CPX terminal Description Electronics CMAX axis controller Type CPX−CMAX−C1−1 System description CMAX axis controller Mounting, installation and diagnostics Positioning system Description 559 751 en 0908NH [727 403]
Contents and general safety instructions Original . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . de Edition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . en 0908NH Designation . . . . . . . . . . . . . . . . . . P.BE−CPX−CMAX−SYS−EN Order no. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 559 751 © (Festo AG & Co. KG, D 73726 Esslingen, 2009) Internet: http://www.festo.com E−mail: service_international@festo.
Contents and general safety instructions Interbus®, DeviceNet®, PROFIBUS®, CC−Link®, EtherNet/IP®, PROFINET®, Adobe Reader® und TORX® are registered trademarks of their respective trademark holders in certain countries. II Festo P.
Contents and general safety instructions Contents Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VII Safety note . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VIII Target group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X Service . . . . . . . . . . . . . . . . . . . . . . . . . .
Contents and general safety instructions 2. Fitting and pneumatic installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2−1 2.1 2.2 2.3 General notes on mounting and installation . . . . . . . . . . . . . . . . . . . . . . . . . . Mounting/dismounting the CMAX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation of the drive and position measuring system . . . . . . . . . . . . . . . . 2.3.1 General mechanical requirements . . . . . . . . . . . . . . .
Contents and general safety instructions 4. Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−1 4.1 Overview/procedure for commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1.1 Instructions for commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1.2 Installing the Festo Configuration Tool and FCT CMAX plug−in . . . . Preparations for commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . .
Contents and general safety instructions 5. Diagnostics and error handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5−1 5.1 5.2 Summary of diagnostics options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Malfunctions and warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2.1 Error numbers on the CPX terminal . . . . . . . . . . . . . . . . . . . . . . . . . 5.2.
Contents and general safety instructions Intended use The CPX−CMAX−C1−1 axis controller documented in this description is intended exclusively for use in Festo CPX terminals for installation in a machine or an automation system.
Contents and general safety instructions Safety note Protection against dangerous movements Warning High acceleration forces at the connected actuators! Unexpected motions can cause collisions and severe injuries. Dangerous movements can occur due to the faulty control ling of connected actuators, e.g. due to: Dirty or faulty wiring/cabling Component operating errors Measured value and signal generator errors Faulty or non−EMC−compliant components Errors in the higher−order control system.
Contents and general safety instructions · The holding brakes controlled by the drive controller are not appropriate for personal protection by themselves. Lock vertical axes additionally to keep them from falling down or sinking when the compressed air and load volt age are switched off, e.g. by means of: mechanical locking of the vertical axis external braking/safety catch/clamping device sufficient counterbalance of the axis.
Contents and general safety instructions Target group This manual is intended exclusively for technicians trained in control and automation technology, who have experience in installing, commissioning, programming and diagnosing posi tioning systems. Service Please consult your local Festo Service agent if you have any technical problems. X Festo P.
Contents and general safety instructions Required software versions for the CPX nodes Particular software versions for the CPX node are required for operating the CMAX (versions as of August 2009): CPX node Required version 1) Use Special features 2) CPX−FEC From Revision 18 (R18) On request Max. 8 CMAX modules CPX−FB6 (Interbus) From Revision 22 (R22) On request Max. 1 CMAX module CPX−FB11 (DeviceNet) From Revision 20 (R20) Suitable Max.
Contents and general safety instructions Important user instructions Danger categories This manual contains instructions on the possible dangers which can occur if the product is not used correctly. These instructions are marked (Warning, Caution, etc), printed on a shaded background and marked additionally with a picto gram. A distinction is made between the following danger warnings: Warning ... means that failure to observe this instruction may result in serious personal injury or material damage.
Contents and general safety instructions Identification of specific information The following pictograms designate texts that contain special information. Pictograms Information: Recommendations, tips and references to other sources of information Accessories: Information about necessary or useful accessories for the Festo product. Environment: Information on the environmentally friendly use of Festo products. Text designations · Bullet points indicate activities that may be carried out in any order.
Contents and general safety instructions Notes on this description This description refers to the following versions: CPX−CMAX−C1−1 axis controller starting from software version V 1.0 This description contains special information on the mode of operation, mounting, installation and commissioning of the CMAX axis controller with the modules and components on the axis string (see Tab. 0/2).
Contents and general safety instructions This description contains information on the following modules and components of the positioning system: Module/component type CMAX−C1−1 CMAX axis controller with 7−segment display as well as an axis interface to the VPWP. The CMAX is a CPX module (technology module) in a CPX terminal. VPWP−... VPWP proportional directional control valve with connections to the CMAX and to the displacement encoder or sensor interface.
Contents and general safety instructions Manual for CMAX axis controller Type Title Electronics de CMAX axis controller scription system description" P.BE−CPX−CMAX−SYS−... Contents Mounting, installation, commissioning and diagnosis of the CMAX axis controller Communica CMAX communication Activation, programming and diagnosis of a CMAX tion profile de profile" with the used CPX node scription P.BE−CPX−CMAX−CONTROL−...
Contents and general safety instructions Glossary The following product−specific terms and abbreviations are used in this description: Term/abbreviation Meaning 0xA0 (A0h) Hexadecimal numbers are marked by a prefixed 0x" or by a subscript h.". Absolute position measuring system A position measuring system with fixed (absolute) assignment of the measured value (position, angle, etc.) and measured variable, for digital" or potentiometer" CMAX.
Contents and general safety instructions Term/abbreviation Meaning Functions Special functions in the different operating modes. e.g.: Jog mode Homing Homing By means of homing, the reference position and thereby the origin of the dimension reference system of the axis are defined. I Digital input. From the point of view of the master controller, the CMAX status outputs are module input data. See section 4.5. I/Os Digital inputs and outputs.
Contents and general safety instructions Term/abbreviation Meaning Pressure/force control Control mode where a defined force is applied via pressure control. In the following, the term force control" will be used. Project zero point (PZ) Dimension reference point for all positions in positioning tasks (project zero point). The project zero point forms the basis for all absolute posi tion specifications (e.g. in the position set table or in direct mode).
Contents and general safety instructions XX Festo P.
CMAX system overview Chapter 1 Festo P.
1. CMAX system overview Contents 1. CMAX system overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−1 1.1 CMAX axis controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1.1 Connection and display components of the CMAX . . . . . . . . . . . . . 1.1.2 CMAX function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1.3 CMAX in the CPX terminal . . . . . . . . . . . . . . . . . .
1. CMAX system overview 1.1 CMAX axis controller 1.1.1 Connection and display components of the CMAX The following connection and display components can be found on the CMAX: 1 Status LED See section 5.3 2 X: Axis interface (connection for VPWP) 5 1 4 Dx X Dy Y 3 Inscription labels (accessories) 4 3−character display See section 5.4 5 Name plate 3 2 (on side surface) Fig. 1/1: Connection and display components of the CMAX Festo P.
1. CMAX system overview 1.1.2 CMAX function The CMAX axis controller, together with a VPWP proportional directional control valve and a drive with a position measur ing system, forms a positioning system for pneumatic axes (see section 1.2). The positioning system permits: Travel at selectable speed in any positions (position con trol) The approach of a position and applying a defined force (force control).
1. CMAX system overview 1.1.3 CMAX in the CPX terminal The CMAX is integrated in a CPX terminal as a CPX module and is controlled by the CPX node via the internal bus using 8 bytes of module output and 8 bytes module input data. See section 4.5. Information about the control and parameterisation of the CMAX via the CPX node can be found in the CMAX communi cation profile" description, P.BE−CPX−CMAX−CONTROL−... . The descriptions are also available as PDF files: è www.festo.
