Festo CMMS-ST-C8-7 Instruction Manual

Cut:
Above: 61.5 mm
Below: 61.5 mm
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Right: 43.5 mm
Motor controller
Manual
Assembly and
installation
Type
CMMS-ST-C8-7
Manual
554 340
en 0903b
[748 685]

Festo.P.BE-CMMS-ST-HW-EN 0903b 3
Edition _____________________________________________________________ en 0903b
Description ______________________________________________ P.BE-CMMS-ST-HW-EN
Order no. ____________________________________________________________ 554 340
(Festo AG & Co KG., D-73726 Esslingen, 2009)
Internet: http://www.festo.com
E-mail: [email protected]
The copying, distribution and utilization 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
carry out patent, utility model or ornamental design registrations.

4 Festo.P.BE-CMMS-ST-HW-EN 0903b
Index of revisions
Author:
Festo AG & Co. KG
Name of manual:
MOTORCONTROLLER CMMS-ST-C8-7
File name:
File saved at:
Consec. no.
Description
Index of revisions
Date of amendment
001
Produced:
0702NH
28.06.2007
002
Revision
0810a
30.10.2008
003
Revision - Functional safety engineering
0903b
07.09.2009

Festo.P.BE-CMMS-ST-HW-EN 0903b 5
Table of contents
1. General information................................................................................................ 9
1.1 Documentation...................................................................................................... 9
1.2 Type key CMMS-ST-C8-7 ....................................................................................... 9
1.3 Scope of delivery................................................................................................. 10
2. Safety instructions for electrical drives and controllers ...................................... 11
2.1 Symbols used...................................................................................................... 11
2.2 General Information ............................................................................................ 12
2.3 Hazards due to improper use .............................................................................. 13
2.4 Safety instructions .............................................................................................. 14
2.4.1 General safety information .................................................................. 14
2.4.2 Safety instructions for assembly and maintenance.............................. 16
2.4.3 Protection aganst touching electric components ................................. 17
2.4.4 Protection by low voltage (PELV) against electric shock ...................... 19
2.4.5 Protection against dangerous movements........................................... 19
2.4.6 Protection aganst touching hot components ....................................... 20
2.4.7 Protection during handling and installation......................................... 20
3. Product description............................................................................................... 22
3.1 General information............................................................................................. 22
3.2 Performance characteristics ................................................................................ 22
3.3 Interfaces ............................................................................................................ 24
3.3.1 Control interfaces ................................................................................ 24
3.3.2 Overview of interfaces ......................................................................... 24
3.3.3 Analogue setpoint specification........................................................... 25
3.3.4 Interfaces for direct synchronous operation ........................................ 25
3.3.5 I/O functions and device control.......................................................... 31
3.3.6 RS232 interface (diagnosis/parameterization interface) ..................... 32
3.3.7 Multi-firmware strategy ....................................................................... 39
3.3.8 Incremental sensor input ..................................................................... 39
3.3.9 Brake chopper ..................................................................................... 39
3.3.10 Control interface X1 ............................................................................. 40

6 Festo.P.BE-CMMS-ST-HW-EN 0903b
3.3.11 Serial parameterization interface RS232 and RS-485 –X5................... 43
3.3.12 SD cardholder –X12 ............................................................................ 43
3.3.13 SD memory card .................................................................................. 43
3.4 Field bus interface ............................................................................................... 44
3.4.1 FHPP .................................................................................................... 45
3.4.2 CAN bus ............................................................................................... 45
3.4.3 PROFIBUS ............................................................................................ 46
3.4.4 DeviceNet ............................................................................................ 46
3.4.5 MTR-ST series stepper motors............................................................. 47
3.4.6 EMMS-ST series stepper motors.......................................................... 47
3.5 Function overview ............................................................................................... 47
3.5.1 Operating modes ................................................................................. 47
3.5.2 Timing diagram operation mode switchover........................................ 49
3.5.3 Setpoint processing............................................................................. 49
3.5.4 Suppression of ranges ......................................................................... 50
3.5.5 I²t function........................................................................................... 50
3.5.6 Positioning controller........................................................................... 50
3.5.7 Homing run .......................................................................................... 52
3.5.8 Timing diagrams for homing run .......................................................... 55
3.5.9 Trajectory generator ............................................................................ 57
3.5.10 I/O sequence control ........................................................................... 58
3.5.11 Fault messages .................................................................................... 60
3.5.12 Behaviour when enable is switched off................................................ 60
3.5.13 Oscilloscope function .......................................................................... 62
3.5.14 Jog and teach function I/O ................................................................... 63
3.5.15 Position record linking with positioning/torque control switching....... 68
3.5.16 On-the-fly measurement ...................................................................... 74
3.5.17 Endless positioning.............................................................................. 74
3.5.18 Relative positioning records ................................................................ 75
4. Functional safety engineering .............................................................................. 76
4.1 General information and intended use ................................................................ 76
4.2 STO, Safe torque off ............................................................................................ 76
4.3 SS1, Safe Stop 1.................................................................................................. 79

