Festo SPC200 Series User manual

Positioning system
Smart Positioning Controller
SPC200

Author: S. Breuer
Editors: H.-J. Drung, M. Holder
Layout: Festo AG & Co., Dept. KI-TD
Typesetting: KI-TD
Edition: 9904a
© (Festo AG & Co., D-73726 Esslingen,
Federal Republic of Germany, 1999)
The copying, distribution and utilization of this docu-
ment as well as the communication of its contents to
others without expressed authorization is prohibited.
Offenders will be held liable for the payment of dam-
ages. All rights reserved, in particular the right to carry
out patent, utility model or ornamental design registra-
tions.
Printed on 100% recycled paper
SPC200... 9904a I

IBM®Registered trademark of
International Business
Machines Corporation
Microsoft®Registered trade mark of the
Windows®Microsoft Corporation
Temposonics®Registered trade mark of
MTS Sensortechnologie GmbH & Co
Order No.: 170 246
Title: Manual
Reference: P.BE-SPC200-GB
II SPC200... 9904a

Contents
Designated use............................................................................................ VI
Target group .............................................................................................. VII
Important user instructions ........................................................................ VII
About this manual........................................................................................ IX
Product-specific terms and abbreviations .................................................. XI
1. System summary
1.1 Positioning systems with the SPC200...........................................1-4
1.1.1 The range of equipment for the SPC200.......................................1-7
1.1.2 Structure of the SPC200................................................................1-9
1.2 Connecting pneumatic axes.........................................................1-13
1.3 Structure of the axis interface string............................................1-17
1.4 Operating modes of the SPC200.................................................1-21
1.5 Multi-axis applications with the SPC200......................................1-23
1.6 Commissioning and programming options...................................1-24
1.7 I/O address range of the SPC200 ...............................................1-28
2. Fitting
2.1 Inserting and removing modules....................................................2-5
2.2 Mounting the basic unit..................................................................2-9
2.3 Fitting the control panel................................................................2-12
2.4 Fitting the axis interface and I/O function module.......................2-14
2.5 Instructions on fitting the pneumatic axis.....................................2-19
3. Installation
3.1 General instructions on installation................................................3-4
3.2 Instructions on pneumatic installation............................................3-5
3.2.1 Pneumatic emergency stop circuit...............................................3-15
3.2.2 Tubing for slide and yoke operation.............................................3-19
3.3 Installing the SPC200...................................................................3-21
3.3.1 Selecting the power unit...............................................................3-22
3.3.2 Connections of the power supply module....................................3-24
3.3.3 Connections of the diagnostic module.........................................3-30
3.3.4 Connections of I/O module SPC200-DIO-...................................3-33
3.3.5 Connections of analogue input module type SPC200-2AI-U ......3-42
SPC200... 9904a III

3.3.6 Connections on the subcontroller module type
SPC200-SCU-AIF........................................................................ 3-45
3.4 Installing the modules on the axis interface string...................... 3-47
3.4.1 Installing the axis interface SPC-AIF-... ......................................3-51
3.4.2 Installing I/O function module SPC-FIO-2E/2A-M8..................... 3-56
4. Commissioning
4.1 Procedure for commissioning........................................................4-5
4.2 Connecting a single axis system for initial commissioning...........4-9
4.3 Commissioning via the control panel .......................................... 4-16
4.3.1 Saving the hardware configuration.............................................. 4-16
4.3.2 Commissioning pneumatic axes.................................................. 4-20
4.3.3 Instructions on commissioning multi-axis systems...................... 4-38
5. Controlling the SPC200
5.1 General instrutions on operation ................................................... 5-4
5.2 Start/stop mode ............................................................................. 5-9
5.2.1 Explanation of all I/O signals in start/stop mode.........................5-11
5.3 Record select mode.....................................................................5-17
5.3.1 Description of all I/O signals in record select mode ................... 5-22
6. Operation of the SPC200 via the
control panel
6.1 Layout and functions of the control panel.....................................6-4
6.1.1 Moving around the menu system.................................................. 6-8
6.2. Setting project-specific parameters ............................................. 6-14
6.3 Editing programs.......................................................................... 6-28
6.3.1 Adding a new program................................................................6-29
6.3.2 Editing instructions....................................................................... 6-35
6.3.3 Instruction set on the control panel............................................. 6-37
6.3.4 Editing an existing program......................................................... 6-40
6.3.5 Deleting a program...................................................................... 6-42
6.4 Editing the position register......................................................... 6-43
6.5 Controlling the program run......................................................... 6-47
6.6 Display of operands and system states...................................... 6-49
6.7 Setting the closed loop control factors........................................6-51
6.8 Test and diagnostic functions of the control panel ..................... 6-53
IV SPC200... 9904a