1. CMAX system overview 1.2 Structure of a positioning system A positioning system typically consists of the following com ponents (see Fig. 1/2): 1 CPX terminal with 1 CMAX 2 3 4 2 VPWP proportional directional control valve 3 A sensor interface with displacement encoder cable (optional, depending on the displacement encoder used) 4 Drive with position measuring system (in this example a DNCI) 5 Pneumatic tubing 6 5 6 Axis string Fig.
1. CMAX system overview 1.3 Parameterisation and commissioning options Tab. 1/1 provides an overview of the commissioning, parameterising and teaching options. Operated via Properties For details, see FCT CMAX plug−in Easy commissioning thanks to special dialogues and functions. Direct on−site" operation with drive monitoring is possible PC must be connected on site with the diagnostic interface of the CPX terminal.
1. CMAX system overview 1.3.2 FHPP communication profile Festo has developed an optimised data profile, the Festo Handling and Positioning Profile (FHPP)", tailored to handling and positioning functions. The FHPP allows the various Festo fieldbus systems and con trollers to be uniformly controlled and programmed. It also uniformly defines the following for the user: Operating modes I/O data structure Parameters Sequence control. Basic information can be found in section 4.5.
Fitting and pneumatic installation Chapter 2 Festo P.
2. Fitting and pneumatic installation Contents 2. Fitting and pneumatic installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2−1 2.1 2.2 2.3 General notes on mounting and installation . . . . . . . . . . . . . . . . . . . . . . . . . . Mounting/dismounting the CMAX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation of the drive and position measuring system . . . . . . . . . . . . . . . . 2.3.1 General mechanical requirements . . . . . . . . . . .
2. Fitting and pneumatic installation 2.1 General notes on mounting and installation Information about mounting the CPX terminal can be found in the CPX system description (P.BE−CPX−SYS−..). Note Using components that have not been approved for oper ation with the CMAX may lead to malfunctions. Use only the special matching components from Festo for setting up and wiring the system.
2. Fitting and pneumatic installation 2.2 Mounting/dismounting the CMAX The CMAX is mounted in an interlinking block (see also section 3.4) of the CPX terminal. See Fig. 2/2. Note · Always switch off the power supply before mounting/ dismounting CPX modules. Note The CMAX contains electrostatically sensitive devices. · Therefore, do not touch any of the components. · Observe the handling specifications for electrostatically sensitive devices. Removal Remove the CMAX as follows: 1.
2. Fitting and pneumatic installation Mounting Mount the CMAX as follows: 1. Place the CMAX in the interlinking block. Make sure that the grooves with the power contact terminals on the bot tom of the CMAX lie above the contact rails. 2. Push the CMAX carefully and without tilting as far as possible into the interlinking block. 3. Tighten the screws only by hand. Place the screws so that the self−cutting threads can be used. 4. Tighten the screws with a size T10 Torx screwdriver with a torque of 0.
2. Fitting and pneumatic installation 2.3 Installation of the drive and position measuring system Use only the drive/displacement encoder combinations approved by Festo for the CMAX. Note In order to avoid damage due to uncushioned movement into the end positions: · Use appropriate shock absorbers. · Define the software end positions. To avoid damage to the displacement encoder when the displacement encoder is shorter than the drive stroke: · Limit the travel range with additional end stops. Tab.
2. Fitting and pneumatic installation 2.3.1 General mechanical requirements Note Connect the drive, guide, displacement encoder and load with as little backlash as possible and align them flush with each other. Mechanical backlash, e.g. between the cylinder piston rod and the mass to be moved, leads to poor movement be haviour (the backlash presents the controller with con stantly changing mass").
2. Fitting and pneumatic installation Note Please observe the notes in the operating instructions for the drive used. Make sure that the following are complied with: the permitted lateral force the permitted longitudinal force the permitted mass moment of inertia the maximum permitted speeds and swivel frequencies. 2.3.2 Drive, shock absorbers and fixed stops Drive Note With all work, be sure to follow the mounting instructions in the operating instructions.
2. Fitting and pneumatic installation Shock absorbers / fixed stops Shock absorbers or fixed stops are recommended, depending on the specific application and the drive used. These fulfil the following functions: Protection of the drive or position measuring system Definition or setting of the end positions, as needed Note Damage due to uncushioned travel into the end positions. · Carry out commissioning again after adjusting the fixed stops or when components and tubing have been re placed.
2. Fitting and pneumatic installation 2.3.3 Position measuring system Tab. 2/3 provides instructions on mounting the displacement encoder. Drive Position measuring system Mounting instructions DGCI Permanently integrated position measuring system. DGP(L) External position measuring system of type MLO−POT−...−TLF. · Only use a displacement encoder and drive DNCI Integrated position measuring system. DNC External position measuring system of type MLO−POT−...−LWG.
2. Fitting and pneumatic installation Note If the positioning range of the drive is longer than the effective stroke of the displacement encoder: · Limit the positioning range using shock absorbers or stops, so that the position measuring system covers the complete possible positioning range. In this way you can protect the displacement encoder from damage. External potentiometer position measuring system If analogue displacement encoders are used (e.g. type MLO−POT−...
2. Fitting and pneumatic installation 2.3.4 Load For good positioning behaviour, the CMAX must be adjusted to the load. Here, the load represents the total mass to be moved with the positioning drive, including the weight of the piston and the slide. It consists of the mass of the workpiece which generally changes during the process and all other parts of the drive with mass, such as pistons, piston rods, slides, workpiece grippers or gripper units, etc.
2. Fitting and pneumatic installation Note Minimum load. A pneumatic positioning axis always requires a minimum load. You can find these values in tables Tab. 2/4 and Tab. 2/6. If necessary, this minimum load must be ensured through the use of an additional weight. For every positioning job, you have the option of specifying the respectively existing load, thereby adjusting the con troller setting of the CMAX to the various loads. Note If the load varies from positioning job to positioning job (e.g.
2. Fitting and pneumatic installation Mounting position Maximum load Minimum load horizontal (á = 0°) mmax = 322 * 6 * 0.008 = 49.15 kg 0.1 * mmax = 4.92 kg vertical (á = 90°) 0.33 * mmax = 16.22 kg 0.1 * mmax = 4.92 kg diagonal (45°) (1 2/3 sin 45°) * mmax = 25.98 kg 0.1 * mmax = 4.92 kg Tab. 2/5: Load example Instructions for coupling (piston rod drives) If a coupling is required between the piston rod and the guide: · Check the backlash of the coupling.
2. Fitting and pneumatic installation Mass moment of inertia for semi−rotary drives Permissible mass moments of inertia for the DSMI swivel module in electronically regulated operation with the CMAX are shown in the following table: Swivel module Permissible mass moment of inertia [kgm2 * 10−4] DSMI−25−... 15 ... 300 DSMI−40−... 60 ... 1200 Tab.
2. Fitting and pneumatic installation 1 Favourable natural 1 vibration behaviour 2 2 Unfavourable natural vibration behaviour Fig. 2/3: Example: Favourable and unfavourable natural vibration behaviour of the mass Mass moment of inertia for semi−rotary drives The mass moment of inertia must not change during the movement.
2. Fitting and pneumatic installation 2.4 2.4.1 VPWP proportional directional control valve Approved drive/valve combinations Tab. 2/7 contains the approved drive/valve combinations (as of August 2009). Use the specified fittings and tubing or appropriate tubes with the corresponding flow rates. VPWP sizes 2 and 10 are in preparation. Depending on the application, you can also use sizes 4 or 8 after consulting with Festo. Drive Valve Type Size Length DGCI 18 100 ...
