Festo CMMD-AS series User manual

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Motor controller
Description
Fitting and
Installation
Typ CMMD-AS-...
Description
571 734
en 1002NH
[751 593]

Festo P.BE-CMMD-AS-HW-EN 1002NH 3
Edition __________________________________________________ 1002NH en
Designation____________________________________ P.BE-CMMD-AS-HW-EN
Order no. ___________________________________________________571 734
Festo AG & Co. KG, D-73726 Esslingen, 2010
Internet: 0Hhttp://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 without expressed authorization is prohibited. Offenders will be
held liable for compensation of damages. All rights reserved, in particular the right to
register patents, utility patents or design patents.

4 Festo P.BE-CMMD-AS-HW-EN 1002NH
Index of revisions
Author:
Festo AG & Co. KG
Name of manual:
Festo P.BE-CMMD-AS-HW-DE 1002NH
File name:
File saved at:
Consec. no.
Description
Index of revisions
Date of amendment
001
Produced:
1002NH
Trademarks
Microsoft®Windows®, CANopen®, CiA®and PROFIBUS®are registered brands of the
respective trademark owners in certain countries.

Contents
Festo P.BE-CMMD-AS-HW-EN 1002NH 5
CONTENTS
1. General information.............................................................................................. 10
1.1 Documentation.................................................................................................... 10
1.2 Type code CMMD-AS-C8-3A................................................................................. 10
1.3 Scope of delivery................................................................................................. 11
2. Safety instructions for electric drives and controllers.......................................... 12
2.1 Icons used ........................................................................................................... 12
2.2 General Information ............................................................................................ 13
2.3 Hazards due to improper use .............................................................................. 14
2.4 Safety instructions .............................................................................................. 15
2.4.1 General safety information .................................................................. 15
2.4.2 Safety instructions for assembly and maintenance.............................. 17
2.4.3 Protection aganst touching electric components ................................. 18
2.4.4 Protection by low voltage (PELV) against electric shock ...................... 20
2.4.5 Protection against dangerous movements........................................... 20
2.4.6 Protection aganst touching hot components ....................................... 21
2.4.7 Protection when handling and assembling .......................................... 22
3. Product description............................................................................................... 23
3.1 General information............................................................................................. 23
3.2 Device description............................................................................................... 23
3.3 Bus connection.................................................................................................... 24
3.4 Performance characteristics ................................................................................ 24
3.5 Interfaces ............................................................................................................ 27
3.5.1 Overview of the setpoint value interfaces............................................ 27
3.5.2 Analogue setpoint specification........................................................... 28
3.5.3 Interfaces for direct synchronous operation ........................................ 28
3.5.4 I/O functions and device control.......................................................... 34
3.5.5 RS232 interface (diagnosis/ parametrisation interface) ...................... 35
3.5.6 Control via RS485 ................................................................................ 40
3.5.7 Multi-firmware strategy ....................................................................... 42
3.5.8 Motor feedback.................................................................................... 42
3.5.9 Brake chopper (Brake control)............................................................. 42
3.5.10 Feedback from motor (angle encoder) ................................................. 42

