Festo CMMP-AS-C2-3A User manual

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Motorcontroller CMMP…
Description
Mounting and
installation
Type
CMMP-AS-3A…
Description
557 326
en 0708NH
[723 739]

Festo P.BE-CMMP-AS-3A-HW-EN 0708NH 3
Edition __________________________________________________ en 0708NH
Description___________________________________P.BE-CMMP-AS-3A-HW-EN
Order no. ___________________________________________________557 326
(Festo AG & Co KG., D-73726 Esslingen, Federal Republic of Germany, 2006)
Internet: http://www.festo.com
E-mail: [email protected]
The reproduction of this document and disclosure to third parties and the utilisation or
communication of its contents without explicit authorization is prohibited. Offenders will
be held liable for compensation of damages. All rights reserved, in particular the right to
carry out patent, utility model or ornamental design registrations.

4 Festo P.BE-CMMP-AS-3A-HW-EN 0708NH
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Table of contents
Festo P.BE-CMMP-AS-3A-HW-EN 0708NH 5
Table of contents
1. General data ............................................................................................... 10
1.1 Documentation .......................................................................................... 10
1.2 Scope of delivery ....................................................................................... 11
2. Safety instructions for electric drives and controllers .................................. 12
2.1 Icons used ................................................................................................. 12
2.2 General information ................................................................................... 12
2.3 Danger through incorrect use ..................................................................... 14
2.4 Safety instructions..................................................................................... 15
2.4.1 General safety information ........................................................... 15
2.4.2 Safety instructions for assembly and maintenance ........................ 16
2.4.3 Protection against touching electric components .......................... 18
2.4.4 Protection by low voltage (PELV) against electric shock ................. 20
2.4.5 Protection from dangerous movements ........................................ 20
2.4.6 Protection against touching hot components ................................ 21
2.4.7 Protection when handling and assembling .................................... 22
3. Product description ..................................................................................... 23
3.1 General data.............................................................................................. 23
3.1.1 Switch-on sequence..................................................................... 26
3.2 Power supply............................................................................................. 27
3.2.1 Single-phase AC supply with active PFC ........................................ 27
3.2.2 Intermediate circuit coupling, DC power supply............................. 29
3.2.3 Mains fuse .................................................................................. 29
3.3 Brake chopper ........................................................................................... 29
3.4 Communication interfaces .......................................................................... 30
3.4.1 Festo profile for handling and positioning (FHPP) .......................... 30
3.4.2 RS232 interface ........................................................................... 31
3.4.3 CAN bus ...................................................................................... 31
3.4.4 Profibus ...................................................................................... 31
3.4.5 DeviceNet ................................................................................... 32
3.4.6 SERCOS....................................................................................... 32
3.4.7 I/O functions and device control................................................... 33
4. Function overview ....................................................................................... 35
4.1Motors ...................................................................................................... 35
4.1.1 Synchronous servo motors........................................................... 35
4.1.2 Linear motors .............................................................................. 35

Table of contents
6 Festo P.BE-CMMP-AS-3A-HW-EN 0708NH
4.2 Functions of the CMMP-AS servo positioning controller ............................... 35
4.2.1 Compatibility............................................................................... 35
4.2.2 Pulse width modulation (PWM) .................................................... 36
4.2.3 Setpoint management.................................................................. 36
4.2.4 Controlled torque mode ............................................................... 37
4.2.5 Controlled speed mode ................................................................ 37
4.2.6 Torque-limited speed control ....................................................... 38
4.2.7 Synchronisation to external clock sources .................................... 38
4.2.8 Load torque compensation for vertical axes .................................. 38
4.2.9 Positioning and position control ................................................... 38
4.2.10 Synchronisation, electrical gearboxes........................................... 40
4.2.11 Brake management...................................................................... 40
4.3 Positioning control..................................................................................... 40
4.3.1 Overview..................................................................................... 40
4.3.2 Relative positioning ..................................................................... 41
4.3.3 Absolute positioning.................................................................... 42
4.3.4 Motion profile generator .............................................................. 42
4.3.5 Homing run ................................................................................. 42
4.3.6 Positioning sequences ................................................................. 43
4.3.7 Optional Stop input ..................................................................... 44
4.3.8 Contour control with linear interpolation ...................................... 44
4.3.9 Time-synchronised multi-axis positioning ..................................... 45
5. Functional safety engineering ..................................................................... 46
5.1 General information and intended use ........................................................ 46
5.2 Integrated "Safe standstill" function .......................................................... 48
5.2.1 General information / description of "Safe standstill" ................... 48
5.2.2 Secure stopping brake control...................................................... 50
5.2.3 Functional method / Timing ......................................................... 51
5.2.4 Typical applications ..................................................................... 54
6. Mechanical installation ............................................................................... 59
6.1 Important instructions ............................................................................... 59
6.2 Device view ............................................................................................... 61
6.3 Assembly................................................................................................... 64
7. Electrical installation .................................................................................. 65
7.1 Connector pin assignments ........................................................................ 65
7.2 Entire CMMP-AS system ............................................................................. 66
7.3Connection: Power supply [X9] ................................................................... 68
7.3.1 Layout on device [X9] ................................................................... 68
7.3.2 Counterplug [X9].......................................................................... 68

