Instruction/ maintenance manual of the product FM-3 Emerson
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Reference Manual P/N 4005 08-01 Revision: A8 Date: March 10, 200 4 © Contro l Techni qu es Drives , Inc. 200 0-2004 FM-3 Programming Module.
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Informat ion furni shed by Cont rol Techniques Drives Inc. (C ontrol Techn iques) is bel ieved to b e accurate and reliable. However, no responsibility is assumed by Control Techniques for its use.
ii © Control Techniq ues Drives, Inc. 2000 -2004 Part Num ber: 4005 08-01 Revisi on: A8 Date: March 2004 Printed in United States of A merica Informat ion in this document is s ubject to chang e without notice.
iii Customer Support Control Techniques 12005 Tech nology Dr ive Eden Prairie, Minnes ota 55344-3620 U.S.A. Telephon e: (952) 9 95-8000 o r (800) 89 3-2321 It is C ontrol Techni ques’ goal to ensure yo ur greatest pos sible satis faction with the operation of our products.
iv • Exact wording o f any messages that app ear on your sc reen • What you w ere doing w hen the prob lem occurred • How you tried to solve the problem Need on-site he lp? Control Techniques prov i des ser vice, in most cases, the next d ay.
v In addition, you will find the following typographic co nvent ions th r oug hou t this manual. Note For the pu rpose of t his manu al and prod uct, “Note” indicates essen tial information about the product o r the respective part of th e manual.
vi Safety Instructions General Wa rning Failure to follow safe installation guidelines can cause death or serious injury. The voltages used in the pro duct can cause severe el ectric sh ock and/ or burns and could be l ethal . Extreme care is necessary at all times when working wi th or adjacent to the pr oduct.
vii Safety Considerations Safety Precautions This product is intended for professional integ ration into a complete system . If you install the product incorrectly, it m ay present a safety h azard.
viii relevan t safety legisla tion in th e country o f use. AC supply i solatio n device The AC suppl y mu st be rem ove d from the drive usin g an approve d isolat i on device or discon nec t before an y servicing wo rk is performed , other than adjustments t o the settings or parameters specified in the manu al.
ix Introduction 1 Operatio na l Over view 3 Software Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 PowerTools Pro Setup Software . . . . . . . . . . . . . . . . . .
x Jog View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 Home View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
xi Diagnostics and T roubleshooting 225 Diagnostic Display. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225 Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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1 Introduction The FM-3 modu le is a compact and r ugged functio n mod ule that attaches to the front o f the drive. It provides eight digital i nput lines an d four digital o utput lines, in addition to t he four input and three output lines availab le on th e driv e.
2 FM-3 Pr ogramming M odule R eference Ma nual Figur e 2: FM-3 Pr ogramming Module Fe atures.
3 Operational Overview This section provid es a complete functio nal description of the FM-3. It is in tended to provide you with a thoroug h understand ing of all op erations.
4 FM-3 Pr ogramming M odule R eference Ma nual Figure 3: Hierarc hy View The “Hierarch y View” (show n above) cont ains expa ndable groups of parameters .
5 Oper ation al Ov ervi ew Figure 4: FM-3 Display Screen and Keypad On the Menu screen, the drive type and axis a ddr ess are always shown on the top line of the display. The seco nd line shows the motor typ e. If a user defined motor is selected, the user defined motor name will appear.
6 FM-3 Pr ogramming M odule R eference Ma nual Parameter Screens After selecting a group using o ne of the soft keys, the FM-3 m odule will d isplay a Paramet er screen for that group. This screen could be either the first screen in the group or the last screen you used in that group.
7 Oper ation al Ov ervi ew each group and returns to that s creen when y ou come back to the gr oup. This is res et on power-up and the FM-3 keypad displays the first Parameter screen in the group. In this screen, the par ameter name is shown on the f irst line of the display.
8 FM-3 Pr ogramming M odule R eference Ma nual Figure 5: Jog Tab How Home Works The Home is used in applicatio ns in which the axis must b e precisely aligned with so me part of the machine.
9 Oper ation al Ov ervi ew Figure 6: Basic Ho me Function, Exa mple The figure abo ve show a basic h ome f unction us ing a ball scr ew. This examp le us es most o f the setup featur es in the PowerTools Pro Ho me tab. Home Sequence 1. Back off t he sensor (if on th e sensor.
10 FM-3 Pr ogramming M odule R eference Ma nual PowerT ools Pro allows selection of on e of thr ee different Home Refer ences: Sensor, Marker, or Sensor an d Marker. Sensor Selecting S ensor means the ri sing edge of the Home Senso r input function is used to estab lish the home reference position.
11 Oper ation al Ov ervi ew Sensor and Marker Selecting Sensor and Marker means th e reference position is established using th e first marker rising edge after the device sees the rising edge of the Home Sensor inp ut function.
12 FM-3 Pr ogramming M odule R eference Ma nual Figu re 10: Senso r and Ma rker Hom e Refer ence P o siti on Exam p le 2 The Home Sensor mu st be “On” for at least 800 µ sec to guarantee that it will be recog nized.
13 Oper ation al Ov ervi ew The Specified Offset allows the user to choos e an exact offset from the Ho me Reference. Once the home reference is d etected, the device will do whatever is necessary to reach the offset position.
14 FM-3 Pr ogramming M odule R eference Ma nual Two examples be low show opera tion when the s pecified offset is greater or less than the calculated offset. This caus es the axis to co ntinue on at speed befo re decelerating and stoppi ng at the of fset positio n, or backi ng up aft er the home sen sor.
15 Oper ation al Ov ervi ew Home Limit Distance This parameter places an upper limit on the incremental d istance the motor will travel during the home.
16 FM-3 Pr ogramming M odule R eference Ma nual Home Sequence 1. If on senso r then back off (if en abled) 2. Se arch f or se nsor 3. Search for marker 4.
17 Oper ation al Ov ervi ew Example 2: Rotary App lication This example uses an external sensor and th e motor’s encoder marker pulse to establish a home referen ce position. Figure 19: Home Sensor an d Marker th en Offset, Exam ple When the device sees the rising edge of the Home Initiate function, it accelerates the motor to the Home Velocity.
18 FM-3 Pr ogramming M odule R eference Ma nual How Indexes Work An index is a co mplete motion sequence that moves the motor a specific incremental distance or to an absolute position. This motion sequence includes an acceleration r amp to a programmed velocity, a run at velocity, an d a deceleration to a stop.
19 Oper ation al Ov ervi ew Figure 22: Indexes View Indexes use acceleration and deceleration r amps which may o r may not reach the sp ecified velocity depending on the to tal distance and the ramp values. For examp l e, a short mo ve with long acceleration and deceler ation ramps may not reach the target velocity entered.
20 FM-3 Pr ogramming M odule R eference Ma nual Absolute v s. Increme ntal The differen ce between absolute and incremental indexes is that absolute indexes m ove to a specific absolute position and incremental inde xes mo ve the motor a specific distance.
21 Oper ation al Ov ervi ew Absolute indexes with Rotary Rollover enabled will take the sh o rtest path to the position entered in the index positio n pa rameter . Note Absolute indexes mov e to positions relativ e to where the machine was homed using the Home, or the DefineHome destination.
22 FM-3 Pr ogramming M odule R eference Ma nual Registration Index A Registration Index is used in applicati ons where the motor must move until an object is detected and then move a specific distance fr om the po int of detecti on, such as finding a regist ration mark and moving a distance beyond .
23 Oper ation al Ov ervi ew Exampl e 3 : If the starting position is 45° and 315° is the specified p osition, an Absolute index would travel 90° in the negative directio n because that is the shortest path between 45° an d 315°. Rotary Plus indexes will m ove to the specified position and are forced in a positive (or plus) di rection.
24 FM-3 Pr ogramming M odule R eference Ma nual NVM Options for Upload ing and Down lo ading Uploading When uploading from a FM-3 module, the values that were l ast downloaded are uplo aded and put into a PowerTools Pro configuration fi le. At the completion of th e upload, th e user will be aske d if they wi sh to upload the NVM v alues.
25 Oper ation al Ov ervi ew Keep opti on does not u pload the NVM values into t he user config uration (Power Tools Pro file). The following table sho ws an example of how th ese options work: Updati ng to RAM The Update to RAM button can be used to send changes to the FM-3 module with out performing a complete download.
