Festo EXCM-30 -PF Series User manual

Description
Commissioning
8059530
1603
[8059532]
EXCM-30/-40-...-PF
Planar surface gantry with
controller

EXCM-30/-40-...-PF
2 Festo – EXCM-30/-40-...-PF-EN – 1603 – English
Translation of the original instructions
EXCM-30/-40-...-PF-EN
CANopen®is a registered trademark of its respective trademark holder 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-30/-40-...-PF
Festo – EXCM-30/-40-...-PF-EN – 1603 – English 3
Table of Contents – EXCM-30/-40-...-PF
1 Requirements for product use 6...............................................
1.1 Target group 6.............................................................
1.2 Intended use 6.............................................................
1.3 Foreseeable misuse 7.......................................................
1.4 Instructions on this documentation 7...........................................
1.5 Applicable documents 7.....................................................
1.6 Range of application and certifications 8........................................
1.7 Obligations of the machine manufacturer 8......................................
2 Overview 9................................................................
2.1 General characteristics 9.....................................................
2.2 System overview 9..........................................................
2.3 Function and application 10....................................................
2.4 Monitoring functions of the controller 10.........................................
2.5 Switch-off functions of the controller 11..........................................
2.5.1 External stop ESTOP 11...............................................
2.5.2 Safety function Safe Torque Off - STO 12.................................
2.6 Drive functions 12...........................................................
2.6.1 Jogging 12.........................................................
2.6.2 Homing 12.........................................................
2.6.3 Brake 13..........................................................
2.7 Operating modes of the controller 15............................................
2.7.1 Direct operation 15..................................................
2.7.2 Record selection 15..................................................
2.8 Measurement system 16......................................................
2.8.1 Basic concepts 16...................................................
2.8.2 Selection of the coordinate system 17...................................
2.8.3 Dimension reference points 18.........................................
2.9 General structure of the controller 19............................................
2.9.1 Interfaces 19.......................................................
2.9.2 LED display components 20...........................................
2.9.3 7-segment display 22................................................
2.10 Emergency stop concept 23....................................................

EXCM-30/-40-...-PF
4 Festo – EXCM-30/-40-...-PF-EN – 1603 – English
3 Electrical installation 24......................................................
3.1 General instructions 24.......................................................
3.2 Connections and interfaces 25.................................................
3.2.1 Power supply [X1] 26.................................................
3.2.2 Functional earth 26..................................................
3.2.3 I/O interface [X2] 27.................................................
3.2.4 CANopen interface [X3] 27............................................
3.2.5 Switch-off functions interface [X4] 28....................................
3.2.6 Ethernet interface [X5] 29.............................................
3.2.7 Encoder connection 29...............................................
3.2.8 Motor connection 29.................................................
4 Commissioning with the FCT 30................................................
4.1 Safety instructions 30........................................................
4.2 Network connection via Ethernet 31.............................................
4.2.1 Connection to PC/laptop 31...........................................
4.2.2 Network settings 31.................................................
4.2.3 Safety in the network 32..............................................
4.2.4 Timeout 32........................................................
4.3 The Festo Configuration Tool (FCT) 33............................................
4.3.1 General information 33...............................................
4.3.2 Installation of the FCT 33..............................................
4.3.3 Starting the FCT 33..................................................
4.3.4 Create new project 33................................................
4.4 Configuration 34............................................................
4.4.1 Create new drive configuration/change drive configuration 34................
4.4.2 Gantry 35..........................................................
4.4.3 Controller 35.......................................................
4.5 Settings of the operating parameters 35.........................................
4.5.1 Record Table 35.....................................................
4.5.2 Teaching 36........................................................
4.5.3 Enable device control via FCT 36........................................
4.5.4 Controller identification 36............................................
4.5.5 Firmware update 37.................................................
5 Operation 38...............................................................
5.1 Instructions for operation 38...................................................
5.2 Communication principle, general 39............................................
5.2.1 Overview of the control and status bytes 39..............................
5.2.2 Description of the control bytes CCON/CPOS 40...........................
5.2.3 Description of the status bytes SCON/SPOS 42............................
5.2.4 Start of positioning 44...............................................