Table of contents
Festo P.BE-CMMP-AS-3A-HW-EN 0708NH 7
7.3.3 Pin assignments [X9].................................................................... 68
7.3.4 Calculating the required braking resistor ...................................... 69
7.4 Connection: Motor [X6]............................................................................... 69
7.4.1 Layout on device [X6] ................................................................... 69
7.4.2 Counterplug [X6].......................................................................... 69
7.4.3 Pin assignments [X6].................................................................... 69
7.5 Connection: I/O communication [X1] ........................................................... 70
7.5.1 Layout on device [X1] ................................................................... 71
7.5.2 Counterplug [X1].......................................................................... 71
7.5.3 Pin assignments [X1].................................................................... 72
7.5.4 Type and layout of cable [X1]........................................................ 72
7.5.5 Connection notes [X1] .................................................................. 73
7.6 Connection: Safe Standstill [X3] .................................................................. 74
7.6.1 Layout on device [X3] ................................................................... 75
7.6.2 Counterplug [X3].......................................................................... 75
7.6.3 Pin assignments [X3].................................................................... 75
7.7 Connection: Resolver [X2A]......................................................................... 75
7.7.1 Layout on device [X2A] ................................................................. 75
7.7.2 Counterplug [X2A]........................................................................ 75
7.7.3 Pin assignments [X2A].................................................................. 75
7.8 Connection: Encoder [X2B] ......................................................................... 76
7.8.1 Layout on device [X2B]................................................................. 76
7.8.2 Counterplug [X2B] ....................................................................... 76
7.9 Connection: Increment encoder input [X10] ................................................. 77
7.9.1 Layout on device [X10] ................................................................. 77
7.9.2 Counterplug [X10]........................................................................ 77
7.9.3 Pin assignments [X10].................................................................. 77
7.9.4 Type and layout of cable [X10]...................................................... 77
7.9.5 Connection notes [X10] ................................................................ 77
7.10 Connection: Incremental encoder output [X11] ............................................ 78
7.10.1 Layout on device [X11] ................................................................. 78
7.10.2 Counterplug [X11]........................................................................ 78
7.10.3 Pin assignments [X11].................................................................. 78
7.11 Connection: CAN bus [X4] ........................................................................... 78
7.11.1 Layout on device [X4]................................................................... 78
7.11.2 Counterplug [X4].......................................................................... 79
7.11.3 Pin assignments [X4].................................................................... 79
7.11.4 Connection notes [X4] .................................................................. 79
7.12 Connection: RS232/COM [X5] ..................................................................... 80
7.12.1 Layout on device [X5] ................................................................... 80
7.12.2 Counterplug [X5].......................................................................... 80

