systems and must be used as follows:
– in excellent technical condition
– in original status, without unauthorised modifications
– within the limits of the product defined by the technical data (appendix A.1)
– in an industrial environment
The safety circuit of the CMCA control solution is only one part of the the safety concept for a machine,
whereby the safety concept must be based on a risk assessment of the entire machine to be performed
by the machine manufacturer.
Note
In the event of damage caused by unauthorised manipulation or other than intended
use, the guarantee is invalidated and the manufacturer is not liable for damages.

1 Safety and requirements for product use
6 Festo – GDCP-CMCA-INST-EN – 1211a – English
1.1.3 Foreseeable misuse
– The safety circuit of the CMCA control solution is changed in its function.
– Safety functions are thus implemented that are not specified in this description.
– An adequate risk assessment is not performed for the machine.
– There is no safety concept of the machine available.
– Suitability of this safety circuit for the application is not established.
– No verification and no validation of the switch is performed in the machine.
1.2 Requirements for product use
• Make this documentation available to the design engineer, installer and personnel responsible for
commissioning the machine or system in which this product is used.
• Make sure that the specifications of the documentation are always complied with. Also consider the
documentation for the other components and modules.
• Take into consideration the legal regulations applicable for the destination, as well as:
– regulations and standards
– regulations of the testing organizations and insurers
– national specifications
1.2.1 Technical requirements
General conditions for the correct and safe use of the product, which must be observed at all times:
• Comply with the connection and environmental conditions of the product (appendix A.1) and all
connected components specified in the technical data.
Only compliance with the limit values or load limits permits operation of the product in accordance
with the relevant safety regulations.
• Observe the instructions and warnings in this documentation.
1.2.2 Qualification of trained personnel
The product should only be installed by properly trained personnel in accordance with these instruc-
tions. The trained personnel must be familiar with:
– installation and operation of electrical control systems
– the applicable regulations for operating safety-engineered systems
– the applicable regulations for accident protection and industrial safety
– the documentation for the product
1.2.3 Range of application and certifications
Standards and test values which the product complies with and fulfils can be found in the technical
data (appendix A.1). The product-relevant EU directives can be found in the declaration of conform-
ity.
Certificates and the declaration of conformity for this product can be found at
www.festo.com.

2Transportandstorage
Festo – GDCP-CMCA-INST-EN – 1211a – English 7
2 Transport and storage
2.1 Transport
The control system is delivered on a pallet and is protected with a cover of plates. The mounting plate
design CMCA-…-C-… is also screwed to the pallet.
2.1.1 Dimensions and weights
CMCA-…- C-… CC-… CS-…
Dimensions [mm]
H565 868 1018
L1010 1140 1140
B640 510 510
Weight [kg]
Control system 41 79 89
Overall weight
1)
85 125 142
1) With max. accessories
Tab. 2.1
Note
• For transport, observe the marking on the upper side of the transport box.
1. Transport the pallet with the control system to the installation/storage location.
2. Set down the pallet on a firm and flat base at the installation/storage location.

2 Transport and storage
8 Festo – GDCP-CMCA-INST-EN – 1211a – English
2.2 Storage conditions
For safe later use, the following storage conditions must be complied with.
Storage conditions
Storage temperature [°C] –20 … +60
Relative air humidity [%] 10 … 95, non-condensing or protected against condensation
Max. storage time 60 months
Requirements of storage location dry, solid and flat base
Tab. 2.2
2.3 Unpacking
Note
Damage to the product from incorrect removal of the transport box.
• Use the correct tool to loosen the screws.
• Make sure that no packaging parts can fall onto the control system.
• Observe the product weight (chapter 2.1.1).
• Keep the packaging for later use or dispose of it in accordance with the instructions
(chapter 7.3).

2Transportandstorage
Festo – GDCP-CMCA-INST-EN – 1211a – English 9
2.3.1 Mounting plate design CMCA-…-C-…
Removing transport packaging
1. Loosen and remove the lower screws of the
cover.
2. Lift the cover up and off.
Remove the packaging foil
3. Cut the foil parallel to the contour of the
product with an appropriate tool. When cut-
ting, make sure that you do not damage or
scratch the components of the control system.
4. Pull the foil up and off. Carefully remove the
bag with desiccant and dispose of it in accord-
ance with the instructions (chapter 7.3).
Loosen mounting plate
5. Loosen and remove the screws with which the
mounting plate is screwed to the pallet.
6. With two people, lift the control system off the
pallet and bring it to the installation site.
Fig. 2.1

