Parker Compax3 Fluid T40 User manual

Compax3 Electromechanical Automation
Technische Änderungen vorbehalten. 18.06.08 14:42 192-121102 N04 June 2008
Daten entsprechen dem technischen Stand zum Zeitpunkt der Drucklegung.
Operating instructions Compax3 Fluid T40: Cam
Hydraulics controller
192-121102 N04
June 2008
Release R08-0
Autoryzowany dystrybutor Parker:
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Introduction C3F_T40
2 192-121102 N04 June 2008
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Contents
1. Introduction.............................................................................................12
1.1 Device assignment Compax3 Fluid...................................................... 12
1.1.1. Type specification plate Compax3 Fluid........................................................... 13
1.2 Safety Instructions................................................................................. 14
1.2.1. General hazards................................................................................................... 14
1.2.2. Safety-conscious working .................................................................................. 14
1.2.3. Special safety instructions ................................................................................. 15
1.3 Warranty conditions .............................................................................. 15
1.4 Conditions of utilization for CE-conform operation............................ 15
2. Positioning with IEC61131-3..................................................................17
3. Compax3F device description...............................................................21
3.1 State of delivery ..................................................................................... 21
3.2 Plug and connector assignment Compax3 Fluid ................................ 21
3.2.1. Meaning of the front panel LEDs (via X10)........................................................ 21
3.2.2. Plug and connector assignment ........................................................................ 22
3.2.3. Plug and connector assignment complete ....................................................... 23
3.2.4. Analog Input (plug X1) ........................................................................................ 25
3.2.4.1 Wiring of the analog inputs ....................................................................... 25
3.2.5. Analog Output (plug X2) ..................................................................................... 26
3.2.5.1 Wiring of analog outputs ........................................................................... 26
3.2.6. Voltage supply (plug X3)..................................................................................... 27
3.2.7. RS232 / RS485 interface (plug X10) ................................................................... 27
3.2.8. Analog / Encoder (plug X11)............................................................................... 28
3.2.8.1 Connections of the encoder interface....................................................... 29
3.2.9. Digital inputs/outputs (plug X12) ....................................................................... 29
3.2.9.1 Connection of the digital Outputs/Inputs................................................... 30
3.2.10. Feedback (connector X13).................................................................................. 30
3.2.10.1 Connections of the encoder interface....................................................... 31
3.2.11. Profibus connector X23 with Interface I20........................................................ 32
3.2.11.1 Adjusting the bus address ........................................................................ 32
3.2.11.2 Function of the Bus LEDs ......................................................................... 32
3.2.12. CANopen connector X23 Interface I21 .............................................................. 33
3.2.12.1 Adjusting the bus address ........................................................................ 33
3.2.12.2 Function of the Bus LEDs ......................................................................... 34
3.2.13. DeviceNet connector X23.................................................................................... 35
3.2.13.1 Adjusting the bus address ........................................................................ 35
3.2.13.2 Function of the Bus LEDs ......................................................................... 36
3.2.14. Ethernet Powerlink (Option I30) / EtherCAT (option I31) X23, X24................. 36
3.2.14.1 Set Ethernet Powerlink (option I30) bus address ..................................... 37
3.2.14.2 Meaning of the Bus LEDs (Ethernet Powerlink) ....................................... 37
3.2.14.3 Meaning of the Bus LEDs (EtherCAT)...................................................... 38

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3.2.15. Mounting and dimensions .................................................................................. 40
4. Setting up Compax3...............................................................................41
4.1 Configuration ......................................................................................... 41
4.1.1. C3HydraulicsManager......................................................................................... 44
4.1.1.1 Function description.................................................................................. 44
4.1.1.2 Structure of the databases........................................................................ 44
4.1.2. Compax3F structure image ................................................................................ 45
4.1.3. Drive configuration.............................................................................................. 46
4.1.4. Configuring drive1............................................................................................... 47
4.1.4.1 Position feedback system drive1 .............................................................. 47
4.1.4.2 Cylinder / motor selection ......................................................................... 48
4.1.4.3 Load configuration drive1 ......................................................................... 48
4.1.5. Configuring drive2............................................................................................... 49
4.1.6. Sensors................................................................................................................. 49
4.1.6.1 Pressure sensors...................................................................................... 49
4.1.6.2 Force sensor drive 1 ................................................................................. 50
4.1.6.3 Pressure and force sensor drive 2............................................................ 51