26 FM-3 Pr ogramming M odule R eference Ma nual Figure 27: Update to RAM Flow Cha rt The Update to RAM b utton operates accordin g to the following rules: If no parameters have b een modified by the user, th e Update to RAM bu tton will be disabled.
27 Oper ation al Ov ervi ew When this checkbox is sel ected the “Ov erwrite” fu nction will default on every download to the module. This function will overwrite the entire FM-3 configuratio n including user defined NVM parameters as set in the NVM setup area of PowerTools Pro.
28 FM-3 Pr ogramming M odule R eference Ma nual Upload Non-Volatile Memory (NVM) Section: “Always upload NVM” When this checkbo x is selected, PowerTool s Pro will default o n an upload to uploading all of the parameter s that have been mapped to t he NVM and upd ating the di splay of t hese parameters in PowerTool s Pro.
29 Oper ation al Ov ervi ew the standard file format (.fm3) , as well as in the secure file format (.fm3s). The “s” at the end of the file ex tension stands for “secure”. The secure file will be sa ved to the same d irectory as the stand ard file.
30 FM-3 Pr ogramming M odule R eference Ma nual Brake Re lease The Brake.Release destination function will r elease the brake under all conditions. When this function is active, the Brake outpu t will be on (that is, release brake).
31 Setting Up Parameters Setup View The Setup View contains all of the primary sy stem setup parameters. These parameters must be setu p prior to using you r system. By selecting Setup in the Hierar chy View, the Setup view will appear on the righ t side of the view (see Figure 28).
32 FM-3 Pr ogramming M odule R eference Ma nual Name This is a 12-character alpha/numeric user-co nfi gured name for this axis . Enter this name for the device you are currently setting up. Assigni ng a unique name for each d evice in your system allows yo u to quick ly identify a devi ce when downloading, editing, and troubleshooting.
33 Setting Up Paramete rs Encoder Scaling Check Box This check box e nables the Scaling pa rameter of the Drive Encod er Output. Encoder Scaling This parameter defines th e encoder r eso lution (lines per revolutio n) o f the drive's en coder output.
34 FM-3 Pr ogramming M odule R eference Ma nual Switchi ng Fr equency Gr ou p This parameter defines the s witching frequency of the electronic amplifier. F or EN drives, the switching f requency must be 20 k Hz and cannot be changed. For MDS, the swit ching freque ncy can be modif ied to change system perfo rmance.
35 Setting Up Paramete rs Motor Position Group Position Command Position co mmand is th e commanded mo tor position sent to th e drive by the F M-3 module . This parameter does no t take following error into account. See also PosnFeedback and FollowingError.
36 FM-3 Pr ogramming M odule R eference Ma nual Control Loop Limit This parameter shows the lowest measured time differ ence (in microseconds) b etween the Trajectory Update R ate and the time taken to p rocess the control loo p since the last reset. Certain features in the FM-3 require more t ime to pro cess (i.
37 Setting Up Paramete rs Foldback RMS This parameter accurately models the therma l h eating an d cooling of the drive and motor. When it reaches 100 percent, current foldb ack will be activated. See the Diagnostics secti on for an exp lanation of foldback.
38 FM-3 Pr ogramming M odule R eference Ma nual User Units View The User Units View is used to scale the desired applicatio n units into known values. All information for d istance, velocity, and accel/decel units are set up here and us ed throughout the sy st e m set u p .
39 Setting Up Paramete rs Decima l Places The number of decimal places set in this parame ter determines the number of digits after the decimal point used in all distance and position p arameters throughout the sof tware. Using a high number of decimal places wi ll improve position resolutio n, but will also li mit the range of absolute pos ition.
40 FM-3 Pr ogramming M odule R eference Ma nual If the user decides to put a 5: 1 reducer on the system, the user simply need s to change the Characteristic Length. Now the belt travels 4.71" in 5 moto r revolutions. Keep in mind that the character istic l ength is always a whole nu mber and the val id range is from 1 t o 2000.
41 Setting Up Paramete rs Separate Distance Units E xample: A user has an ap plication using a leadscrew with a 0.5 "/turn lead. The user wan ts to have Distance Units of Inches, but wants Velocity Un it s of F eet so mot i on can be prog ramm ed in feet/minute.
42 FM-3 Pr ogramming M odule R eference Ma nual Decima l Places The number of decimal places set in this parame ter determines the number of digits after the decimal po int used i n all torque paramet ers throu ghout th e software . Using a high num ber of decimal places will imp rove torque resolution, but will also limit th e maximum torque.
43 Setting Up Paramete rs Encoder Setup Group Mast er Sour ce Master Source indicates the hard ware location of the master en coder input. Select module to use the sync input co nnector on the FM-3 mo dule; select drive to use the drive 44-pin command connector on the drive.
44 FM-3 Pr ogramming M odule R eference Ma nual Rollover value and then reset to zero and continue to count up. If rotating in the negative direction, the mast er position feedback will decr ease until it reaches zero, and then start over at the Rotary Rollover valu e.
45 Setting Up Paramete rs Master Position Filter The master filter is design ed for applications where the master encoder input require s smoothing due to low resoluti on or high gai n. Thes e appli cations i nclude low s peed mas ters, low resolution ma ster encoders, and la rge follower to mas ter gear ratios.
46 FM-3 Pr ogramming M odule R eference Ma nual Enable Feedforward Ch eck Box The Enable Feedfor ward Check Box is used to turn on or turn off f eedforward. If checked, feedforward is active. If unch ecked, f eedforward is n ot used. Position View The Position View allows you to set up and view th e parameters related to drive pos itioning.
47 Setting Up Paramete rs In Position The In Position (InPosn) source will activate at the end of a move if the absolute value of following error is less th an or equal to the In Position Window for th e In Po siti on Time.
48 FM-3 Pr ogramming M odule R eference Ma nual Softwar e Travel Limits Software Travel limits can be used to limit machine travel. They ar e often setup insid e the hardware travel limits to add another level of security or protection from ex ceeding the machines travel limits.
49 Setting Up Paramete rs Distance Units Decimal Places parameter o n the SetupUser Units View in the PowerTools Pro so ftware. If an absolute index is used with a non-zero rotary rollover point, the FM-3 module will calculate the shortest path to its des tin ation an d move in the required direction.
50 FM-3 Pr ogramming M odule R eference Ma nual Velocity View The Velocity View allows the setup of f eedrate overr ide details . By selecting Velocity in the Hierarchy View, the Velocity View will appear on the right (see Figure 33 ). Figure 33: Velocity View Settin gs Grou p FeedRate Override This parameter is used to scale all motion.
51 Setting Up Paramete rs FeedRate De ce l/A cc el The FeedRate Decel/Accel param eter specifies the ramp u sed when velocity cha nges due to a change in the Feed Rate Override value. The un its of FeedRate Decel/Accel are Seconds/ 100% of Feed R ate.
52 FM-3 Pr ogramming M odule R eference Ma nual Ramps View The Ramps View co ntains all setup informatio n for the global acceler ation and deceleration profiles. By selecting Ramps in th e Hierarchy View, th e Ramps View will appear on the right (see Figure 34 ).
53 Setting Up Paramete rs This is used to select the acceleration/d eceler ation type for all mo tion (homes, jogs and indexes). The “S-Curve” ramps offer the sm oothes t motion, bu t lead to hi gher peak acceleration/deceleration rates.
54 FM-3 Pr ogramming M odule R eference Ma nual Torque View The Torque View allows you to edit torque level and lim it p arameters as well as view real- time torque values when online. By selecting Torque in the Hierarchy View, the Torque View will appear on th e right (see Figure 35 ).
55 Setting Up Paramete rs Limits Group Torque Limit This parameter sets the value to wh ich the Torque Comman d will be limited when the Torque Limit Enable destination is active. To make the Torque Limit alway s active, assign the Torque Limit Enable destination to the Init ially Active source on the Assignments view.
56 FM-3 Pr ogramming M odule R eference Ma nual Tuning View The Tuni ng View allows you to modi fy tuning p arameters ba sed on sp ecific applicat ion information. By selecting Tuning in the Hierarchy View, the Tuning View will appear on the right (see Figure 36 ).
57 Setting Up Paramete rs value higher than the actual inertia, the resultant mot or response will tend to be more oscillatory. Friction This parameter is characterized in terms of th e rate of friction increase pe r 100 motor RPM. If estimated, always use a conservative ( less than or equal to actual) estimate.
