Festo EXCM-10-***-E User manual

Description
Commissioning
8068047
1612b
[8068049]
EXCM-10/-30-...-E
Planar surface gantry with
controller

EXCM-10/-30-...-E
2 Festo – EXCM-10/-30-...-E-EN – 1612b –
Translation of the original instructions
EXCM-10/-30-...-E-EN
Adobe Reader®, CANopen®and CiA®are registered trademarks of the respective trademark owners in
certain countries.
Identification of hazards and instructions on how to prevent them:
Danger
Immediate dangers which can lead to death or serious injuries
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
èResult of an action/References to more detailed information

EXCM-10/-30-...-E
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Table of Contents – EXCM-10/-30-...-E
1 Safety and requirements for product use 7......................................
1.1 Safety 7..................................................................
1.1.1 General safety instructions 7.........................................
1.1.2 Intended use 8.....................................................
1.2 Requirements for product use 9...............................................
1.2.1 Technical requirements 9............................................
1.2.2 Qualification of the specialists (requirements for the personnel) 9............
1.2.3 Range of application and certifications 9................................
2 Overview 10................................................................
2.1 General properties 10........................................................
2.2 Function and application 10....................................................
2.3 Monitoring functions 11.......................................................
2.4 Switch-off functions 11.......................................................
2.4.1 Torque Off - TO 11...................................................
2.4.2 External stop - ES 11.................................................
2.5 Drive functions 12...........................................................
2.5.1 Jogging 12.........................................................
2.5.2 Homing 12.........................................................
2.5.3 Brake 12..........................................................
2.6 Operating modes 13.........................................................
2.6.1 Direct mode 13.....................................................
2.6.2 Record selection 13..................................................
2.7 Measuring reference system 14.................................................
2.7.1 Basic concepts 14...................................................
2.7.2 Selection of the coordinate system 15...................................
2.7.3 Dimension reference points 16.........................................
2.7.4 Calculation rules 16..................................................
2.8 General structure 17.........................................................
2.8.1 Control interfaces 17.................................................
2.8.2 LED display components 18...........................................
2.8.3 7-segments display 20...............................................
2.9 System overview 21..........................................................
2.10 Emergency stop concept 22....................................................
3 Assembly 23...............................................................
3.1 General instructions 23.......................................................
3.2 Dimensions of the controller 23.................................................
3.3 Mounting the controller 24....................................................

EXCM-10/-30-...-E
4 Festo – EXCM-10/-30-...-E-EN – 1612b – English
4 Electrical installation 25......................................................
4.1 General instructions 25.......................................................
4.2 Connections and interfaces 26.................................................
4.2.1 Power supply [X1] 28.................................................
4.2.2 Functional earth 29..................................................
4.2.3 I/O interface [X2] 29.................................................
4.2.4 CANopen interface [X3] 30............................................
4.2.5 Emergency stop interface [X4] 30.......................................
4.2.6 Ethernet interface [X5] 30.............................................
4.2.7 Encoder connection 31...............................................
4.2.8 Motor connection 31.................................................
5 Commissioning with the FCT 32................................................
5.1 Safety instructions 32........................................................
5.2 Network connection via Ethernet 33.............................................
5.2.1 Connection to PC/laptop 33...........................................
5.2.2 Network settings 33.................................................
5.2.3 Safety in the network 34..............................................
5.2.4 Timeout 34........................................................
5.3 The Festo Configuration Tool (FCT) 35............................................
5.3.1 General information 35...............................................
5.3.2 Installation of the FCT 35..............................................
5.3.3 Starting the FCT 35..................................................
5.3.4 Creating a new project 36.............................................
5.3.5 Component settings 36...............................................
5.3.6 Record table 37.....................................................
5.3.7 Teaching 37........................................................
5.3.8 Enable device control via FCT 37........................................
5.3.9 Controller identification 37............................................
5.3.10 Firmware update 38.................................................
6 Operation 39...............................................................
6.1 Instructions on operation 39...................................................
6.2 Communication principle, general 40............................................
6.2.1 Overview of the control and status bytes 40..............................
6.2.2 Description of the control bytes CCON/CPOS 41...........................
6.2.3 Description of the status bytes SCON/SPOS 42............................
6.2.4 Timing diagram 43...................................................
6.3 Control via I/O interface 44....................................................
6.3.1 General remarks 44..................................................
6.3.2 Communication 44..................................................
6.3.3 Examples 45.......................................................