Table of contents
8 Festo P.BE-CMMP-AS-3A-HW-EN 0708NH
7.12.3 Pin assignments [X5].................................................................... 81
7.13 Instructions on safe and EMC-compliant installation.................................... 82
7.13.1 Explanations and terms................................................................ 82
7.13.2 Connection instructions ............................................................... 82
7.13.3 General information on EMC......................................................... 82
7.13.4 EMC areas: First and second environments ................................... 83
7.13.5 EMC-compliant wiring .................................................................. 84
7.13.6 Operation with long motor cables................................................. 84
7.13.7 ESD protection ............................................................................ 85
8. Startup........................................................................................................ 86
8.1 General connection instructions ................................................................. 86
8.2 Tools / material ......................................................................................... 86
8.3 Connecting the motor................................................................................. 86
8.4 Connect the CMMP-AS servo positioning controller to the power supply ....... 87
8.5 Connecting a PC......................................................................................... 87
8.6 Checking readiness for operation ............................................................... 87
9. Service functions and error messages.......................................................... 89
9.1 Protective and service functions ................................................................. 89
9.1.1 Overview..................................................................................... 89
9.1.2 Overload current and short-circuit monitoring............................... 89
9.1.3 Overvoltage monitoring for the intermediate circuit ...................... 89
9.1.4 Temperature monitoring for the heat sink ..................................... 89
9.1.5 Motor monitoring ........................................................................ 90
9.1.6 I²t monitoring .............................................................................. 90
9.1.7 Power monitoring for the brake chopper ....................................... 90
9.1.8 l²t monitoring of the PFC stage ..................................................... 90
9.1.9 Commissioning status.................................................................. 90
9.1.10 Operating time counter ................................................................ 91
9.2 Operating mode and error messages .......................................................... 91
9.2.1 Operating mode and error display ................................................ 91
9.2.2 Error messages............................................................................ 91
9.2.3 Acknowledge error..................................................................... 100
A. Technical specifications ............................................................................ 101
A.1 Operation and display components........................................................... 102
A.2 Power supply [X9] .................................................................................... 102
A.3 Motor connection [X6] .............................................................................. 104
A.4 Angle encoder connections [X2A] and [X2B] ............................................... 104
A.4.1 Resolver connection [X2A].......................................................... 104
A.4.2 Encoder connection [X2B]........................................................... 105

Table of contents
Festo P.BE-CMMP-AS-3A-HW-EN 0708NH 9
A.4.3 Encoder connection [X2B] for EMMS-AS ...................................... 105
A.5 Communication interfaces ........................................................................ 106
A.5.1 RS232 [X5] ................................................................................ 106
A.5.2 CAN bus [X4].............................................................................. 106
A.5.3 I/O interface [X1] ....................................................................... 107
A.5.4 Increment encoder input [X10] ................................................... 108
A.5.5 Incremental encoder output [X11]............................................... 108
B. Glossary ................................................................................................... 109

1. General data
10 Festo P.BE-CMMP-AS-3A-HW-EN 0708NH
1. General data
1.1 Documentation
This product manual is intended to help you safely operate the CMMP-AS-…-3A series of
single-phase servo positioning controllers. It contains safety instructions which must be
followed.
See the following manuals on the CMMP-AS product family for further information:
-"P-BE-CMMP-AS-..-11A Servo positioning controller product manual": Describes the
technical data and device functionality and also provides information on the instal-
lation and operation of the CMMP-AS-C5-11A-P3 servo positioning controller and the
CMMP-AS-C10-11A-P3 for 3-phase servo positioning controllers.
-CANopen manual: P.BE-CMMP-CO-SW "CMMP-AS Servo positioning controller": De-
scription of the implemented CANopen protocol as per DSP402.
-PROFIBUS manual: P-BE-CMMP-FHPP-PB-SW "CMMP-AS servo positioning controller":
Description of the implemented PROFIBUS-DP protocol.
-SERCOS manual: P-BE-CMMP-SC-SW "CMMP-AS servo positioning controller": De-
scribes the implemented SERCOS functionality.
-Ethernet manual: P-BE-CMMP-ET-SW "Ethernet technology module": Describes the
technical data and device functionality when using the Ethernet technology module.
(in preparation)
-DeviceNet manual: P.BE-CMMP-FHPP-DN-SW Describes the implemented DeviceNet
protocol.
-FHPP manual: P.BE-CMM-FHPP-SW Describes the implemented FHPP data profile.
The entire software functionality of the new CMMP-AS series of devices has been imple-
mented in a stepwise development process.

1. General data
Festo P.BE-CMMP-AS-3A-HW-EN 0708NH 11
1.2 Scope of delivery
The delivery includes:
Number
Delivery
1 x
CMMP-AS servo positioning controller
Inserted plug for motor connection and power
Table 1.1 Scope of delivery
Counterplugs for control or shaft encoder connections are not in-
cluded in the standard scope of delivery. However, they can be or-
dered as accessories.