2 Transport and storage
10 Festo – GDCP-CMCA-INST-EN – 1211a – English
2.3.2 Control cabinet versions CMCA-…-CC-…/CMCA-…-CS-…
Warning
Danger of injury/damage due to falling loads.
The device to lift the control cabinet out of the transport packaging must be sufficiently
dimensioned for the weight of the control cabinet.
• Observe the product weight (chapter 2.1.1).
Removing transport packaging
1. Loosen and remove all screws of the cover.
2. Remove the cover up and off the transport
box.
Fig. 2.2
3. Loosen and remove all screws of the side wall
near the control cabinet doors.
4. Pull the side wall forward and off.
Fig. 2.3

2Transportandstorage
Festo – GDCP-CMCA-INST-EN – 1211a – English 11
5. Mount an appropriate lifting device to the
transport lugs of the control cabinet.
Fig. 2.4
6. Lift the control cabinet out of the transport
packaging.
Fig. 2.5

2 Transport and storage
12 Festo – GDCP-CMCA-INST-EN – 1211a – English
Unpack filter mats
Caution
Fire danger from overheating.
At delivery, the filter mats for control cabinet fans and outlet filters are packed in plastic
and placed in the filter cassettes.
Operation of the control system with packaged filter mats results in overheating and
related consequential damage.
• Remove the plastic packaging from both filter mats as described below.
1. Pull the covers of the filter housing off to the
front.
2. Take out the packaged filter mats.
3. Remove the packaging.
Fig. 2.6
4. Place the unpackaged filter mats in the filter
housing.
5. Put the covers back on.
Fig. 2.7
Remove drying agent
The control cabinet includes several bags with drying agent to protect against damage
due to moisture. Before installation of the control system, carefully remove the desiccant
and dispose of it in accordance with the instructions (chapter 7.3)

2Transportandstorage
Festo – GDCP-CMCA-INST-EN – 1211a – English 13
2.4 Checking control system and scope of delivery
1. After unpacking, check whether the product corresponds to the version you ordered.
2. After unpacking, check the following parts:
Check Possible malfunction Remedy
Fuses Open Close
Ethernet cable Unplugged Plug in
CMXR memory card Not completely plugged in Plug in completely
Component Damaged Replace
1) 2)
1) www.festo.com/spareparts
2) Chapter 7
Tab. 2.3
3. Check that the delivery is complete.
Documentation Number
Electrical installation CMCA control system 1
Circuit diagram, CMCA control system 1
Controller CMXR-C1 1 (for characteristic C1)
Controller CMXR-C2 1 (for characteristic C2)
Motor controller CMMP-AS + CD-ROM 1
I/O module CECX-D-8E8A-NP-2 1
Power supply SVG-1 1
Subcon cable interface 1
Ethernet switch SFNB 1
Controller PNOZ S7 + supplement 1
Controller PNOZmulti Mini + DVD 1
Buffer module 1 (for characteristic S2)
Terminals with filter 1, 21108-2EN-04 1
Tab. 2.4
Accessories (for characteristic CC and CS) Number
Keyforkeyswitch 2 each
Key for control cabinet doors 1
Inscription labels for control elements, German 6
Tab. 2.5

3Overview
14 Festo – GDCP-CMCA-INST-EN – 1211a – English
3Overview
3.1 Characteristics
The control system CMCA can be equipped with the following characteristics:
Characteristic Code Brief description
Kinematics -K1 – For parallel kinematic robot EXPT
-K2 – For H-gantry or surface gantry
-K3 – For T-gantry or linear gantry
Multi-axis
controller
-C1 – Multi-axis controller CMXR-C1
-C2 – Multi-axis controller CMXR-C2 with integrated PLC
Motor
controller
-A1 – 2 motor controllers CMMP-AS-C5-3A for 2 main axes
-A2 – 2 motor controllers CMMP-AS-C5-3A for 2 main axes
– 1 motor controller CMMP-AS-C2-3A for 1 supplemental axis
-A3 – 2 motor controllers CMMP-AS-C5-3A for 2 main axes
– 2 motor controllers CMMP-AS-C2-3A for 2 supplemental axes
-A4 – 3 motor controllers CMMP-AS-C5-3A for 3 main axes
-A5 – 3 motor controllers CMMP-AS-C5-3A for 3 main axes
– 1 motor controller CMMP-AS-C2-3A for 1 supplemental axis
-A6 – 2 motor controllers CMMP-AS-C5-11A for 2 main axes
-A7 – 2 motor controllers CMMP-AS-C5-11A for 2 main axes
– 1 motor controller CMMP-AS-C2-3A for 1 supplemental axis
-A8 – 2 motor controllers CMMP-AS-C5-11A for 2 main axes
– 2 motor controllers CMMP-AS-C2-3A for 2 supplemental axes

3Overview
Festo – GDCP-CMCA-INST-EN – 1211a – English 15
Characteristic Brief descriptionCode
Design -C Mounting plate design
– For integration into a customer-provided control cabinet
– Various operator control elements and safety equipment must
themselves be connected
–CC Control cabinet version
– Operator control elements and safety equipment specific to the
control cabinet are connected
– Additional safety equipment must be connected or deactivated
through bridges
-CS Control cabinet version with base
– Operator control elements and safety equipment specific to the
control cabinet are connected
– Additional safety equipment must be connected or deactivated
through bridges
– The control cabinet is mounted on a base
Safety
engineering
-S1 – Integrated safety switching device
-S2 – Integrated safety switching device with power failure detection
Tab. 3.1
3.2 Function and application
The control system CMCA serves to control and monitor a connected kinematics system with several
axes
Each axis of the kinematics system is controlled by a motor controller.
For characteristic C1 and C2, a higher-order multi-axis controller coordinates the movement of the indi-
vidual axes through the corresponding motor controller.