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6.4 Controller via CANopen interface 46.............................................
6.4.1 General remarks 46..................................................
6.4.2 Communication 46..................................................
6.4.3 Examples 47.......................................................
6.5 Control via Ethernet (CVE) 50...................................................
6.5.1 General remarks 50..................................................
6.5.2 Communication 50..................................................
6.5.3 CVE protocol 51.....................................................
6.5.4 Examples 57.......................................................
7 Diagnostics 60..............................................................
7.1 Diagnostic memory 60........................................................
7.2 Types of malfunctions 60......................................................
7.3 Error messages 61...........................................................
7.4 Malfunctions: Causes and remedy 62............................................
7.4.1 Error responses 62..................................................
7.4.2 Table of error messages 62............................................
7.4.3 Problems with the Ethernet connection 72................................
7.4.4 Other problems and remedies 72.......................................
A Technical data 73............................................................
A.1 General data 73.............................................................
A.2 Electrical data 73............................................................
B CANopen 74................................................................
B.1 CANopen object overview 74...................................................
C Control via Ethernet (CVE) 78..................................................
C.1 CVE object overview 78.......................................................
D Glossary 81................................................................

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Instructions on this documentation
This documentation serves to promote safe commissioning and operation of the planar surface
gantries EXCM with the controller belonging to it.
Product identification, versions
The hardware version specifies the version status of the controller’s electronics. The firm
ware version indicates the version status of the operating system.
You can find the specifications of the version status as follows:
– Hardware version and firmware version in the Festo Configuration Tool (FCT) with act
ive online connection to the controller on the “Controller” page.
Firmware design
from
What's new? Which FCT plug-in?
V 1.0.0.x The controller supports the following planar surface
gantries:
– EXCM-10
– EXCM-30
EXCM V 1.0.0.x
Tab. 1 Firmware Design
Service
Please consult your regional Festo contact if you have any technical problems.
Documentation
You will find more extensive information in the following documentation:
User documentation for the EXCM-10/-30-...-E
Name TYPE Contents
Help system for the software
(included in the FCT software)
Dynamic and static Help for the
FCT plug-in “EXCM”.
Functional descriptions for the
Festo Configuration Tool
configuration software.
Operating instructions Such as for the planar surface
gantry EXCM-10 or EXCM-30
Description and mounting of
the planar surface gantry.
Tab. 2 Documentation for EXCM-10/-30-...-E

1 Safety and requirements for product use
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1 Safety and requirements for product use
1.1 Safety
1.1.1 General safety instructions
In the commissioning and programming of positioning systems, the safety regulations in this descrip
tion and in the documentation for the other components must always be observed.
The user must ensure that nobody is within the sphere of influence of the connected planar surface
gantry. Access to the possible danger zone must be prevented by suitable measures such as shut-offs
and warning signs.
Warning
Planar surface gantries travel with great force and speed. Collisions can lead to serious
injury to people and damage to components.
 Make sure that nobody can grasp into the sphere of influence of the planar surface
gantry as well as other connected actuators – e.g. through protective guards – and
no items are located in the travel range as long as the system is connected to energy
sources.
Caution
Parameterisation errors can cause injury to people and damage to property.
 Enable the controller only if the planar surface gantry has been professionally in
stalled and parameterised.
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 a product when powered!
 Observe the handling specifications for electrostatically sensitive devices.

1 Safety and requirements for product use
8 Festo – EXCM-10/-30-...-E-EN – 1612b – English
1.1.2 Intended use
The controller is used for controlling planar surface gantries with a single rotating toothed belt in ac
cordance with the Festo catalogue and is used exclusively for controlling planar surface gantries of type
EXCM.
The functions of the controller are documented in this description.
The planar surface gantries of type EXCM as well as the additional components are documented in
separate documentation.
The controller and the connectable modules and cables may only be used as follows:
– in perfect technical condition
– in original status without unauthorised modifications, except for the adaptations described in this
documentation.
– within the limits of the product defined through the technical data
(èA Technical data).
 Observe the safety instructions and intended use in the documentation for all the components and
modules.
 Observe the standards specified in the relevant chapters as well as the regulations of the trade
associations, the German Technical Control Board (TÜV), the VDE conditions or relevant national
regulations.
 Observe the limit values for all additional components (e.g. sensors, actuators).
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
Festo – EXCM-10/-30-...-E-EN – 1612b – English 9
1.2 Requirements for product use
 Make this documentation available to the design engineer, installer and personnel responsible for
commissioning the machine or system in which this product is used.
 Make sure that the specifications of the documentation are always complied with. Also consider the
documentation for the other components and modules.
 Take into consideration the legal regulations applicable for the destination as well as:
– regulations and standards
– regulations of the testing organizations and insurers
– national specifications
1.2.1 Technical requirements
General conditions for the correct and safe use of the product, which must be observed at all times:
 Comply with the connection and environmental conditions specified in the technical data of the
product (èA Technical data) and of all connected components.
Only compliance with the limit values or load limits permits operation of the product in accordance
with the relevant safety regulations.
 Observe the instructions and warnings in this documentation.
1.2.2 Qualification of the specialists (requirements for the personnel)
The product may be placed in operation only by a qualified electrotechnician, who is familiar with:
– installation and operation of electrical control systems
– the applicable regulations for operating safety-engineering systems
– the applicable regulations for accident protection and industrial safety
– the documentation for the product
1.2.3 Range of application and certifications
Standards and test values that the product complies with and fulfils can be found in appendix
(èA Technical data). The product-relevant EU directives can be found in the declaration of conformity.
Certificates and the declaration of conformity for this product (èwww.festo.com).