58 FM-3 Pr ogramming M odule R eference Ma nual Time Constant Position Error In tegral is a control term, whic h can be used to comp ensate for the continuou s torque requ ired to hold a ver tical load agai nst gravity. It is also usefu l in low speed applicat ions , which have high fri ct ion.
59 Setting Up Paramete rs Faults View The Faults View displays any active faults . Figure 37 below shows the Fau lts v iew. Figu re 37: Fau l ts Vi ew Active Faults Group The Active F aults gro up contains t he Active Faults window. Active Fa ults Window This wind ow displays any active fa ults in the sys tem.
60 FM-3 Pr ogramming M odule R eference Ma nual Power Up G roup These parameters will be active when online with the drive. Power Up Count This parameter shows the number s of times the dr ive that the FM-3 is attached to has been powered up since the last reset be the f actory.
61 Setting Up Paramete rs PLS View The PLS View allows users to d efine Progra mmable Limit Switches (PLS) for adv anced machine operation. By selecting PLS in the Hierarchy View, the PL S View will appear on th e right (see Figure 38).
62 FM-3 Pr ogramming M odule R eference Ma nual Number of PLS P oints This param e ter d eter mines the number of PLS Poi nts th at will be us ed. Co unt al ways beg i ns with 0, so 5 points will be 0 to 4. Up to eigh t PLS p oints may be used simultane ously .
63 Setting Up Paramete rs is moving in th e positive direction. If set to Minus, the PLS will activate only when the motor is moving in the negative di recti on. For examp le: A flyi ng cutoff or flying sh ear application may us e this feature to activate the PLS to fire the knife only when the axis is mov ing in the positive direction.
64 FM-3 Pr ogramming M odule R eference Ma nual Setup NVM View At power-down, parameters can be saved to Non-Volatile Memo ry (NVM) . See the "How Communicat ions Work" sect ion of the "Oper ation al Overview" chap ter for more details.
65 Setting Up Paramete rs User Variable s View User variables allow th e user to store data rela ted to their system into a param eter, which the user can n ame. The user must d efine each us er va riable by giving it a name, resolution (number of decimal places), and initial value.
66 FM-3 Pr ogramming M odule R eference Ma nual Initial Value This is the initial value of the user variable that will be used on power up. If the user variable has been configured as a Save to NVM paramete r, then the value in NVM will overwrite the initial value on power up.
67 Setting Up Paramete rs User Bits View User Bits act just like User Va riables except that they allow the user to store bit level parameters rather than 32-b it parameters. The user may custom ize each User Bit by giving it a Name and an Initial Value.
68 FM-3 Pr ogramming M odule R eference Ma nual Figure 4 1: U se r Bits Vi e w Adding and Delet ing User Bits User bits c a n be a d ded or dele ted in gr oups of 32 - bits. Indi vidua l bit s c anno t be ad ded o r deleted. The default number of User Bits available is 32.
69 Setting Up Paramete rs User 32-bi t Bit Regist er and Use r Bit Maskin g When usin g differen t communicati ons protoco ls (i. e. DeviceNet, Prof ibus, Mo dbus), i t is often desirabl e to access groups of User Bits in a single p arameter, rather than h aving to access them individually.
70 FM-3 Pr ogramming M odule R eference Ma nual Figure 43: User Bits Read/Write Process Configuring the User Bit Mask Register The User B it Mask is a 32 -bi t p a ramete r t hat can be configur ed t hr oug h Po wer To ols Pr o, in the User Pro gram, or ov er the communi cations networ k.
71 Setting Up Paramete rs Figure 4 4: U se r Bits Mask View To confi gure th e mask i n a user p rogram, th e parameter named BitRegisiter.# .ValueMask is written to.
72 FM-3 Pr ogramming M odule R eference Ma nual I/O Setup Group The I/O Se tup group co ntains four v iews that cont rol input and output fun ctions as we ll as other drive f unctions. These views are as foll ows: Se lecto r , Assi gnment s , Inpu t Line s and Output Lines.
73 Setting Up Paramete rs Figure 4 5: A ssignme n ts View The Assignments View is used to tie a source to a destinatio n. Destinations are functions that need to be triggered, such as Index Initiates , Progr am Ini tiates, J og Initiates and so on.
74 FM-3 Pr ogramming M odule R eference Ma nual Drag and Drop Meth od First, position y our pointe r over the sour ce on the left that you wi sh to assig n to the destin ation on the ri ght. Press the left mous e button wh ile over the s ource, and ho ld the button down.
75 Setting Up Paramete rs Figure 46: Tying a Sour ce to a Des tination Assignment Po la rity The active state of an assignment can be progr am med to be Active Of f, Active On, or Custom using PowerTools Pro .
76 FM-3 Pr ogramming M odule R eference Ma nual Note Destination functio ns which in itiate motion (Jog.PlusIniti ate, Jog.Min usInitiate, Index.#.Initiate, and H ome.#.Initiate) cannot be set “Active Of f”. Default polarity for a new assig nment is Active On.
77 Setting Up Paramete rs that it is assigned to. The destination may th en use the cap tured data to accurately in itiate motion (if it is a motion-related destination). Motor Encoder Marker – The rising ed ge of the motor encoder marker pulse will automatically capture data.
78 FM-3 Pr ogramming M odule R eference Ma nual Figure 47: Selector View The selector allows cons ervation of the number o f input lines by us ing a binary inpu t conversion to d ecimal. The binary select lines are set up by assigning so urces to the selector.
79 Setting Up Paramete rs Figure 4 8: A ssignme n t View For example, i f we entered 2 for the number of Sel ector Input Destinations, w e would have 4 selection lines (Selector.Selec tion0 through Selector.Selecti on3). The Selector.Selection number that is activated is deter mi ned by th e status of the Selector.
80 FM-3 Pr ogramming M odule R eference Ma nual The following examples demonstrate how to determine which Selector.Selection will activate based on the Selector.Select lines. Example 1: If Selector.Select2 is active, Selector.Select1 is inactive, and Selector.
81 Setting Up Paramete rs Input Lines View The Input Li nes Vi ew dis pl ays any fu ncti ons that h a ve b een assig ned to the dr ive or mod ule hardware inputs. See F igure 49. Note No assi gnments can be m ade using the In put Lines View , assignments are only displa yed in the Input Lin es View.
82 FM-3 Pr ogramming M odule R eference Ma nual Figu re 50: Input Lin e Diag ra m If the Input Line at tached to the home s ensor is deboun ced, the actual rising edge of th e Home Sensor is used to determine the Home Refe rence Position (the debounce time ensures a mini mum pu lse wi dth) .
83 Setting Up Paramete rs Analog Inputs View The FM-3 modu le is able to use the analog inpu t circuitry located on th e drive. The analog input accepts a +10 to –10 Volt signal. The an alog input can be setup on the Analog view, which is lo cated undern eath the I/O Set up grou p in the PowerToo ls Pro hierar chy.
84 FM-3 Pr ogramming M odule R eference Ma nual Bandwidth This parameter sets the low-pass filter cutoff freque ncy applied to the analog input. S ignals exceeding this frequency will be filtered at a rate of 20 dB per decade. Maximum Value This parameter is u sed for user unit scalin g.
85 Setting Up Paramete rs Motion Group All motion p arameters related to Jogs, Homes, Indexes and Gearing are located in the Motion hierarchy group. Motion views will use units that correspon d to Realtime or Synchronized motion. This choice is made on each motion view.
86 FM-3 Pr ogramming M odule R eference Ma nual Jog View Jogging produces rotat ion of th e moto r at controlled velocities in a positive or nega tive direction. The jog is initiated with the Jo g.#.Initiate destination or from a program . Figu re 53: Jog V iew Jog Number This scro ll box allo ws you to s elect between Jog0 and Jog1 setup views .
87 Setting Up Paramete rs Jog Velocity This parameter specifies th e target jo g velo city for the individual Jog. The motor will run at this velo city when jogg ing with an as signment o r through a p rogram. Thi s value is a si gned number. The direction of the jog is determined by the sign of the jog velocity as well as using the Jog.
88 FM-3 Pr ogramming M odule R eference Ma nual Jog.#.Decelerating This source is active while a jog is decelerating from its target velocity. Once the J og reaches zero velocity (or its new target velocity), the Jog.#.Decelerating source will deactivate.