EXCM-30/-40-...-PF
Festo – EXCM-30/-40-...-PF-EN – 1603 – English 5
5.3 Control via I/O interface 45....................................................
5.3.1 General 45.........................................................
5.3.2 Communication 45..................................................
5.3.3 Examples 46.......................................................
5.4 Controller via CANopen interface 48.............................................
5.4.1 General 48.........................................................
5.4.2 Communication 48..................................................
5.4.3 Examples 49.......................................................
5.5 Control via Ethernet (CVE) 51...................................................
5.5.1 General 51.........................................................
5.5.2 Communication 51..................................................
5.5.3 CVE protocol 52.....................................................
5.5.4 Examples 58.......................................................
6 Diagnostics 61..............................................................
6.1 Diagnostic memory 61........................................................
6.2 Error messages 61...........................................................
6.3 Malfunctions: causes and remedy 63............................................
6.3.1 Error responses 63..................................................
6.3.2 Table of error messages 63............................................
6.3.3 Problems with the Ethernet connection 73................................
6.3.4 Other problems and remedies 73.......................................
A Technical appendix 74........................................................
A.1 CMXH 74...................................................................
A.1.1 General product characteristics 74......................................
A.1.2 Operating and environmental conditions 74...............................
A.1.3 Product conformity and certifications 74.................................
A.1.4 Electrical characteristics 75...........................................
A.2 System characteristics 75.....................................................
B CANopen 76................................................................
B.1 CANopen object overview 76...................................................
C Control via Ethernet (CVE) 79..................................................
C.1 CVE object overview 79.......................................................
D Glossary 82................................................................

1 Requirements for product use
6 Festo – EXCM-30/-40-...-PF-EN – 1603 – English
1 Requirements for product use
1.1 Target group
 Provide this documentation to the following persons:
– Design engineer
– Machine manufacturer
– Installer
– Commissioner
Only qualified personnel may perform mounting, installation, commissioning, maintenance and disas
sembly of the product. Qualified personnel must be familiar with:
– Mounting and operation of mechatronic systems
– Installation and operation of electrical control systems
– Installation and operation of pneumatic systems
– Regulations for accident prevention and occupational safety
– Documentation and mode of operation of the product
1.2 Intended use
This product is a handling system. The handling system executes positioning tasks within machines or
automated systems with a higher-order controller. The controller CMXH is used exclusively for control
of planar surface gantries with a circulating toothed belt of type EXCM-30/-40-…-SB/-ST.
Only use the product as follows:
– in perfect technical condition
– in its original condition, without unauthorised modifications
– within the limits of the product defined by the technical data
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 Requirements for product use
Festo – EXCM-30/-40-...-PF-EN – 1603 – English 7
1.3 Foreseeable misuse
Never use the product as follows:
– with unauthorised modifications or alterations to the product
– in an invalid mounting position
– with load limits exceeded
– without a risk assessment of the complete system
– without a safety concept for the complete system
1.4 Instructions on this documentation
This document solely describes commissioning of the planar surface gantry EXCM-30/40 with the re
lated controller CMXH and refers to the following versions of the software:
CMXH firmware version Required CMXH plug-in
V1.2 or later V2.0 or later
Tab. 1.1 Software versions
1.5 Applicable documents
The complete description of the system, comprising controller and gantry, includes the following docu
ments:
Designation Contents
Assembly instructions
CMXH
Notes on mechanical installation of the CMXH
Description
EXCM-30/-40
Description of the mechanical installation of the planar surface gantry
EXCM-30/-40
Description
EXCM-30/-40-...-PF-...
Commissioning of the planar surface gantry EXCM-30/-40 with the CMXH
controller
Help system
for the FCT plug-in CMXH
Help system in the FCT for support of commissioning and
parameterisation of the CMXH controller
Description
CMXH
Use of the STO safety function (Safe torque off)
Tab. 1.2 Documentation for the system EXCM-30/-40 with CMXH
All available documents for the product èwww.festo.com/pk.