Contents
6 Festo P.BE-CMMD-AS-HW-EN 1002NH
3.5.11 Control interface [X1] ........................................................................... 43
3.5.12 Increment generator interface [X10]..................................................... 44
3.5.13 SD card holder [M1] ............................................................................. 44
3.5.14 SD memory card .................................................................................. 44
3.6 Field bus interface ............................................................................................... 45
3.6.1 FHPP (Festo Handling and Positioning Profile)..................................... 46
3.6.2 CAN bus ............................................................................................... 47
3.6.3 PROFIBUS ............................................................................................ 48
3.6.4 DeviceNet ............................................................................................ 48
3.7 Function overview ............................................................................................... 49
3.7.1 Operating modes ................................................................................. 49
3.7.2 Setpoint value processing ................................................................... 50
3.7.3 I²t function........................................................................................... 51
3.7.4 Positioning controller........................................................................... 51
3.7.5 Homing ................................................................................................ 53
3.7.6 Trajectory generator ............................................................................ 57
3.7.7 I/O sequence control ........................................................................... 58
3.7.8 Safety functions, error messages......................................................... 60
3.7.9 Behaviour when switching off enable .................................................. 60
3.7.10 Oscilloscope function .......................................................................... 62
3.7.11 Jog and teach function I/O ................................................................... 63
3.7.12 Position record linking with positioning/
torque control switching ...................................................................... 68
3.7.13 On-the-fly measurement ...................................................................... 74
3.7.14 Endless positioning.............................................................................. 74
3.7.15 Relative positioning records ................................................................ 76
3.7.16 Adjustment to the axis and motor construction set.............................. 76
4. Functional safety engineering .............................................................................. 77
4.1 General information and intended use ................................................................ 77
4.2 Integrated function "Safe Torque Off" (STO)....................................................... 80
4.2.1 General remarks/description "Safe Torque Off" (STO)........................ 80
4.2.2 Timing diagram, STO............................................................................ 81
4.2.3 Switching example STO ....................................................................... 83
4.2.4 EMERGENCY STOP request, monitoring of protective door .................. 85
4.2.5 Testing the safety function STO ........................................................... 86

Contents
Festo P.BE-CMMD-AS-HW-EN 1002NH 7
4.3 Integrated function "Safe Stop 1" (SS1) ............................................................. 87
4.3.1 General remarks/description "Safe Stop 1" SS1................................. 87
4.3.2 Timing diagram, SS1............................................................................ 88
4.3.3 Activation of SS1.................................................................................. 90
4.3.4 Setting the switch-off delay ................................................................. 90
4.3.5 Parameterization example FCT............................................................. 91
4.3.6 Sample circuit SS1............................................................................... 92
4.3.7 EMERGENCY STOP request, monitoring of protective door .................. 94
4.3.8 Restoration of normal operation.......................................................... 95
4.3.9 Testing the safety function................................................................... 95
4.3.10 Determination of the brake time .......................................................... 95
4.3.11 Setting the delay time.......................................................................... 96
5. Mechanical installation ........................................................................................ 97
5.1 Important instructions......................................................................................... 97
5.2 Mounting............................................................................................................. 98
6. Electrical installation.......................................................................................... 100
6.1 Device view ....................................................................................................... 100
6.2 Interfaces .......................................................................................................... 102
6.3 Entire system CMMD-AS.................................................................................... 103
6.4 Interfaces and plug assignments....................................................................... 105
6.4.1 I/O interface [X1.1/2]......................................................................... 105
6.4.2 Shaft encoder motor –EnDat 2.1 and 2.2 [X2.1/2]............................. 108
6.4.3 Safe stop [X3.1/2].............................................................................. 109
6.4.4 Field bus CAN [X4].............................................................................. 109
6.4.5 RS232/RS485 [X5] ............................................................................. 109
6.4.6 Motor connection [X6.1/2]:................................................................ 110
6.4.7 Power supply [X9] .............................................................................. 110
6.4.8 Synchronisation control [X10.1/2] ..................................................... 111
6.4.9 SD card [M1] ...................................................................................... 111
6.4.10 Field bus settings and boot loader..................................................... 112

