Festo CPX-CMAX Operating and installation instructions

Description
Axis controller
CPX-CMAX-C1-1
System description
Mounting,
installation and
diagnostics of
positioning system
559751
en 2017-09b
[8065002]
Axis controller CPX-CMAX
Terminal CPX

Axis controller CPX-CMAX
2 Festo – P.BE-CPX-CMAX-SYS-DE – en 2017-09b –
Original instructions
P.BE-CPX-CMAX-SYS-DE
Interbus®, DeviceNet®, PI PROFIBUS PROFINET®, CC-Link®,EtherNET/IP®,Adobe Reader®and TORX®
are registered trademarks of the respective trademark owners in certain countries.
Identification of hazards and instructions on how to prevent them:
Warning
Hazards that can cause death or serious injuries
Caution
Hazards that can cause minor injuries
Other symbols:
Note
Material damage or loss of function
Recommendations, tips, references to other documentation
Essential or useful accessories
Information on environmentally sound usage
Text designations:
 Activities that may be carried out in any order
1. Activities that should be carried out in the order stated
– General lists

Axis controller CPX-CMAX
Festo – P.BE-CPX-CMAX-SYS-EN – en 2017-09b – English 3
Table of Contents – Axis controller CPX-CMAX
Index 98........................................................................
Instructions on this documentation 6.................................................
Target group 7...................................................................
Versions 7......................................................................
Service 7.......................................................................
Product identification 8...........................................................
Type codes 8....................................................................
Documentation for the CPX terminal 9................................................
1 Safety and requirements for product use 10......................................
1.1 Safety 10..................................................................
1.1.1 General safety information 10..........................................
1.1.2 Intended use 11.....................................................
1.2 Requirements for product use 12...............................................
1.2.1 Transport and storage conditions 12....................................
1.2.2 Technical prerequisites 12............................................
1.2.3 Qualification of the specialists (requirements for the personnel) 12............
1.2.4 Range of application and certifications 12................................
1.2.5 Permitted CPX bus nodes and control blocks 13...........................
1.2.6 Festo Configuration Tool with plug-in for the CMAX 14......................
2 Product overview 15.........................................................
2.1 Structure of a positioning system 15.............................................
2.2 Connection and display components 16..........................................
2.3 Function and application 16....................................................
2.3.1 Tasks of the CMAX 16................................................
2.3.2 Mode of operation 16................................................
2.3.3 General instructions on use of the CMAX 17...............................
2.3.4 CMAX in the CPX terminal 17...........................................
3 Mounting and pneumatic installation 18.........................................
3.1 General instructions on mounting and installation 18...............................
3.2 Dismantling and mounting CMAX 19.............................................
3.3 Mounting of the drive and displacement encoder 21................................
3.3.1 General requirements of the mechanical system 21........................
3.3.2 Drive, shock absorbers and fixed stops 23................................
3.3.3 External displacement encoders 23.....................................
3.3.4 Load 25...........................................................
3.4 Proportional directional control valve VPWP 28....................................

Axis controller CPX-CMAX
4 Festo – P.BE-CPX-CMAX-SYS-EN – en 2017-09b – English
3.4.1 Approved drive/valve combinations 28..................................
3.4.2 Mounting the VPWP proportional directional control valve 30.................
3.5 Mounting the CASM sensor interface 32..........................................
3.6 Pneumatic installation 33.....................................................
3.6.1 Compressed air supply 33.............................................
3.6.2 Filter regulator 34...................................................
3.6.3 Air pressure reservoir (optional) 34.....................................
3.6.4 Proportional directional control valve VPWP and drive 34....................
3.6.5 Compressed air tubing and fittings 38...................................
4 Electrical installation 39......................................................
4.1 Safety instructions 39........................................................
4.2 Earthing 40.................................................................
4.3 Axis connection 41...........................................................
4.3.1 Proportional directional control valve VPWP 42............................
4.3.2 Sensor interface CASM 43............................................
4.4 Power supply 44.............................................................
4.4.1 Determining the current consumption 44.................................
4.4.2 Power supply concept, formation of power zones 45........................
5 Commissioning 48...........................................................
5.1 Important notes on commissioning 48...........................................
5.2 Parameterisation and commissioning options 49...................................
5.2.1 Communication profile FHPP 49........................................
5.2.2 Festo Configuration Tool (FCT) 49.......................................
5.3 Preparations for commissioning 52..............................................
5.3.1 Checking the axis string 52............................................
5.3.2 Switching on the supply voltage, switch-on behaviour 52....................
5.3.3 Make connection to the PC 54..........................................
5.4 Commissioning with the FCT (overview) 55........................................
5.4.1 Overview of commissioning steps 55....................................
5.5 Notes on operation 56........................................................
5.5.1 Control of the CMAX 56...............................................
5.5.2 General instructions on operation 56....................................
6 Diagnostics and error handling 57..............................................
6.1 Summary of diagnostics options 57.............................................
6.2 Diagnostics via LEDs 58.......................................................
6.2.1 CMAX-specific LEDs 59...............................................
6.2.2 Axis-specific LEDs 59.................................................
6.2.3 LEDs at the proportional directional control valve VPWP 60..................
6.2.4 LEDs at the sensor interface CASM 61...................................