89 Setting Up Paramete rs Figure 54: Jog Activatio n Figure 55: Jog S elect Deta ils If the Jog direction is reversed, the Jog.#.Decel v alue will be used to decelerate the motor to zero speed and then the Jog.#.Accel will be used to accelerate to the new (opposite sign) velocity.
90 FM-3 Pr ogramming M odule R eference Ma nual The St op des tina t ion (f ound u nder t he Ramp s grou p in th e Assi gn ment s view ) wil l ov erri de the Jog operation and decelerat e the motor to zero s peed at the stop deceleration rate. If the motor r eaches a Travel Limit, you can Jog off the Travel Limit in the opposite direction .
91 Setting Up Paramete rs Home View The Home is used in applicati ons in which the axis must be precisely aligned with some par t of the machine. The Home is initiated with the Home.
92 FM-3 Pr ogramming M odule R eference Ma nual home position. W hen the home reference is 'Marker' the rising edge of the mo tor encoder's marker chann el is used to esta blish the home position.
93 Setting Up Paramete rs distance is used to guarantee that the motor will not need to backup after the deceleration ramp. Specified Offset Radio Button The specified offset allows the user to choose an ex act offset from the Home Reference point.
94 FM-3 Pr ogramming M odule R eference Ma nual Home Sources and Destin atio ns Sources Home.AbsoluteP osnValid This source is activated when a Home is successf ully completed. It indicates that the d evice has be en ho m ed pr oper l y. It is w ill be deac tiv ated by the Home.
95 Setting Up Paramete rs Destinations Home.#.Initiate The Home.#.Initiate destination is used to initiate th e hom e function. The Hom e is initiated on the rising edge of this function. The device will not initiate a Home if there is an Index, Jog, or Program in progress, or if the Stop des tin ation is active or if a travel limit is active.
96 FM-3 Pr ogramming M odule R eference Ma nual Index View An index is a co mplete motion sequence that moves the motor a specific incremental distance or to an absolute position . The index is initiated with the Index.#.Ini tiate destination or from a program.
97 Setting Up Paramete rs Index Name The User can specify an Index nam e of up to 12 alphanumeric characters. T his allows assigning a descriptive name to each inde x indicating d ifferent machin e operations. IndexType Select the i ndex type from Incremental, Abso lute, Registration, Rotary Plus, o r Rotary Minus.
98 FM-3 Pr ogramming M odule R eference Ma nual Timed Inde xes A Timed In dex allows the user to specify the amount of time in which to perform an index rather than s pecifying the Velocity, Acceleration, an d Deceleration.
99 Setting Up Paramete rs Figure 59 : Time Checkbox Enab led If the values for Max.Velocity, Max.Acceleration, and Max.D eceler ation are such that the distance cannot be covered in the specified time, the Index.Pr o fileLimited flag will activate when the index is initiated, indicating the in dex cannot be performed as desired.
100 FM-3 Pr ogramming M odule R eference Ma nual The units for the Time parameter depe nd on the current settin g of the Time B ase parameter. If Time Base is set to “Realtime” (default), then the units f or the Time parameter are Seconds. The user can program the index time with resolutio n of 0.
101 Setting Up Param eters is only updated when In dex# is run . The directi on of the P LS does not matter, the Index.#.PLSStatus will activate and deactiv ate the sa me incremental dist ance from the start of the index. PLS O n Poin t This parameter is an incremental distance from the start posi tion of the index, at which the PLS.
102 FM-3 Progr amming M odule Referen ce Manual Registration Parameters The following pa rameters are only used if R egistration is selected as the In dex Type. ’Analog’ or ’Sensor’ Radio Butt ons Select one of these radio buttons to determine what sign al will be used as your registration trigger.
103 Setting Up Param eters (or distance) sho uld be greater than the R egistration Window Start p osition. If a registratio n sensor is seen outs ide of this window (not b etween the Wi ndowStart an d WindowE nd positions) then it will b e igno red. Example: Index 0 is defined as a Regist ration type of index.
104 FM-3 Progr amming M odule Referen ce Manual Index.#.AtVel This source activates when the target index ve locity is reached. If Feedr ate override is changed or FeedHold is activated AtVelo city shall remain active. Index.#.AtVel will deactivate at the start of any deceleration or accel eration.
105 Setting Up Param eters Destinations Index.ResetProfileLimited If a timed index was not able to complete in the specified time, the Ind ex.ProfileLimited source will activate. Index.Rese tProfileLimited is used to clear the ProfileLimited flag and acknowledge that the index did not complete in the specified time.
106 FM-3 Progr amming M odule Referen ce Manual Deleting an Index Navigate to the Indexes View, and select the Index you wish to delete. From the PowerTools Pro menu bar, select Edit/Delete/Index. The selected Index will be deleted from the configurat ion.
107 Setting Up Param eters Gearing View Figure 6 1: G e aring Vie w Gearing is used to fix the motion of the mot or to the motion of the master ax is signal at a specified ratio. This is commonly called “electr onic line shafting” or “electronic gearin g”.
108 FM-3 Progr amming M odule Referen ce Manual Acceleration and Deceleration ramps may be en ab led on th e Gearin g se tup scr een as s een in Figure 61 above (B3 firm ware or later is required for Accel / Decel). If enabled, the accel and decel ramps are specified in units of Follower Units / Velocity Time Base / Acceleration Time Base.
109 Setting Up Param eters Initiating Gearing Motion Gearing can be activated through an As signment, or from a pr ogram inst ruction (Gear.Initiate). If initiated from an assignm en t, the Gear.Activate destination is a level- sensitive event. This means that gearin g wil l be active as lo ng as the source to which it is assigned is active.
11 0 FM-3 Progr amming M odule Referen ce Manual Stopping Motion Motion Stop from a Program The MotionStop command will cause all motion to stop regardless of what type of moti on it is, or where it was initiated from. Upon activatio n of the MotionStop, all motion will begin to decelerate to a stop using the standard Stop d eceleration ramp.
111 Setting Up Param eters Netw ork Gr oup For information on the DeviceNet and Pr ofibus V iew, please refer to the F M-3 and FM-4 Connectivi ty Reference Manual (P/N 40050 8-0 4). Modbus View The Modbus View is used t o assign Modbu s addresses t o indiv idual parameters .
11 2 FM-3 Progr amming M odule Referen ce Manual An external dev ice such as a Human Machine In terface (HMI) or PLC can be used to monitor or edit ind ividual FM-3 module p arameters. The F M-3 module and drives u se a 32-bit Modbus R TU communicat ions prot ocol.
11 3 Setting Up Param eters DeviceNet View For thos e modules that h ave the De viceNet option , please refer to the FM-3 a nd FM-4 Connectivi ty Reference Manual , P/N 4005 08-04, which can be found on t he Cont rol Techniques MME Po wer CD.
11 4 FM-3 Progr amming M odule Referen ce Manual.
11 5 Pro grammi ng By selecting Program in the hierarchy view, th e Program View will appear in the right (see Figure 65 ). Th e left si de o f thi s view co ntai ns the p rog ram i n st ru ctio ns . Th e righ t sid e of the Program view con tains the Progr am Tool bar above the p rogram.
11 6 FM-3 Progr amming M odule Referen ce Manual Program Toolbar Icons Following is a detailed desc ription of each of the icons fou nd on the Program Toolba r. These icons will help the user edit programs as well as debug errors and tr oubl esh oot p rog ram functionality.
11 7 Progra mming Next Book Mark This icon will position the cursor on the n ext available bookmark ahead of the cursor in the progr am. Previous Book Mark This icon will pos ition the cursor on the previous bookmark be hind the cursor in th e program.
11 8 FM-3 Progr amming M odule Referen ce Manual Drag In Variables This icon will bring up the Drag In Variables pop-up window. From this win dow, the user can find any var iable they wish to use in a prog ram, and simply drag it into the program code.
11 9 Progra mming disable the program parser, enter all of the chang e s , and th en re-enable the parser to check for errors. ( Only available while online ) Programs Motion Prog rams are a ser ies of indexes , homes and jogs that hav e been previou sly setup.
