Emerson 400508-02 manual

P/N 400508-0 2 Revision: A 2 Date: August 23 , 2000 © EMERSON Motion Control , Inc . 2000 F M- 3 P r og r a mm i ng M odu l e I n s t a ll a t i on M a nu a l[...]

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Information furnished by EMERSON Motion Control is believed to be accurate and reliable. However, no responsibility is assumed by EMERSON Motion Control for its use. EMERSON Motion Control reserves the right to change the design or operation of the equipment described herein and any associated motion products without notice. EMERSON Motion Control [...]

ii © EMERSON Motion Control , Inc . 2000 Part Number: 40050 8 -0 2 Revision: A 2 Date: August 2000 Printed in United States of America Information in this document is subject to change without notice. Companies, names, and data used in examples herein are fictitious unless otherwise noted. No part of this document may be reproduced or transmitted [...]

iii Customer Service It is EMERSON Motion Control’s goal to ensure your greatest possible satisfaction with the operation of our products. We are dedicated to providing fast, friendly, and accurate assistance. That is why we offer you so many ways to get the support you need. Whether by phone, fax or modem, you can access EMERSON Motion Control s[...]

iv Need on-site help? EMERSON Motion Control provides service, in most cases, the next day. Just call EMERSON’s customer service center when on-site service or maintenance is required. Training Services ( 800)397-3786 or Fax (952)995-8011 EMERSON Motion Control maintains a highly trained staff of instructors to familiarize customers with EMERSON [...]

v Document Conventions Manual conventions have been established to help you learn to use this manual quickly and easily. As much as possible, these conventions correspond to those found in other Microsoft® Windows® 1 documentation. Menu names and options are printed in bold type: the File menu. Dialog box names begin with uppercase letters: the A[...]

vi Safety Instructions General Warning Failure to follow safe installation guidelines can cause death or serious injury. The voltages used in the product can cause severe electric shock and/or burns, and could be lethal . Extreme care is necessary at all times when working with or adjacent to it. The installation must comply with all relevant safet[...]

vii Safety Considerations Safety Precautions This product is intended for professional in tegra tion into a complete system. If you install the product incorrectly, it may present a safety hazard. The product and system may use high voltages and currents, carry a high level of stored electrical energy, or control mechanical equipment that can cause[...]

viii relevant safety legislation in the country of use. AC supply isolation device The AC supply must be removed from the drive using an approved isolation device or disconnect before any servicing work is performed, other than adjustments to the settings or parameters specified in the manual. The drive contains capacitors which remain charged to a[...]

ix Customer Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii Reference Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vi Safety Considerations . . . . . . . . . . . . . . . . . . . . .[...]

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1 Introduction FM-3 is a compact and rugged function module that attaches to the front of the E Series drive. It provides eight digital input lines and four digital output lines, in addition to the four input and three output lines available on the E Series E N drive. Unlike other function modules, the FM-3 offers complex motion profiling. A comple[...]

2 FM-3 Programming Module Installation Manual The FM-3 stores E Series drive setup parameters within the module itself. This allows you to transfer the FM-3 to another E Series drive without losing setup parameters. Figure 2: FM-3 Programming Module Features 485 + 485 - SHLD Aligning Tabs 100-Pin Connector Front Back Inputs Outputs 10-30 VDC 1 2 3 [...]

3 Installation Basic Installation Notes You are required to follow all safety precautions during start-up such as providing proper equipment grounding, correctly fused power and an effective Emergency Stop circuit which can immediately remove power in the case of a malfunction. See the “Safety Considerations” section for more information. Mecha[...]

4 FM-3 Programming Module Installation Manual Figure 4: Detaching the FM-3 from the Drive Connections Caution Do not attach or detach the FM-3 when power is applied to the drive It could cause drive instability. Modbus Communications The drive’s serial communication protocol is Modbus RTU slave with a 32 bit data extension. The Modbus protocol is[...]

5 Installation Software Installation Emerson Motion Control PowerTools® FM-3 software was designed for users who need access to all setup options and diagnostic information for the drive. The software provides access to all commonly used drive parameters. PC System Configuration Required: • Microsoft ® Windows ® 95/98 or Microsoft Windows NT ?[...]

6 FM-3 Programming Module Installation Manual 3. In the Run dialog box, type a:/setup , where a is the letter assigned to your 3.5" floppy drive. 4. Click the OK button, then follow the instructions on your screen. Installation will take about five minutes. The install program automatically: • Creates the directory on your hard drive named: [...]

7 Installation Exiting the Software Choose File from the menubar, then click Exit. If you are using the keyboard, press the shortcut key combination Alt+F, X. If you made changes, PowerTools displays an Alert dialog box asking whether you want to save your current work. Click the Yes button or press Enter to save your work, or click the No button t[...]

8 FM-3 Programming Module Installation Manual[...]

9 Diagnostics and Troubleshooting Diagnostic Display The diagnostic segment display on the front of the drive shows drive status , FM-3 status, and fault codes. When a fault condition occurs, the drive will display the fault code, overriding the status code. The alphanumeric display on the FM-3 provides additional fault information. The decimal poi[...]

