Festo CMMS-ST-C8-7-G2 User manual

CMMS-ST-C8-7-G2
Festo AG & Co. KG
Postfach
73726 Esslingen
Germany
[phone]
www.festo.com
Brief description 8034543
1404NH
[8034431]
Original: de
Motor controller CMMS-ST-C8-7-G2 English..............................
Translation of the original instructions
You can find the complete documentation for the motor controller
CMMS-ST-...-G2 in PDF format on the CD-ROM accompanying the motor
controller or via the support portal (www.festo.com/sp).
User documentation on the motor controller CMMS-ST-...-G2
Description, mounting and installation,
GDCP-CMMS-ST-G2-HW-...
Mounting, installation, pin allocations and error
messages
Description of the safety function STO,
GDCP-CMMS-ST-G2-S1-...
Functional safety engineering for the motor controller
with the STO safety function
Description, functions and
commissioning, GDCP-CMMS/D-FW-...
Functional description and commissioning with FCT
Control interfaces and device profiles
Description of device profile FHPP,
GDCP-CMMS/D-C-HP-...
Description of the bus interfaces, control and
parameterisation of the motor controller via the device
profile FHPP from Festo
Description of device profile CiA 402,
GDCP-CMMS/D-C-CO-...
Description of CAN interface of the motor controller,
control and parameterisation via device profile CiA 402.
Help on the FCT plug-in CMMS-ST User interface and functions of the CMMS-ST plug-in for
the Festo Configuration Tool www.festo.com/sp
1 Safety and requirements for product use
1.1 Safety
Caution
Short circuits can lead to sudden unloading of the intermediate circuit condens-
ers and energy development:
– when the module or cover plate is not mounted on the card slot [EXT]
– when cables are not mounted to the plugs [X6] and [X9]
– when connecting cables are disconnected when powered.
The product must be installed in a control cabinet. The product may only be used
if all safeguarding has been installed and is operational. Before maintenance,
repair and cleaning work and when there have been long service interruptions:
1. Switch off power to the electrical equipment via the mains switch and secure
it against being switched on again.
2. After switch-off, wait at least 1 minutes discharge time and check that power
is turned off before accessing the controller.
Caution
Danger of burns from hot surfaces
Dependent on the load, housing temperatures > 80 °C are possible in operation.
• Protect hot surfaces from contact in operation.
• Touch them only in a switched-off, cooled-off status.
Note
Danger from unexpected movement of the motor or axis
• Make sure that the movement does not endanger anyone.
• Perform a risk assessment in accordance with the EC Machinery Directive.
• Based on this risk assessment, design the safety system for the entire ma-
chine, taking into account all integrated components.
Intended use
The motor controller CMMS-ST-...-G2 is a digital positioning controller for stepper
motors for
– supply and activation of the motor
– regulation of speed (current), torque and position.
The motor controller supports the following safety function:
– “Safe torque off ” (STO)
Category 3 / PL d in accordance with EN ISO 13849-1.
Use exclusively:
– in an excellent technical status
– in original status, without unauthorised modifications
– within the limits of the product defined through the technical data
–for the safety function within the specified service life of the switching elements
Section 9
– in an industrial environment
– as an installed device in a control cabinet.
Issue status of the specified standards
EN 60204-1:2006/A1:2009-02 EN 61800-5-1:2007-09
EN 61800-2:1998-04 EN ISO 13849-1:2008-06
Foreseeablemisuseofthesafetyfunction
– use outside or in a non-industrial area (residential area),
– use in applications where switching off can result in hazardous movements or
conditions.
Note
– The STO function is insufficient as the sole safety function for drives subject to
permanent torque or force (e. g. suspended loads).
– Bypassing of safety equipment is impermissible.
– Repairs to the motor controller are impermissible!
The STO (Safe Torque Off) function does not provide protection against
electric shock, only against dangerous movements!
In applications with extremely high requirement rates, the service life of the
switching elements must be taken into account in the design (replacement interval
for the motor controller) Section 9.