120 FM-3 Progr amming M odule Referen ce Manual Jog.0. Plus Initia te ‘Vel=2 0in/s Wait Fo r Modu leInpu t.2=OF F ‘Stop when the in put goes OFF Jog.St op ‘D eceler ate to a sto p Endif If (M odul eInput .3=ON) The n ‘Jog- w hen Mo duleIn put.
121 Progra mming Module Outp ut.1=O FF ‘T urn Mo duleOu tput.1 Off Next Do While/Loop This prog ram instructio n is used f or repeating a sequence of code as lon g as an express ion is true. To loo p forever us e “TR UE” as the tes t exp ression as shown in the th ird ex ample b elow.
122 FM-3 Progr amming M odule Referen ce Manual Jog.St op ‘D eceler ate to a sto p Endif If (M odul eInput .3=ON) The n ‘Jog- w hen Mo duleIn put. 3=ON Jog.0. Minu sIniti ate ‘Vel =20in/ s Wait Fo r Modu leInpu t.3=OF F ‘Stop when the in put goes OFF Jog.
123 Progra mming In the diagram below, => Represents a Call Program in struction Examples: Call Pr ogra m.10 ‘Pr ogra m 10 conta ins a comp lex ho me ‘routi ne. Call Pr ogra m.100 ‘Prog ram 10 0 contai ns a “teac h posi tion” ‘routi ne.
124 FM-3 Progr amming M odule Referen ce Manual Bit And This operator may be u sed when it is desi reable to AND each indi vidual bit of a 32 -bit parameter. var. v ar2 = var.va r0 bi t and va r.var 1 For examp le: if var.va r0 = 1000 an d var.var1 = -1 var.
125 Progra mming DriveO utpu t.1 = ON End See GoTo instruction fo r additional examples. GoTo The GoTo instruction is us ed in conjunction with the Label: instr uction to cause program flow to transfer to a s pecified locat ion within a program. The desti nation label is allowed to be above or below the GoTo instructio n within the same program.
126 FM-3 Progr amming M odule Referen ce Manual The “Dwell For Time” ins truction is in units o f seconds with a resolutio n of milliseconds (0.000 seconds). If you wan t to pause the p rogram while an index is executing you should use a “Wait for Time” instruc tion descri bed belo w.
127 Progra mming the following erro r is less than a specified amount. This is accom plished by changing the “Wait Fo r Index.AnyCom mandComplete” to “Wait For InPos n”. The In Pos ition Wind ow is configured in the Position view. Examples: Index.
128 FM-3 Progr amming M odule Referen ce Manual Figu re 66: Ind ex Vel ocit y Prof i le Index. 0.Co mpound Initia te ‘Incre mental ,Dist= 5.000i n,Ve l=50in /s Index. 1.Co mpound Initia te ‘Incre mental ,Dist= 20.000 in,V el=75i n/s Index. 2.In itiate ‘I ncreme ntal,D ist=10 .
129 Progra mming Jog.Stop This program ins truction is used to halt jogg ing using the deceleration ramp setu p for the currently operating jog. Examples: Wait For Modul eInput .2=ON ‘Wait fo r “Jog –“ input to turn on Jog.0. Minu sIniti ate ‘Vel =27.
130 FM-3 Progr amming M odule Referen ce Manual Jog.1. Minu sIniti ate ‘Syn c,Vel= 1.000i n/in Gear Stop Gear Stop will stop gearing motion that has been initiated from a p rogram. Example: Gear.I niti ate Wait fo r Driv eInput .2=ON Gear.S top Gear.
131 Progra mming exact ending point o f the last prof ile. Because of this, the pro cessor would adjust the current motion profile to co mpensate for the lost time, therefore keeping the time line intact. The user may or may not have b een aware that this was happening.
132 FM-3 Progr amming M odule Referen ce Manual Deleting a Program Navigate to the Programs view on the hierarchy, and s e lect the progr am you wis h to del ete . From the Po werToo ls Pro m enu ba r, select Ed i t/Delete/Program. The s elected Program will be deleted from the configuration.
133 Progra mming Figure 68: Program View wi th "Run Anytime" Checkbox Ena bled When a fault o ccurs, the drive will s till be disabled, and no motion wil l be possible. For this reason, it may be necessary to res et the f ault in the "Ru n Any time" pr ogr am pr ior to ru nning motion again.
134 FM-3 Progr amming M odule Referen ce Manual Resetting Faults in "Run Anytime" Programs To reset a fault from a "Run Anytime" progr am, use Fault.Reset = ON command in the user program. The Fault.Reset command doe s not clear all ty pes of faults .
135 Progra mming Punch a Hole in a Web a Specified Distance Beyond a Registration Mark Description: Index a web to a position 2 inches be yond a registration mark. Then fir e a solenoid to punch a hole in the web. Wait for a sensor to indicate that the punch is in the down position.
136 FM-3 Progr amming M odule Referen ce Manual Simple Jogging within a Program Jog+ when DriveInput. 2 goes ON an d stop w hen it goes off. Jog- when DriveInput. 3 goes ON and stop wh en it goes off. This could also b e accomplished using the Jog input function s when there is no p rogram running.
137 Progra mming Knife Travel Distance = 20 inches PLS.0 is used to initiate Index.0 every 100 inches. PLS.0 has an “ON” point at 0.000 inches and an “OFF” point at 90.000 inches. PLS.0 has a rollover position of 100.000 inches. The rollover position is u sed to set the part length.
138 FM-3 Progr amming M odule Referen ce Manual Wait Fo r Modu leInpu t.1=ON ‘Star t when a mas ter lug is detecte d Jog.0. Plus Initia te ‘Sync, Vel=1. 000in/ in Do While (TRUE ) ‘Repea t unti l the prog ram is hal ted If (Mod uleI nput.2 =ON) The n ‘Phas e Advanc e when Mod uleI nput.
139 Progra mming Module Outp ut.3=O FF Endif ‘Decre ase th e fill amo unt once every tim e Module Input. 4 is press ed. If ((Mo dule Input. 4=ON) AN D (Mod uleOut put.4= OFF) ) Then Index .1.D ist = Inde x.1.Di st - 0.1 0 ‘ounce s Module Outp ut.4=O N ‘Modul eOut put.
140 FM-3 Progr amming M odule Referen ce Manual If (Mod uleI nput.1 =ON) The n ‘Learn th e new po sition if the “Lea rn” ‘input is on Index .2.D ist = Posn Comman d ‘Read th e Pos ition C ommand into Index. 2’s ‘absol ute po sition . Endif Wait For Modul eInput .
141 Progra mming Endif Loop Jog.St op ‘Stop jo ggin g when the Jog+ input goes off. Endif Loop Playback Program (P rogram 2) Home. 0.In itiate ‘ Sensor ,Off set=0. 000in, Vel= -10in/ s Do While (TRUE ) ‘Repea t unti l the prog ram is hal ted Index.
142 FM-3 Progr amming M odule Referen ce Manual.
143 Parameter Descriptions This section lists all programmable and feedback parameters available. Th e parameters are listed alphabetical ly by variabl e name (shown in italics b elow the on screen name) and give a description. Range is dynamic and depen ds on User Unit scaling.
144 FM-3 Progr amming M odule Referen ce Manual Acceleration Decimal P laces AccelUnits.Decima l This parameter is the decimal point loca tion for all real-time accel./dec el. ramps. Acceleration Time Scale AccelUnits.TimeScale This parameter is the time units for accel.
145 Para meter Des cripti ons Bit Register Number V alue Mask BitRegiste r .#.V alueMask This parameter is the Mask for the BitRegister.#.Valu e. Each bit location is set to either transfer the current data in the corresponding bit locatio n of BitRegister.
146 FM-3 Progr amming M odule Referen ce Manual Decelerating Decelerating This source is active when the FM-3 module is decelerating. A no rmal index consists of 3 segments: Accelerating, At Velocity, and Decel erating. Decelerating follows the accelerating segment and the At Velocity segm ent.
147 Para meter Des cripti ons Distance Decimal Plac es DistUnits.D ecimal This parameter is used to select the number of decimal places used in the DistUnits.Characteristi cDist. Using a hi gh number of decimal places will improve positioning resolution , but will also limit the maximum travel distan ce.
148 FM-3 Progr amming M odule Referen ce Manual Drive Input Debounce Ti me DriveInput.#.DebounceTime The Drive Input Debounce Time parameter is the minimum time a di gital inpu t must be steady in order to be r ecognized by t he FM-3. This feat ure helps p revent false t riggering in applications in electrica lly noisy environments.