1 Requirements for product use
8 Festo – EXCM-30/-40-...-PF-EN – 1603 – English
1.6 Range of application and certifications
Standards and test values that the product complies with and fulfills (èA Technical appendix).
Version status
ENISO13849-1:2008-06/AC:2009-03
EN 50178:1997-10
EN 60068-2-6:2008-02
EN 60068-2-27:2009-05
EN 60204-1:2006-06
EN 61800-5-2:2007-10
EN62061:2005-04
Tab. 1.3 Standards specified in the document
Certificates and the declaration of conformity for this product (èwww.festo.com).
1.7 Obligations of the machine manufacturer
The product is an incomplete machine. Commissioning of the product is prohibited until it has been
established that the machinery in which the product will be installed is in compliance with the provi
sions of EU Machinery Directive.
Take the following into consideration for the destination:
– regulations and standards
– regulations of the testing organisations and insurers
– national specifications

2Overview
Festo – EXCM-30/-40-...-PF-EN – 1603 – English 9
2Overview
2.1 General characteristics
– FCT-compatible: configuration, parameterisation and backup via Festo Configuration Tool (FCT)
– Energy-optimised operation and low heat development
– Separation between load and logic voltage
– LED-display components for representation of device and communication status
– 7-segment display for representation of equipment statuses, errors and warnings
2.2 System overview
1
2
3
4
ÌÌÌÌÌ
ÏÏ
ÏÏ
ÏÏ
Ï
Ï
Ï
Ï
Ï
Ï
Ï
Ï
Ï
ÏÏ
ÏÏ
ÏÏ
Ï
Ï
Ï
Ï
Ï
Ï
ÏÏ
ÏÏ
ÏÏ
Ï
Ï
Ï
Ï
Ï
Ï
ÏÏ
ÏÏ
ÏÏ
Ï
Ï
Ï
Ï
Ï
Ï
Ï
Ï
Ï
1Higher-order control level: PLC/IPC
2Parameterisation and commissioning level:
Festo Configuration Tool (FCT)
3Controller level
4Drive level: planar surface gantry
Fig. 2.1 System overview

2Overview
10 Festo – EXCM-30/-40-...-PF-EN – 1603 – English
2.3 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. 2.2 Operational principle).
Operational principle
Motor 1
Motor 2
Motor 1 Motor 2
X-axis
Y-axis
Fig. 2.2 Operational principle
2.4 Monitoring functions of the controller
The controller has numerous monitoring functions, such as:
– monitoring of logic and load voltage
– current monitoring/I²t monitoring
– software end-position detection
– standstill and following error monitoring
– short circuit detection

2Overview
Festo – EXCM-30/-40-...-PF-EN – 1603 – English 11
2.5 Switch-off functions of the controller
The drive can be switched off through the switch-off functions Safe Torque Off (STO) and External Stop
(ESTOP).
Logic voltage Driver supply
Activation/shut-down of the driver supply
Driver supply
monitoring
Driver supply
acknowledgment contact
PWM driver
step
IGBT output stage
μP
+24 V
GND
STO1
DIAG1
DIAG2
ESTOP
STO2
Fig. 2.3 Switch-off functions - block diagram
2.5.1 External stop ESTOP
If the External Stop - ESTOP switch-off function is requested, the motors are decelerated with the quick
stop braking ramp (Quick Stop) until they are at rest. After standstill is reached, the brake control is
activated and the output stage switched off.