4.1.7. Valve configuration ............................................................................................. 51
4.1.7.1 Selection and configuration of the valves ................................................. 52
4.1.8. Defining the reference system ........................................................................... 53
4.1.8.1 Position transducer ................................................................................... 53
4.1.8.2 Machine Zero ............................................................................................ 54
4.1.8.3 Travel Limit Settings ................................................................................. 70
4.1.8.4 Change assignment direction reversal / limit switches............................. 74
4.1.8.5 Change initiator logic ................................................................................ 74
4.1.8.6 Debouncing: Limit switch, machine zero and input 0 ............................... 74
4.1.9. Ramp upon error and switch to currentless..................................................... 74
4.1.10. Limit and monitoring settings of force.............................................................. 75
4.1.10.1 Force window - force achieved ................................................................. 75
4.1.10.2 Maximum control deviation of force controller .......................................... 76
4.1.10.3 Maximum force ......................................................................................... 76
4.1.10.4 Hydraulic corner power limitation.............................................................. 76
4.1.11. Positioning window - Position reached........................................................... 77
4.1.12. Following error limit ............................................................................................ 78
4.1.13. Maximum permissible speed.............................................................................. 78
4.1.14. Encoder Simulation............................................................................................. 79
4.1.15. Recipe table.......................................................................................................... 80
4.1.16. Error response ..................................................................................................... 80
4.1.17. Configuration name / comments........................................................................ 81
4.2 Configuring the signal source .............................................................. 82
4.2.1. Physical Source ................................................................................................... 82
4.2.1.1 Encoder A/B 5V, step/direction or SSI feedback as signal source........... 82
4.2.1.2 +/-10V Master speed ................................................................................ 85
4.2.2. Internal virtual master ......................................................................................... 85
4.2.3. HEDA Master signal source................................................................................ 85
4.3 Optimization ........................................................................................... 87
4.3.1. Optimization window........................................................................................... 88
4.3.2. Scope .................................................................................................................... 89
4.3.2.1 Monitor information ................................................................................... 89
4.3.2.2 User interface............................................................................................ 90

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4.3.2.3 Example: Setting the Oscilloscope ........................................................... 95
4.3.3. Control Loop Dynamics ...................................................................................... 97
4.3.3.1 Preparatory settings for the controller alignment...................................... 98
4.3.3.2 Signal filtering with external command value ........................................... 102
4.3.3.3 Controller structure of main axis ............................................................... 105
4.3.3.4 Controller strucutre auxiliary axis.............................................................. 106
4.3.3.5 Feedforward main axis (status controller)................................................. 107
4.3.3.6 Feedforward auxiliary axis (status controller) ........................................... 108
4.3.3.7 Position controller main axis (status controller) ........................................ 109
4.3.3.8 Position controller auxiliary axis (status controller)................................... 113
4.3.3.9 Filter main axis.......................................................................................... 116
4.3.3.10 Filter auxiliary axis .................................................................................... 117
4.3.3.11 Analog Input.............................................................................................. 118
4.3.3.12 Force-/Pressure Control main axis ........................................................... 123
4.3.3.13 Force-/Pressure Control auxiliary axis...................................................... 127
4.3.3.14 Output signal conditioning 0 ..................................................................... 131
4.3.3.15 Step-by-step optimization ......................................................................... 138
4.3.4. Input simulation ................................................................................................... 147
4.3.4.1 Calling up the input simulation.................................................................. 147
4.3.4.2 Functionality.............................................................................................. 148
4.3.5. Setup mode .......................................................................................................... 149
4.3.5.1 Motion objects in Compax3 ...................................................................... 150
4.3.6. ProfileViewer for the optimization of the motion profile ................................. 150
4.3.6.1 Mode 1: Time and maximum values are deduced from Compax3
input values............................................................................................... 151
4.3.6.2 Mode 2: Compax3 input values are deduced from times and
maximum values....................................................................................... 151
5. Motion control.......................................................................................152
5.1 Programming based on IEC61131-3................................................... 152