149 Para meter Des cripti ons Drive Out put Force E nable DriveOutput.#.ForceEnable If DriveOut put.#.Fo rceEnable param eter is activated, then the s tate of the DriveOutput.#.Force bi t will override the current outpu t state. Drive Output Name DriveOut put.
150 FM-3 Progr amming M odule Referen ce Manual 3 = Drive p ower module fault 4 = Low DC bus fault 5 = High DC bus fault 8 = Drive internal fault 1 9 = Drive trajectory fault 10 = Drive internal fault.
151 Para meter Des cripti ons 5 = Mo dule t rav el lim it pl us 6 = Module travel limit minus 7 = Mo dule p rogra m faul t All other bits are not used. A "1" in these bit locations indicates the specific fault is active, and a "0" is inactive.
152 FM-3 Progr amming M odule Referen ce Manual come to a halt, b ut the index's velo city command remains at the velocity it was at before the feedhold was activated. When the feedhold is deactivated time will ramp b ack up and the index will continue on to its p rog ramm ed distance or position.
153 Para meter Des cripti ons Foldback RMS FoldbackRMS This read-only parameter accurately models the therma l h eating an d cooling of the drive. When this parameter reaches 100 percent, current fold back will be activated.
154 FM-3 Progr amming M odule Referen ce Manual Gear Acc el Enable Gear .AccelEnable Gear.AccelEnable is a Destination that when it is "on" allows a gear to ru n a specified accel ramp after the gearing comman d is turned on. Gear Acc elerating Gear .
155 Para meter Des cripti ons Gear Dec el Gear .Decel This parameter sets the decelerati on of th e r ealtime gearing ramp. Gear. Decel units are in Follower Units/Velocity Time Base/Accelerati on Time Base. The Gear .Decel functions only when the f ollower is ramp ing its s peed down aft er the gearin g function has turned of f.
156 FM-3 Progr amming M odule Referen ce Manual Accelerating Home.#.Acc elerating Active during any acceleration while the specifie d home is in progress. Accelerating may turn off and on again based on the type of Home selected. Accelerating will activate during the Home back o ff s e nsor m otion .
157 Para meter Des cripti ons Decelerating Home.#.Dec elerating This source is active during any deceleration while the s pecified home is in progress . Decelerating will turn off a nd on based on th e typ e of Home select ed. Decelerating will activate during the Home back off sensor m otion.
158 FM-3 Progr amming M odule Referen ce Manual Home Offset T ype Home.#.OffsetT ype Selects calculated or specified home offs et. Calc ulated of fset is the distance traveled during the deceleration ramp from the ho me velocity. Th e specified offs et allows the user to ch oose an exact offset fro m the Home Reference.
159 Para meter Des cripti ons Tim e B as e Home.#.TimeBase The time base selects either realtime, which allows velocities , acceleration and deceleration to be ba sed on real t ime, or synch ronized, which al lows for an ext ernal synch ronization signal.
160 FM-3 Progr amming M odule Referen ce Manual Acceleration Inde x. #.Ac cel This parameter is the average Acceleratio n rate used dur ing the index . Units are specified o n the User Units view in the Po werTools Pro software. Accelerating Inde x.#.
161 Para meter Des cripti ons Command In Progress Index.#.CommandInProgr ess The Index.# .CommandInProgress so urce is active througho ut an entire index p rofile. The source activates at the beginning o f the index acceleration ramp , and deac tivates at the end of the index deceleration ramp.
162 FM-3 Progr amming M odule Referen ce Manual Initiate Index.#.Initiate The Index.#.Initiate destinatio n is used to initiate the specific inde x. The Index is initiated on the rising edge of this function. An Index cannot be initiated if there is an Home, Jog, or Program in progress , or if the Stop des tination o r if a travel limit is active.
163 Para meter Des cripti ons PLS Status Index .#.PL SSt atus Controlled by the PLSOn and PLSOff Points, this is relative to the distance commanded si nce the start of the index. Index.#.PLSStatus will b e active if the distance tr aveled from the start of the index is greater than the Index.
164 FM-3 Progr amming M odule Referen ce Manual Registration Sensor Index.#.Sensor Trigger If registration to Sensor is selected, when this destination activates, motor positio n is captured and is used as the registrati on point for registration type in d exes.
165 Para meter Des cripti ons In Position InPosn This source activates when co mmanded velocity is zero and the absolute value of the following error is less than the InPos nWindow fo r at least the amount of time specified in the InPosnTi me parameter.
166 FM-3 Progr amming M odule Referen ce Manual Select Jog.Select0 This destination is used to select between the jogs. It is used along with the Jog.PlusActivate and Jog.MinusActivate destin ations. If the Jog.Select0 destination is not active then the Jog.
167 Para meter Des cripti ons Command In Progress Jog.#.CommandInProgress The Jog. #.CommandIn Progress source is high thro ughout an en tire jog profile. Th e bit goes high at the st art of a jog acceleration ramp , and turns of f at the end of a jog deceleration ram p.
168 FM-3 Progr amming M odule Referen ce Manual Line V olt age (EN ONL Y ) LineV o ltage This parameter is used to calculate critical internal gain s. There are two possible v a lue: 11 5 or 230 VA C. A value of 1 15 VAC shou ld not be u sed if the actu al line voltag e is 230, otherwise damage to the EN drive may result.
169 Para meter Des cripti ons Module Input Name ModuleInput.#.Name This is a text string up to ten characters that can be assi gned to a given input. It allo ws the user to use application specific termin olog y in naming digital inputs. Module Input Raw ModuleInput.
170 FM-3 Progr amming M odule Referen ce Manual Motion Stop MotionS top This destinat ion is used to stop all mo tion operating without stoppi ng programs. Motion Stop can be activated th rough an assignment, or in a user prog ram. This function is level sensitive, meaning that as lon g as MotionStop is active, all motio n will be prevented.
171 Para meter Des cripti ons If usi ng negative values for the On Posn and OffPosn, th e most neg ative value sh ould go in the OnPosn parameter, and the least negative val ue should go in the OffPosn.
172 FM-3 Progr amming M odule Referen ce Manual PLS Roll over Positi on PLS.#.R otaryRollov erPosn This parameter is th e absolute position of t he first repeat position for th is PLS. When enabled it causes the PLS to rep eat every time this distance is passe d.
173 Para meter Des cripti ons Position Error Integral T ime Const ant PosnErrorInte gralTimeConstant Position Error Integral parameter is a control term, which can be used in Pulse mode to compensat e for the cont inuous tor que required to hold a vertical load against gravity or to minimize following err or.
174 FM-3 Progr amming M odule Referen ce Manual PowerUpT imeT ot al PowerUpT imeT otal Total power up time since the dr ive was manufactured. Units is h ours. Any Complete Program.AnyComplet e This source is activated when any progra m ends normally. If a program ends due to a fault or the stop des tination, this source does not activate.
175 Para meter Des cripti ons zero when the axi s posi tion gets to 360 degrees. (3 58, 359 , 359. 999, 0. 000 0, 1, 2 , and s o on. ) The rollover point is defined to be exactly the same posi tion as 0. Selector Input Destinations Selector .Selec tLinesUsed The selector is a binary to decimal decoder.
176 FM-3 Progr amming M odule Referen ce Manual Enable Soft ware T r avel Limits SoftwareT ravelLimitEnable Software travel limits can be used to lim it m achine travel. They are often setup inside the hardware travel limits to add a level of prot ection fro m exceeding the machines travel limits.
177 Para meter Des cripti ons Start U p St ar t U p This source can be u sed to trig ger an event to occu r on startup (when th e FM-3 module powers up or is rebo oted). This source is ty pically used to initiate a p rogram or to initiate a h ome so that a machine will automatically home on power up or reboot.
178 FM-3 Progr amming M odule Referen ce Manual T orque Level T orqueLev el This parameter is compared to the TorqueComm and. If the absolute v alue of the TorqueCommand is g reater than or eq ual to the T orqueLevel th e Torq ueLev elActive source is activated.
179 Para meter Des cripti ons T orque Limit T orqueLimitEnable This destination is used to enable the TorqueLimit. This is lev e l sen sit ive. T ravel Limit Minus Activate TravelLimitMinusAc tivate This destination is used to activate the trav el lim it minus fault.