Attainable safety level in accordance with EN ISO 13849-1
The motor controller can be used in applications up to Cat. 3 / PL d in accordance
with EN ISO 13849-1. The overall achievable safety level depends on the other
components used to achieve the safety function.
1.2 Requirements for product use
For correct and safe use of the product:
• Comply with the connection and ambient conditions of the product and all con-
nected components specified in the technical data. Compliance with the limit
values and load limits permits operation of the product in compliance with the
relevant safety regulations.
• Observe the instructions and warnings in the documentation.
•For the safety function: If the safety function is demanded, protection against
automatic restart corresponding to the required category must be furnished,
e.g. via an external safety switching device.
Qualification of the specialists (requirements for the personnel)
The product may only be placed in operation by a qualified electrotechnician who
is familiar with:
– the installation and operation of electrical control systems,
– the applicable regulations for operating safety-engineered systems,
– the applicable regulations for accident protection and occupational safety, and
– the documentation for the product.
Diagnostic coverage (DC) for the safety function
Diagnostic coverage depends on the interconnection of the motor controller with
the control loop system as well as the implemented diagnostics measures.
If a potentially dangerous malfunction is recognised during the diagnostics, appro-
priate measures must be taken to maintain the safety level.
Note
Check whether a fault exclusion of cross circuits in the input circuit and connec-
tion wiring is possible in your application.
If necessary, use a safety switching device with cross-circuit detection.
Range of application and certifications
The motor controller with integrated STO safety function is a safety-related part of
the control systems. The motor controller carries the CE marking.
Certificates and the declaration of conformity for this product
www.festo.com/sp.

2 Product overview
2.1 Device view
123
4
5
6
7
8
9
aJ
aA
aB
aC
aD
aE
aF
aG
aH
aE
1Front view
2View underneath
3View on top
4Earthing screw (central FU
connection)
5LED status display
67-segments display
7[S1]: DIP switch
8[X5]: RS232/RS485
9[EXT]: Slot for CAMC-...
aJ [X4]: CAN bus
aA [M1]: SD memory card
aB [X3] STO interface
aC [X2] Encoder
aD [X6] Motor
aE Shield connection terminal
aF [X9] Power supply
aG [X10] Master/slave
aH [X1] I/O interface
Fig. 1 Motor controller CMMS-ST-...-G2
2.2 Display and control elements
7-segments display
1)
Rotating out-
side segments
Speed mode (speed adjustment):
Display changes corresponding to rotor position and speed.
Middle segment Controller enable active (motor is energised).
I Force mode (current control).
Pxxx Positioning mode, record number x x x
PHx Homing phase x
HTwo-channel safety function requested (DIN4 [X1.21] and Rel [X3.2]).
POINT Start program (Bootloader) active.
Flashing point – Firmware file (memory card) is being read.
– Display of errors through the start program.
Exxy Error (E = error)
Number: Two-position main index (x x), single-position subindex (y)
Example: E 0 1 0 Section 7.
–xxy– Warning
Number: Two-position main index (x x), single-position subindex (y).
Example:-170-Section 7.
1) Several characters are displayed one after the other.
LED display
Ready Green Operating status/controller enable
Flashing green Parameter file (memory card) is being read/written
CAN Yellow Status display: CAN bus active
DIL switch
S1.1 … 7 CAN bus address or MAC-ID
S1.8 Automatic loading of new firmware from memory card
S1.9 … 10 Setting the CAN-bus transmission rate
S1.11 Activation of the CAN-bus interface
S1.12 Terminating resistor for CAN-bus
3 Mechanical installation
3.1 Mounting
Observe the information on the installation dimensions and free spaces in
the Mounting and installation description GDCP-CMMS-ST-G2-HW-...
For vertical mounting onto a control cabinet mounting plate:
• Use the motor controller exclusively in a control cabinet:
– mounting position vertical with the power supply lines [X9] on top
– attachment to the mounting holes with two M4 screws.
4 Electrical installation
Caution
Danger from unexpected movement
Faulty pre-assembled lines may destroy the electronics and trigger unexpected
movements of the motor.