Festo.P.BE-CMMS-ST-HW-EN 0903b 7
5. Mechanical installation ........................................................................................ 85
5.1 Important instructions......................................................................................... 85
5.2 Assembly............................................................................................................. 87
6. Electrical installation............................................................................................ 88
6.1 Device view ......................................................................................................... 88
6.2 Interfaces ............................................................................................................ 90
6.3 CMMS-ST complete system ................................................................................. 91
6.4 Interfaces ............................................................................................................ 93
6.4.1 I/O interface [X1].................................................................................. 93
6.4.2 Incremental encoder input [X2] ............................................................ 97
6.4.3 Field bus CAN [X4]................................................................................ 97
6.4.4 RS232/RS-485 [X5] .............................................................................. 98
6.4.5 Motor connection [X6].......................................................................... 98
6.4.6 Power supply [X9] ................................................................................ 99
6.4.7 Increment generator interface/control signals [X10]............................ 99
6.4.8 SD card .............................................................................................. 100
6.4.9 Field bus settings and boot loader..................................................... 100
6.5 Instructions on safe and EMC-compliant installation......................................... 101
6.5.1 Explanations and terms ..................................................................... 101
6.5.2 General information on EMC .............................................................. 101
6.5.3 EMC areas: second environment........................................................ 102
6.5.4 EMC-compliant wiring ........................................................................ 102
6.5.5 Operation with long motor cables...................................................... 103
6.5.6 ESD protection................................................................................... 103
7. Preparations for commissioning......................................................................... 104
7.1 General connection instructions........................................................................ 104
7.2 Tools/material................................................................................................... 104
7.3 Connecting the motor........................................................................................ 104
7.4 Connect the CMMS-ST stepping motor controller to the power supply ............. 105
7.5 Connecting a PC................................................................................................. 105
7.6 Checking readiness for operation...................................................................... 105
7.7 Timing diagram switch-on sequence ................................................................. 106

8 Festo.P.BE-CMMS-ST-HW-EN 0903b
8. Service functions and error messages................................................................ 107
8.1 Protective and service functions........................................................................ 107
8.1.1 Overview............................................................................................ 107
8.1.2 Overload current and short-circuit monitoring................................... 107
8.1.3 Voltage monitoring for the intermediate circuit ................................. 107
8.1.4 Temperature monitoring for the heat sink ......................................... 107
8.1.5 I²t monitoring..................................................................................... 108
8.1.6 Power monitoring for the brake chopper ........................................... 108
8.1.7 Commissioning status........................................................................ 108
8.2 Operating mode and error messages ................................................................ 108
8.2.1 Operating mode and error display ..................................................... 108
8.2.2 Error messages .................................................................................. 109
A. Technical specifications...................................................................................... 114
A.1 General information........................................................................................... 114
A.2 Operation and display components................................................................... 115
A.3 Interfaces .......................................................................................................... 116
A.3.1 Power supply [X9] .............................................................................. 116
A.3.2 Motor connection [X6]........................................................................ 116
A.3.3 Incremental encoder input [X2] .......................................................... 117
A.3.4 Incremental sensor interface [X10]..................................................... 117
A.3.5 RS232/RS-485 [X5] ............................................................................ 118
A.3.6 CAN bus [X4] ...................................................................................... 118
A.3.7 I/O interface [X1]................................................................................ 118
B. Glossary .............................................................................................................. 120
C. INDEX .................................................................................................................. 121