180 FM-3 Progr amming M odule Referen ce Manual Percent Continuous T orqueUnits.Pe rcentContinuousCurrent This parameter is the denominator of torque scaling facto r. T his is an amount of continuous current in per cent that is equal to the TorqueUnits.
181 Para meter Des cripti ons Decimal Plac es V elocityUnits.D ecimal This parameter is used to select the number of decimal places us ed in velocity units scaling . Using a high number of decimal places will impro ve ve lo city resolu tion, but will also limit the maximum velo city.
182 FM-3 Progr amming M odule Referen ce Manual.
183 Installation Basic Installa tion Notes You are requir ed to follow all sa fety precaution s during st art-up such as p roviding pro per equipmen t gro un ding, correctly fu sed powe r an d an effective Emergency Stop circuit wh ich can immediately remov e power in the case of a malfunction.
184 FM-3 Progr amming M odule Referen ce Manual Figure 70 : Detaching the FM-3 f rom the Drive C onnections Do not attach or d etach the FM-3 module wh en power is applied to the drive It could cause drive instability and may cause property damage .
185 Installation Software Inst allation PowerTools Pro sof tware was designed for users who need acces s to all setup options and diagnostic informa tion for the d rive. The soft ware provides access to all commonly used drive para meter s. PC System Config uration Required: • Microso ft® Windows® 98, Microsoft® Windows NT® 4.
186 FM-3 Progr amming M odule Referen ce Manual PowerCD doesn’t auto s tart use Windows Expl orer to navigate to the CDROM d rive and open the HELP.TXT file for additional information. 2. When promp ted, install the software on to your hard drive following the instructions on your scr een.
187 Installation Opening a New File To start a new file o r configuration, select fi le f rom the menubar, and then select New. You may also click on the File New icon on the toolbar. The New dialog box will appear promptin g the user to select FM-3 Dr ive Setup or F M-3DN Drive S etup (see figur e 71).
188 FM-3 Progr amming M odule Referen ce Manual • Click the Help button on a dialog bo x or tab. • Click the Help icon on the toolbar. • Click the Context Sens itiv e Help button on the toolbar and then the field on the tab.
189 Quick Start The quick start guide p rovides information o n th e basi c oper atio n and fu ncti ons of the FM -3. The quick start steps cover only the most basic steps required to setup a FM-3 modu l e for use with a drive.
190 FM-3 Progr amming M odule Referen ce Manual To select one of the individu al setup views, click on the element in the hierarchy view. Th e element will then be highlighted, and the right side of the view will show all setup parameter s for that subj ect.
191 Quick S t art User Units View Determine which types of u nits the drive should use to measure motion and enter them on thi s view. Figur e 74 shows the S etup group in the hi erarch y expanded with th e User Units element selected. Figure 7 4: U se r Units Vi e w Now setup the param eters in the Distance group on the Us er Units view.
192 FM-3 Progr amming M odule Referen ce Manual Because of internal math in the FM-3/4, so me user unit combinations may cause module or drive trajectory faults. The maximum moto r velo city allowed by the drive is detailed und er the distance section of the User Units View an d is lab eled “User Unit Limited Speed”.
193 Quick S t art Enable Followin g E rror – This checkbox enables (when checked) and disables the following error fault capability. If checked, a following error fa ult is gener a ted when ever following error exceeds the value entered in th e parameter box .
194 FM-3 Progr amming M odule Referen ce Manual Figu re 76: Ramp s Vie w Travel Limit Decel – The deceleration ramp is used if e ither a Software or Hardware Travel Limit is encountered. Th e deceleration u nits of the ram p ar e def ined in the User Units setup view under the Acceleration gr oup.
195 Quick S t art Figure 77: Tuning View Inertia Rati o - This parameter is the ratio bet ween th e reflected iner tia of the load and th e inertia of the m otor rotor. F or assistance in calcu lating the In ertia ratio, see the Determining Tuning Parameter Values secti on of th is m a nual.
196 FM-3 Progr amming M odule Referen ce Manual “Assigned To” and th e “Set From” columns should then reflect the as signment that has been made. Figur e 78 show s how these as signments ar e made. Figur e 78: Making As signments Notice that a Name can be as sociated to each input line.
197 Quick S t art Figure 79 : Output Lines Vi ew A name can also be given to each h ardware out pu t line. Double click the Output line name field to enter a name for that individual outp ut li ne. Name – T his 12-c harac ter s tring all ows a desc ript i ve name assignment to an output line.
198 FM-3 Progr amming M odule Referen ce Manual Figure 80 : Jog Setup View Jog Deceleration - Is the average deceler ation rate us ed when decelerating to zero speed or to the new target velocity. Home Setup Next, select the Home view from the hier arch y window.
199 Quick S t art Figure 81 : Home Setup View Deceleration - Is the average deceleration rate used to decelerate from the target velocity to zero velocity at the co mpletion of the home.
200 FM-3 Progr amming M odule Referen ce Manual Figu re 82: Inde x Setu p Vie w ( Absol ute Ty p e) Inde xes us e the f ollow ing pa r ame t ers: Index Na me - Is a 12-character s tring that gi ves a descriptiv e name to an index. Index T ype – Selects the de sired type of index from the lis t box .
201 Quick S t art Position/Distance – If us ing an absolute index, t his is the desired f inal position after th e index is complete. If using an in cremental index, then this is t he distance you want the load to move from th e start of th e index.
202 FM-3 Progr amming M odule Referen ce Manual Now that all of the motion parameters are setup, the jogs and indexes can be initiated through assignmen ts to hard ware inputs th at were made on the assign ment view.
203 Quick S t art To expand the usable area of the programming view, use the Hide/Show Hierarchy button on the PowerTools P ro toolbar. Figu re 85 shows this utility. By clicking on the button once, the hierarchy windo w will be hidden, allowing for a lar ger programming windo w.
204 FM-3 Progr amming M odule Referen ce Manual Now the program is complete, and is ready to be run. In order to run the program, the drive must be enab led and the setup param eters mu st be d ownloaded. Once the downlo ad is complete, verify the drive is enabled and initiate your program.
205 Quick S t art Example Application Start Up Figure 86 : Example System In order to make the setup easier to underst and in this guide, the guide will use an example setup. The ex ample application used in the qui ck start guide is a b all screw application (see the drawing above).
206 FM-3 Progr amming M odule Referen ce Manual selects three digits allo win g resolution of 0. 001 Inches on all distance var iables. Use the spinn er window U p/down b uttons. Distance Units Scaling – Enter the number of User Units the motor/load travels f or each revolution of the motor.
207 Quick S t art Making Assignments Using thi s process, three individual ass ignments are made. T he example application wants to turn on an output when each index completes. Therefore, Index Complete sources will be ass i gn ed t o t he har dwa r e Outp ut des tina tions .
208 FM-3 Progr amming M odule Referen ce Manual Figu re 89: Input Lin e s View Notice that a Name can be as sociated to each input line. Each inp ut line can also have a debounce t ime. Figure 8 9 demonstrates how to enter a debounce tim e for an input line.
209 Quick S t art Home Setup The example app lication calls for setup of the following parameters: Home Reference –The example calls fo r a Home to Sens or; theref ore, “Sensor” is selected as the home reference. Because of this selection, the home profile will travel at its target velocity until the Home.
210 FM-3 Progr amming M odule Referen ce Manual Inde x Type – S el ect t he d esi red typ e of index fro m the list bo x. Ind e x2 has been defi n ed as an Incremental type of index. This means that the load travels an exact distance from the star t of the index.
21 1 Quick S t art Figure 92 : Index Setup View (I ncremental T ype) Now that all of the motion parameters are setup, the jogs and index es can be initiated through assignments to hardware inputs that were mad e on the assignment v iew. See Figure 89 to determine which input is used to activ ate which functions.
212 FM-3 Progr amming M odule Referen ce Manual The example pro gram uses the fo llowing instru ctions: Do While / Loop – This program instru ction is used to repeat a sequence of code as long as a test expression is t rue. Th e t est exp res sion i s validated befo re the loop is entered.
213 Tuning Procedures The drive uses closed loop contro llers to contro l the position and velocity Travel Limit of the attached motor. These position an d velocity co ntrollers and the associated tuning parameters are in effect when the drive is in velocity or pu lse mode and ha ve no effect when the drive is in Torque mode.