• When wiring the system, use only the supplied plug connectors and preferably
the cables listed in the catalogue as accessories.
www.festo.com/catalogue
• Lay all flexible lines so that they are free of kinks and free of mechanical
stress; if necessary in an energy chain.
Note
ESD (electrostatic discharge) can cause damage to the device or other system
parts at plug connectors that are not used.
• Before installation: Earth the system parts and use appropriate ESD equip-
ment (e.g. shoes, earthing straps etc.).
• After installation: Seal unassigned D-sub plug connectors with protective caps
(available at authorized dealers).
• Observe the handling specifications for electrostatically sensitive devices.
Observe the information on safe and EMC-suitable installation and on
protective earthing in the mounting and installation description, GDCP-
CMMS-ST-G2-HW-....
4.1 I/O interface [X1]
Pin Value Assignment in 0 mode – positioning
1SGND 0V Screening for analogue signals
2DIN12/AIN0 –/max. 30 V Mode bit 0/setpoint input 0
2)
3DIN10 –Record selection bit 4 (high active)
4+VREF +10 V ±4 % Reference output for setpoint value potentiometer
5 – – –
6GND24 –Reference potential for digital I/O modules
7DIN1 –Record selection bit 1 (high active)
8DIN3 –Record selection bit 3 (high active)
9DIN5 –Controller enable (high active)
10 DIN7 –Limit switch 1
11 DIN9 –Mode bit 1
12 DOUT1 24 V 100 mA Motion complete (high active)
1)
13 DOUT3 24 V 100 mA Common error (low active)
1)
14 AGND 0V Reference potential for analogue signals
15 DIN13/#AIN0 –/Ri = 20 kΩ Stop (low active)/reference potential AIN0
2)
16 DIN11 –Record selection bit 5 (high active)
2)
17 AMON0 0…10V±4% Output: analogue monitor 0
18 +24VDC 24 V 100 mA Output: 24 V DC, looped through from [X9.6]
19 DIN0 –Record selection bit 0 (high active)
20 DIN2 –Record selection bit 2 (high active)
21 DIN4 –Output stage enable (high active)
22 DIN6 –Limit switch 0
23 DIN8 –Start for the positioning procedure (high active)
24 DOUT0 24 V 100 mA Output: Controller ready for operation (high active)
25 DOUT2 24 V 100 mA Start acknowledged (low active)
1)
1) Default setting, configurable in the Festo Configuration Tool (FCT).
2) Pin allocation with control via analogue input
4.2 Encoder [X2]
[X2] Pin Value
1)
Description
6
7
8
9
2
1
3
4
5
1A+ 5 V, Ri = 120 Ohm Increment generator signal A, positive polarity
2B+ 5 V, Ri = 120 Ohm Increment generator signal B, positive polarity
3N+ 5 V, Ri = 120 Ohm Zero pulse N, positive polarity
4GND -Reference GND for the encoder
5VCC +5 V +-5 % 100 mA Auxiliary supply, max. 100 mA
6A- 5 V, Ri = 120 Ohm Increment generator signal A, negative polarity
7B- 5 V, Ri = 120 Ohm Increment generator signal B, negative polarity
8N- 5 V, Ri = 120 Ohm Zero pulse N, negative polarity
9GND -Internal screen for the connecting cable
1) R
i=
Internal resistance

4.3 STO interface [X3]
Interface [X3] (Circuitry without use of the STO safety function)
[X3] Pin Value Description
1
2
3
4
5
6
124 V 24 V DC Voltage output (24 V DC logic supply carried
out as auxiliary voltage)
2REL 0V/24VDC Setting and resetting the relay for interrupting
the driver supply
30V 0V(GND24VDC) Reference potential for PLC (24 V DC)
4 – – –
5NC1 Max. 25 V AC,
30 V DC, 2 A
Potential-free feedback contact for driver supply,
N/C contact
6NC2
Circuitry without use of the STO safety function
If you do not need the integrated safety function STO in your application,
to operate the motor controller you must bridge Pin 1 and Pin 2 at the X3
interface (delivery status).
This deactivates the integrated safety function!