7. Description of the commands
7.1 General notes on programming .....................................................7-4
7.1.1 Coordinated and autonomous mode..............................................7-5
7.2 Notes on programming via the control panel.................................7-8
7.2.1 Explanation of the NC commands on the control panel..............7-13
8. Diagnosis and error treatment
8.1 On-the-spot dagnosis.....................................................................8-4
8.2 Error messages on the control panel.............................................8-9
8.3 Eliminating errors on the system..................................................8-24
8.3.1 Errors when the system is switched on.......................................8-24
8.3.2 Errors in positioning......................................................................8-25
A. Optimizing the positioning behaviour
A.1 Basic information on control..........................................................A-3
A.2 Description of the controller factors .............................................. A-6
A.3 Optimizing the positioning behaviour............................................A-9
A.3.1 How to deal with an instable compressed air supply .................A-15
B. Technical appendix
B.1 Internal structure of the inputs and outputs..................................B-3
B.2 Technical specifications.................................................................B-7
B.2.1 Technical specifications of the SPC200........................................B-7
B.2.2 Technical specifications of axis interface type SPC-AIF-...........B-13
B.2.3 Technical specifications of I/O function module
type SPC-FIO-.............................................................................B-14
B.2.4 Technical specifications of control panel type SPC200-MMI-1 ..B-15
C. Index
C.1 Index..............................................................................................C-3
SPC200... 9904a V

Designated use
The SPC200 Smart Positioning Controller is designed
for fitting into a control cabinet. It serves as a position-
ing controller and closed loop controller for pneumatic
axes, as well as a positioning controller for stepping
motor axes. Basic modules and modules for the
SPC200 are described in this manual. Special exten-
sion modules are described in separate manuals.
The safety instructions must be observed at all times
and the various components and modules must be
used as intended. Please observe also the safety in-
structions listed in the operating instructions for the
pneumatic and electrical components used.
The SPC200 and the associated modules and cable
are only to be used as follows:
– as designated
– in original condition
– without unauthorised modifications
– in faultless technical condition.
The specified limit values for pressures, temperatures,
electrical data, torques, etc., must be observed when
additional commercially-available components such as
sensors and actuators are connected. Please comply
also with national and local safety laws and regulations.
VI SPC200... 9904a

Target group
This manual is directed exclusively at technicians who
are trained in control and automation technology and
who have experience in installing, commissioning, pro-
gramming and diagnosing positioning systems.
Important user instructions
This manual contains instructions on the dangers which
may occur if the SPC200 system is not used correctly.
These instructions are always printed in italics, are
framed and also marked with a pictogram.
Danger
categories
A distinction is made between the following:
WARNING
This means that serious injury to human beings
and/or damage to property can occur if this
instruction is not observed.
CAUTION
This means that injury to human beings and/or
damage to property can occur if this instruction is not
observed.
PLEASE NOTE
This means that damage to property can occur if this
instruction is not observed.
SPC200... 9904a VII

Pictograms and symbols complement the danger warn-
ings and draw attention to the nature and conse-
quences of dangers.
Pictograms
The following pictograms are used:
Uncontrolled movements of loose tubing.
Unintentional movements of the connected actuators.
High electric voltage or undefined voltage states of the
electronic components which can affect connected cir-
cuits.
Electrostatically vulnerable components.
These will be damaged if you touch the contact sur-
faces.
Recommendations and tips are identified by the icon
shown here.
•This mark indicates activities which can be carried
out in any order.
Text
markings
1. Figures indicate activities which must be carried out
in the given numerical order.
– Hyphens indicate general items.
VIII SPC200... 9904a

About this manual
This manual contains general, fundamental information
on the functions, assembly, installation and
commissioning of pneumatic axes in conjunction with
the SPC200. This manual refers to the Smart Position-
ing Controller SPC200 with operating system version
V 3.x.
Particular information relating to the commissioning,
programming and diagnosis of the SPC200 using the
WinPISA software is to be found in the WinPISA
manual.
Information on the pneumatic components will be found
in the Operating Instructions accompanying the product.
The following table provides an overview.
SPC200... 9904a IX

Manuals for the SPC200 Smart Positioning Controller
Type Title Contents
System manual SPC200
Smart Positioning Controller,
Manual
type P.BE-SPC200-..
Installation, commissioning and
diagnosis of pneumatic axes with the
SPC200; standard components and
modules
Software manual Software package WinPISA
type P.SW-WIN-PISA-... Functions of the WinPISA software package
Help system Help system for WinPISA
(included in WinPISA) Help system for WinPISA
Manuals Field bus module
type P.BE-SPC200-... Installation, commissioning and diagnosis of the relevant field bus
module
Stepping motor module type
P.BE-SPC200-SMX-1-... Installation, commissioning and diagnosis when a stepping motor is
used
Electric positioning system
type P.BE-ATP-... Further information on electric positioning systems
Information on the pneuamtic components can be found
in the operating instructions for the relevant product.
XSPC200... 9904a