10 FM-3 Programming Module Installation Manual Fault Codes A number of diagnostic and fault detection circuits are incorporated to protect the drive. Some faults, such as high DC bus and amplifier or motor over temperature can be reset with the Reset button on the front of the drive or the Reset input function. Other faults, such as encoder faults,[...]

11 Diagnostics and Troubleshooting Invalid Configuration Button or Input Yes Invalid Conf Power Module Button or Input Yes Power Module High DC Bus Button or Input Yes High DC Bus Low DC Bus Button or Input Yes Low DCBus Encoder State Power Yes Encoder State Encoder Hardware Power Yes Encoder HW Motor Overtemp Button or Input Yes MotorOvrTemp RMS S[...]

12 FM-3 Programming Module Installation Manual Fault Descriptions Flash Invalid This fault indicates that the firmware checksum has failed. Use the Tools Program Flash menu item from Emerson Motion Control PowerTools® to reprogram/upgrade the firmware stored in flash memory. If this problem persists, call EMERSON Motion Control. A common cause wou[...]

13 Diagnostics and Troubleshooting Invalid Configuration The FM was not on this drive during its previous power-up and it is not known if the setup data in the FM matches the drive and motor to which the FM is now attached. This can also happen when a FM is removed from a drive and the drive is powered-up. To reset the fault, create or open a confi[...]

14 FM-3 Programming Module Installation Manual Encoder Hardware If any pair of encoder lines are in the same state, an encoder line fault is generated. The most likely cause is a missing or bad encoder connection. Motor Overtemp This fault is generated when the motor thermal switch is open due to motor over-temperature or incorrect wiring. RMS Shun[...]

15 Diagnostics and Troubleshooting FM-3 Specific Fault Descriptions Figure 5: FM-3 display is used to displa y drive and FM-3 faults Traj Fault This fault occurs when the drive has received trajectory data from the FM-3 that indicates a problem. Check the user units, velocities, accels and decels for correct values. ISR Overrun This fault is genera[...]

16 FM-3 Programming Module Installation Manual Brake Operation MG motor brake operation is controlled by the Brake Release and Brake Control destina tions. These destina tions can be used together to control the state of the Brake source . The table below shows the relationship between the Brake sources and destina tions (see “Diagnostic Display?[...]

17 Diagnostics and Troubleshooting Analog Outputs The drive has two 10 bit Analog Outputs which may be used for diagnostics, monitoring or control purposes. These outputs are referred to as Channel 1 and Channel 2. They can be accessed from the command connector on the drive or from the diagnostics output pins located on the front of the drive. Eac[...]

18 FM-3 Programming Module Installation Manual Diagnostic Analog Output Test Points The DGNE cable was designed to be use with either an oscilloscope or a meter. The wires are different lengths to avoid shorting to each other. However, if signals do get shorted to GND, the drive will not be damaged because the circuitry is protected. Figure 6: Diag[...]

19 Diagnostics and Troubleshooting Figure 7: Diagnostic Cable (DGNE) Diagram 10 Ohm 10 Ohm Yellow Black (GND) Blue D/A D/A DGNE Cable Command Connector (J5) DGNE Cable[...]

20 FM-3 Programming Module Installation Manual Drive Faults The Active Drive Faults dialog box is automatically displayed whenever a fault occurs. There are two options in this dialog box: Reset Faults and Ignore Faults. Figure 8: Active Drive Faults Dialog Bo x Resetting Faults Some drive faults are automatically reset when the fault condition is [...]

21 Diagnostics and Troubleshooting The terms below appear in the list the of common problems you might encounter when working with PowerTools software alon g with the error message displayed, the most likely cause and solution. Assign means to set a value using an equation. For example, x = 2, you are assigning the value of 2 to x. A Boolean value [...]

22 FM-3 Programming Module Installation Manual Programming Error Messages These Red Dot Error messages occur while you are working in the Program View. When creating a program, the parser is executed when you left mouse click, when you arrow off the current Line, when you enter the carriage return, when you paste or when you drop a drag source. The[...]

23 Diagnostics and Troubleshooting Error: A string variable can only be assigned a quoted text string The Variable is string. It only accepts types consisting of text strings. Error: Can only compare(>,<,etc) numeric results This message occurs in conditional Expressions (i.e. If then). Variables are type identified, so equation and assignmen[...]

24 FM-3 Programming Module Installation Manual Error: Syntax error encountered Parser Error Message. The Parser can not understand your text sequence. Error: Text Strings are limited to 12 characters... To change a Name you assign a quoted text string to that name. In FM3, text strings are fixed at 12 characters. If you use fewer than 12 characters[...]

25 Diagnostics and Troubleshooting Error: The destination variable's resolution is less than the resolution of the number You attempted to assign a number with a greater resolution of decimal points than the variable will accept (ie index.0.vel = 2.34567). The User Units setup will allow you to define the desired decimal point resolution. Erro[...]