2Overview
12 Festo – EXCM-30/-40-...-PF-EN – 1603 – English
2.5.2 Safety function Safe Torque Off - STO
The safety function STO (“Safe Torque Off ”) is described in detail in the document
“CMXH description STO” and may only be used in the manner described there.
(èTab. 1.2 Documentation for the system EXCM-30/-40 with CMXH)
The safety function enables two-channel shut-down of the voltage supply to the motors connected to
the CMXH and therefore a safely switched-off torque (Safe Torque Off, STO) via the connection [X4].
Two channels are achieved through the inputs STO1 and STO2. The power supply to the motor is se
curely interrupted through shut-down of the output stage. At the same time, the brake control is activ
ated.
2.6 Drive functions
2.6.1 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 a control interface, but the I/O interface cannot.
This function is normally used to run the slide manually into a defined basic position.
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.
2.6.2 Homing
In homing, the reference point of the dimension system is determined. The reference point is the abso
lute reference point for the axis zero point. Orders can only be started if homing has been completed
successfully (exception: jogging).
Note
The reference point is saved temporarily in the controller. When there is an open circuit
in the logic power supply, the homing point is lost.
Homing can be started through selection of record 0 or through the control byte CPOS
(è5.2.2 Description of the control bytes CCON/CPOS) and always takes places to the stop at the
origin of the selected coordinate system (è2.8.2 Selection of the coordinate system). The stop is
detected by a motor standstill in combination with a sharp rise in the motor current. After the fixed
stop is reached, a movement to zero is automatically performed in order to reach a permanently
defined and unchangeable minimum distance from the mechanical stop.

2Overview
Festo – EXCM-30/-40-...-PF-EN – 1603 – English 13
2.6.3 Brake
If the motors are equipped with a brake, they are controlled as follows:
Automatic activation of the brake
The motor controller automatically controls the brake through release of the drive:
– The brake is opened when the drive is enabled.
– The brake is closed when the drive is blocked (either through a pilot signal or an error with error
response “Output stage off”).
Through the mechanical inertia of the brake, opening and closing take a certain length of time. The
behaviour of the controller when the drive is enabled is adjusted to the mechanical inertia of the brake
through the switch-on and switch-off delay.
Switch-on delay
When enable is being set (ENABLE), the switch-on delay time (150 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 (150 ms). The
brake closes during this time. The position controller holds the drive in position. The position control
ler and the output stage are only switched off after expiration of the switch-off delay.
Note
When the output stage is switched off, such as through blocking of the drive, or when
the power supply is interrupted during movement, there is no deceleration of the drive
via a braking ramp. The holding brake is closed immediately. This results in increased
wear and can lead to damage to the motors if it occurs repeatedly.
– Avoid immediate blocking of the drive during movement
– Before blocking the drive, make sure that the drive is stopped, such as by resetting
STOP (control byte CCON bit 1) or by triggering an external stop (input ESTOP at [X4])

2Overview
14 Festo – EXCM-30/-40-...-PF-EN – 1603 – English
Manual releasing of the brake
Warning
Unexpected movement of the product. Risk of impact and crushing injuries.
 Before manual release of the brake, make sure that the axes are in a stable end
position or secure axes against unexpected movements.
The brake can be manually released when the drive is blocked (either through a pilot signal or an error
with error response “Output stage off”).
This is possible in the following ways:
– through a hardware input (è3.2.5 Switch-off functions interface [X4])
– through a control bit in the CCON control word
(è5.2.2 Description of the control bytes CCON/CPOS)
– through the FCT
In the case of a blocked drive, if the command to release is issued over at least one of these signals,
the brake is released.
Note
The signal to release the brake always has priority. If a voltage of +24 V is applied to
the RB input (release brake), the brake is released permanently. In case of error (for
errors with error response “Output stage off”), the brake remains released, as the
signal for releasing the brake is present:
– Leave the signal at “brake active” (0 V at the input RB).
– Release the brake only in a concrete case of need

2Overview
Festo – EXCM-30/-40-...-PF-EN – 1603 – English 15
2.7 Operating modes of the controller
2.7.1 Direct operation
The CANopen or Ethernet interface can be used as a control interface. The X-Y position and travel
speed are transmitted by the higher-order controller/PC. The target position is linearly approached by
the current actual position.
Other possible functions are:
– Jogging
– Homing
2.7.2 Record selection
The I/O, CANopen or Ethernet interface can be used as a control interface. Records consist of record
type, target position X and Y, speed, acceleration and jerk. They are saved in the controller in a record
table with record number (è4.5.1 Record Table). A maximum of 31 records can be configured by the
user. Record 0 is reserved for homing. In operation, the higher-order controller/PC then selects indi
vidual records by transferring a record number (record selection). The target position is linearly ap
proached by the current actual position.
Other possible functions are:
– Jogging
– Homing run
– 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.
– Records can only be parameterised via the Festo Configuration Tool (FCT)
(è4.5.1 Record Table).
– Coordinate transformation is performed in the CMXH controller.