2 Overview
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2 Overview
2.1 General properties
– FCT-compatible: configuration, parameterisation and backup via Festo Configuration Tool (FCT)
– Energy-optimised operation and low heat development
– Separated load and logic supply (renewed homing not required after emergency stop)
– LED-display components for representation of device and communication status
– 7-segments display for representation of equipment statuses, malfunctions and warnings
2.2 Function and application
The controller controls two servo motors, which drive an H-shaped rotating toothed belt. The toothed
belt moves a slide, whose position is calculated by the controller from the encoder signals of the mo
tors.
The motors are not directly assigned to an axis (X- or Y-axis) of the planar surface gantry. Instead, the
movement of the slide towards an axis is achieved through the interaction of the two motors, which is
controlled by the controller (èFig. 2.1 Functional principle).
Functional principle
Motor 1
Motor 2
Motor 1 Motor 2
X-axis
Y-axis
Fig. 2.1 Functional principle

2 Overview
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2.3 Monitoring functions
The controller has numerous monitoring functions:
– Monitoring of the logic and load voltage supply
– Current monitoring/I²t monitoring
– Software end-position detection
– Standstill and following error monitoring
2.4 Switch-off functions
The drive can be switched off through the switch-off functions Torque Off - TO and External Stop - ES.
2.4.1 Torque Off - TO
In the case of a requirement of the switch-off function Torque OFF - TO, the energy supply to the mo
tors is interrupted through switching off of the output stage. The motor brake is not activated thereby.
The status of the driver supply is acknowledged through the two contacts DIAG1 and DIAG2.
2.4.2 External stop - ES
If the External stop - ES switch-off function is requested, the motors are run down in a controlled way
until they are at rest. After the rest state is reached, the motor brakes are activated and the output
stage is switched off.
+24 V
GND
TO
DIAG1
DIAG2
ES
+24 V
Logic voltage
+24 V
Driver supply
Activation/switch-off of the driver supply
Driver supply acknow
ledgment contact
Driver supply
monitoring
μP PWM driver
step
IGBT output stage
Emergency stop interface [X4]
Fig. 2.2 Switch-off functions - block diagram

2 Overview
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2.5 Drive functions
2.5.1 Jogging
During jogging, the slide of the planar surface gantry moves as long as a corresponding signal is
present. Jogging can always take place only in one direction, either in the direction of the X-axis or in
the direction of the Y-axis, whereby differentiation is made between creeping run and normal run. The
CANopen or Ethernet interface can be used as control interfaces, but the I/O interface cannot.
This function is normally used to run the slide off the path.
As long as a valid reference point has not been reached, the software end positions are
deactivated and the slide can also be positioned behind the software end positions
through jogging.
2.5.2 Homing
After each restart of the controller, a homing run must be performed to anchor the reference point, and
thus the dimension reference system, in the travel range of the planar surface gantry. Without success
ful homing, positioning cannot be started (exception: jogging). Homing can be started via the control
byte CPOS (è6.2.2 Description of the control bytes CCON/CPOS) or through selection of record 0 and
always takes place to the stop in the origin of the selected coordinate system
(è2.7.2 Selection of the coordinate system). The stop is detected by a motor shutdown in combina
tion with a sharp rise in the motor current. After the fixed stop is reached, a movement to zero is auto
matically performed in order to reach a permanently defined and unchangeable minimum distance
from the mechanical stop.
2.5.3 Brake
If the motors are equipped with a brake, they are controlled as follows:
Switch-on delay
When enable is being set (ENABLE), the switch-on delay time (10 ms) starts to run and the position
controller of the controller takes over control of the connected planar surface gantry. The brake opens
simultaneously. The controller accepts positioning jobs only after the switch-on delay has expired.
Switch-off delay
When the enable signal is removed, the time set for the switch-off delay starts to run. The brake closes
during this time. But the position controller still holds the drive in position. The position controller is
only switched off after expiration of the switch-off delay.
If enable is withdrawn while the drive of the planar surface gantry is carrying out a record, the drive is
brought to a rest with the quick stop edge (Quick Stop). As soon as the drive has come to a rest, the
brake output is reset: the brake/clamping unit closes. Simultaneously, the switch-off delay time be
gins to run. The controller continues to control the position. Then the controller end stage is switched
off after the switch-off delay.