With this circuitry, safety in the application must be ensured through other
appropriate measures.
Use of the STO safety function
For intended use of the safety function STO – “Safe Torque Off ”, observe
the information in the STO description GDCP-CMMS-ST-G2-S1-...
Use the “Safe torque off” function (STO) whenever you have to reliably disconnect
the energy supply to the motor in your application. To ensure the function STO
“Safe Torque Off”, the control ports DIN4 [X1.21] and Rel [X3.2] must be connec-
ted in two channels through parallel wiring. This interface can be part of an emer-
gency stop circuit or a protective door arrangement, for example.
Recommendation for first commissioning without safety engineering:
Minimum circuitry with emergency stop switching device and two-channel switch-
off via the control ports REL [X3.2] and DIN4 [X1.21].
Note
Loss of the safety function.
Lack of the safety function can result in serious, irreversible injuries, e.g. due to
uncontrolled movements of the connected actuator technology.
– The STO function request must always run over X3.2 and X1.21 (end stage
enable).
– If uncontrolled coasting can result in a hazard or damage, additional meas-
ures are required.
– A clamping unit is actuated by the non-safety-relevant firmware of the CMMS-
ST-...-G2 motor controller.
• Make sure that no jumpers or the like can be inserted parallel to the safety
wiring, e.g. through the use of the maximum wire cross section of 1.5 mm² or
suitable wire end sleeves with insulating collars.
• Use twin wire end sleeves for looping through lines between neighbouring
devices.
• Comply with the specified environmental and connection conditions, in partic-
ular the input voltage tolerances.
• Place the motor controller in operation only if all safeguarding, including the
safety function, has been installed and checked.
• The safety function must be checked and, prior to the intended use, a corres-
ponding validation must be carried out.
4.4 CAN [X4]
[X4] Pin Value Description
5
1
2
3
4
6
7
8
9
2CANL 5V,Ri=60Ω CAN low, signal line
3GND –CAN GND, not galvanically isolated
5Screening –Connection for the cable screening
6GND –CAN GND, not galvanically isolated
7CANH 5V,Ri=60Ω CAN high signal line
4.5 Serial interface RS232/RS485 [X5]
[X5] RS232 Pin
1)
Value Description
5
1
2
3
4
6
7
8
9
2RS232_RxD 10 V, Ri >2kΩ Receive signal
3RS232_TxD 10 V, Ra <2kΩ Transmission signal
4RS485_A Positive transmission and reception signal
5GND 0V Reference potential 0 V DC
9RS485_B Negative transmission and reception signal
1) Connect only the pins for RS232 or RS485, dependent on the interface used!
4.6 Motor [X6]
[X6] Pin Value Description
1
2
3
4
5
6
7
8
1 A 4x0…58V
Max. 12 A
eff
Connection power train A
2A/
3 B Connection power train B
4B/
5T+ +3.3V,5mA Temperature sensor (N/C contact, N/O contact /
PTC or KTY)
6T- 0V
7BR+ 24 V Motor holding brake
1)
8BR- 0V
1) In the motor and connecting cable, reliable separation of the motor temperature sensor from the motor
circuit must be ensured.
If third-party cables are used: Place the complete screening of the motor-
side cable flat on the plug or motor housing. Length ≤40 mm.
• Place the complete screening of the motor cable at the screening con-
nection terminal of the related motor controller so that the leaked cur-
rent can flow back into the controller that causes the leak
• Do not use the complete screening as strain relief
Connection of a holding brake
Holding brakes are not appropriate for braking the motor. They only serve
functional holding of the motor shaft. Additional measures are required for
use in safety-oriented applications.
4.7 Power supply [X9]
Protection against electric shock through protective extra-low voltage (PELV):
Warning
Danger of electric shock
• For the electric logic supply and electric load voltage, use only PELV circuits in
accordance with EN 60204-1 (Protective Extra-Low Voltage, PELV). Also take
into account the general requirements for PELV circuits in accordance with
EN 60204-1.
• Make sure that the reference potential of the logic and load supply is connec-
ted to FE at a central position.
• Use only voltage sources that ensure a reliable electric separation of operat-
ing voltage in accordance with EN 60204-1.
Through the use of PELV circuits, protection from electric shock (protection from
direct and indirect contact) in accordance with EN 60204-1 is ensured (Electrical
equipment of machines. General requirements). A 24 V power supply unit used in
the system must satisfy the requirements of EN 60204-1 for DC power supply (be-
haviour during power interruptions, etc.).
[X9] Pin Value Description
IC+

24 V

0V
1IC+ 12 V DC … 58 V DC Intermediate circuit voltage
224 V 24 V DC _20 % Supply of the control section
30V -Common reference potential for the
intermediate circuit and control section
4.8 Master/slave interface [X10]
[X10] Pin Description
6
7
8
9
2
1
3
4
5
1A/CLK/CW Tracking signal A/pulse CLK/steps CW
2B/DIR/CCW Tracking signal B/direction DIR/steps CCW
3 N Incremental encoder zero pulse N
4GND
1)
Reference GND for incremental encoder
5VCC Auxiliary supply, maximum load 100 mA
6#A/#CLK/#CW Tracking signal A/pulse CLK/steps clockwise CW
7#B/#DIR/#CCW Tracking signal B/direction DIR/steps CCW
8#N Zero pulse N
9GND
1)
Screening for the connecting cable
1) Pin 4 and pin 9 are connected internally
5 Commissioning
Note
Danger from unexpected movement of the motor or axis
• Make sure that the movement does not endanger anyone.
• Parameterise the motor controller with the Festo Configuration Tool (FCT)
before enabling the controller via DIN5 [X1.9].
– Bypassing of safety equipment is impermissible
Recommendation for first commissioning without safety equipment
Section 4.3

Note
Damage to the motor controller
The motor controller is damaged in case of
– excessive operating voltage
– polarity reversal of the operating voltage connections
– interchange of operating voltage and motor connections
– short circuits in the motor circuit between the motor phases and FU
• Comply with the specified values for the supply voltage.
• Before switching on, check the connections [X9] and [X6].
• Check to ensure there is no FU short in the motor connection circuit.
Before switching on the power supply:
Check the installation of the motor controller:
• Check all connections.
• Connect all FU conductors, even for brief measuring and test purposes.
• Mounted module or cover plate on the card slot [EXT]. Mounted line on [X9]
and [X6].
Checking ready status
1. Make sure that the controller enable is switched off (controller enable: DIN 5
[X1.9] ).
2. Switch on the power supplies of all devices. The READY LED on the front of the
device should now light up.
If the READY LED is not lit, there is a malfunction. If an “E” appears in the 7-seg-
ments display followed by a sequence of numbers, this is an error message and
you must eliminate the cause of the error.
Additional steps for preparation of commissioning can be found in the
Function description GDCP-CMMS-ST-G2-FW- ...
6 Obligations of the operator for the safety function
The operational capability of the safety device is to be checked at adequate intervals. It
is the responsibility of the operator to choose the type of check and time intervals in
the specified time period. The check is to be conducted so the excellent functioning of
the safety device in interaction with all the components can be verified.
Recommendation: Carry out a performance test at least every 24 hours.
7 Diagnostics and fault clearance
No. Message group Cause/measure
01-x Internal error – stack overflow Load approved firmware.
02-x Undervoltage in intermediate
circuit
Check power supply, intermediate circuit voltage,
undervoltage monitoring (threshold value).
03-x Temperature monitoring, motor Check parameterisation (current regulator, limits).
04-x Temperature monitoring,
electronics
Check installation conditions and cylinder sizing.
05-x Internal power supply Check 24 V logic supply. If error is present without
connected peripheral equipment Repair.
06-x Intermediate circuit
(over-current)
Check motor, cable and motor controller.
07-x Intermediate circuit
(overvoltage)
Check design and connection of the braking resistor.
08-x Angle encoder Check encoder and encoder signals.
11-x Homing Check homing, switch arrangement.
12-x CAN Re-start CAN controller. Check CAN configuration in the
controller. Check wiring.
14-x Motor identification Check intermediate circuit voltage, encoder cable.
Motor blocked, e.g. holding brake does not release?
16-x Initialization Load firmware again. Hardware defective?
17-x Following error monitoring Increase error window. Parameterise acceleration to
be less. Motor overloaded?
18-x Temperature monitoring Check installation conditions.
19-x I²t monitoring Motor/mechanics blocked or sluggish?
21-x Current measurement If the error occurs repeatedly Hardware defective.
22-x PROFIBUS Check slave address, bus termination, cabling.
25-x Firmware Update the firmware.
26-x Data flash Load factory setting. Hardware defective?
29-x SD card Check SD card.
31-x I²t monitoring Check motor and mechanical system.
32-x Intermediate circuit Check mains voltage/power supply, braking resistor.
35-x Fast stop Check parameterisation.
40-x Software limit Check target data and positioning range.
41-x Path program Check parameterisation.
42-x Positioning Parameterisation/sequence control, homing?
43-x Limit switch error Check parametrisation, wiring and limit switches.
45-x STO error Check activation; the error must not recur.
64-x DeviceNet error Check configuration and network.
65-x DeviceNet error Check configuration and network.
70-x Operating mode error Check factor group and impermissible change.
79-x RS232 error Check wiring and transferred data.
8 Repair and disposal
Repair or maintenance of the motor controller is not permissible. If re-
quired, replace the motor controller.
Observe the local regulations for environmentally friendly disposal of elec-
tronic components.
9Technicaldata
The complete technical data on CMMS-ST-...-G2 Mounting and installa-
tion description GDCP-CMMS-ST-G2-HW-....
When using the safety function, observe the special technical data and
restrictions on environmental conditions in dependence on required out-
put nominal power in the description STO GDCP-CMMS-ST-G2-S1-...
Safety reference data and safety specifications
Safety function STO STO, Safe Torque Off
Category 3Grading in categories in accordance with EN ISO 13849-1
Performance Level PL d Performance level in accordance with EN ISO 13849-1
T[Years] 20 Proof test interval
Duration of use in accordance with EN ISO 13849-1
MTTF
d
[Years] 2521 Mean time to dangerous failure.
Due to the service life of the internal switching relay, the safety data for the STO function apply
for an annual actuation rate of nop = 500,000 / a (CMMS-ST-...-G2 from Rev. 02).
Type t est The functional safety engineering of the product has been
certified by an independent testing authority (certificate
www.festo.com/sp).
Reliable component yes, for the STO safety function
General technical data
Product conformity and certifications
CE marking (declaration of conformity
www.festo.com/sp)
in accordance with EU Machinery Directive 2006/42/EC
In accordance with EU EMC Directive 2004/108/EC
The device is intended for use in an industrial environment. Measures for interference suppression
may need to be implemented in residential areas.
Operating and environmental conditions
Permissible setup altitude above sea level
with nominal power [m] 1000
with power reduction [m] 1000 … 3000
Air humidity [%] 0 … 90 (non-condensing)
Degree of protection IP20
Degree of contamination 2
Ambient temperature
with nominal power [°C] 0…+40
with power reduction [°C] +40 … +50
Storage temperature [°C] –25 … +70
Vibration and resistance to shocks
Operation in accordance with EN 61800-5-1, section 5.2.6.4
Conveying in accordance with EN 61800-2, section 4.3.3
Power supply/braking resistor [X9]
Load voltage
Nominal voltage, load voltage supply [V DC] 48
Alternative load voltage supply (parameterisable) [V DC] 24, 48
Voltage range [V DC] 12 … 58
Nominal current [A] 8 (with nominal motor current)
PWM switching frequency (permanently set) [kHz] 50
Logic supply
Nominal voltage [V DC] 24 ± 20 %
Nominal current (outputs unloaded, without holding
brake)
[A] 0.2
Maximum current (incl. holding brake) [A] 1.5
Integrated braking resistor
Braking resistor [Ω] 17
Pulse power (for 50 ms) [W] 500
Nominal power [W] 10
Rated trigger level [V DC] Adjustable in FCT up to 58