5.1.1. Prerequisites ........................................................................................................ 152
5.1.2. CoDeSys / Compax3 target system (Target Package) ..................................... 153
5.1.2.1 Program development and test................................................................. 153
5.1.2.2 Recipe management................................................................................. 154
5.1.3. Languages supported ......................................................................................... 154
5.1.4. Function range supported .................................................................................. 154
5.1.4.1 Operators supported................................................................................. 154
5.1.4.2 Standard functions supported................................................................... 155
5.1.4.3 Standard function modules supported...................................................... 156
5.1.5. Data types supported.......................................................................................... 157
5.1.6. Retain Variables................................................................................................... 157
5.1.7. Recipe table with 9 columns and 32 lines......................................................... 157
5.1.8. Maximum program size....................................................................................... 158
5.1.9. Cycle time............................................................................................................. 158
5.1.10. Access to the Compax3 object directory.......................................................... 158
5.1.11. Compilation, debugging and down/upload of IEC61131 programs ............... 159
5.1.12. General rules / timing.......................................................................................... 160
5.1.13. Library constants................................................................................................. 161
5.2 Status diagrams................................................................................... 162
5.2.1. Status diagram of Compax3F main axis ........................................................... 162
5.2.2. Status diagram of Compax3F auxiliary axis ..................................................... 163
5.2.3. Status diagram of the virtual master ................................................................. 164

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5.3 Control functions................................................................................. 165
5.3.1. Activation of the drive (MC_Power) ................................................................... 165
5.3.2. Stop (MC_Stop).................................................................................................... 166
5.3.2.1 MC_Stop at pressure/force control........................................................... 167
5.3.2.2 MC_Stop: Example 1................................................................................ 167
5.3.2.3 MC_Stop: Example 2................................................................................ 168
5.3.3. C3_SetControlMode ............................................................................................ 169
5.4 Reading values..................................................................................... 170
5.4.1. Reading the current position (MC_ReadActualPosition) ................................ 170
5.4.2. Read access to the (C3_ReadArray) array........................................................ 172
5.4.3. Reading the device status (MC_ReadStatus) ................................................... 173
5.5 Determine valve/range parameters (C3_GetSystemFingerPrint)..... 174
5.5.1. Important notes.................................................................................................... 176
5.5.2. Procedure when working with the C3_getSystemFingerPrint........................ 177
5.6 Positioning functions (standard)........................................................ 178
5.6.1. Value range for positioning parameters............................................................ 178
5.6.2. Absolute positioning (MC_MoveAbsolute) ....................................................... 179
5.6.2.1 Position mode in reset operation .............................................................. 182
5.6.2.2 Description of jerk ..................................................................................... 183
5.6.3. Relative positioning (MC_MoveRelative) .......................................................... 184
5.6.4. Additive positioning (MC_MoveAdditive).......................................................... 186
5.6.5. Continuous positioning (MC_MoveVelocity) .................................................... 188
5.6.6. Manual operation (C3_Jog)................................................................................. 190
5.6.7. Homing (MC_Home) ............................................................................................ 192
5.6.8. Electronic gearbox (MC_GearIn)........................................................................ 195
5.7 Superimposed motion ......................................................................... 198
5.7.1. Dynamic positioning ........................................................................................... 198
5.7.2. Superimposed positioning (MC_MoveSuperImposed).................................... 199
5.7.3. Zero point shift caused by superimposed positioning
(C3_ShiftPosition)................................................................................................ 201
5.8 Adjust force / pressure (C3_PressureForceAbsolute)...................... 203
5.9 Dynamic switching: Position- on force/pressure - adjustment........ 204
5.9.1. Switching: from force to position mode (C3_pQ) ............................................ 205
5.10 Cam Control ......................................................................................... 207
5.10.1. Introduction: Electronic cam control................................................................. 208
5.10.1.1 Function principle...................................................................................... 209
5.10.2. Overview............................................................................................................... 210
5.10.3. Basics 211
5.10.3.1 Cam types................................................................................................. 211
5.10.3.2 Cam parameters / terms ........................................................................... 212
5.10.3.3 Basic procedure ........................................................................................ 213
5.10.4. Generating cams.................................................................................................. 214