2 Overview
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2.6 Operating modes
If positioning is begun, it is always continued to the end in all operating modes.
A new positioning job is ignored before the end of a started positioning.
2.6.1 Direct mode
A target position (X- and Y-coordinates) as well as values for travel speed and acceleration are trans
ferred to the controller. The target position is linearly approached by the current actual position. Addi
tional possible functions in direct mode are jogging as well as homing. The CANopen or Ethernet inter
face can be used as control interfaces.
2.6.2 Record selection
Positioning jobs are saved in the controller in a record table in the form of parameter records
(è5.3.6 Record table). In operation, the higher-order controller (PLC/IPC) then selects individual
records by transferring a record number (record selection).
Additional possible functions in record selection are jogging as well as homing.
The I/O, CANopen or Ethernet interface can be used as a control interface.
Parameter records can only be parameterised via the Festo Configuration Tool (FCT)
(è5.3.6 Record table).

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2.7 Measuring reference system
2.7.1 Basic concepts
Homing
During homing, the position of the axis zero point AZ is determined.
Stop point BZ (block zero)
A fixed point in the origin of the selected coordinate system, which is travelled to in homing.
Movement to zero
After the stop point BZ is reached, the drive is travelled to at a defined distance in order to reach the
axis zero point AZ.
Axis zero point AZ (Axis Zero)
It is shifted by a defined distance from the stop point BZ in the origin of the selected coordinate sys
tem. This distance is established with 1.2 mm each in the direction of the X- and Y-axis.
The software end positions and the project zero point PZ refer to the axis zero point AZ.
Project zero point PZ (Project Zero)
is a point to which the actual position and the absolute target positions from the position record table
refer. The project zero point is shifted by a defined distance from the axis zero point AZ.
Software end positions SLN (Software Limit Negative)/SLP (Software Limit Positive)
Limit the effective stroke in the direction of the X- or Y-axis. If the target position of a positioning job is
outside the software end positions, the positioning job is not executed and a malfunction is reported.
Usable stroke
The distance of the software end positions in the direction of the X- or Y-axis. Maximum stroke by
which the planar surface gantry can travel in the corresponding direction.
Increments
The controller works in the range of the drive controller with encoder increments (EINC). In contrast,
so-called interface increments (SINC) are used at all user interfaces and in the field of internal data
management.
1 mm = 1000 SINC
1 EINC k19.5 μm

2 Overview
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2.7.2 Selection of the coordinate system
The following 4 selection options are available for establishing the axis zero point:
Selection 1 Selection 2
Fig. 2.3 Axis zero point at corner point 1 (default) Fig. 2.4 Axis zero point at corner point 2
Selection 3 Selection 4
Fig. 2.5 Axis zero point at corner point 3 Fig. 2.6 Axis zero point at corner point 4
Establishment of the axis zero point is performed exclusively through the Festo Configur
ation Tool (FCT) (è5.3.5 Component settings) .

2 Overview
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2.7.3 Dimension reference points
Dimension reference points (example for axis zero point at corner point 1)
AZ
A
SLN SLP
f
PZ
b
e
c
TP/AP
BZ
d
+X–X
+Y–Y
Fig. 2.7 Dimension reference points
Explanation
BZ Stop point BZ (block zero)
AZ Axis zero point AZ (Axis Zero)
PZ Project zero point PZ (Project Zero)
SLN Negative software end position SLN (Software Limit Negative)
SLP Positive software end position SLP (Software Limit Positive)
TP/AP Target position/actual position TP/AP (Target Pos./Actual Pos.)
aOffset BZ to AZ (fixed)
bOffset AZ to PZ
cOffset PZ to TP/AP
dOffset AZ to SLN
eUsable stroke
fOffset AZ to SLP
Tab. 2.1 Explanation of dimension reference points
2.7.4 Calculation rules
Point Calculation rule
AZ Axis zero point = BZ + a (a = 1.2 mm)
PZ Project zero point = AZ + b
SLN Negative software limit = AZ + d
SLP Positive software limit = AZ + f
TP/AP Target position/actual position = PZ + c = AZ + b + c
Tab. 2.2 Calculation rules