Product-specific terms and abbreviations
The following product-specific terms and abbreviations
are used in this manual:
Term/
Abbreviation Meaning
0-signal 0 V input or output signals
1-signal 24 V input or output signals
Axis data Configuration information, describing the structure, properties and
components of the axis used.
Axis interface The measuring system and the proportional directional control valve
are connected to the SPC200 via the axis interface.
Axis interface
string The totality of the modules, connected in common to the axis interface connection of the SPC200
Application data Configuration information, describing the conditions of use determined
by the application.
CP cable Special cable for connecting the various CP modules
FFlag
I Digital input
I/O module Common term for the CP modules, which provide digital inputs and
outputs
I/Os Digital inputs and outputs
Modules Plug-in cards, which can be inserted into the SPC200 rack or field
device and which can be connected to the axis interface string.
PLC/IPC Programmable logic controller/PC
Q Digital output
RRegister
String The total number of modules connected together on the axis interface
string.
SPC200... 9904a XI

XII SPC200... 9904a

Chapter 1
System summary
1. System summary
SPC200... 9904a 1-1

Contents
1. System summary
1.1 Positioning systems with the SPC200........................................... 1-4
1.1.1 The range of equipment for the SPC200...................................... 1-7
1.1.2 Structure of the SPC200 ...............................................................1-9
1.2 Connecting pneumatic axes........................................................ 1-13
1.3 Structure of the axis interface string ........................................... 1-17
1.4 Operating modes of the SPC200................................................ 1-21
1.5 Multi-axis applications with the SPC200..................................... 1-23
1.6 Commissioning and programming options..................................1-24
1.7 I/O address range of the SPC200............................................... 1-28
1. System summary
1-2 SPC200... 9904a

This chapter gives a summary of the possibilities of ex-
tending positioning systems with the SPC200; it de-
scribes the devices which can be used with the
SPC200 as well as the structure of the SPC200. This
chapter also contains basic information on:
Contents of
this chapter
– connecting pneumatic axes to the axis interface
string
– the operating modes, commissioning and program-
ming possibilities of the SPC200
– the address range of the SPC200.
Coupling to field bus systems is made possible by
special field bus modules. Detailed information on these
can be found in the manual for the relevant field bus
module.
Further
information
Electric axes can be connected by means of special
modules. Detailed information on these can be found in
the manual for the relevant module.
1. System summary
SPC200... 9904a 1-3

1.1 Positioning systems with the SPC200
Festo can help you solve your positioning tasks with the
SPC200 Smart Positioning Controller. The SPC200 is a
universal, modular-structured controller which enables
pneumatic and electric axes to be coupled and con-
nected to field bus systems.
1
2
3
4
Field bus connection (optional)
SPC200 Smart Positioning Controller
Control cabinet
Power controller
5
6
7
8
Stepping motor axis
Further field bus slaves
Pneumatic axis
Axis interface string (max. 2 axes)
Fig. 1/1: Extension possibilities for positioning systems with the SPC200
7
2
1
8
7
3
56
4
1. System summary
1-4 SPC200... 9904a

Depending on the equipment fitted on the controller, up
to four axes can be coupled. Pneumatic and electric
axes can be operated together. The components of the
pneumatic axes as well as external I/O modules, where
applicable, are connected to the SPC200 via maximum
two axis interface strings each with one cable.
1
2
First axis interface string
Second axis interface string (optional)
3
4
Axis interface
External I/O modules
Fig. 1/2: Connecting pneumatic axes and external I/O modules
12
3
4
3
3
1. System summary
SPC200... 9904a 1-5

The SPC200 can be operated either independently or
in conjunction with a higher-order PLC/IPC. To a limited
extent, it can also perform control functions. For this
purpose, I/O modules with digital inputs/outputs can be
integrated in the SPC200 or external I/O modules can
be connected to the axis interface string.
Coupling to a higher-order PLC/IPC can be made via
digital inputs/outputs or via special field bus modules
with integrated field bus interface (e.g. Interbus;
PROFIBUS-DP etc.).
1. System summary
1-6 SPC200... 9904a

1.1.1 The range of equipment for the SPC200
The range of equipment for the SPC 200 includes the
following components:
Components Function
SPC200
type SPC200-...-... The SPC200 is accomodated in a rack. Appropriate modules can be installed in
the rack according to the requirements
of the positioning task.
Control panel
type SPC200-MMI-1 The control panel can be plugged directly into the SPC200.
All functions can be operated through a
menu interface using the 6 keys on the
panel.
Axis interface
type SPC-AIF-... The axis interface forms the connection between the components on the
pneumatic axis and the SPC200.
It receives the values issued by the
measuring system, passes them to the
SPC200 and supplies the signal for
setting the proportional directional
control valve.
I/O function module
(optional) type
SPC-FIO-2E/2A-M8
Provides two inputs and two outputs on
the axis allowing direct connection of
sensors and actuators.
Additional functions e.g. gripping, lifting,
lowering and turning can be
implemented with these sensors and
actuatrs.
1. System summary
SPC200... 9904a 1-7