5.10.4.1 Introduction to the CamDesigner (example)............................................. 215
5.10.4.2 Cam functions of the Compax3 ServoManager / motion laws ................. 220
5.10.5. Cam function structure ....................................................................................... 224
5.10.5.1 Function modules of the cam.................................................................... 224
5.10.5.2 Signal image ............................................................................................. 225
5.10.5.3 Cam reference systems............................................................................ 229

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5.10.6. Master signal source ........................................................................................... 235
5.10.6.1 Setting the position of the selected master source
(C3_SetMaster)......................................................................................... 236
5.10.6.2 Recording the position of the selected master source
(C3_MasterControl) .................................................................................. 237
5.10.6.3 Control of the cam generator (C3_CamTableSelect) ............................... 240
5.10.6.4 C3_MasterConfig...................................................................................... 243
5.10.6.5 Master signal phase shift (MC_Phasing).................................................. 244
5.10.7. Alignment of the slave axis ................................................................................ 246
5.10.7.1 Start cam / coupling .................................................................................. 246
5.10.7.2 Exiting the active curve with coupling movement (C3_CamOut) ............. 257
5.10.8. 10 Steps for cam generation .............................................................................. 261
5.10.8.1 Step 1: C3 ServoManager ........................................................................ 261
5.10.8.2 Step 2: Connect motor.............................................................................. 261
5.10.8.3 Step 3: Supply & I/O wiring....................................................................... 261
5.10.8.4 Step 4: RS232 connection & C3 ServoManager ...................................... 261
5.10.8.5 Step 5: Set Compax3 device type ............................................................ 262
5.10.8.6 Step 6: Configuration ................................................................................ 262
5.10.8.7 Step 7: Selecting Master signal source .................................................... 262
5.10.8.8 Step 8: Generating the cam...................................................................... 262
5.10.8.9 Step 9: Create IEC program ..................................................................... 263
5.10.8.10Step 10: Starting and monitoring cam ...................................................... 263
5.10.9. Cam applications................................................................................................. 264
5.10.9.1 Example 1: Single start of a closed cam................................................... 264
5.10.9.2 Example 2: Change between single start of an open cam and
POSA ........................................................................................................ 267
5.10.9.3 Example 3: Single Start for run through curve 5 times............................. 269
5.10.9.4 Example 4: Composing curves ................................................................. 271
5.10.9.5 Example 5: Cyclic operation with event-triggered change of curve.......... 274
5.10.9.6 Example 6: Operation with curve segments and standstill area............... 276
5.10.9.7 Example 7: Curve operation with slave reg synchronization.................... 279
5.10.9.8 Example 8: Curve operation with master reg synchronization ................. 281
5.10.9.9 Example case of damage ......................................................................... 284
5.10.9.10Application note: Drift................................................................................ 286
5.11 Cam switching mechanism................................................................. 288
5.11.1. Cam switching mechanism function overview................................................. 288
5.11.1.1 Example of cam function .......................................................................... 289
5.11.1.2 Examples of a cam cycle .......................................................................... 289
5.11.2. Redirect the fast cams directly to the physical output
(C3_OutputSelect) ............................................................................................... 291
5.11.3. Objects of the cam switching mechanism........................................................ 292
5.11.4. Behavior of the switch-on/switch-off anticipation ........................................... 293
5.11.4.1 Behavior depending on the travel direction .............................................. 293
5.11.4.2 Switching behavior with reset operation ................................................... 295
5.11.4.3 Switch-on anticipation is corrected via reset distance .............................. 295
5.11.4.4 Note: No switching operation with overlapping cams ............................... 296
5.11.5. Hysteresis............................................................................................................. 296
5.11.6. CoDeSys-Project for the configuration of the cams ........................................ 297
5.11.7. Example: Working with fast cams ..................................................................... 298
5.12 Error handling ...................................................................................... 300
5.12.1. Acknowledging errors (MC_Reset).................................................................... 300
5.12.2. Reading axis errors (MC_ReadAxisError)......................................................... 301
5.12.3. Set error reaction (C3_SetErrorReaction)......................................................... 302

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5.13 Process image...................................................................................... 303
5.13.1. Reading digital inputs (C3_Input) ...................................................................... 303
5.13.2. Write digital outputs (C3_Output) ...................................................................... 303
5.13.3. Reading/writing optional inputs/outputs........................................................... 304
5.13.3.1 C3_IOAddition_0....................................................................................... 304
5.13.3.2 C3_IOAddition_1....................................................................................... 304