2. Fitting and pneumatic installation Drive Valve Type Size Length DGP(I)(L) 25 225 ... 750 Drive VPWP−4−... QS−1/8−8 QS−1/8−8 PUN−8x1.25 1000 ... 2000 VPWP−6−... QS−1/8−8 QS−1/8−8 PUN−8x1.25 225 ... 300 VPWP−4−... QS−1/8−8 QS−1/8−8 PUN−8x1.25 360 ... 2000 VPWP−6−... QS−1/8−8 QS−1/8−8 PUN−8x1.25 225 VPWP−4−... QS−1/8−8 QS−1/4−8 PUN−8x1.25 300 ... 750 VPWP−6−... QS−1/8−8 QS−1/4−8 PUN−8x1.25 1000 ... 2000 VPWP−8−... QS−1/4−10 QS−1/4−10 PUN−10x1.5 225 ...
2. Fitting and pneumatic installation 2.4.2 Mounting the VPWP proportional directional control valve Mount the VPWP proportional directional control valve on an even surface with two M3 screws and one retaining washer each. See Fig. 2/4. Tightening torque: 1.5 Nm ±10% 1 M3 screws with retaining washers 2 Earth terminal (see section 3.1) 1 1 2 Fig. 2/4: Mounting the VPWP When mounting on moving parts: · Attach the VPWP perpendicular to the direction of move ment.
2. Fitting and pneumatic installation H−rail mounting You will require the following mounting kit to mount the VPWP on H−rails. Valve Mounting P. No. Type VPWP−2, ...−4, ...−6 527392 CPASC1−BG−NRH VPWP−8, ...−10 123491 CPV10−VI−BG−NRH Tab. 2/8: VPWP H−rail mounting set Mounting onto an H−rail: 1. Ensure that the mounting surface can carry the weight of the VPWP. 2. Mount the H−rail (DIN mounting rail EN 60715−TH35). Be sure to leave sufficient space for connecting the supply cables and tubes. 3.
2. Fitting and pneumatic installation 1 Fixing bolts (underneath the VPWP−8/10) 2 M4x10 screw 3 H−rail 4 H−rail clamping 1 2 3 4 Fig. 2/6: Mounting the VPWP on an H−rail Festo P.
2. Fitting and pneumatic installation 2.5 Mounting the CASM sensor interface Mount the CASM−... sensor interface on an even surface with two M4 screws and one retaining washer each. See Fig. 2/7. The symbol marks the position of the mounting screws. The outer mounting screw also serves for earthing ( 1 ). Tightening torque: 2 Nm. 1 Mounting screw 1 S2 S1 (connect earthing) Approx. 30 mm Approx. 126 mm Fig.
2. Fitting and pneumatic installation 2.6 Pneumatic installation Note Observe the following instructions for installing the pneu matic components. Only then can you guarantee trouble− free operation. Section 2.6.3 Section 2.6.2 Section 2.6.4 Section 2.6.5 Section 2.6.1 Fig. 2/9: Overview of pneumatic installation 2.6.1 Compressed air supply Requirements of the compressed air supply: · Use only dry, unlubricated, 5 m filtered compressed air. · Permissible pressure range: 3 ... 8 bar. Festo P.
2. Fitting and pneumatic installation 2.6.2 Filter regulator · Use a filter regulator consisting of a compressed air filter and a regulating valve (e.g. LFR−...−D−... with 5 ìm filter cartridge) in conjunction with a soft−start valve (e. g. HEL): without lubricator with a 5 m filter with sufficiently large standard nominal flow rate corresponding to the air requirement of the connected drive during positioning.
2. Fitting and pneumatic installation 2.6.3 Air reservoir (optional) If the positioning behaviour does not conform to your require ments, and if you ascertain fluctuations in pressure of over 1 bar at the measuring point, then proceed as follows: · Install an air reservoir (e.g. type VZS−...−B) between the filter regulator and the proportional directional control valve. This way, you can reduce pressure fluctuations during posi tioning.
2. Fitting and pneumatic installation 1 Working line 2 + (blue releasing ring): } Drive moves in a positive direction 2 2 Working line 4 1 (black releasing ring): } Drive moves in negative direction 3 3 VPWP proportional directional control valve 4 4 Filter regulator with 5 m filter, without lubricator Fig. 2/10: Pneumatic circuit diagram Drive with dis Direction of movement placement l t encoder d Negative ( ) Positive (+) Block circuit diagram DGCI DGP(L) with MLO−POT−...
2. Fitting and pneumatic installation Tubing aid for DGCI and DSMI−...−B When ordering the DGCI with fittings standard (no modular system feature) or modular system feature QD" or QR", as well as for DSMI−...−B: The fittings on the valve and drive have colour−coded releas ing rings. · Connect the fittings with the respective blue and black releasing rings. Note Check the tubing connection with the movement test. Silencer The VPWP is available with an integrated flat plate silencer.
2. Fitting and pneumatic installation Instructions on converting systems When converting systems you should still use the existing drives. Often, only drives with a unilateral air connection are available here and the cushioning path (PPV) is used as the drive stroke. In some cases the specified positioning times cannot be fully achieved. The specified positioning times and optimum system behaviour can only be achieved if the installation instructions described in the previous section are observed.
2. Fitting and pneumatic installation 2.6.5 Tubing and fittings · Use only straight fittings. If elbow connectors cannot be avoided, use push−in fittings from the Quick Star series. · Size the tubing and tubing connectors as specified in sec tion 2.4.1. · Arrange the tubing between the valve (VPWP) and the drive symmetrically. · Use only clean tubing and fittings. · Do not use flow control valves or non−return valves in the supply lines.
2. Fitting and pneumatic installation 2−30 Festo P.
Electrical installation Chapter 3 Festo P.
3. Electrical installation Contents 3. Electrical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−1 3.1 3.2 Earthing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Axis interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2.1 VPWP proportional directional control valve . . . . . . . . . . . . . . . . . . 3.2.
3. Electrical installation The CMAX power is supplied via the CPX terminal. See section 3.4. 3.1 Earthing The CMAX is earthed via the CPX terminal. See the CPX system description. Observe the additional earthing measures described below, depending on the components used. Note Operative malfunctions can occur due to incorrect or no earthing. · Make the specified connections at low impedance (short cable with large cross−section) to the earth potential.
3. Electrical installation Earthing the drives/displacement encoders... Depending on the drive or displacement encoder used, these must be earthed. See Tab. 3/1. Drive Description Earthing instructions DGCI Linear drive with permanently integrated position measuring system. · Make a low−impedance connection (earthing Linear drive with external position measuring system MLO−POT−...−TLF. · Mount the position measuring system so that it Standard cylinder with integrated position measuring system.
3. Electrical installation 3.2 Axis interface The VPWP proportional directional control valve is connected to axis interface ’X’ of the CMAX. The position measuring sys tem or a sensor interface (depending on the displacement encoder) is connected to the VPWP. This forms an axis string. The axis interface pin allocation for the CMAX, VPWP and sen sor interface are shown in Tab. 3/2.
3. Electrical installation Connecting cables for the axis string Length Type Connecting cable WS−WD angled plug/angled socket 0.25 m KVI−CP−3−WS−WD−0.25 0.5 m KVI−CP−3−WS−WD−0.5 2m KVI−CP−3−WS−WD−2 5m KVI−CP−3−WS−WD−5 8m KVI−CP−3−WS−WD−8 2m KVI−CP−3−GS−GD−2 5m KVI−CP−3−GS−GD−5 8m KVI−CP−3−GS−GD−8 KVI−CP−3−SSD Connecting cable GS−GD straight plug/straight socket Connecting piece for control cabinet feedthrough Tab.
3. Electrical installation 3.2.1 VPWP proportional directional control valve The VPWP has one incoming (In) and one outgoing (Out) axis interface. See Tab. 3/2. Digital output DO (brake) A digital output (DO) at pin 2 is also available for controlling a valve for a brake or clamping unit. This is controlled via the CMAX I/O data (see section 4.5).
3. Electrical installation Technical data Value Digital output (pin 2) Activation Supply Max. current Fuse protection Version Galvanic isolation Via I/O data from 24 VVAL 500 mA protected against short circuits 1) in acc. with IEC 61131−2, positive logic (PNP) no Voltage output (load voltage, pin 4) Supply Max.
3. Electrical installation 3.2.2 CASM sensor interface The CASM sensor interface has an incoming (S1) axis inter face. See section 3.2. A corresponding input (S2) for connecting the specific posi tion measuring system is also available. See Tab. 3/6. Drive Position measuring Sensor interface system Connecting cable to the displacement encoder DGCI Permanently integrated (no sensor interface required) KVI−CP−3−... DNCI Integrated CASM−S−D3−R7 Permanently connected to DNCI.
3. Electrical installation CASM−S−D3−R7 Sensor interface for digital, incremental displacement encoders with M12 displacement encoder connection (socket, 8 pin). Pin Allocation 1 + Ub sensor (5 V) S2 7 1 6 2 0V 3 Sine signal + 4 Sine signal 8 5 2 4 3 5 Cosine signal 6 Cosine signal + 7 Screen 8 n.c. (not connected) Housing Earth terminal (FE) The cable screening is connected to the earth terminal of the sensor interface. Tab.
3. Electrical installation 3.3 Ensuring protection class IP65 With a completely installed axis string (all plug connectors inserted), the CMAX in the CPX terminal complies with protec tion class IP65. Note To comply with protection class IP65: · Seal unused connections with the corresponding protec tive caps. If the axis interface is not used, then seal this using a FLANGE RECEPTACLE, S712 protective cap. You will then comply with protection class IP65.
3. Electrical installation 3.4 Power supply The power for the positioning system with the CMAX is supplied via the following connections on the CPX terminal (interlinking blocks with voltage input): Interlinking block CPX−EV−S... or CPX−M−EV−S...
3. Electrical installation 3.4.1 Determining the current consumption The current consumption of a CMAX system depends on the number and type of the modules connected to the axis inter face. Recommendation: Calculations · Use a closed−loop regulated power supply. · When selecting the power supply unit, check that it pro vides a sufficient output. Calculate the total current con sumption, if necessary. Tab. 3/10 and Tab. 3/11 show the current consumption for a positioning system.
3. Electrical installation 3.4.2 Power supply concept, formation of power zones The modular power supply concept of the CPX terminal allows power zones to be formed. Observe the following: The internal electronics of the VPWP and the digital posi tion measuring system and, if present, the sensor inter face are supplied with power by the electronics/sensors operating voltage supply (UEL/SEN). The VPWP load supply and the VPWP outputs are sup plied with power by the valve load supply (UVAL).
3. Electrical installation Basic information on the power supply concept of the CPX terminal can be found in the CPX system description. A few examples can be found in Fig. 3/1, Fig. 3/2 and Fig. 3/3. A central (shared) power supply (Fig. 3/1) In the example, the entire CPX terminal and the CMAX positioning system are provided with power via the system supply.
3. Electrical installation Valve load voltage supply can be disconnected separately (Fig. 3/2) In the example, CMAX, and therefore the positioning system, are supplied via the system supply 1. The MPA pneumatics are supplied via the valve supply 2 (only permitted with MPA electronic modules of type VMPA..−FB−EMG−...). The MPA pneumatics can be switched off at all poles (galvanically isolated).
3. Electrical installation Load voltage supply of the CMAX and the valves can each be disconnected separately (Fig. 3/3) In the example, CMAX, and therefore the positioning system, are supplied via the valve supply 2. Only one pole of the VPWP load voltage can be disconnected. The MPA pneumatics are supplied via the valve supply 3 (only permitted with MPA electronic modules of type VMPA..−FB−EMG−...). The MPA pneumatics can be discon nected at all poles.
3. Electrical installation 3.4.3 Disconnecting the load voltage in connection with a brake or clamping unit In the example, circuitry for a brake or clamping unit is con nected to the brake output. When switching off, or when the CMAX valve load supply drops out, the brake or clamping unit is activated.
Commissioning Chapter 4 Festo P.
4. Commissioning Contents 4. Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−1 4.1 Overview/procedure for commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1.1 Instructions for commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1.2 Installing the Festo Configuration Tool and FCT CMAX plug−in . . . . Preparations for commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4. Commissioning 4.1 Overview/procedure for commissioning This chapter provides an overview for commissioning the positioning system with the CMAX using the Festo Configuration Tool with the CMAX plug−in. Information about the configuration of the CMAX with specific CPX nodes, as well as the description for commissioning via the CPX node, can be found in the CMAX communication profile" description, P.BE−CPX−CMAX−CONTROL−... . Note Incorrectly set parameters can damage the fixed stops and the drive.
4. Commissioning 4.1.1 Instructions for commissioning System structure Note Errors in the system structure and incorrectly set parameters can cause the drive to move to an end position uncushioned. This can damage the drive. You must observe the following instructions in order to pre vent such collisions. The CMAX must be set to certain configuration and application data. Before applying compressed air, you must adapt these settings to your application and to the axes which you are using.
4. Commissioning 4.1.2 Installing the Festo Configuration Tool and FCT CMAX plug−in The Festo Configuration Tool (FCT) is the software platform for configuring and commissioning different components and devices from Festo. The FCT consists of the following components: A framework as program start and entry point with uni form project and data management for all supported types of devices. A plug−in for each of the special demands of each device type (e.g.
4. Commissioning The current installation files for the FCT with CMAX plug−in can be found on Festo’s website at: è www.festo.com ˛ Downloads ˛ Download Area: Software, drivers and firmware ˛ Enter search term: CMAX 1. Download the installation program from the website. 2. Close all programs. 3. Start the installation program (e.g. Setup_FCT_CMAX.exe"). 4. Follow the instructions on the screen. Starting the FCT 1. Connect the CPX terminal with the CMAX to your PC via the NEFC−M12G5−0.
4. Commissioning Additional information about the FCT Additional information can be found in the general help for the Festo Configuration Tool. FCT help with the menu command [Help] [Contents FCT General] e.g. Plug−in help for working with projects for working with components, e.g. for inserting a component (of a device) in a project. with the menu command [Help] [Contents of installed PlugIns] [Festo (manufacturer name)] [CMAX], e.g.
4. Commissioning 4.2 4.2.1 Preparations for commissioning Checking the axis string Prior to commissioning: · Check the complete system structure, especially the drive tubing connections and the electrical installation (see chapters 2 and 3). It is possible to pre−parameterize the CMAX even without the components on the axis interface. 4.2.
4. Commissioning Delivery status (first switch−on or after data reset) The connected components (valve and displacement en coder/sensor interface) are automatically looked for at the axis interface. The contained information is read out. The recognised components are not automatically ac cepted as the target state. The controller cannot be activated until the axis data is completely parameterised 1). Actual values are then not updated.
4.
4. Commissioning 4.2.3 Establishing a connection to the PC To connect the service interface on the CPX node with the PC, use the NEFC−M12G5−0.3−U1G5 adapter as well as an addi tional commercially−available USB cable with mini USB plug. Information on how to install the adapter as well as the used COMx interface can be found in the adapter documentation. 1 Adapter 1 2 USB cable 2 Fig. 4/2: Adapter for connecting with the PC Note The service interface (V.
4. Commissioning 4.3 Commissioning with the FCT (overview) Detailed information about commissioning with the FCT can be found in the Help for the FCT CMAX plug−in. Information for specialists concerning commissioning via the CPX node can be found in the CMAX communication profile" description. 4.3.1 Overview of commissioning steps The following steps are typically carried out during commis sioning: 1.
4. Commissioning 6. Parameterise application data and download it to the CMAX: Mass Supply pressure Mounting position This application data is the basis for configuring the con troller. 7. Set the other parameters (e.g. software end positions, record list, ...) and download them to the CMAX. 8. Switch on the compressed air supply. 9. Carry out the movement test: 10. Only with incremental position measuring system: Carry out homing. 11. Carry out identification run. 12. Carry out a test run.
4. Commissioning 4.4 4.4.1 Operation instructions CMAX control An overview of the I/O signals for controlling the CMAX can be found in section 4.5. More detailed information can be found in the CMAX com munication profile" description. 4.4.2 General operation instructions Warning High acceleration forces on the connected actuators! Unexpected motions can cause collisions and severe injuries. · Switching on: Always first switch on the power supply and then the compressed air supply.
4. Commissioning Positioning jobs After switching on the operating voltage, it must be waited until the CMAX is completely installed, signals no error (see Fig. 4/1) and delivers the inputs SCON.ENABLED and SCON.OPEN logic 1. Afterwards, the corresponding position ing job can be executed via the control bytes (module out put data) (see section 4.5 and the CMAX communication profile" description).
4. Commissioning 4.5 Structure of the cyclical I/O data Data Byte 1 O data Bytes 1 and 2 (fixed) are retained in every operating mode (except for byte 2 during parameter isation). They contain control and status bytes (e.g. CCON, SCON, ...) for enab ling the CMAX and setting the operat ing modes I data Byte 2 Byte 3 Byte 4 Byte 5 Byte 6 Byte 7 Byte 8 Bytes 3 to 8 depend on the selected operating mode (record select mode) and transmit further control and status bytes (e.g. CDIR, SDIR,...
4. Commissioning 4.5.1 Defining the operating mode with CCON Operating mode Description Record select operating mode Record select mode (OPM1 = 0; OPM2 = 0) The PLC selects a record from a record list stored in the CMAX. A record contains all the parameters which are specified for a posi tioning job. The record number is transferred to the cyclical I/O data as the setpoint or actual value.
4. Commissioning The operating mode is defined with CCON.OPM1 and OPM2 and is signalled back in SCON.OPM1 and OPM2. CCON/SCON Operating mode OPM2 (B7) OPM1 (B6) 0 0 Record select operating mode Record select mode 0 1 Direct operating mode Direct mode 1 0 Commissioning operating mode 1 1 Parametrising operating mode Tab. 4/3: Defining the operating mode 4−18 Festo P.
4. Commissioning 4.5.2 Controlling the CMAX in record select operating mode I/O data: Record select mode Data Byte 1 Byte 2 Byte 3 Byte 4 Byte 5 Byte 6 Byte 7 Byte 8 O data CCON CPOS Record no. Reserved Reserved I data SCON SPOS Record no. RSB Primary actual value (actual position, actual force) Allocation of the control bytes (overview) CCON y 1 Byte CPOS Byte y 2 B7 OPM2 B6 OPM1 B5 LOCK B4 B3 RESET To select the operat ing mode, see Tab.
4. Commissioning 4.5.
4. Commissioning Allocation of the status bytes (overview) SCON Byte y 1 SPOS Byte y 2 SDIR Byte y 3 B7 OPM2 B6 OPM1 B5 FCT_MMI B4 24VL B3 FAULT B2 WARN B1 OPEN B0 ENABLED For operating mode acknowledgement, see Tab.
4. Commissioning 4.5.4 Execute record (record select mode) I/O diagram 1 Requested record no Output data N−1 N N−1 N N+1 0 1 Start CPOS.START 0 1 Acknowledge start SPOS.ACK 0 1 Motion complete SPOS.MC 0 1 Actual record no Input data 0 1 2 tmin 3 4 5 6 7 tmin: At least 1 bus cycle waiting time Recommendation: 1 PLC cycle Not required if consistent data transmission is used Fig. 4/3: Record start sequence 1 Set the desired record number in the PLC’s output data.
4. Commissioning 4 The CMAX now signalises with the rising edge at SPOS.ACK that the PLC output data have been accepted and that the positioning job is now active. 5 The PLC detects the acknowledgement ACK (SPOS.ACK = 1) in its input data and resets CPOS.START in its output data. 6 CMAX acknowledges the resetting of CPOS.START by resetting SPOS.ACK. The positioning command will be further executed. 7 After the PLC has detected SPOS.ACK = 0, it may write new setpoint values in its output data.
4. Commissioning Example The following applies for all examples: x: = not relevant 1/0= Brake control 0 or 1 depending on configuration 1. Step: Enable CMAX In the first step, CMAX must be prepared for the record execution: Control bytes (step 1) Bit B7 B6 B5 B4 B3 B2 B1 B0 CCON Byte 1 OPM2 OPM1 LOCK RESET BRAKE STOP ENABLE 0 0 0 0 0 1/0 1 1 CPOS Byte 2 CLEAR TEACH JOGN JOGP HOM START HOLD 0 0 0 0 0 0 0 0 x x Record no.
4. Commissioning 2. Step: Specify record number Control bytes (step 2) Bit B7 B6 B5 B4 B3 B2 B1 B0 CCON Byte 1 OPM2 OPM1 LOCK RESET BRAKE STOP ENABLE 0 0 0 0 0 1/0 1 1 CPOS Byte 2 CLEAR TEACH JOGN JOGP HOM START HOLD 0 0 0 0 0 0 0 0 Record no. Record number of the record to be started, example record 36 (0x24): Byte 3 0 0 1 0 0 1 0 0 res. Byte 4 ...
4. Commissioning 3. Step: Start record Control bytes (step 3) Bit B7 B6 B5 B4 B3 B2 B1 B0 CCON Byte 1 OPM2 OPM1 LOCK RESET BRAKE STOP ENABLE 0 0 0 0 0 1/0 1 1 CPOS Byte 2 CLEAR TEACH JOGN JOGP HOM START HOLD 0 0 0 0 0 0 1 0 0 0 Record no. Record number of the record to be started, example record 36: Byte 3 0 0 1 0 0 1 res. Byte 4 ... 8: reserved (= 0) The record number is accepted and MC reset. Wait until the record start is signalled back with SPOS.
4. Commissioning 4. Step: Record is running After the record start with SPOS.ACK = 1 has been detected, CPOS.START can be reset. Control bytes (step 4) Bit B7 B6 B5 B4 B3 B2 B1 B0 CCON Byte 1 OPM2 OPM1 LOCK RESET BRAKE STOP ENABLE 0 0 0 0 0 1/0 1 1 CPOS Byte 2 CLEAR TEACH JOGN JOGP HOM START HOLD 0 0 0 0 0 0 0 0 x x x Record no. Record number of the next record to be started. Any Byte 3 x x x x x res. Byte 4 ...
4. Commissioning 5. Step: Record ended As soon as SPOS.ACK = 0, another record number can be specified or another job started. SPOS.MC remains 0 until the record or record chaining has been ended. Control bytes (step 5) Bit B7 B6 B5 B4 B3 B2 B1 B0 CCON Byte 1 OPM2 OPM1 LOCK RESET BRAKE STOP ENABLE 0 0 0 0 0 1/0 1 1 CPOS Byte 2 CLEAR TEACH JOGN JOGP HOM START HOLD 0 0 0 0 0 0 0 0 x x x Record no.
4. Commissioning 4.5.5 Direct mode I/O diagram 1 Setpoint values Output data N−1 N+1 N N+2 0 1 Start CPOS.START (B1) 0 1 Acknowledge start SPOS.ACK (B1) 0 1 Motion complete SPOS.MC (B2) 0 1 2 3 4 tmin tmin: At least 1 bus cycle waiting time Recommendation: 1 PLC cycle Not required if consistent data transmission is used Fig. 4/4: Start the positioning job The sequence of the remaining control and status bits behave according to the record select operating mode. See sections 4.5.4, Fig.
4. Commissioning 3 After resetting CPOS.START and acknowledging SPOS.ACK = 0, a new setpoint value can be written at any time. There is no need to wait for MC. The CMAX calculates the necessary steps internally to execute the new positioning job. When a reversal of direction is required, the drive is first braked, for example, until speed = 0 is reached. Only after this is the new setpoint position transferred to the controller. No error message will be generated.
4. Commissioning Example In the example, the following direct mode is started: Target setpoint, absolute Control mode, position control Free profile No tracking mode (executed one time) Fast stop The following applies for all examples: x: = not relevant 1/0= Brake control 0 or 1 depending on configuration FHPP setting (PNU 523): Secondary setpoint = speed Festo P.
4. Commissioning 1.
4. Commissioning 2.
4. Commissioning 3.
4. Commissioning 4. Step: Task running After the start with SPOS.ACK = 1 has been detected, CPOS.START can be reset.
4. Commissioning 5. Step: Job completed As soon as SPOS.ACK = 0, another setpoint value can be specified or another job started. SPOS.MC remains 0 until the last job has been completed.
4. Commissioning 4.5.6 Acknowledge error 1. Step: Error message Allocation of the control bytes (step 1) Bit B7 B6 B5 B4 B3 B2 B1 B0 CCON Byte 1 OPM2 OPM1 LOCK RESET BRAKE STOP ENABLE x x x 0 0 1/0 x x ... Byte 2 ... 8: Depending on the operating mode Allocation of the status bytes (step 1) Bit B7 B6 B5 B3 B2 B1 B0 SCON Byte 1 OPM2 OPM1 FCT_MMI 24VL B4 FAULT WARN OPEN ENABLED x x x 1 x 0 x ... Byte 2 ...
4. Commissioning 4.6 Flow charts for programming In the following, you will find flow charts for controlling the CMAX via I/Os for typical applications. Additional information can be found in the CMAX communi cation profile" description. 4.6.1 Establish ready status Requirements Operating voltage and valve load voltage OFF. The fieldbus master is ready for communication so that communication is established as soon as the CPX terminal is switched on.
4. Commissioning Operating voltage = 0 V Load voltage (valve) = 0 V CMAX is OFF [m] It is imperative that this action be executed. [o] This action is a recommendation. It does not have to be executed. The output data should be filled at the beginning in Reset PLC output any case so that no control signals from the last data [m] operating phase can affect the CMAX.
4. Commissioning Page 1 CCON.ENABLE = 1 [m] [m] SCON.FAULT = 1 Cancel Error handling SCON.FAULT = 0 SCON.ENABLED = 0 [m] SCON.ENABLED = 1 CCON.BRAKE = 1 Release the clamping unit, [m] if present CCON.STOP = 1 [m] [m] SCON.FAULT = 1 Cancel Error handling SCON.FAULT = 0 SCON.OPEN = 0 [m] SCON.OPEN = 1 Ready 4−40 Festo P.
4. Commissioning 4.6.2 Start record SCON.ENABLED = 1 SCON.OPE N = 1 Enable operation [m] It is imperative that this action be executed. [o] This action is a recommendation. It does not have to be executed. Output data byte 3 = Target record number [m] Wait time 1 bus cycle For all fieldbuses which do not support consistent data transmission, after entering the record number, one bus cycle must be waited, during which the record number is transferred to the CMAX on the fieldbus.
4. Commissioning 4.6.3 Acknowledge malfunction [m] It is imperative that this action be executed. Active malfunction [o] This action is a recommendation. It does not have to be executed. Wait until malfunction reaction is finished. (Attention: not in parametrising operating mode) A reset is ignored before this. SPOS.MC = 0 [m] SPOS.MC = 1 Use a reset counter (of type integer) to limit the maximum number of resets. CMAX always attempts to reset all active fault signals.
4. Commissioning 4.6.4 Switch operating mode Old operating mode active CCON.STOP = 0 SCON.OPEN = 1 [m] It is imperative that this action be executed. Assumption: CCNON. ENABLE = 1 and CCON.STOP = 1 [o] This action is a recommendation. It does not have to be executed. When switching between record select and direct modes, Disable operation" is not [m] required. This can be used for optimising the control function. [m] SCON.OPEN = 0 All bytes which depend on the operating mode are set to zero.
4. Commissioning 4−44 Festo P.
Diagnostics and error handling Chapter 5 Festo P.
5. Diagnostics and error handling Contents 5. Diagnostics and error handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5−1 5.1 5.2 Summary of diagnostics options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Malfunctions and warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2.1 Error numbers on the CPX terminal . . . . . . . . . . . . . . . . . . . . . . . . . 5.2.
5. Diagnostics and error handling 5.1 Summary of diagnostics options The CMAX supports a number of different options for diag nostics and error handling with the CPX terminal. A summary is shown in Tab. 5/1. Access/ function Diagnostic options Brief description Local Display on the device LED display The LEDs directly indicate the operating Section 5.3 and error statuses. Fast diagnostics on site" Display / The operating status and any error 7−segment display messages are shown on the display.
5. Diagnostics and error handling 5.2 Malfunctions and warnings The CMAX constantly monitors the operating state and out puts the corresponding diagnostic messages if there is a deviation from the target status or special events. Diagnostic messages are rated as a malfunction (error) or warning according to the cause/effect and can be evaluated in detail and handled. Malfunctions Events and statuses which endanger or prevent proper CMAX operation are signalled as malfunctions.
5. Diagnostics and error handling Acknowledging malfunctions Reported malfunctions must be acknowledged with CCON.RESET. It might be necessary to remedy the cause of the malfunction. 1. Positive edge on CCON.RESET. 2. Wait 3 s (depending on the malfunction, CMAX requires a maximum of 3 seconds, e.g. for initialising the axis). 3. Check whether the malfunction has been remedied: if SCON.FAULT = 0: ok if SCON.FAULT = 1: Check the malfunction number and eliminate any cause. See section 5.2.4.
5. Diagnostics and error handling 5.2.1 Error numbers on the CPX terminal All CMAX malfunctions are also signalled as CPX error messages 10x (100 ... 109). These can be evaluated via the CPX nodes, e.g. via the I/O diagnostic interface. Function number Module diagnostic data 2008+m*4+1 Module error number (CO error) 5.2.2 Malfunction groups: Classification according to the cause CMAX malfunctions and warnings are organised into groups.
5. Diagnostics and error handling 5.2.3 Error level and reset type: Classification according to effect and acknowledgement All malfunctions and warnings are classified according to the effect (error level, Tab. 5/2) and the necessary action for acknowledgement (reset type, Tab. 5/3). Error level Description W Warning F1 Malfunction 1: Stop with stop ramp F2 Malfunction 2: Controller disabled FS System error: System stopped Tab.
5. Diagnostics and error handling 5.2.4 Error numbers and warning numbers Malfunction group 0 Configuration error CPX error group 100 (CPX−MMI: [Configuration error] ) No. Message Cause/description Error handling Type1) 01 The target configuration differs from the actual configuration 2) A component on the axis string is not part of the target configuration: Displacement encoder or sensor interface (type, length). Cylinder (type, length, diameter). Valve (size).
5. Diagnostics and error handling Malfunction group 0 Configuration error CPX error group 100 (CPX−MMI: [Configuration error] ) Continued No. Message Cause/description Error handling 05 Project is not completely loaded or block down load is still active The controller cannot be · Complete the target enabled because the configuration, e.g. target configuration is not project download. yet complete. (Configur ation status C00, C01 or C02).
5. Diagnostics and error handling Malfunction group 1 Execution error CPX error group 101 (CPX−MMI: [Execution error] ) No. Message Cause/description Error handling Type1) 10 Homing not executed Drive with incremental dis placement encoder is not referenced. · Carry out homing. Error level: F1 Reset: R 11 Homing not required Homing for absolute dis placement encoder. · Carry out homing.
5. Diagnostics and error handling Malfunction group 1 Execution error CPX error group 101 (CPX−MMI: [Execution error] ) Continued No. Message Cause/description Error handling Type1) 16 Dynamic Identification failed Incorrect mass was parameterised or trans ferred to parameter 2. 2) · Check the mass and Error level: F1 Reset: R Too much mechanical backlash in the system. · Check the system Design not stable enough. · Check the system Used tubes are too long.
5. Diagnostics and error handling Malfunction group 2 Position record error CPX error group 102 (CPX−MMI: [Record error] ) No. Message Cause/description Error handling Type1) 21 Invalid record number At the start there was an invalid record number (0 or > 64). · Check the record Error level: F1 Reset: R Called record was not configured and does not contain valid positioning data. · Check record and The called record is not enabled for execution.
5. Diagnostics and error handling Malfunction group 2 Execution error CPX error group 102 (CPX−MMI: [Record error] ) Continued No. Message Cause/description Error handling Type1) 27 Switching condition can not be reached during movement Switching position does not lie between the start position (last setpoint/ actual value at the time of the switch) and the new setpoint position or both positions are the same.
5. Diagnostics and error handling Malfunction group 3 Regulation error CPX error group 103 (CPX−MMI: [Control error] ) No. Message 30 Timeout: Target value not Obstacle in the position ing range (position con reached 2) troller only). 1) 2) Cause/description Error handling Type1) · Remove the obstacle Error level: F1 Reset: R or correct the target position. Compressed air is not sufficient. · Check the supply Very high friction or ir regular friction (position controller only).
5. Diagnostics and error handling Malfunction group 3 Regulation error CPX error group 103 (CPX−MMI: [Control error] ) Type1) No. Message Cause/description Error handling 31 No movement after start 2) Pressure could not build up. · Check the supply pres Error Drive is stuck or slug gish. · Check the drive and sure. level: F1 Reset R Reset: guide friction. Working pressure insuffi · Set sufficient working cient to move the mass. pressure and check the configuration of the mass.
5. Diagnostics and error handling Malfunction group 3 Regulation error CPX error group 103 (CPX−MMI: [Control error] ) Continued No. Message Cause/description Error handling Type1) 33 Target position outside software or hardware endpositions Target position lies out side of the set software end positions. · Check target position, Error level: F1 (W) Reset: R Target position lies out side of the reachable hardware end positions.
5. Diagnostics and error handling Malfunction group 3 Regulation error CPX error group 103 (CPX−MMI: [Control error] ) Continued No. Message Cause/description Error handling Type1) 36 Software end position reached with force control 2) No workpiece. · Check workpiece, Error level: F1 Reset: R 37 Switch to Free Profile check workpiece position. · Use record switching to move back or stop. The software end posi tions can be reached in the desired sequence.
5. Diagnostics and error handling Malfunction group 3 Regulation error CPX error group 103 (CPX−MMI: [Control error] ) Continued No. Message Cause/description Error handling Type1) 39 Velocity with force control too high Configured permissible speed limit was ex ceeded with force con trol. · Check workpiece, Error level: F1 Reset: R Speed setpoint of the force record is set too high compared to the speed limit.
5. Diagnostics and error handling Malfunction group 4 System error A CPX error group 104 (CPX−MMI: [System error A] ) No. Message Cause/description Error handling Type1) 40 Invalid control mode with force control Force control set for DSMI. · DSMI cannot execute Error level: F1 Reset: R Impermissible control mode set in RCB1 or CDIR. · Correct RCB1 or CDIR. Positioning mode ’Rela tive’ with tracking mode not allowed Relative bit (CDIR.ABS=1) set in tracking mode.
5. Diagnostics and error handling Malfunction group 4 System error A CPX error group 104 (CPX−MMI: [System error A] ) Continued Error handling Type1) No. Message Cause/description 44 Teaching not possible 2) Teaching (falling edge at · Only activate Error CPOS.TEACH) was trig CPOS.TEACH = 1 (pre level: F1 gered accidentally due to pare teaching) directly Reset: R breaking a connection or before the teaching switching off the control. operation. Always end teaching immediately.
5. Diagnostics and error handling Malfunction group 4 System error A CPX error group 104 (CPX−MMI: [System error A] ) Continued No. Message Cause/description Error handling Type1) 44 Teaching not possible 2) (continued) Specified record number is not permissible during teaching in record select operating mode. · Correct record Error level: F1 Reset: R number. Parametrising control · Correct the control mode of the selected re mode, correct the re cord is not permissible cord number.
5. Diagnostics and error handling Malfunction group 5 System error B CPX error group 105 (CPX−MMI: [System error B] ) No. Message Cause/description Error handling Type1) 50 Operating pressure is too low 2) Pressure in both cylinder chambers is < 1.5 bar. · Check the pressure Error level: F2 (W) Reset: F 51 Controller load voltage outside tolerance range (undervoltage) Load voltage < 20 V for en · Check the valve load abled controller or over supply (UVAL). load on axis string.
5. Diagnostics and error handling Malfunction group 5 System error B CPX error group 105 (CPX−MMI: [System error B] ) Cause/description Continued No. Message Error handling 54 Controller: Overload power Short circuit in the cables · Check the cables and of the axis string (between modules in the axis supply the controller and valve or string (e.g. for a cable valve and sensor inter breakage), and replace face). if necessary.
5. Diagnostics and error handling Malfunction group 6 Valve error CPX error group 106 (CPX−MMI: [Error in valve] ) No. Message Cause/description Error handling Type1) 60 Communication with valve disturbed or valve not available Only the position measur ing system/sensor inter face was found at switch−on. The valve was not detected. · Check the lines to the Error level: F2 Reset: N Communication between CMAX and the valve was interrupted.
5. Diagnostics and error handling Malfunction group 6 Valve error CPX error group 106 (CPX−MMI: [Error in Valve] ) Continued Error handling Type1) No. Message Cause/description 65 Valve operating voltage outside tolerance range (undervoltage) The valve signals an · Check the cables on the Error level: F2 operating voltage which is axis string. Reset: F too low. Either the line be · Check the valve and tween CMAX and the valve exchange, if necessary. is defective or the valve is.
5. Diagnostics and error handling Malfunction group 7 Controller error CPX error group 107 (CPX−MMI: [Controller error] ) No. Message Cause/description Error handling Type1) 72 System software failure Internal software error (firmware). · If possible, read Error level: FS Reset: Poff out the diagnostic memory, save the project and archive it. · Switch the controller on and off and see whether the error occurs again. · Contact Support.
5. Diagnostics and error handling Malfunction group 8 Displacement encoder error CPX error group 108 (CPX−MMI: [Encoder error] ) No. Message Cause/description Error handling Type1) 80 Communication with measuring system/sen sor interface is disturbed or measuring system/ sensor interface not available Position measuring system / sensor interface was not detected at switch−on.
5. Diagnostics and error handling Malfunction group 8 Displacement encoder error CPX error group 108 (CPX−MMI: [Encoder error] ) Continued No. Message Cause/description Error handling Type1) 84 Reference position of dis placement encoder was lost Although the controller has set the Referenced" status, the displacement encoder/sensor interface signalled Not refer enced". · Reference again.
5. Diagnostics and error handling 5.3 Diagnostics via LEDs LEDs for diagnosing the CPX terminal are provided on the CMAX as well as on the individual modules at the axis con nection. LEDs on the CMAX 1 Errors 1 P (red) 2 Power Load 2 PL PL (yellow) Dx X 3 3 MC X axis X (green) 4 4 Status X axis Dx (green/red) Fig. 5/1: LEDs on the CMAX Description LED PL Error LED Illuminated in red: Malfunction Power Load Illuminated in yellow: Load voltage supply (UVAL) correct.
5. Diagnostics and error handling 5.3.1 CMAX−specific LEDs (Error) LED (red) CMAX error Sequence Status ON No malfunction. OFF LED is off ON OFF LED ill i CMAX malfunction. Error number indicated on display (after switching on the voltage supply, the LED is illuminated briefly). d PL (Power Load) Valve power load supply LED (yellow) Sequence Status ON 24 V valve load voltage supply is present.
5. Diagnostics and error handling 5.3.2 Axis−specific LEDs Dx (X axis display) Status indication of X axis LED (green/red) Sequence Status ON No malfunction: The operating status is indicated on the X−axis dis play. OFF Illuminated in green ON X axis signals a malfunction. Error number indicated on display.
5. Diagnostics and error handling 5.3.3 LEDs on the VPWP Power VPWP logic supply LED (green) Sequence Status ON 24 V logic supply is present. OFF LED illuminated ON OFF VPWP logic supply is not available. CMAX error: E60 LED is off Error VPWP error LED (red) Sequence Status ON No error.
5. Diagnostics and error handling 5.3.4 LEDs on the sensor interface LEDs on the CASM−S−D2−R3 LED S1 LED S2 Status CMAX error: Green Off Ready for operation without errors. Green Red Initialising via CAN completed. Flashes green Red 24 V present. Off Off 24 V not available. E80 Green Flashes red once Error: Sensor error (supply voltage < 12 V for longer than E82 15 ms).
5. Diagnostics and error handling 5.3.5 LEDs on the displacement encoder (DGCI only) LEDs on the DGCI displacement encoder Power LED Error LED Status CMAX error: Green Off No error (normal operating status) Off Off No power supply E80 Off Red Error: Initialising via CAN failed E80 Green Red Error: Magnet not detected or incorrect number of magnets E82 Flashes green Flashes red Error: Operating voltage not within permissible range E85 5−34 Festo P.
5. Diagnostics and error handling 5.4 Diagnostics via the display/7−segment display The CMAX shows status and diagnostic information directly on the display/7−segment display. 1 1. position (e.g. code letter for parameter or status type) 1 2 2 Point for separation 3 2. and 3rd position 3 (e.g. value, error level or status information) Fig. 5/2: Display/7−segment display 5.4.1 Error status Error messages are shown on the display in addition to the red error LED on the CMAX.
5. Diagnostics and error handling 5.4.2 Status display Possible status information No. Status display Additional Information Description 1 ." flashing An Initialisation of components at the axis interface n n nn After initialising components at the axis interface, the firmware version is displayed for about 1 s (e.g. V 1.00). 2 C nn Parameterisation phase, with current status nn 3 0 nn Initialisation is successfully completed. There is no enable.
5. Diagnostics and error handling Possible status information No.
5. Diagnostics and error handling Possible status information No. Status display Additional Information Description 13 P nn Parameterisation is active, current parameter nn PNU/100 14 E nn Error active, error number: nn 0x: Configuration error 1x: Execution error 2x: Positioning record error 3x: Regulation error 4x: System error A 5x: System error B 6x: Valve error 7x: Controller error 8x: Displacement encoder error 15 " flashes " flashes Device data reset.
5. Diagnostics and error handling 5.5 Diagnostic functions with the CPX−MMI General information on operating and commissioning the CPX terminal using the CPX operator unit (handheld) can be found in the description for the CPX−MMI, type P.BE.CPX−MMI−1−... . 5.5.1 Error display ([Diagnostics] menu) Modules that signal an error are marked in the main menu by an exclamation mark (!) in front of the module number. Any errors are displayed as input channel errors in the [Diagnostics] menu.
5. Diagnostics and error handling 5.5.2 Information on the CMAX ([Module data] menu) The module data of the CMAX is displayed in the [Module data] menu. System Overview _ CPX terminal 0: ... Module ... 1: ... Module ... 2: CMAX−C1−1 1 Serð 3: ... Module ...
Technical appendix Appendix A Festo P.
A. Technical appendix Contents A. Technical appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A−1 A.1 A.2 A.3 CMAX technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacing components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Additional pneumatic circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A−3 A−6 A−7 A−2 Festo P.
A. Technical appendix A.1 CMAX technical data CMAX, general General technical data see CPX system manual P.BE−CPX−SYS−... Product weight (with CPX−GE−EV−S) Approx.
A. Technical appendix Positioning system with CMAX Axis string Number of axis strings / number of axes Max.
A. Technical appendix Horizontal Vertical 1 with analogue position measuring system MLO−POT 2 with digital position measuring system MME−MTS or linear drive DGCI and DGPI/DGPIL 3 DNCI standard cylinder Tab. A/4: Repetition accuracy of the linear drives Festo P.
A. Technical appendix A.2 Replacing components When replacing components, observe the instructions in Tab. A/5. Replacement Description ... of a CMAX or CPX terminal · Parameterisation / identification / adaptation: A lot of acquired data depends on the individual components and can therefore not be parameterised. Therefore, after exchanging, complete commissioning is to always be carried out again.
A. Technical appendix A.3 Additional pneumatic circuits You may require additional pneumatic circuits in order to attain a particular status for the system in certain applica tions. Note If the operating voltage for the CMAX is switched off, the VPWP proportional directional control valve will move to the mid−position.
A. Technical appendix A.4 Index A Abbreviations, product−specific . . . . . . . . . . . . . . . . . . . XVII Absolute (position measuring system) . . . . . . . . . . . . . . XVII Adaptation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . XVII Air reservoirs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2−25 Axis string . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . XVII C CCON . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A. Technical appendix D Diagnostics, with the handheld unit . . . . . . . . . . . . . . . . 5−39 Diagnostics options, summary . . . . . . . . . . . . . . . . . . . . . 5−3 Direct mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−17 Displacement encoder . . . . . . . . . . . . . . . . . . . . . . . . . . . 2−10 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . XVII , 2−8 E Errors, Error numbers . . . . . . . . . . . . . . . . . . . . . . . .
A. Technical appendix I I/O data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4−16 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . XVIII Incremental (position measuring system) . . . . . . . . . . . XVIII Installation instructions Air reservoirs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Compressed air supply . . . . . . . . . . . . . . . . . . . . . . . . Converting systems . . . . . . . . . . . . . . . . . . . . . . .
A. Technical appendix M Mass moment of inertia . . . . . . . . . . . . . . . . . . . . . . . . . . 2−15 Minimum load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2−13 Mounting Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2−8 Fixed stops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2−9 Mounting position . . . . . . . . . . . . . . . . . . . . . . . . . 2−12 , 2−16 Mounting position (of the axis) . . . . . . . . . . . . .
A. Technical appendix Positioning system Parameterisation and commissioning options . . . . . . . 1−7 Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1−6 Power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−12 Power supply concept, Formation of power zones . . . . 3−14 Power zones . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3−14 Pressure control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A. Technical appendix T Target group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A−3 Text designations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . XIII Tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2−29 U User instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . XII W Warnings, Warning numbers . . . . .
A. Technical appendix A−14 Festo P.