1. General information
Festo.P.BE-CMMS-ST-HW-EN 0903b 9
1. General information
1.1 Documentation
This product manual is meant to promote safe work with the CMMS-ST-series stepping
motor controller. It contains safety instructions that must be followed.
This document provides information on:
-mechanical fitting
-electrical installation and an
-overview of the range of functions.
See the following manuals on the CMMx product family for further information:
-CANopen manual ‚P.BE-CMMS-CO-…‛: Description of the implemented
CANopen protocol according to 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 key CMMS-ST-C8-7
CMM
—
S
—
ST
—
C8
—
7
Series
CMM
Motor controller
Version
S
Standard
Motor technology
ST
Stepper motor
Rated motor current
C8
8 A
Input voltage
7
48 V DC

1. General information
10 Festo.P.BE-CMMS-ST-HW-EN 0903b
1.3 Scope of delivery
The delivery includes:
Number
Delivery
1
Stepping motor controller CMMS-ST-C8-7
1
CD (configuration software, documentation, S7 module, GSD, EDS, firmware)
1
Brief description
1
NEKM-C-1 plug assortment
Tab. 1.1: Scope of delivery

2. Technical specificationsSafety instructions for electrical drives and controllers
Festo.P.BE-CMMS-ST-HW-EN 0903b 11
2. Safety instructions for electrical drives and
controllers
2.1 Symbols 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.
Accessory
Environment

2. Safety instructions for electrical drives and controllers
12 Festo.P.BE-CMMS-ST-HW-EN 0903b
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
Before commissioning, the Safety instructions for electrical drives
and controllers must be read from page 11 and the chapter 6.5 In-
structions on safe and EMC-compliant installation page 101.
If the documentation in the language in question cannot be understood fully, please
contact your vendor and inform them.
In order for the stepping motor controller to operate without problems and safely, it must
be transported, stored, mounted, planned properly and correctly, taking the risks and
protection 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
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 setting up,
mounting, commissioning 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 first start-up of the sytem in order that
bodily injuries and/or damage to property can be avoided.
These safety instructions must be observed at all times.
Do not attempt to install or commission the stepping motor
controller until you have read all safety instructions related to
electrical drives and control systems in this document.
These safety instructions and all other user instructions must be
read before performing any work with the stepping motor controller.

2. Technical specificationsSafety instructions for electrical drives and controllers
Festo.P.BE-CMMS-ST-HW-EN 0903b 13
If you do not have user instructions for the stepping motor
controller, contact your local sales representative.
Ask them to send the documents to the person responsible for
safe operation of the stepping motor controller immediately.
If the stepping motor controller is sold, rented and/or passed on in
any other way, these safety instructions must also be passed on
with it.
Due to safety and warranty reasons, the operator must not open
the stepping motor controller.
Correct planning is required for the stepping motor controller to
function properly.
Warning
DANGER!
Incorrect use of the stepping motor controller, failure to follow the
warnings in this manual and improper manipulation of safety
equipment can cause material damage, injury, electric shock, and
in extreme cases, even be fatal.
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 resulting from incorrect connection!
Danger of death or bodily injury from electric shock!
Warning
DANGER!
Surfaces of the device housing may be hot!
Danger of injury! Danger of burns!

2. Safety instructions for electrical drives and controllers
14 Festo.P.BE-CMMS-ST-HW-EN 0903b
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 stepping motor 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 stepping motor controllers must be connected to the grid in
such a way that they can be disconnected using appropriate
isolating equipment (e.g. main switch, contactor, circuit
breaker).
Warning
Gold contacts or contacts with high contact pressure should be
used for switching the control 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
country in which the device is to be used.