5.13.3.3 C3_IOAddition_2....................................................................................... 305
5.13.4. Memorizing the signals with the trigger event (C3_TouchProbe) .................. 306
5.13.5. Integration of Parker I/Os (PIOs) ........................................................................ 309
5.13.5.1 Initializing the PIOs (PIO_Init)................................................................... 309
5.13.5.2 Reading the PIO inputs 0-15 (PIO_Inputx...y) .......................................... 310
5.13.5.3 Writing the PIO outputs 0-15 (PIO_Outputx...y) ....................................... 311
5.13.5.4 Example: Compax3 as CANopen Master with PIOs ................................ 312
5.14 Interface to C3 powerPLmC ................................................................ 314
5.14.1. Interface module "PLmC_Interface"................................................................. 315
5.14.2. Cyclic data channel for C3T30 and C3T40 ........................................................ 317
5.14.3. Example: C3 powerPLmC Program & Compax3 Program .............................. 319
5.15 IEC examples........................................................................................ 322
5.15.1. Example in CFC: Using Compax3-specific function modules and
Compax3 objects................................................................................................. 322
5.15.2. Example in CFC: Positioning 1 .......................................................................... 323
5.15.3. Example in CFC: Positioning 2 .......................................................................... 324
5.15.4. Example in CFC: Positioning with set selection .............................................. 325
5.15.5. Example in CFC: Cycle mode............................................................................. 326
5.15.6. Example in ST: Cycle mode with a Move module ............................................ 327
5.16 Profibus: Emulating the ProfiDrive profile
(C3F_ProfiDrive_Statemachine) ......................................................... 329
6. Communication ....................................................................................333
6.1 Compa3 communication variants....................................................... 333
6.1.1. PC <-> Compax3 (RS232).................................................................................... 334
6.1.2. PC <-> Compax3 (RS485).................................................................................... 335
6.1.3. PC <-> C3M device combination (USB) ............................................................. 336
6.1.4. USB-RS485 Moxa Uport 1130 adapter.............................................................. 337
6.1.5. ETHERNET-RS485 NetCOM 113 adapter........................................................... 338
6.1.6. Modem Westermo TD-36 485.............................................................................. 340
6.1.7. C3 settings for RS485 two wire operation......................................................... 343
6.1.8. C3 settings for RS485 four wire operation........................................................ 344
6.2 COM port protocol ............................................................................... 345
6.2.1. RS485 setting values........................................................................................... 345
6.2.2. ASCII - record....................................................................................................... 346
6.2.3. Binary record ....................................................................................................... 347
6.3 Remote diagnosis via Modem............................................................. 350
6.3.1. Structure............................................................................................................... 350
6.3.2. Configuration of local modem 1......................................................................... 351
6.3.3. Configuration of remote modem 2..................................................................... 352
6.3.4. Recommendations for preparing the modem operation ................................. 353

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6.4 Profibus ................................................................................................ 354
6.4.1. Typical application with fieldbus and IEC61131............................................... 354
6.4.2. Profibus configuration ........................................................................................ 354
6.4.2.1 Configuration of the process-data channel............................................... 355
6.4.2.2 PKW parameter channel........................................................................... 356
6.4.2.3 Error reaction to a bus failure ................................................................... 356
6.4.3. Cyclic process data channel .............................................................................. 356
6.4.3.1 Control and status word............................................................................ 356
6.4.4. Acyclic parameter channel ................................................................................. 357
6.4.4.1 Parameter access with DPV0: Required data channel............................. 357
6.4.4.2 Data formats of the bus objects ................................................................ 363
6.4.5. Simatic S7 -300/400 - modules ........................................................................... 366
6.5 CANopen - Node Settings ................................................................... 367
6.5.1. CANopen - configuration .................................................................................... 367
6.5.1.1 CANopen Operating Mode ....................................................................... 367
6.5.1.2 Error reaction to a bus failure ................................................................... 368
6.5.1.3 Baud rate .................................................................................................. 368
6.5.1.4 Possible PDO assignment ........................................................................ 369
6.5.1.5 Transmission cycle time............................................................................ 369
6.5.2. Supporting IEC modules..................................................................................... 369
6.5.2.1 C3_CANopen_State ................................................................................. 370
6.5.2.2 C3_CANopen_GuardingState .................................................................. 371
6.5.2.3 C3_CANopen_AddNode........................................................................... 372
6.5.2.4 C3_CANopen_ConfigNode....................................................................... 373