2. Safety instructions for electric drives and controllers
12 Festo P.BE-CMMP-AS-3A-HW-EN 0708NH
2. Safety instructions for electric drives and
controllers
2.1 Icons used
Information
Note
Important information and instructions.
Caution
Considerable damage to property may occur if these instructions
are not observed.
Warning
DANGER!
Considerable damage to property and injury to human beings may
occur if these instructions are not observed.
Warning
Dangerous voltage
The safety instructions contain reference to dangerous voltages
which may occur.
2.2 General information
Festo AG & Co.KG is not liable for damage caused by failure to observe the warning instruc-
tions in these operating instructions.
Note
Before commissioning, the Safety instructions for electric drives
and controllers from page 12 must be read, and also chapter 7.13
Instructions on safe and EMC-compliant installation (page 82).
If the documentation is not clearly understood in this language version, please inform the
supplier.
In order for the servo drive controller to operate without problems and safely, it must be
transported, stored, mounted, planned properly and correctly, taking the risks and pro-

2. Safety instructions for electric drives and controllers
Festo P.BE-CMMP-AS-3A-HW-EN 0708NH 13
tection and emergency measures into account, as well as operated and maintained with
due care.
Note
Only trained and qualified personnel should be allowed to handle
the electric systems:
Trained and qualified personnel
In accordance with this product manual or the warnings on the product itself, anyone in-
volved in planning, installing, mounting, commissioning and operating the product and are
sufficiently familiar with all warnings and precautionary measures in these operating in-
structions and who have the appropriate qualification for their work:
-Training and instructions on or authorization to switch on and switch off devices/sys-
tems in accordance with technical safety standards, and to earth and mark them ap-
propriately in accordance with the application requirements.
-Training or instructions in using and maintaining suitable safety equipment in accor-
dance 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 attempt to install or commission the servo drive control-
ler until you have read all safety instructions related to electri-
cal drives and control systems in this document.
These safety instructions and all other user instructions must be
read before performing any work with the servo drive controller.
If you do not have user instructions for the servo drive controller,
contact your local sales representative.
Ask them to send the documents to the person responsible for
safe operation of the servo drive controller immediately.
If the servo drive controller is sold, rented and/or passed on in any
other way, these safety instructions must also be passed on with it.

2. Safety instructions for electric drives and controllers
14 Festo P.BE-CMMP-AS-3A-HW-EN 0708NH
For safety and warranty reasons, the operator may not open the
servo drive controller.
Correct planning is required for the servo drive controller to func-
tion properly!
Warning
DANGER!
Incorrect use of the servo drive controller and failure to follow the
warnings in this manual, as well as incorrect manipulation of safety
equipment can cause material damage, injury, electric shock, and
in extreme cases, even be fatal.
2.3 Danger through incorrect 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!
Warning
DANGER!
Dangerous movements!
Danger of death, serious bodily injury or damage to property due to
unintentional movement of the motors!

2. Safety instructions for electric drives and controllers
Festo P.BE-CMMP-AS-3A-HW-EN 0708NH 15
2.4 Safety instructions
2.4.1 General safety information
Warning
The servo drive controller conforms to protection class IP20, and
contamination class 1.
Ensure that the working environment also complies with this
protection/contamination class.
Warning
Use only accessories and spare parts which are approved of by the
manufacturer.
Warning
In accordance with the EN standards and the VDE regulations, the
servo drive controller must be connected to the grid such that they
can be disconnected using appropriate isolating equipment (e.g.
main switch, contactor, circuit breaker).
The servo drive controller can be fused with a 300 mA all-current
sensitive fault-current circuit breaker (RCD = Residual Current pro-
tective Device).
Warning
For switching the control contacts you should use gold-plated con-
tacts or high-pressure contacts.
Precautionary measures must be taken for preventing interference
to switching systems, e.g. switching protective switches and relays
with RC elements or diodes.
You must observe the safety regulations and directives of the coun-
try in which the device is to be used.
Warning
The environmental conditions specified in the product docu-
mentation must be observed.
Safety-critical applications are not permitted if they are not explic-
itly approved of by the manufacturer.

2. Safety instructions for electric drives and controllers
16 Festo P.BE-CMMP-AS-3A-HW-EN 0708NH
See Chapter 7.13 (page 82) for instructions on EMC-compliant in-
stallation.
The manufacturer of the system or machine is responsible for en-
suring that the limit values requested by the national regulations
are observed.
Warning
See this product manual for the specifications, connection and
installation conditions for the servo drive controller, which must
always be observed.
Warning
DANGER!
The general installation and safety regulations for working on
high-current systems (e.g. DIN, VDE, EN, IEC or other national
and international regulations) must be observed here.
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
Machine safety –definitions, general design guide-
lines
EN 1050
Machine safety –risk evaluation guidelines
EN 1037
Machine safety –preventing unexpected starts
EN 954-1
Safety related control system parts
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 regu-
lations are observed:

2. Safety instructions for electric drives and controllers
Festo P.BE-CMMP-AS-3A-HW-EN 0708NH 17
Warning
The servo drive controller may only be operated, maintained and/or
serviced by persons qualified and trained to work on or with elec-
trical devices.
Avoiding accidents, bodily injury and/or material damage:
Warning
Secure vertical axes to prevent them falling or lowering after the
motor is switched off using methods such as:
- mechanical locking of the vertical axis,
- external brake / arrester / clamp or
- sufficient counterweight of the axis.
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!
Warning
Switch the electrical equipment free of voltage via the main switch
and make sure that it cannot be switched on again. Wait until the
intermediate circuit is discharged in the following cases:
-Maintenance work and commissioning
-Cleaning
-Long shutdown periods
Warning
The external or internal braking resistance is live and can carry a
dangerous intermediate circuit voltage for up to approx. 5 minutes
after the servo drive controller has been switched off. This can
cause serious bodily injury or even death if it is touched.
Before carrying out maintenance work, make sure that the
power supply is switched off and locked and that the intermedi-
ate circuit is discharged.
Warning
Proceed carefully with mounting. Ensure that no drilling shav-
ings, metal dust or mounting material (screws, nuts, wire cut-
tings) fall into the servo drive controller during mounting work
and subsequent operation.
Make also sure that the external voltage supply of the controller
(24V) is switched off.

2. Safety instructions for electric drives and controllers
18 Festo P.BE-CMMP-AS-3A-HW-EN 0708NH
The intermediate circuit or the mains voltage must always be
switched off before the 24V controller supply is switched off.
Warning
Other work in the vicinity of the machine must only be carried
out when the AC or DC 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.
Exceptions to this are drives with the "Safe standstill" safety fea-
ture as per EN 954-1 CAT 3
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 servo drive controller and in particular the braking resistance,
external or internal, can become very hot. This can cause serious
burning if the devices are touched.
2.4.3 Protection against 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.

2. Safety instructions for electric drives and controllers
Festo P.BE-CMMP-AS-3A-HW-EN 0708NH 19
Warning
Dangerous voltage
High electric voltage!
Danger of death or serious bodily injury due to electric shock!
For operation 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
Before switching the device on, fit the covers and protective
devices so that the device cannot be touched.
For devices which are to be fitted in a control cabinet, make sure
that a housing is fitted so that the electric components cannot be
touched. The EN 60204-1 standard must be observed!
Warning
Always connect the protective earth conductor of the electrical
equipment and the devices firmly to the supply network.
Due to the integrated network filter, the leakage current is greater
than 3.5 mA!
Warning
Before commissioning, and also for brief measuring and test
purposes, always connect the protective earth to all electric
devices or connect an earth cable in accordance with the con-
nection 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.

2. Safety instructions for electric drives and controllers
20 Festo P.BE-CMMP-AS-3A-HW-EN 0708NH
Warning
During installation note the amount of intermediate circuit volt-
age, especially with regard to insulation and protective meas-
ures.
Make sure that the earthing, the cross section size of the conductor
and the corresponding short-circuit protection are correct.
Warning
The device has an intermediate fast discharge circuit in accordance
with EN 60204-1. However, in certain device constellations, particu-
larly where several servo drive controllers are connected in parallel
to the intermediate circuit or when a braking resistance is not con-
nected, the fast discharge may not work. The servo drive controllers
can then contain dangerous voltages for up to 5 minutes after be-
ing switched off (capacitor residual charge).
2.4.4 Protection by low voltage (PELV) against electric shock
All connections and terminals with voltages from 5 to 50 volts on the servo drive controller
are PELVs designed to be safe to touch in accordance with the following standards:
Standards
-International: IEC 60364-4-41
-European: EN 50178 and EN60204-1
Warning
DANGER!
High electric voltage due to incorrect connection
Danger of bodily injury or death due to electric shock
Devices, electrical components and cables may only be connected to connections and ter-
minals from 0 to 50 V, providing they have a protective low voltage (PELV = Protective
Extra Low Voltage).
Connect only voltages and current circuits which have reliable separation of dangerous
voltages. Safe isolation is achieved via isolating transformers, secure optocouplers or non-
mains connected battery-powered operation.
2.4.5 Protection from dangerous movements
Dangerous movements can be caused by incorrect control of connected motors. There are
various causes: