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Control Techniques
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FM-3
Control Techniques FM-3 User Manual
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1
3
Table of Contents
Default Chapter
1
Reference Manual
1
Customer Support
5
Document Conventions
6
General Warning
8
Qualified Person
8
Safety Instructions
8
Safety Considerations
9
Safety of Machinery
9
Safety Precautions
9
Setup, Commissioning and Maintenance
9
Grounding (Earthing, Equipotential Bonding)
10
Products Connected by Plug and Socket
10
Fuses
10
AC Supply Isolation Device
10
Table of Contents
11
Introduction
15
EN Drive with FM-3 Function Module
15
FM-3 Programming Module Features
16
Operational Overview
17
Software Interface
17
Powertools Pro Setup Software
17
Keypad Interface
18
Hierarchy View
18
FM-3 Display Screen and Keypad
19
Parameter Screens
20
How Motion Works
21
How Jogging Works
21
How Home Works
22
Jog Tab
22
Home Sequence
23
Basic Home Function, Example
23
Establishing a Home Reference Position
23
Sensor
24
Marker
24
Sensor Home Reference Position
24
Marker Home Reference Position
24
Accuracy and Repeatability
25
Sensor and Marker
25
Sensor and Marker Home Reference Position Example 2
26
Home Offset
26
Calculated Home Offset, Peak Velocity Not Reached
27
Calculated Home Offset, Peak Velocity Reached
27
Specified Home Offset, Greater than Calculated Offset
28
Specified Home Offset, Backup Required
28
End of Home Position
28
Home Examples
29
Home Limit Distance
29
Example 1: Linear Application
29
Home to Sensor and Marker, Example
29
Home Velocity Profile
30
Home Move Sequence
30
Example 2: Rotary Application
31
Home Sensor and Marker then Offset, Example
31
How Indexes Work
32
Index Motion Sequence
32
Indexes View
33
Absolute Vs. Incremental
34
Absolute Indexes
34
Incremental Indexes
35
Registration Index
36
Rotary Plus and Rotary Minus Indexes
36
Indexes with Rotary Rollover Enabled
36
How Communications Work
37
Uploading
37
Downloading
37
NVM Options for Uploading and Downloading
38
Updating to RAM
39
Update to RAM Flow Chart
40
Options/Preferences/Ptools Operation
40
Upload Non-Volatile Memory (NVM) Section
42
Secure Downloading
42
Brake Operation
43
Brake Release
44
Brake Activate
44
Brake Disengaged
44
Setting up Parameters
45
Setup View
45
Identification Group
45
Configuration Group
46
Target Drive Address
46
Drive Type List Box
46
Motor Type List Box
46
Positive Direction Group
47
Encoder Scaling Check Box
47
Encoder Scaling
47
CW Motor Rotation Radio Button
47
Status Online Tab (Online Only)
48
Switching Frequency Group
48
Motor Position Group
49
Motor Velocity Group
49
Control Loop Group
49
Velocity Feedback
49
Master Feedback Group
50
Control Loop Limit
50
Margin Average
50
Master Position
50
Information Tab (Online Only)
51
Firmware Part Number
51
Foldback RMS
51
Shunt Power RMS
51
User Units View
52
Distance Group
52
Units Name
52
Decimal Places
53
Scaling
53
Characteristic Distance
53
Characteristic Length
53
Velocity Group
54
Enable Separate Distance Units Check Box
54
Scaled Distance Name
54
Velocity Distance Units Scale Factor
54
Time Scale List Box
55
Acceleration Group
55
Torque Group
55
Master Units View
56
Encoder Setup Group
57
Master Position Setup Group
57
Define Home Position
57
Output Source
57
Master Position Filter
59
Enable Check Box
59
Position View
60
Enable Feedforward Check Box
60
Settings Group
60
In Position
61
In Position Window
61
In Position Time
61
Enable Following Error Check Box
61
Software Travel Limits
62
Software Travel Limit +
62
Software Travel Limit -
62
Rotary Rollover Check Box
62
Velocity View
64
Feedrate Override
64
Feedrate Decel/Accel
65
Velocity Command
65
Ramps View
66
Acceleration Type
66
Ramps Group
67
Stop Deceleration
67
Feedhold Decel/Accel
67
Travel Limit Decel
67
Torque View
68
Torque Level
68
Limits Group
69
Peak Torque
69
Online Status Tab
69
Tuning View
70
Load Group
70
Inertia Ratio
70
Low Pass Filter Group
71
Low Pass Filter Enable Checkbox
71
Low Pass Frequency
71
Tuning Group
71
Time Constant
72
Faults View
73
Active Faults Group
73
Active Faults Window
73
Power up Group
74
Power up Count
74
Power up Time
74
Total Power up
74
PLS View
75
Number of PLS Points
76
Source
76
On Point
76
Off Point
76
Rotary Enable
77
Rollover Point
77
Setup NVM View
78
User Variables View
79
Name
79
Decimal
79
Adding and Deleting Variables
80
Using Variables in a Program
80
Online Tab (Not Shown)
80
User Bits View
81
Adding and Deleting User Bits
82
User 32-Bit Bit Register and User Bit Masking
83
Writing to the User Bit Register
83
Configuring the User Bit Mask Register
84
User Bits Read/Write Process
84
User Bits Mask View
85
I/O Setup Group
86
Assignments View
86
Creating an Assignment
87
Deleting an Assignment
88
Drag and Drop Method
88
Assign Button Method
88
Delete Button Method
88
Assignment Polarity
89
Tying a Source to a Destination
89
User Level
90
Only Show Assigned
90
Assignments that Automatically Use Position Capture
90
Polarity Button Method
90
Selector View
91
Motor Encoder Marker
91
Master Encoder Marker
91
Index/Jog Command Complete
91
Input Lines View
95
Debounce
95
Output Lines View
96
Input Line Diagram
96
Analog Inputs View
97
Bandwidth
98
Maximum Value
98
Maximum Voltage
98
Minimum Value
98
Motion Group
99
Jog View
100
Jog Number
100
Jog Name
100
Time Base
100
Jog Sources and Destinations
101
Jog Velocity
101
Jog Acceleration
101
Jog Deceleration
101
Destinations
102
Jog.plusactivate
102
Jog.minusactivate
102
Jog.select0
102
Jog Activation
103
Jog Select Details
103
Home View
105
Home Number
105
Home Reference
105
Velocity
106
Home Offset Group
106
Limit Distance
107
Home Reference Position
107
Home Sources and Destinations
108
Home.absoluteposnvalid
108
Home.anycommandcomplete
108
Home.#.Accelerating
108
Home.#.Initiate
109
Home.#.Sensortrigger
109
Index View
110
Index Number
110
Indextype
111
Distance/Position
111
Timed Indexes
112
Time Checkbox Enabled
113
Enable Index PLS
114
Timed Index Profiles
114
PLS on Point
115
PLS off Point
115
Registration Parameters
116
’Analog’ or ’Sensor’ Radio Buttons
116
Registration to Analog Input Value
116
Registration Offset
116
Index Sources and Destinations
117
Index.anycommandcomplete
117
Index.#.Accelerating
117
Index.#.Atvel
118
Index.#.Command Complete
118
Index.#.Command in Progress
118
Index.#.Decelerating
118
Index.resetprofilelimited
119
Index.#.Initiate
119
Index.#.Sensor Trigger
119
Toolbar Icon Method
119
Right Click Method
120
Deleting an Index
120
Adding an Index
120
Gearing View
121
Gearing Acceleration Ramp Description
122
Initiating Gearing Motion
123
Stopping Gearing Motion
123
Stopping Motion
124
Motion Stop from a Program
124
Motionstop for an Assignment
124
Network Group
125
Modbus View
125
Modbus Address Assignment Box
126
Devicenet View
127
Profibus View
127
Ethernet View
127
Programming
129
Program View
129
Find
130
Program Toolbar Icons
130
Redo Last Change
130
Undo Last Change
130
Delete All Book Marks
131
Next Book Mark
131
Previous Book Mark
131
Red Dot Help
131
Drag in Variables
132
Lock Program
132
Program Where am I?
132
Run this Program
132
Program Flow Instructions
133
Program Instruction Types
133
For Count/Next
134
Do While/Loop
135
Wait for
135
Call Program
136
Wait for Time
136
End
137
Formula
137
Bit and
138
Bit or
138
Dwell for Time
139
Goto
139
Motion Instructions
139
Dwell for Master Dist
140
Index.initiate
140
Complex Velocity Profile
141
Index.compoundinitiate
141
Home.initiate
142
Index Velocity Profile
142
Index Velocity Profile with Drive Outputs
142
Jog.minusinitiate
143
Jog.plusinitiate
143
Jog.stop
143
G
144
Motion Modifiers
144
Gear Stop
144
Gear.initiate
144
Using Last
144
Adding and Deleting Programs
145
Add Program Button
145
Powertools Menu Bar Method
145
Adding a Program
145
Run Anytime Programs
146
Deleting a Program
146
Program View with "Run Anytime" Checkbox Enabled
147
Resetting Faults in "Run Anytime" Programs
148
Out and Return - Simple
148
Out and Return – more Complex
148
Example Programs
148
Punch a Hole in a Web a Specified Distance Beyond a Registration Mark
149
Registration Index to Place a Product on a Conveyor after each Lug
149
Elevator (Accumulator) with 100 Stop Positions
149
Simple Jogging Within a Program
150
Rotary Table with “Calibrated” Stop Positions
150
Flying Cutoff/Shear
150
Synchronized Jog with Manual Phase Adjustment
151
Auger Filler with Inputs to Adjust the Fill Amount
152
Sequence Learn and Playback
153
Playback Program (Program 2)
155
Parameter Descriptions
157
Absolute Position Valid
157
Accelerating
157
Acceleration Decimal Places
158
Acceleration Time Scale
158
At Velocity
158
Bit Number Value
158
Bit Register Number Value Mask
159
Clear Following Error
159
Commanding Motion
159
Drive Input Debounce Time
162
Drive Input Force
162
Drive Input Force Enable
162
Drive Input Name
162
Drive Output Encoder Scaling
163
Drive Output Force Enable
163
Drive Output Name
163
Drive Output State
163
Drive OK
164
Faulted
164
Module Faults Bitmap
164
Active Fault
165
Enable Feedforwards
165
Fault Counts
165
Reset Faults
165
Feedhold Deceleration Time
166
Feedrate Deactivate
166
Foldback Active
166
Gear Accel Enable
168
Gear Accelerating
168
Gear at Velocity
168
Gear Command Complete
168
Any Command Complete
169
Gear Decel
169
Gear Decel Enable
169
Gear Recovery Distance
169
Calculated Offset
170
Command Complete
170
Command in Progress
170
If on Sensor
172
Sensor Trigger
172
Specified Offset
172
Compound Initiate
175
Distance
175
Enable PLS
176
Limit Distance Hit
176
Index Timed Index Enable
178
Initially Active
178
Initiate Minus
181
Initiate Plus
181
Baudrate
182
Debounced
182
Line Voltage (en ONLY)
182
Modbus ID
182
Module Input Name
183
Module Input Raw
183
Module Input Status
183
Module Output Force
183
PLS Rollover Position
186
PLS Source
186
PLS Status
186
Positive Direction
186
Position Error Integral Time Constant
187
Position Feedback
187
Position Feedback in Counts
187
Power Stage Enabled
187
Initiate
188
Poweruptimetotal
188
Rotary Rollover Enable
188
Selector Input Destinations
189
Shuntactive
189
Shuntpowerrms
189
Enable Software Travel Limits
190
Software Travel Limit Minus Activate
190
Software Travel Limit Plus Activate
190
Software Travel Limit Plus Active
190
Limited Torque Command
191
Start up
191
Stop
191
Torque Command
191
Torque Level Active
192
Torque Limit Active
192
Travel Limit Minus Activate
193
Travel Limit Minus Active
193
Travel Limit Plus Active
193
Percent Continuous
194
Variable Decimal
194
Attaching the FM-3 to an en Drive
197
Basic Installation Notes
197
Mechanical Installation
197
Detaching the FM-3 from the Drive Connections
198
Modbus Communications
198
Serial Communications Specifications
198
Installing Powertools Pro
199
PC System Configuration
199
Preparing for Powertools Pro Installation
199
Software Installation
199
If You Need Help with Installation
200
Starting and Exiting Powertools
200
Accessing Help
201
Exiting the Software
201
New Configuration Dialog Box
201
Opening a New File
201
Quick Start
203
Basic Setup Steps
203
Opening a New Configuration Window
203
Enter All Setup Data
203
General Setup View
204
Making Assignments
209
Setting up Motion Parameters
211
Jog Setup
211
Index Setup
213
Index Setup View (Absolute Type)
214
Index Setup View (Incremental Type)
215
Creating a Program
216
Example Application Start up
219
Tuning Procedures
227
PID Vs. State-Space
227
Initial Settings
228
No Tuning
228
Basic Level
228
Intermediate Level
228
Tuning Procedure
228
Fully Optimized Level
229
General Tuning Hints
229
Tuning Parameters
230
Friction
230
Feedforwards
231
Determining Tuning Parameter Values
232
Initial Test Settings
233
Determining Friction
233
Procedure for Determining Friction
233
Determining Inertia Ratio
234
Trapezoidal Velocity Waveform with Torque Waveform
234
Inertia Measurement Procedure
235
Ramp Units Conversion
236
Diagnostics and Troubleshooting
239
Diagnostic Display
239
Fault Codes
240
Fault Descriptions
242
Flash Invalid
242
Watchdog Timer
242
Power up Test
242
FM-3 Fault
243
Invalid Configuration
243
Power Module
243
High DC Bus
243
Encoder State
244
Encoder Hardware
244
Motor Overtemp
244
RMS Shunt Power
244
FM-3 Specific Fault Descriptions
245
FM-3 Display Is Used to Display Drive and FM-3 Faults
245
Enc St
245
Enc HW
245
Isr Ovr
246
Traj Flt
246
Drv Syn
246
Watchdg
246
Mtr Tmp
247
Dvovrtmp
247
Inv Parm
247
Inv NVM
247
Analog Outputs
248
Default Analog Output Source
248
Analog Output Offset Units
248
No Prog
248
Diagnostic Analog Output Test Points
250
Diagnostic Cable (DGNE) Diagram
251
Drive Faults
252
Resetting Faults
252
Viewing Active Drive Faults
252
Rebooting the Drive
252
Error Messages
252
Non-Programming Error Messages
253
Error: the Maximum Limit of Instances Is Reached
253
Programming Error Messages
254
Error: Couldn't Find Named Variable
255
Error: Couldn't Find Named Variable from Text
255
Error: Program Instance Does Not Exist
255
Error: String Is Not a Selection
255
Error: Syntax Error Encountered
256
Error: the Destination Variable Does Not Accept Data
256
Error: the Destination Variable Is Read Only
256
Error: this Instance Does Not Exist
258
Error: this Is Not a Fully Qualified Variable
258
Error: this Variable Cannot be Assigned a Selection Value
258
Error: this Variable Type Cannot be Assigned a Value
258
Online Status Indicators
259
Watch Window
259
Select Drive Parameters Dialog Box
260
Clear All
260
Save Selections
260
Restore Selections
260
Global Where am I Button
261
Motion Status
261
Specifications
263
Dimensions and Clearances
263
Cable Diagrams
265
SNCE-XXX Cable
266
SNCDD-001.5 Cable
266
SNCO-003 Cable
267
SNCI-003 Cable
267
CMDX-XXX Cable
269
Cmdo-XXX Cable
270
Cdro-XXX Cable
271
TIA-XXX Cable
272
DDS-XXX Cable
272
Cmds-XXX Cable
274
Cmms-XXX Cable
274
Cfcs-XXX Cable
275
Cfco-XXX Cable
276
Cfos-XXX Cable
277
Glossary
279
Configuration
280
Crc
280
Destination
280
Dialog Box
280
Firmware
281
Flash
281
Flash File
281
Fm
281
Input Function
282
Input Line
282
Least Significant Bit
282
List Box
282
Option Button
283
Opto-Isolated
283
Output Function
283
Parameters
283
Powertools Pro
284
Radio Button
284
Rms
284
Rom
284
Index
287
Symbols
287
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Control Techniques FM-3 Specifications
General
Brand
Control Techniques
Model
FM-3
Category
Network Hardware
Language
English
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General
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