Axis controller CPX-CMAX
Festo – P.BE-CPX-CMAX-SYS-EN – en 2017-09b – English 5
6.2.5 LEDs at the displacement encoder DGCI 61...............................
6.3 Diagnostics via display 62.....................................................
6.3.1 Error display 62.....................................................
6.3.2 Status display 63....................................................
6.4 Faults and warnings 67.......................................................
6.4.1 Effect on the sequence control and axis – error level 67.....................
6.4.2 Acknowledgement of faults and warnings – reset type 68....................
6.4.3 Illustration of CMAX error numbers in the CPX terminal 69...................
6.4.4 Error and warning numbers 70.........................................
6.5 Diagnostic functions with the CPX-MMI 87........................................
6.5.1 Error display (menu [Diagnostics] ) 87...................................
6.5.2 Information on the CMAX (menu [Module Data] ) 88........................
A Technical appendix 89........................................................
A.1 Technical data CMAX 89.......................................................
A.2 Replacement of components 92................................................
A.3 Additional pneumatic circuits 93................................................
B Glossary 94................................................................

Axis controller CPX-CMAX
6 Festo – P.BE-CPX-CMAX-SYS-EN – en 2017-09b – English
Instructions on this documentation
This description contains information on the functioning, mounting, installation and commissioning of
the CPX-CMAX axis controller with the following modules and components of the positioning system
(èTab. 1).
Module/component - type Description
CPX-CMAX-C1-1 Axis controller with 7-segments display and an axis connection
to the proportional directional control valve VPWP. The axis
controller – hereafter also called CMAX for short – is a CPX
module (technology module) in a CPX terminal.
VPWP-... VPWP proportional directional control valve for connection of
the pneumatic drive with connections to the CMAX and to the
displacement encoder or sensor interface. In addition, it has a
digital output and a voltage output for control of a brake or
clamping unit.
CASM-S-D2-R3
CASM-S-D3-R7
Sensor interfaces with connection to the VPWP for connecting
special displacement encoders to the axis string:
– analogue, absolute displacement encoders (potentiometer)
– digital, incremental displacement encoders
Approved drives with displacement encoder1)
DDLI – Linear drive with integrated displacement encoder
(digital – absolute)
DDPC – Standard cylinder with integrated displacement encoder
(incremental displacement encoder)
DGCI – Linear drive with permanently attached displacement
encoder (digital – absolute)
DNCI – Standard cylinder with integrated displacement encoder
(incremental displacement encoder)
DNC with MLO-
POT-..-LWG
– Standard cylinder with external displacement encoder
(potentiometer – absolute)
DSMI – Semi-rotary drive with integrated displacement encoder
(potentiometer – absolute)
1) Support for other drives in preparation
Tab. 1 Overview of modules and components of positioning system

Axis controller CPX-CMAX
Festo – P.BE-CPX-CMAX-SYS-EN – en 2017-09b – English 7
Target group
This documentation is intended exclusively for technicians trained in control and automation techno
logy, who have experience in installation, commissioning, programming and diagnostics of positioning
systems.
Versions
This documentation refers to the following versions:
– Axis controller CPX-CMAX with firmware V 2.3 and above.
Note
Before using a newer firmware version, check whether a newer version of the FCT
plug-in or user documentation is available for it
(èwww.festo.com/sp, search term CPX-CMAX-C1-1).
Additional information on the version statuses èHelp on the FCT-plug-in CMAX.
Service
Consult your regional Festo contact if you have any technical problems.