3Overview
16 Festo – GDCP-CMCA-INST-EN – 1211a – English
3.3 Product overview
3.3.1 Control sections and connections, control cabinet CMCA-…-CC-…/CMCA-…-CS-…
5
6
2
3
4
1
79
8
aJ
aA
1Base (only for characteristic CS)
2Control cabinet door, left
3Control cabinet fan cover
4Power switch
5Connection for handheld terminal CDSA
6Operating and signal elements
7Emergency stop switches
8Transport lugs
9Outlet filter cover
aJ Control cabinet doors interlock
aA Control cabinet door right
Fig. 3.1

3Overview
Festo – GDCP-CMCA-INST-EN – 1211a – English 17
3.3.2 Control and signal elements on the control cabinet CMCA-…-CC-…/CMCA-…-CS-…
562341
1Illuminated push-button (S20/P20) “quit emergency stop”: Confirms unlocking of the emergency
stop circuit
2Indicator light (P21) “external emergency stop”: External emergency stop circuit triggered
3Indicator light (P4) “automatic control”: automatic operation active
4Key switch (S2) “automatic/manual”: Switch between automatic and manual override
The switch is only active when the “local” operating mode has been selected by means of link
plug operating mode selection (Tab. 4.17). In case of “external” operating mode, the switch is
without effect.
5Indicator light (P5) “manual control”: manual operation active
6Key switch (S3) “brake release”: releases the motor brakes (only possible in manual override and
in combination with the enabling button on the handheld terminal)
Fig. 3.2
Note
The labels for marking the control elements in German are also included in the control
cabinet.

3Overview
18 Festo – GDCP-CMCA-INST-EN – 1211a – English
3.3.3 Components and connections inside the control cabinet or mounting plate design
This controller’s equipment can deviate from that of the illustration.
5
6
2
4
1
3
7 8 9aJaA aB aC aD aE
1Terminal strips X0 … X6
2Fuses F1 … F20
3Protective contact socket type F (230 V AC, max. 10 A) for PC
4Controller, safety control circuit
5Controller, safety control circuit expansion
6Multi-axis controller
7Control module for mains failure detection (only for characteristic S2)
8Ethernet switch
9Connection for CDSA (with control cabinet design on the left door)
aJ Buffer module 24 V DC (only for characteristic S2)
aA Power supply unit 24 V DC
aB Motor controller for axis 1
aC Motor controller for axis 2
aD Motor controller for axis 3 (only for characteristic A2, A3, A4, A5, A7, A8)
aE Motor controller for axis 4 (only for characteristic A3, A5, A8)
Fig. 3.3

3Overview
Festo – GDCP-CMCA-INST-EN – 1211a – English 19
3.3.4 Overview, terminal strips
56
23 41
1X0: Feed upstream of power switch
2X1: Feed downstream of power switch
3X2: Control circuit 24 V DC
4X3: Emergency stop
5X4: External emergency stop
6X6: Control and signal elements
Fig. 3.4

3Overview
20 Festo – GDCP-CMCA-INST-EN – 1211a – English
3.3.5 Overview, fuses
56234178
9
aJ
aA
1F1 (B 10 A):
power supply 230 V AC, power supply unit 24 V DC
2F2 (B 10 A):
power supply 230 V AC, load circuit motor controller axis 1
(for characteristic A6, A7 and A8, three-phase)
3F3 (B 10 A):
power supply 230 V AC, load circuit motor controller axis 2
(for characteristic A6, A7 and A8, three-phase)
4F4 (B 10 A):
power supply 230 V AC, load circuit motor controller axis 3
(only for characteristic A2, A3, A4, A5, A7, A8)
5F5 (B 10 A):
power supply 230 V AC, load circuit motor controller axis 4
(only for characteristic A3, A5, A8)
6F6 (B 10 A):
power supply 230 V AC, plug
7F20 (B 10 A):
voltage supply 24 V DC
8F10 (2 A):
power supply 230 V AC, control cabinet fan
9F11 (2 A):
power supply, control cabinet lighting
aJ F12 (6.3 A):
external emergency stop
aA F13 (6.3 A):
external emergency stop
Fig. 3.5