2. Technical specificationsSafety instructions for electrical drives and controllers
Festo.P.BE-CMMS-ST-HW-EN 0903b 15
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.
See chapter 6.5 Instructions on safe and EMC-compliant
installation (page 101) for the instructions for EMC-compliant
installation.
The manufacturer of the system or machine is responsible for
ensuring that the limit values required by the national regulations
are observed.
Warning
See this product manual for the specifications, connection and
installation conditions for the stepping motor controller and
absolutely must 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.
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
Electrical equipment for machines.
EN 50178
Equipping high-voltage systems with electronic
operating media.
EN ISO 12100
Safety of machines –basic concepts, general
guidelines
EN 1050
Safety of machines –guidelines for risk
evaluation
EN 1037
Safety of machines –avoiding unintentional
starting
EN ISO 13849-1
Safety-relevant parts of controllers
EN 61800-5-2
Variable-speed electric drives –functional safety
requirements

2. Safety instructions for electrical drives and controllers
16 Festo.P.BE-CMMS-ST-HW-EN 0903b
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 stepping 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 suit-
able for protecting human beings.
Vertical axes must be additionally secured against falling or
sliding down when the motor is switched off with e.g.
–mechanical locking of the vertical axis,
–external braking, safety catch or clamping devices or
–sufficient weight compensation of the axis.
Warning
During operation and up to several minutes after the stepping
motor controller is deactivated, the internal brake resistance can
cause dangerous intermediate circuit voltage. 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 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 after
–maintenance work and repairs
–cleaning
–long periods out of use.
Warning
Proceed carefully with mounting. Ensure that no drilling chips,
metal dust or mounting material (screws, nuts, wire cuttings) fall
into the stepping motor controller during mounting work and
subsequent operation.

2. Technical specificationsSafety instructions for electrical drives and controllers
Festo.P.BE-CMMS-ST-HW-EN 0903b 17
Ensure that the external power supply of the controller (24 V) is
switched off.
The intermediate circuit or the load voltage must always be
switched off before the 24 V control voltage 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.
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 stepping motor controller and, in particular, the braking
resistor can become very hot, and can cause serious burns if
touched.
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!

2. Safety instructions for electrical drives and controllers
18 Festo.P.BE-CMMS-ST-HW-EN 0903b
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.
Warning
Before switching the device on, fit the 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.
Regulations BGVA3 must be observed.
Warning
Ensure that the minimum copper cross section is observed for the
entire length of the protective earth conductor in accordance with
standard EN 60617.
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. Technical specificationsSafety instructions for electrical drives and controllers
Festo.P.BE-CMMS-ST-HW-EN 0903b 19
2.4.4 Protection by low voltage (PELV) against electric shock
All connections and terminals with voltages from 5 to 60 volts on the stepping motor
controller are PELVs which are designed to be safe to touch in accordance with the
following standards:
Standards
-international: IEC 60364-4-41
-European countries in the EU: EN 50178/1998, section 5.2.8.1.
Warning
DANGER!
High electric voltage resulting from 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 60 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
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
-Faults in the software in the higher-order control system
-Removal of end-stage enable
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 human
beings, especially the danger of bodily injury and/or material damage, one must not rely
on these circumstances alone. Until the fitted monitoring functions become effective, you
must reckon with at least one incorrect drive movement, the extent of which depends on
the type of control and on the operating state.
Warning
DANGER!
Dangerous movements!
Danger of injury or death, serious bodily injury or material damage.

2. Safety instructions for electrical drives and controllers
20 Festo.P.BE-CMMS-ST-HW-EN 0903b
For the above-mentioned reasons, the protection of human beings must be ensured with
the aid of monitoring systems or by measures which are of higher order than the system.
These measures are foreseen depending on the specific features of a danger and fault
analysis by the system manufacturer. The safety regulations applicable to the system
must be observed here as well. Undesired movements of the machine or other incorrect
functions can occur as a result of switching off, avoiding or failing to activate safety
devices.
2.4.6 Protection aganst touching hot components
Warning
DANGER!
Surfaces of the device housing may be hot!
Danger of injury! Danger of burns!
Warning
Danger of burns!
Do not touch the surface of the housing in the vicinity of heat
sources.
After switching devices off, leave them for 10 minutes to cool
down before touching them.
If you touch hot parts of the device such as the housing, which
contains the heat sink and resistors, you may burn yourself.
2.4.7 Protection during handling and installation
Handling and assembling certain components in an unsuitable manner can cause injury
under unfavourable circumstances.
Warning
DANGER!
Danger of injury as a result of incorrect handling
Bodily injury caused by squeezing, cutting, impact!