6.5.2.5 C3_CANopen_NMT.................................................................................. 374
6.5.2.6 Reading an object in another node (C3_CANopen_SDO_Read4) .......... 375
6.5.2.7 Writing an object in another node (C3_CANopen_SDO_Write4)............. 376
6.5.3. CANopen communication profile....................................................................... 377
6.5.3.1 Object types .............................................................................................. 378
6.5.3.2 Communication objects............................................................................. 378
6.5.4. Acyclic parameter channel ................................................................................. 382
6.5.4.1 Service Data Objects (SDO)..................................................................... 382
6.5.4.2 Object up-/download via RS232 / RS485 ................................................. 384
6.5.4.3 Data formats of the bus objects ................................................................ 384
6.6 DeviceNet ............................................................................................. 385
6.6.1. DeviceNet Configuration..................................................................................... 385
6.6.1.1 Error reaction to a bus failure ................................................................... 385
6.6.2. DeviceNet object classes.................................................................................... 386
6.6.2.1 Overview of the DeviceNet object classes................................................ 387
6.6.2.2 Object classes........................................................................................... 387
6.6.3. Data formats of the bus objects......................................................................... 387
6.7 Ethernet Powerlink .............................................................................. 388
6.7.1. Configuring Ethernet Powerlink / EtherCAT..................................................... 388
6.7.1.1 CN Controlled Node (Slave) ..................................................................... 388
6.7.1.2 Slave with configuration via master .......................................................... 388
6.7.1.3 Error reaction to a bus failure ................................................................... 388
6.7.1.4 Possible PDO assignment ........................................................................ 389
6.8 HEDA Bus............................................................................................. 390
6.8.1. HEDA standard mode.......................................................................................... 391
6.8.1.1 Error reaction to a bus failure ................................................................... 391
6.8.1.2 HEDA-Master............................................................................................ 392
6.8.1.3 HEDA-Slave.............................................................................................. 392

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6.8.2. HEDA expansion (HEDA advanced) .................................................................. 393
6.8.2.1 The possibilities of the HEDA expansion.................................................. 393
6.8.2.2 Technical data of the HEDA interface / overview ..................................... 394
6.8.2.3 Definitions ................................................................................................. 395
6.8.2.4 Calling up the HEDA wizard in the C3 ServoManager ............................. 395
6.8.2.5 Configuration of the HEDA communication .............................................. 395
6.8.3. Coupling objects.................................................................................................. 412
7. Compax3 - Objects...............................................................................414
7.1 Objects for the process data channel ................................................ 415
7.2 Object overview sorted by object name (T40)................................... 417
7.3 Detailed object list ............................................................................... 426
8. Status values ........................................................................................427
8.1 D/A-Monitor .......................................................................................... 427
8.2 Status values........................................................................................ 427
9. Error:......................................................................................................428
10.Order code ............................................................................................429
10.1 Order code device: Compax3 Fluid.................................................... 429
10.2 Accessories order code ...................................................................... 429
11.Compax3 Accessories .........................................................................432
11.1 ZBH plug set......................................................................................... 432
11.2 Cable for path measurement systems ............................................... 432
11.2.1. Encoder cable ...................................................................................................... 433
11.2.2. Feedback cable (Balluff) ..................................................................................... 434
11.2.3. Feedback cable EnDat2.1.................................................................................... 435
11.3 Operator control module BDM............................................................ 436
11.4 EAM06: Terminal block for inputs and outputs................................. 437
11.5 Interface Cables ................................................................................... 440
11.5.1. RS232 cable.......................................................................................................... 441
11.5.2. RS485 cable to Pop ............................................................................................. 442
11.5.3. I/O interface X12 / X22 ......................................................................................... 443
11.5.4. Ref X11.................................................................................................................. 444
11.5.5. Encoder coupling of 2 Compax3 axes............................................................... 445
11.5.6. Modem cable SSK31............................................................................................ 446
11.6 Options M1x ......................................................................................... 447
11.6.1. Input/output option M12...................................................................................... 447