Contents
8 Festo P.BE-CMMD-AS-HW-EN 1002NH
6.5 Instructions on safe and EMC-compliant installation......................................... 113
6.5.1 Explanations and terms ..................................................................... 113
6.5.2 Connection instructions ..................................................................... 113
6.5.3 General information on EMC .............................................................. 113
6.5.4 EMC areas: second environment........................................................ 114
6.5.5 EMC-compliant wiring ........................................................................ 114
6.5.6 Operation with long motor cables...................................................... 115
6.5.7 ESD protection................................................................................... 115
7. Preparations for commissioning......................................................................... 116
7.1 General connection instructions........................................................................ 116
7.2 Tools / material ................................................................................................. 116
7.3 Connect the motor to the motor controller ........................................................ 116
7.4 Connecting motor controller to the power supply.............................................. 117
7.5 Connecting a PC................................................................................................. 117
7.6 Checking readiness for operation...................................................................... 117
7.7 Timing diagram switch-on sequence ................................................................. 118
8. Service functions and error messages................................................................ 119
8.1 Protective and service functions........................................................................ 119
8.1.1 Overview............................................................................................ 119
8.1.2 Temperatur monitoring for motor and power section,
shaft encoder monitoring................................................................... 119
8.1.3 Short-circuit monitoring of the output stage/overload current
and short-circuit monitoring .............................................................. 119
8.1.4 Voltage monitoring for the intermediate circuit ................................. 120
8.1.5 I²t monitoring..................................................................................... 120
8.1.6 Temperature monitoring for the heat sink ......................................... 120
8.1.7 Power monitoring for the brake chopper ........................................... 120
8.2 Operating mode and error messages ................................................................ 121
8.2.1 Operating mode and error display ..................................................... 121
8.2.2 Error messages .................................................................................. 121
A. Technical data..................................................................................................... 125
A.1 General.............................................................................................................. 125
A.2 Operation and display components................................................................... 126
A.2.1 Status display .................................................................................... 126
A.2.2 Control elements ............................................................................... 126

Contents
Festo P.BE-CMMD-AS-HW-EN 1002NH 9
A.3 Interfaces .......................................................................................................... 127
A.3.1 I/O interface [X1.1/2]......................................................................... 127
A.3.2 Shaft encoder motor [X2.1/2] ............................................................ 128
A.3.3 CAN bus [X4] ...................................................................................... 128
A.3.4 RS232/RS485 [X5] ............................................................................. 128
A.3.5 Motor connection [X6.1/2] ................................................................. 129
A.3.6 Power supply [X9] .............................................................................. 130
A.3.7 Increment generator interface [X10.1/2]............................................ 130
B. Index ................................................................................................................... 131

1. General information
10 Festo P.BE-CMMD-AS-HW-EN 1002NH
1. General information
1.1 Documentation
This product manual is intended to help you safely work with the servo motor controller of
the CMMD-AS series. It contains safety instructions which must be followed.
This document provides information on:
-mechanical mounting
-electrical installation
-and an overview of the range of functions.
See the following manuals on the CMMS product family for further information:
-CANopen manual "P.BE-CMMS-CO-…":
Description of the implemented CANopen protocol as per DSP402.
-PROFIBUS manual "P.BE-CMMS-FHPP-PB-…":
Description of the implemented PROFIBUS-DP protocol.
-DeviceNet manual "P.BE-CMMS-FHPP-DN-…":
Description of the implemented DeviceNet protocol.
-FHPP manual "P.BE-CMM-FHPP-…":
Description of the implemented Festo profiles for handling and positioning.
1.2 Type code CMMD-AS-C8-3A
Motor controller for servo motors, 8 A nominal current, 230 V AC
CMM
—
D
—
AS
—
C8
—
3A
Series
CMM
Motor controller
Version
D
Dual converter
Motor technology
AS
AC-Servo
Rated motor current
C8
8 O
Input voltage
3A
230 V AC power section

1. General information
Festo P.BE-CMMD-AS-HW-EN 1002NH 11
1.3 Scope of delivery
The delivery includes:
Number
Delivery
1
Servo motor controller CMMD-AS-C8-3A
1
CD (parametrisation software, documentation, S7 module, GSD, EDS, firmware)
1
Plug range
Table 1.1 Scope of delivery