2Overview
16 Festo – EXCM-30/-40-...-PF-EN – 1603 – English
2.8 Measurement system
2.8.1 Basic concepts
Homing
During homing, the position of the axis zero point AZ is determined.
Stop point BZ (block zero point)
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 at a defined distance in order to reach the axis
zero point AZ.
Axis zero point AZ
It is shifted by a defined distance from the stop point BZ in the origin of the selected coordinate sys
tem. This distance is determined dependent on the size of the planar surface gantry in the direction of
the X- and Y-axis (èTab. 2.1 Explanation of dimension reference points).
Project zero point (PZ)
A point to which the actual position and the absolute target positions 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.
The software end positions are shifted by a defined distance from the axis zero point AZ.
Working 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 L19 μm

2Overview
Festo – EXCM-30/-40-...-PF-EN – 1603 – English 17
2.8.2 Selection of the coordinate system
The following 4 selection options are available for establishing the axis zero point:
Selection 1 Selection 2
Fig. 2.4 Axis zero point at corner point 1 (default) Fig. 2.5 Axis zero point at corner point 2
Selection 3 Selection 4
Fig. 2.6 Axis zero point at corner point 3 Fig. 2.7 Axis zero point at corner point 4
Establishment of the axis zero point is performed exclusively through the Festo Configur
ation Tool (FCT) (è4.4 Configuration).

2Overview
18 Festo – EXCM-30/-40-...-PF-EN – 1603 – English
2.8.3 Dimension reference points
Dimension reference points (example for axis zero point at corner point 1)
Fig. 2.8 Dimension reference points
Explanation Calculation
BZ (Block Zero) stop point
AZ (Axis Zero Point) axis zero point = BZ + a
PZ (Project Zero Point) project zero point = AZ + b
SLN (Software Limit Negative) software end position negative = AZ + d
SLP (Software Limit Positive) software end position positive = AZ + f
TP/AP (Target Pos./Actual Pos.) target position/actual position = PZ + c = AZ + b + c
aOffset BZ to AZ (fixed) EXCM-30: 1.4 mm
EXCM-40: 2.0 mm
bOffset AZ to PZ
cOffset PZ to TP/AP
dOffset AZ to SLN
eWorking stroke
fOffset AZ to SLP
Tab. 2.1 Explanation of dimension reference points

2Overview
Festo – EXCM-30/-40-...-PF-EN – 1603 – English 19
2.9 General structure of the controller
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]
7Switch-off functions interface [X4]
8Ethernet interface [X5]
97-segment display
aJ LED indicators
aA CANopen interface [X3]
Fig. 2.9 General structure
2.9.1 Interfaces
The controller has three interfaces in order to communicate with a higher-order controller:
– I/O interface
– CANopen interface
– Ethernet interface
The active control interface is established via the Festo Configuration Tool (FCT) (è4.4 Configuration).

2Overview
20 Festo – EXCM-30/-40-...-PF-EN – 1603 – English
2.9.2 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-segment display
2COM (green/yellow/red)1)
3Device (green/red)1)
4Power (green)2)
1) Static and dynamic behaviour
2) Only static behaviour (on/off)
Fig. 2.10 Display components
Power
The LED indicator “Power” is illuminated only when the load voltage is present and simultaneously
(STO1 = 1) and (STO2 = 1).
Device
The operational readiness of the controller and existing malfunctions (errors/warnings) are signaled
through the “Device” LED display (èTab. 2.2 LED indicator - device).
LED (green/red) Status Meaning
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 identi
fication is active
(è4.5.4 Controller identification)
ON
OFF
Tab. 2.2 LED indicator - device