Axis controller CPX-CMAX
8 Festo – P.BE-CPX-CMAX-SYS-EN – en 2017-09b – English
Product identification
Product label (example) Significance
CPX-CMAX-C1-1
548932 X407
Rev 08
00000001502152
CPX-CMAX-C1-1 Type designation
548932 Part number
X407 Production time period and plant
Rev 08 Revision status
00000001502152 14-character serial number
Tab. 2 Product label Axis controller CPX-CMAX
Type codes
CPX –
Valve terminal
CMAX C1 1 –
–
CPX Terminal
Type
CMAX Axis controller
Function module
C1 Controller
Axes
1 One axis
Fig. 1 Type codes

Axis controller CPX-CMAX
Festo – P.BE-CPX-CMAX-SYS-EN – en 2017-09b – English 9
Documentation for the CPX terminal
General basic information about the mode of operation, mounting, installation and com
missioning of CPX terminals èCPX system description, P.BE-CPX-SYS-...
(èwww.festo.com/sp, search term CPX). Information about additional electronic mod
ules from CPX èdescription on the respective electronics module. Overview of the struc
ture of user documentation for the CPX terminal èCPX system description.
Documentation for Axis controller CPX-CMAX
Type Title Type Contents
Electronics
description
CPX-CMAX axis
controller (system
description)
P.BE-CPX-CMAX-SYS-... – Mounting
– Installation
– Commissioning
– Diagnostics
Communication
profile
description
FHPP for the
CPX-CMAX axis
controller
P.BE-CPX-CMAX-CONTROL-... – Control
– Programming
– Diagnostics of a CMAX
with the used CPX node
Software Help Help for Festo Configuration Tool with CMAX plug-in Configuration and
commissioning of the CMAX
axis controller with the FCT
Operating
instructions
Operating instructions for the components used
Tab. 3 Documentation for Axis controller CPX-CMAX
Electronic versions of the documentation for the CMAX axis controller in the Internet
èwww.festo.com/sp, search term CPX-CMAX-C1-1.

1 Safety and requirements for product use
10 Festo – P.BE-CPX-CMAX-SYS-EN – en 2017-09b – English
1 Safety and requirements for product use
1.1 Safety
1.1.1 General safety information
Warning
Danger from unexpected movement of the axis
Accidental movements of the connected actuators can cause collisions, with serious
injuries. Dangerous movements due to incorrect control of connected actuators, for
example caused by:
– untidy or faulty wiring/cabling
– errors in operating the components
– errors in the measured value and signal encoders
– defective or non-EMC-compliant components
– errors in the higher-order control system
Switching off the compressed air or load voltage is not a suitable locking method. In
case of malfunction, drives can travel unintentionally.
 Before carrying out mounting, installation and maintenance work, place the system
in a safe status (e.g. by placing the drive in a safe position and locking it).
 Make sure that no one enters the sphere of influence of the drives and actuators.
 Switch on the compressed air only when the system has been professionally in
stalled and parameterised.
 Note that the controlled brake/clamping unit alone is not appropriate for personal
protection.
 Provide additional support to protect vertical axes from falling or sliding down when
the compressed air and load voltage are switched off, such as by:
– mechanical locking of the vertical axis
– external brake/clamping unit
– sufficient counterbalance of the axis
Caution
Danger of injury due to incorrect handling of pressurised lines
Uncontrolled movements of the connected actuator technology and loose tubing can
cause injury to persons and/or damage to property.
 Do not disconnect, open or cap pressurised lines.
 Exhaust lines before dismantling (release compressed air).
 Use suitable protective equipment (e.g. safety goggles, safety shoes).