2. Safety instructions for electric drives and controllers
12 Festo P.BE-CMMD-AS-HW-EN 1002NH
2. Safety instructions for electric drives and
controllers
2.1 Icons used
Information
Note
Important information and remarks.
Caution
Failure to comply can result in severe property damage.
Warning
Failure to comply can result in property damage and personal
injury.
Warning
DANGER!
Considerable property damage and personal injury can occur if
these instructions are not observed.
Warning
Dangerous voltage
The safety instructions contain reference to dangerous voltages
which may occur.
Accessories
Environment

2. Safety instructions for electric drives and controllers
Festo P.BE-CMMD-AS-HW-EN 1002NH 13
2.2 General Information
Festo AG & Co.KG is not liable for damage caused by failure to observe the warning
instructions in these operating instructions.
Note
Prior to commissioning, read through the "211HSafety instructions for
electric drives and controllers" (starting on page 212H12) and the
chapter 213H6.5 214H"Instructions on safe and EMC-compliant installation"
(page 215H113).
If the documentation in the language in question cannot be understood fully, please
contact your vendor and inform them.
Proper and safe operation of the motor controller requires correct transport, storage,
mounting and installation as well as project planning that takes into account the risks,
protection and emergency measures, as well as careful operation and maintenance.
Note
Only trained and qualified personnel should be allowed to handle
the electric systems.
Trained and qualified personnel
For the purpose of this manual and the warning instructions on the product itself,
technicians working with this product must be adequately familiar with the erection,
mounting, setting-up and operation of the product as well as with all warnings and
precautionary measures in accordance with the operating instructions in this product
manual, and must be sufficiently qualified for this task:
-Training and instructions on or authorization to switch on and switch off
devices/systems in accordance with technical safety standards, and to earth
and mark them appropriately in accordance with the application requirements.
-Training or instructions in using and maintaining suitable safety equipment in
accordance with technical safety standards.
-Training in first aid.
The following instructions must be read before the system is commissioned for the first
time to prevent injury and/or material damage:
These safety instructions must be observed at all times.
Do not try to install or commission the motor controller before
you have carefully read through all safety instructions for
electric drives and controllers in this documentation.
You must read through these safety instructions and all other user
instructions before working with the motor controller.

2. Safety instructions for electric drives and controllers
14 Festo P.BE-CMMD-AS-HW-EN 1002NH
If you do not have any user instructions for the motor controller,
please contact your relevant sales representative.
Ask them to send the documents to the person responsible for
safe operation of the stepping motor controller immediately.
If the motor controller is sold, rented and/or passed on in any other
way, these safety instructions must also be passed on with it.
For safety and guarantee reasons it is not permitted for the motor
controller to be opened by the user.
Correct project planning is required for the motor controller to
function properly.
Warning
DANGER!
Incorrect handling of the motor controller and failure to observe the
specified warning instructions as well as incorrect manipulation of
the safety devices can lead to damage to property, bodily injury,
electric shock or in extreme cases death.
2.3 Hazards due to improper use
Warning
DANGER!
High electric voltage and high working current!
Danger of death or serious bodily injury due to electric shock!
Warning
DANGER!
High electric voltage due to incorrect connection!
Danger of death or bodily injury due to electric shock!
Warning
DANGER!
Surfaces of the device housing may be hot!
Danger of injury! Danger of burning!

2. Safety instructions for electric drives and controllers
Festo P.BE-CMMD-AS-HW-EN 1002NH 15
Warning
DANGER!
Dangerous movements!
Danger of death, serious bodily injury or damage to property due to
unintentional movement of the motors!
2.4 Safety instructions
2.4.1 General safety information
Warning
The motor controller corresponds to protection class IP20 as well
as degree of contamination 2.
The environment must conform to this protection class or the
degree of contamination (see chapter 5.1).
Warning
Use only accessories and spare parts which are approved of by
the manufacturer.
Warning
The motor controllers must be connected to the mains network
in accordance with EN standards and VDE or appropriate
national regulations, so that they can be disconnected with
suitable de-energising devices (e.g. power switch, fuse, circuit
breaker).
Warning
For switching the control contacts, gold contacts or contacts with
high contact pressure should be used.
Precautionary measures must be taken for preventing interference
to switching systems, e.g. wiring fuses and relays with RC elements
or diodes.
You must observe the safety regulations and directives of the
country in which the device is to be used.