26 FM-3 Programming Module Installation Manual Error: The Selection variable can only be assigned a Selection value. The destination variable only accepts selection values. Selection values are fixed unquoted text. The selection text must exactly match the available selections of the Destination variable. Error: This instance does not exist. This v[...]

27 Diagnostics and Troubleshooting Online Status Indicators Global Where Am I Button The Program View, when online and executing a program or sequence of programs, can display current program status. Pressing the Where Am I button on the PowerTools FM-3 toolbar creates a blue triangle that appears on the line of the program currently being executed[...]

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29 Specifications Power consumption: 3 W from E Series drive power supply. I/O Supply Voltage: 10-30 VDC. Dimensions and Clearances Function Electrical Characteristics Inputs ON State Voltage 10-30 VDC ON State Current 2mA-6.5mA OFF State Voltage 0-3VDC OFF State Current 0-400µA Outputs Max. ON State Voltage I/O Supply Voltage -1.5V Max. ON State [...]

30 FM-3 Programming Module Installation Manual 2.6 (66.0)[...]

31 Specifications Cable Diagrams Customer Supplied Cable Sync. Input Sync. Input Sync. Input Sync. Input Sync. Output Sync. Output M F M F M F SNCE-xxx 15', 25' or 50' SNCDD-001.5 1.5' SNCO-003 3' SNCI-003 3' SNCO-003 3' SNCI-003 3' SCS-x Encoder E Series Drive w/ FM-3 E Series Drive w/ FM-3 E Series Drive w/[...]

32 FM-3 Programming Module Installation Manual SNCE-XXX Cable SNCDD-001.5 Cable A H B I J D C F 3 8 4 7 6 5 1 2 B GRD +5 M M B A A SHIELD GRD +5 M M B B A A[...]

33 Specifications SNCO-003 Cable SNCI-003 Cable[...]

34 FM-3 Programming Module Installation Manual SNCLI-003 Cable[...]

35 Specifications CMDX-XXX Cable Note Some CMDX cables may have White/Yellow and Yellow/White wires in place of the White/Orange and Orange/White shown in the figure above (pins 6 and 21).[...]

36 FM-3 Programming Module Installation Manual CMDO-XXX Cable Note Some CMDO cables may have White/Yellow and Yellow/White wires in place of the White/Orange and Orange/White shown in the figure above (pins 6 and 21).[...]

37 Specifications CDRO-XXX Cable 8 9 24 23 38 37 11 12 34 16 14 15 29 4 19 26 40 18 17 31 33 43 44 41 27[...]

38 FM-3 Programming Module Installation Manual TIA-XXX Cable DDS-XXX Cable[...]

39 Specifications TERM-H (Head) Terminator TERM-T (Tail) Terminator Note See the "Multi-drop Communications" section for resistor values.[...]

40 FM-3 Programming Module Installation Manual CMDS-XXX Cable CMMS-XXX Cable[...]

41 Specifications CFCS-XXX Cable[...]

42 FM-3 Programming Module Installation Manual CFCO-XXX Cable[...]

43 Specifications CFOS-XXX Cable[...]

44 FM-3 Programming Module Installation Manual Vendor Contact Information Schaffner (AC Line Filters) (800) 367-5566 or (201) 379-7778 www.schaffner.com Cooper Industries, Inc. Crouse-Hinds Division (Cable Shield Grommets) (315) 477-5531 www.crouse-hinds.com Bussman P.O. Box 14460 St. Lo u is, MO. 63178-4460 (314) 394-3877 www.bussman.com Littlefus[...]

45 Index Symbols +/- Limit, 14 A All "On", 14 Analog Output, 17 B Brake Operation and Wiring, 16 C Cable Diagrams, 31 CDRO-XXX Cable, 37 CFCO-XXX Cable, 42 CFCS-XXX Cable, 41 CFOS-XXX Cable, 43 CMDO-XXX Cable, 36 CMDS-XXX Cable, 40 CMDX-XXX Cable, 35 CMMS-XXX Cable, 40 D DDS-XXX Cable, 38 Diagnostic Display, 9 Drive Faults, 20 E Encoder L[...]

46 FM-3 Programming Module Installation Manual N Non-volatile Memory Invalid, 12 O Over Speed Fault, 14 P Power Stage Fault, 13 Power-Up Self-Test Failure, 12 Programming Error Messages, 22 R RMS Shunt Power Fault, 14 S Safety Considerations, vii Safety of Machinery, vii Safety Precautions, vii Setup, Commissioning and Maintenance, vii status codes[...]

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Since 1979, EMERSON Motion Control, a subsidiary of the Emerson Electric Company, has been a leader in the development and manufacturing of motion control equipment and software. EMERSON Motion Control continues to lead the industry in supplying motion control devices designed to improve production efficiency. For more information about EMERSON Mot[...]