1 Safety and requirements for product use
Festo – P.BE-CPX-CMAX-SYS-EN – en 2017-09b – English 11
Note
Damage to the product from incorrect handling.
 Switch off the supply voltage before mounting and installation work. Switch on sup
ply voltage only when mounting and installation work are completely finished.
 Never unplug or plug in the product and components attached to the axis connec
tion when powered!
 Observe the handling specifications for electrostatically sensitive devices.
1.1.2 Intended use
The Axis controller CPX-CMAX is intended to serve as a position controller for location and force control
of pneumatic drives. Operation is permitted only in combination with:
– an appropriate CPX bus node or control block ( èSection 1.2.5)
– components approved for this purpose on the axis string (èChapter 3)
The product is intended for use in industrial environments. Outside of industrial environments, e.g. in
commercial and mixed-residential areas, actions to suppress interference may have to be taken. The
Axis controller CPX-CMAX is intended exclusively for use in CPX terminals from Festo for installation in
machines or automated systems.
Use exclusively:
– in perfect technical condition
– In original condition, without unauthorised modifications
– within the limits of the product defined by the technical data (èAppendix A.1)
– in an industrial environment
Note
In the event of damage caused by unauthorised manipulation or other than intended
use, the guarantee is invalidated and the manufacturer is not liable for damages.

1 Safety and requirements for product use
12 Festo – P.BE-CPX-CMAX-SYS-EN – en 2017-09b – English
1.2 Requirements for product use
 Make this documentation available to the design engineer, installer and person responsible for
commissioning of the machine or system in which this product will be used.
 Always comply with the specifications of the documentation. Also consider the documentation for
the other components and modules.
 Take into consideration the legal regulations applicable for the location as well as:
– regulations and standards
– regulations of testing organisations and insurers
– national specifications
1.2.1 Transport and storage conditions
 Protect the product during transport and storage from excessive stress factors, such as:
– mechanical loads
– impermissible temperatures
– moisture
– aggressive atmospheres
 Store and transport the product in its original packaging. The original packaging offers sufficient
protection from typical stresses.
1.2.2 Technical prerequisites
General conditions for the correct and safe use of the product, which must be observed at all times:
 Comply with the connection and ambient conditions of the product and all connected components
specified in the technical data. Technical data of the product èAppendix A.1. The product can only
be operated in compliance with the relevant safety regulations if you comply with the limit values
and load limits.
 Observe the notes and warnings in this documentation.
1.2.3 Qualification of the specialists (requirements for the personnel)
The product may only be placed in operation by a qualified electrotechnician who is familiar with:
– Installation and operation of electrical control systems
– the applicable regulations for operating safety-engineered systems
– the applicable regulations for accident prevention and occupational safety and
– the documentation for the product
1.2.4 Range of application and certifications
Test values, which the product must comply with and fulfil èTechnical data in appendix A.1. Product-
relevant EC directives èDeclaration of conformity.
For certificates and the declaration of conformity for this product èwww.festo.com/sp.

1 Safety and requirements for product use
Festo – P.BE-CPX-CMAX-SYS-EN – en 2017-09b – English 13
Specified standards
Version status
EN 60204-1:2006-06/A1:2009-02 ISO 8573-1:2010
Tab. 1.1 Standards specified in the document
1.2.5 Permitted CPX bus nodes and control blocks
The following CPX bus nodes and control blocks are approved for operation with the CMAX axis control
ler starting with the revisions named here (at the time this description was printed). Older revisions are
not supported and can lead to unpredictable behaviour.
Current information on this ècatalogue from Festo (èwww.festo.com/catalogue).
Observe the notes on the software status in the documentation for the bus node or con
trol block.
Bus node/
control block
Protocol Approved revision1) Max. number2)
CMAX
CPX-CEC (Control block) Revision 5 and above 8
CPX-FEC Revision 19 (R19) and above 8
CPX-CEC-C1 Revision 7 (R7) and above 8
CPX-CEC-M1 Revision 3 (R3) and above 8
CPX-FB6 Interbus Revision 22 (R22) and above 1
CPX-FB11 DeviceNet Revision 20 (R20) and above 8
CPX-FB13 PROFIBUS-DP Revision 23 (R23) and above 8, 73)
CPX-FB14 CANopen Revision 20 (R20) and above 4
CPX-M-FB20 Interbus Revision 2 (R2) and above 1
CPX-M-FB21 Interbus Revision 2 (R2) and above 1
CPX-FB23-24 CC-Link (function module F23) Revision 19 (R19) and above 4
CC-Link (function module F24) 8
CPX-FB32 EtherNet/IP Revision 14 (R14) and above 8
CPX-FB33 PROFINET Revision 7 (R7) and above 8
CPX-M-FB34 Revision 7 (R7) and above 8
CPX-M-FB35 Revision (R20) and above 8
CPX-FB36 EtherNet/IP Revision 5 (R5) and above 8
CPX-FB38 EtherCAT All 8
1) Revision status (Rev...) èProduct label.
2) The maximum number within a CPX terminal can be further restricted through the available address range.
3) If acyclic services (DPV1) are used, a maximum of 7 CMAX modules are permitted.
Tab. 1.2 Required revisions