2. Safety instructions for electric drives and controllers
16 Festo P.BE-CMMD-AS-HW-EN 1002NH
Warning
The environmental conditions specified in the product
documentation must be observed.
Safety-critical applications are not permitted if they are not
explicitly approved by the manufacturer.
For instructions on safe and EMC-compliant installation,
see chapter 216H6.5 "Instructions on safe and EMC-compliant
installation" (page 218H113).
The manufacturer of the system or machine is responsible for
ensuring that the limit values required by the national regulations
are observed.
Warning
The technical data and connection and installation conditions for
the motor controller must be taken from this product manual and
complied with.
Warning
DANGER!
The general installation and safety regulations for working on
high-voltage systems (e.g. DIN, VDE, EN, IEC or other national
and international regulations) must be observed.
Failure to observe these regulations can lead to bodily injury, death
or considerable damage to property.
The following precautionary measures also apply without claim to
completeness:
VDE 0100
Regulations for setting up high-voltage systems
up to 1,000 volts
EN 60204-1
Electrical equipment for machines
EN 50178
Equipping high-voltage systems with electronic
devices
EN ISO 12100
Safety of machines –basic concepts,
general guidelines
EN ISO 14121-1
Safety of machines –guidelines for risk
evaluation
EN 1037
Safety of machines –avoiding unintentional
starting up
EN ISO 13849-1
Safety-related parts of controllers

2. Safety instructions for electric drives and controllers
Festo P.BE-CMMD-AS-HW-EN 1002NH 17
2.4.2 Safety instructions for assembly and maintenance
For assembling and maintaining the system, the relevant DIN,
VDE, EN and IEC regulations as well as all national and local safety and accident
prevention regulations must always be observed. The system manufacturer or the user is
responsible for ensuring that these regulations are observed.
Warning
The motor controller may only be operated, maintained and/or
serviced by persons qualified and trained to work on or with
electrical devices.
Avoiding accidents, bodily injury and/or material damage:
Warning
The series-supplied motor holding brake or an external motor-
holding brake controlled by the drive controller alone is not
suitable for protecting human beings.
Vertical axes must be additionally secured against falling or
sliding down when the motor is switched off with, for example,
- mechanical locking of the vertical axis,
- external braking, safety catch or clamping devices or
- sufficient weight compensation of the axis.
Warning
The internal brake resistance can cause dangerous intermediate
circuit voltage during operation and up to several minutes after the
motor controller is switched off. If touched, this can lead to fatal or
serious injuries.
Before carrying out maintenance work, make sure that the
power supply is switched off and locked and that the
intermediate circuit is discharged.
Switch off power to the electrical equipment and secure it
against being switched on again. Wait until the intermediate
circuit is discharged in the case of:
- maintenance and repair
- cleaning
- long service interruptions.
Warning
Proceed carefully with mounting. Make sure that , during mounting
as well as later during the operation of the drive, no drilling
shavings, metal dust or mounting parts (screws, nuts, pieces of
wire) can fall into the motor controller.
Ensure that the external power supply of the controller (mains
voltage 230 V) is switched off.

2. Safety instructions for electric drives and controllers
18 Festo P.BE-CMMD-AS-HW-EN 1002NH
The intermediate circuit or the 230 V mains voltage must always be
switched off before the 24 V logic power supply is switched off.
Warning
Work in the vicinity of the machine must only be carried out
when the AC or DC power supply is switched off and locked.
Switched-off final stage or switched-off controller enable are not
suitable locking conditions. In the event of a fault, this could lead
to unintentional movement of the drive.
Warning
Carry out commissioning with a free-running motor in order to
avoid mechanical damage, e.g. due to incorrect direction of
rotation.
Warning
Electronic devices are never fail-proof.
The user is responsible for ensuring that his system is brought into
a safe state if the electric device fails.
Warning
DANGER!
The motor controller and, in particular, the brake resistance can
take on high temperatures, which can cause severe bodily burns on
contact.
2.4.3 Protection aganst touching electric components
This section concerns only devices and drive components with voltages over 50 V. It is
dangerous to touch components with voltages of more than 50 V, as this can cause an
electric shock. When electric devices are operated, certain components in these devices
are always under dangerous tension.
Warning
Dangerous voltage
High voltage!
Danger of death or serious bodily injury due to electric shock!
For operation, the relevant DIN, VDE, EN und IEC regulations, as well as all national and
local safety and accident prevention regulations must always be observed. The system
manufacturer or the user is responsible for ensuring that these regulations are observed.

2. Safety instructions for electric drives and controllers
Festo P.BE-CMMD-AS-HW-EN 1002NH 19
Warning
Before switching the device on, attach the intended covers and
protective screens so that the device cannot be touched.
For built-in devices, make sure that there is an external housing,
such as a control cabinet, to ensure that the electric components
cannot be touched.
The standards EN 60204-1 and EN 50178 must be observed.
Warning
Ensure that the minimum copper cross section is used for the entire
length of the protective earth conductor in accordance with
standard EN 60204.
Warning
Before commissioning, also for brief measuring and test
purposes, always connect the protective conductor to all
electric devices or connect to an earth cable in accordance with
the connection diagram.
Otherwise, high voltages may occur on the housing. These could
cause an electric shock.
Warning
Do not touch the electrical connection points of the components
when the device is switched on.
Warning
Before touching electric components with voltages over 50 V,
disconnect the device from the mains or voltage source.
Protect the device against being switched on again.
Warning
During installation note the amount of intermediate circuit
voltage, especially with regard to insulation and protective
measures.
Make sure that the earthing, the cross section size of the conductor
and the corresponding short-circuit protection are correct.

2. Safety instructions for electric drives and controllers
20 Festo P.BE-CMMD-AS-HW-EN 1002NH
2.4.4 Protection by low voltage (PELV) against electric shock
Voltages from 5 to 50 V on the connections and terminals of the motor controller are
protective small voltages which can be touched without danger in accordance with the
following standards:
Standards
-International: IEC 60364-4-41
-European: EN 50178
Warning
DANGER!
High electric voltage due to incorrect connection!
Mortal danger, danger of injury from electric shock.
Devices, electrical components and cables may only be connected to connections and
terminals from 0 to 50 V, providing they have protective low voltage (PELV = Protective
Extra Low Voltage).
Connect only voltages and current circuits which have reliable separation of dangerous
voltages. Such separation is achieved e.g. with isolating transformers, reliable
optocouplers or battery operation separate from the mains network.
2.4.5 Protection against dangerous movements
During startup, the safety functions used, e.g. "Safe halt", must be checked for proper
functioning.
The user shall establish a regular inspection of the safety function.
Dangerous movements can be caused by incorrect control of connected motors. There are
various causes:
Causes
-Unsafe or faulty circuitry or cabling
-Faults in operating the components
-Faults in the measured value and signal generators
-Faults or non-EMC-compliant components
-Errors in the software in the higher-order control system
These faults can occur immediately after the device is switched on or after an uncertain
period of operation.
The monitoring functions in the drive components exclude to a large extent the possibility
of incorrect operation of the connected drives. WIth regard to the protection of people,
especially the danger of bodily injury and/or material damage, one must not rely on these
circumstances alone. Until the installed monitoring functions become effective, you must
reckon with at least one faulty drive movement, the extent of which depends on the type
of control and on the operating state.