2 Overview
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2.8 General structure
1
2
3
4
5
6
7
8
9
aJ
aA
1Mounting slots
2Connection side to the planar surface gantry
3Mounting slots
4Functional earth connection
5Voltage supply [X1] connection
6I/O interface [X2]
7Emergency stop interface [X4]
8Ethernet interface [X5]
97-segments display
aJ LED indicators
aA CANopen interface [X3]
Fig. 2.8 General structure
2.8.1 Control interfaces
The controller has three control interfaces in order to communicate with a higher-order controller. The
active control interface is established via the Festo Configuration Tool (FCT)
(è5.3.5 Component settings).
– I/O interface
– CANopen interface
– EtherCat interface
The Ethernet interface can thereby be used both for control via the FCT and also for control via Ether
net (CVE).
Of the control interfaces named, at all times only one can have the master control.

2 Overview
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2.8.2 LED display components
Equipment and function statuses of the controller are displayed over the three LED display compon
ents.
The behaviour and the colour of the LEDs differ dependent on the type of status display.
1
234
17-segments display
2COM (green/yellow/red)1)
3Device (green/red)1)
4Power (green)2)
1) Static and dynamic behaviour
2) Only static behaviour (LED on/off)
Fig. 2.9 LED display components
Power
An existing load voltage is displayed over the “Power” LED indicator.
If there is no load voltage present or it is too low, the LED indicator remains dark.
Device
The operational readiness of the controller and existing malfunctions (errors/warnings) are signalled
through the “Device” LED display (èTab. 2.3 Possible statuses of the LED display - device).
LED (green/red) Status Significance
Illuminated green Ready for operation (controlled status)
Flashes green (– – – …) Not ready for operation (uncontrolled
status)
ON
OFF
Illuminated red Error is present
Flashes red (–– –– –– …) Warning is present or controller
identification is active
(è5.3.9 Controller identification)
ON
OFF
Tab. 2.3 Possible statuses of the LED display - device

2 Overview
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COM
The LED display “COM” displays an active communication through a green-flashing display compon
ent. The interface assignment is shown through the flashing behaviour of the LED indicator.
A CANopen-specific message is signaled through a yellow or red LED display component.
COM - I/O operation
LED
(green/yellow/red)
Status Significance
Flashes green (– – – …) Communication active.
ON
OFF
Tab. 2.4 LED indicator COM - I/O operation
COM - CANopen operation
LED
(green/yellow/red)
Status Significance
Illuminated green Normal operating status.
Communication through SDOs and
PDOs possible (operational).
Flashes green (· · · · …) Normal status after switch-on. Com
munication only possible through
SDOs (pre-operational).
ON
OFF
Illuminates yellow No bus cable connected or no bus
parameters configured.
Illuminated red No bus connection (bus OFF).
Flashes red (· · · …) Telegrams cannot be received or sent
(Warning Limit).
ON
OFF
Flashes red (·· ·· ·· …) Time exceeded for communication
monitoring (Node Guarding).
ON
OFF
Tab. 2.5 LED indicator COM - CANopen operation
COM - CVE operation
LED
(green/yellow/red)
Status Significance
Flashes green (– · – · …) Communication active.
ON
OFF
Tab. 2.6 LED indicator COM - CVE operation

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2.8.3 7-segments display
Operating mode, record number and malfunctions are displayed over the 7-segments display. For mes
sages, 4 characters are displayed in succession; after that a time delay follows.
1
1Point for controller identification (è5.3.9 Controller identification)
Fig. 2.10 7-segments display
Possible messages
Display Operating mode/event Priority
BLE Bootloader error 1
E0xx (xx = error no.) System error 2
E1xx (xx = error no.) Error motor 1
E2xx (xx = error no.) Error motor 2
Exxx TO – Torque Off
Axxx (xxx = error no.) Warning 3
P000 Homing 4
P070 Jog positive (X-axis)
P071 Jog negative (X-axis)
P072 Jog positive (Y-axis)
P073 Jog negative (Y-axis)
P1xx (xx = record number) I/O operation
P2xx (xx = record no.)
P200 (00 = direct mode)
CANopen operation
P3xx (xx = record number)
P300 (00 = direct mode)
CVE operation or
control via FCT
Tab. 2.7 Messages of the 7-segments display
Messages with a higher priority interrupt messages with a lower priority. As malfunctions
can occur faster than they can be displayed on the 7-segments display, it may be the
case that not all malfunctions are displayed.
 Read the diagnostic memory (è7.1 Diagnostic memory) in order to have all mes
sages displayed.