1 Safety and requirements for product use
14 Festo – P.BE-CPX-CMAX-SYS-EN – en 2017-09b – English
1.2.6 Festo Configuration Tool with plug-in for the CMAX
The Festo Configuration Tool (FCT) is the software platform for configuring and commissioning the CMAX.
FCT with plug-in for the CMAX èwww.festo.com/sp, search term: CMAX.

2 Product overview
Festo – P.BE-CPX-CMAX-SYS-EN – en 2017-09b – English 15
2 Product overview
2.1 Structure of a positioning system
1
2
3
45
6
1CPX terminal with Axis controller CPX-CMAX
2Sensor interface with connecting cable
(optional, depending on the displacement
encoder used)
3Drive with displacement encoder
4Pneumatic tubing
5Proportional directional control valve VPWP
6Axis string
Fig. 2.1 Structure of a positioning system with Axis controller CPX-CMAX – example

2 Product overview
16 Festo – P.BE-CPX-CMAX-SYS-EN – en 2017-09b – English
2.2 Connection and display components
12
3
4
1Seven-segments display
2Status LEDs
3Inscription labels (6)
4Axis connection (connection for VPWP)
Fig. 2.2 Control section and connections Axis controller CPX-CMAX
2.3 Function and application
2.3.1 Tasks of the CMAX
The CMAX takes over the following functions:
– storage of all project parameters (e.g. hardware configuration, records, controller settings)
– determination of system characteristic values of the connected components (identification)
– specification of the setpoint values (position or force) calculated from the specified target value and
the parameterised movement profile
– tracking of the actual value (position or force control) in case of deviation through corresponding
control of the proportional directional control valve
2.3.2 Mode of operation
The CMAX, valve, drive and displacement encoder are connected with each other to form a closed-loop.
In combination with a proportional directional control valve VPWP and a drive with a displacement en
coder, the CMAX axis controller forms a positioning system for pneumatic axes (èSection 1.2). The
positioning system permits the following:
– travel at selectable speed with previously configured acceleration in any positions (position control)
– application of a defined force with configured force edge [N/s] (force control) with simultaneous
speed and position monitoring

2 Product overview
Festo – P.BE-CPX-CMAX-SYS-EN – en 2017-09b – English 17
2.3.3 General instructions on use of the CMAX
Fundamentals for planning and execution of positioning systems with CMAX
In the CPX terminal, a maximum of 8 CMAX modules are permitted - dependent on the bus node
(èTab. 1.2).
The maximum permitted length (total) of the used connecting cables KVI-CP-3-... of the axis string is
30 m (total length CMAX – VPWP – sensor interface or displacement encoder; èFig. 2.1).
 Attach drive backlash-free to the application and displacement encoder.
 Comply with minimum load (èSection 3.3.4).
 Comply with requirements for compressed air supply (èSection 3.6.1 and 3.6.2)
 Take into account emergency stop processing of an axis from the start (additional pneumatic cir
cuitry èA.3).
 Always select tubing between cylinder and VPWP valve to be as short as possible. A tube length of
60 % of the cylinder stroke length is optimal (max. tube length = cylinder stroke length).
 Avoid elbow connectors as much as possible. Elbow connectors reduce the flow by up to 30 %. This
reduces the possible top speed and maximum acceleration.
 Take into account power requirements of the components used. For example, the max. current con
sumption of the valve VPWP is up to 1.35 A (valve drive 1.2 A, logic 0.15 A) - without current con
sumption for the optionally usable outputs (èSection 4.4.1).
To achieve good positioning behaviour:
 Feed compressed air at the cylinder on both sides.
 Comply with stroke reduction in accordance with the catalogue specifications.
Stroke reduction is 10 ... 35 mm per side – dependent on the cylinder (èwww.festo.com/catalogue).
Tip: The best positioning behaviour is achieved when only 80 % of the cylinder stroke is used and 10 %
remains on each side as reserve.
The CMAX is not suitable for:
– cylinder lengths > 2000 mm
– cylinder lengths > 50 mm
– repetition accuracy < ±0.2 mm
– speeds < 30 mm/s
– positioning strokes < 10 mm
– force values that lie underneath the friction of the system
2.3.4 CMAX in the CPX terminal
The CMAX is integrated into a CPX terminal as a CPX module and is controlled by the CPX bus node or
control block via the internal bus using 8-byte module output data and 8-byte module input data.
Information on control and parameterisation of the CMAX over the CPX node
èCommunication profile description, P.BE-CPX-CMAX-CONTROL-... .

3 Mounting and pneumatic installation
18 Festo – P.BE-CPX-CMAX-SYS-EN – en 2017-09b – English
3 Mounting and pneumatic installation
3.1 General instructions on mounting and installation
When mounting the components, observe also the mounting instructions in the accompa
nying operating instructions and the notes on installation in this chapter. Only then can
you guarantee trouble-free operation. Information about mounting of the CPX terminal
èCPX system description (P.BE-CPX-SYS-...).
Note
Malfunctions due to impermissible components
The use of components that have not been approved for operation with the CMAX may
cause malfunctions.
 Use only the special matching components from Festo for setting up and wiring the
system.
Section 3.4
Section 3.6.3
Section 3.2
Section 3.6.1
Section 3.6.2
Section 3.3.4
Section 3.6.5
Section 3.5
Section 3.3
Section 3.6.4
Fig. 3.1 Overview of mounting and pneumatic installation

3 Mounting and pneumatic installation
Festo – P.BE-CPX-CMAX-SYS-EN – en 2017-09b – English 19
3.2 Dismantling and mounting CMAX
The CMAX is mounted in an interlinking block (èSection 4.4) of the CPX terminal (èFig. 3.2).
Note
Damage to the product from incorrect handling.
 Switch off the supply voltage before mounting and installation work. Switch on sup
ply voltage only when mounting and installation work are completely finished.
 Never push/pull the electronics module into/out of the interlinking block when un
der power!
Note
The CMAX contains electrostatically sensitive devices. Electrostatic discharge caused by
improper handling or incorrect earthing can damage components.
 Do not touch any components.
 Observe the handling specifications for electrostatically sensitive devices.
Dismantling CMAX
1. Switch off the operating and load voltage supplies.
2. Unscrew 4 CMAX screws using a TORX screwdriver, size T10.
3. Pull CMAX carefully and without tilting away from the contact rails of the interlinking block.
1
2
3
4
1CMAX
2Interlinking block
3Contact rails
4Torx T10 screws
Fig. 3.2 Dismantling/mounting the CMAX

3 Mounting and pneumatic installation
20 Festo – P.BE-CPX-CMAX-SYS-EN – en 2017-09b – English
Mounting CMAX
Note
Always use the correct screws for the interlocking block, which depend on the material
the block is made of (metal or plastic). Both types of screws are enclosed when the
CPX-CMAX is ordered as a single part.
– for plastic interlinking blocks: self-tapping screws
– for metal interlinking blocks: screws with metric thread
1. Check seal and seal surfaces.
2. Insert CMAX correctly positioned into the interlinking block. The corresponding slots with the power
contact terminals on the bottom of the CMAX must lie above the contact rails.
3. Push the CMAX carefully and without tilting into the interlinking block up to the stop.
4. Screws must be set so that the available self-cutting threads can be used. Then tighten all four
screws in diagonally opposite sequence with a Torx screwdriver size T10 – tightening torque 0.9 ...
1.1 Nm.
The parameterisation is saved in the CMAX. After replacing a CMAX, check the parameters
and perform commissioning again (èChapter 5). Observe the instructions in ap
pendix A.2.