214 FM-3 Progr amming M odule Referen ce Manual Tuning Procedure Once the initial setup has been completed, you can run the system to determine if the level of tuning is ad equate for the application. Ther e ar e basicall y four level s of tuning for a dr ive.
215 T uni ng Pr oc edu r e s 3. Enter the inertia value calculated into the Inertia Ratio parameter. 4. Set the Line Voltage to the applied v oltage (default is 230 VAC). 5. Leave all other tuning parameters at the initial v alues. 6. Enable the drive and run the sys tem.
216 FM-3 Progr amming M odule Referen ce Manual Tuning Parameters Inertia Ratio Inertia Ratio specifies the load to motor inerti a rat io and has a ra nge of 0.0 to 50.0. A val ue of 1.0 specifies that load inertia equals the motor inerti a (1:1 load to motor inertia).
217 T uni ng Pr oc edu r e s Response The Resp onse ad justs th e velo city an d posi tion lo op ban dwidths with a range of 1 to 500 Hz. In general, it affects how quickly the drive will respon d to commands, load disturbances and velocity corrections.
218 FM-3 Progr amming M odule Referen ce Manual Friction parameter is less than the actual friction, velocity error will b e reduced b ut not eliminated. Feedforwards can be enabled in any op erati ng mode , however, there are certain modes in which they do not function.
219 T uni ng Pr oc edu r e s Initi al Test Setti ngs When running the tests o utlined in this section, the motor and driv e m ust be operational so you will need to enter starting values. If your application has less th an a 10:1 inertia mismatch, the default p arameter settings will be acceptable.
220 FM-3 Progr amming M odule Referen ce Manual Note If the f riction loadi ng of your system vari es when opera ting at const ant speed, due to a load or spring load that changes as th e mo tor rotates, use the lowest value m easured. 3. Repeat Step 1 using a vel ocity at least two times the low speed.
221 T uni ng Pr oc edu r e s Consider the followin g before determining the iner tia: • If your application allows a great deal of motor motio n without interference, it is recommended that you use a Preset Veloc ity to produce accurate acceler ation ramps.
222 FM-3 Progr amming M odule Referen ce Manual IR = Inertia Ratio R = ra mp in ms /kRPM Ta = (uns igned ) p ercent co ntinu ous tor que required dur ing acceleration r amping (0 - 300) Td = (uns igne.
223 T uni ng Pr oc edu r e s Moto r Drive Vm Percen t Contin uous/ volt Scal ed T orque Command Outp ut (def aul t) ) RPM /vo lt Scale d V elocity Comman d Output (def a ult)) NT -320 EN-204 4.30 30 600 MG-205 4. 77 30 600 MG-208 5.1 1 30 600 MG-316 3.
224 FM-3 Progr amming M odule Referen ce Manual.
225 Diagnostics and Troubleshooting Diagnostic Display The d i agnost ic se gment di spla y on the fron t of the drive shows drive s tatus, FM-3 modu le status, and fault co des. When a fault con dition occurs, the drive will di splay the fault code, overridi ng the statu s code.
226 FM-3 Progr amming M odule Referen ce Manual Fault Codes A numbe r of diagn ostic and f ault detection c ircu its are incor porated to protect the drive. Some faults, such as high DC bus and amplifier or motor over temper ature can be reset with the Reset button on the front of the drive or the Reset input functio n.
227 Diagnos tics and Troubleshoo ting Power Up T est Cycle Power Y es Power Up T st NVM Invalid Reset Button or Input Line Y es NVM Invalid Invalid Configur ation Reset Button or Input Line Y es Inval.
228 FM-3 Progr amming M odule Referen ce Manual Fault Descrip tion s Flash Invalid This fault indicates that the firmware check sum has failed. Use the T ools Prog ram Flash menu item f rom Po werTools to reprogram/ upgrade the fi rmware sto red in flas h memory.
229 Diagnos tics and Troubleshoo ting FM-3 Fault A 3 will be display ed in the segment display on the dr ive when the FM-3 module experiences a fault. See the table above for more information about the vario us faults .
230 FM-3 Progr amming M odule Referen ce Manual Encoder S t ate Certain encoder states and state transitio ns are inva lid and will cause the drive to report an encoder state fault. This is usually the re sult of noi sy encoder feedb ack caused by poor shielding.
231 Diagnos tics and Troubleshoo ting FM-3 Specific Fault Descrip tion s Figure 95 : FM-3 display is used to dis play drive and FM-3 faul ts Enc St Certain encoder states and state transitio ns are inva lid and will cause the drive to report an encoder state fault.
232 FM-3 Progr amming M odule Referen ce Manual Isr Ovr This fault is g enerated when a modu le flash memory pr oblem occurs. If pr oblem is persi stent, replace the FM-4 mod ule. Tr a j F l t This fault occurs when the drive has received trajectory data f rom the FM-3 modu le that indicates a problem.
233 Diagnos tics and Troubleshoo ting Mtr Tmp This fault is generated when the motor thermal switch is open due to motor over-temper ature or incorrect wiring. DvOvrTmp This fault is generat ed when the drive thermal switch is open due to drive over-tem perature.
234 FM-3 Progr amming M odule Referen ce Manual No Prog This fa ult will be displayed on initia l power-up indicating that no conf iguratio n has been downloaded to the FM-3 module. To clear the fault, download a valid configuratio n to the FM-3 mo dule.
235 Diagnos tics and Troubleshoo ting • Torque Co mmand = Percen t of continuo us torque Analog Output Scale units: • Velocity Feedback = RPM/volt • Torque Co mmand = Percen t of continuo us tor.
236 FM-3 Progr amming M odule Referen ce 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 signa ls do get shorted to GND, the drive will not be damaged because the circuitry is protected.
237 Diagnos tics and Troubleshoo ting Figur e 97: Diagnost ic Cable (DG NE) Diagr am.
238 FM-3 Progr amming M odule Referen ce Manual Drive F aults The Active Drive Faults dialog box is automati cally displayed whenever a fau l t occurs.
239 Diagnos tics and Troubleshoo ting The terms below appear in the list the of common probl ems you mig ht encounter when working with PowerTools so ftw a re alon g with th e error message displayed, the most likel y cause and solution. Assign means to set a value using an equation.
240 FM-3 Progr amming M odule Referen ce Manual Programming Error Messages These Red Dot Erro r messages occu r while you are working in the Program View.
241 Diagnos tics and Troubleshoo ting Error: A string va riable can only be assigned a quoted text string The Variable is string. It only accepts types cons isting of text strings. Err or: C an onl y co mp are (>,< ,et c) n umeri c re sult s This message occurs in conditional Expres sions (i .
242 FM-3 Progr amming M odule Referen ce Manual Error: Synt ax error encountered Parser Error Message. The Parser c an not underst and your text sequ ence. Error: T ext Strings are l imited to 12 character s... To change a N ame you assign a quoted te xt string to t hat name.
243 Diagnos tics and Troubleshoo ting Error: T he destin ation variab le's resolu tion is less than the resolutio n of the number You attempted to assign a number with a greater resolution o f decimal points than the variable will accept (i.e. index.
244 FM-3 Progr amming M odule Referen ce Manual Error: T he Select ion varia ble can o nly be assi gned a Selec tion value . The destination variable o nly accepts selection values. Selection values are f ixed unquoted text. The selection text must exactly matc h the available s elections of the Destination varia ble.
245 Diagnos tics and Troubleshoo ting Online Status Indicators Watch Window PowerTools Pro contains a diagnostic utility called the Watch Window. The Watch Window can be us ed while Power Tools Pro is runn ing and the PC is onl ine with t he FM-3 modul e.
246 FM-3 Progr amming M odule Referen ce Manual Figu re 100: Sele ct Driv e Para mete rs Dial og Box Once a parameter is added to the Watch Wind ow, its current value or state is constantly monitored. I f a parameter in the window changes valu e or state, it w ill change to a red color.
247 Diagnos tics and Troubleshoo ting User Level - The User Level setting is a filter for the parameters that are seen in the Select Drive Parameters list. If set to Easy, the p a rameter s u sed in mo st basic applications will be seen while the more advanced parameters are hi dde n.
248 FM-3 Progr amming M odule Referen ce Manual.
249 Specifications Power cons umption: 3W from dri ve power sup ply. I/O Supply Voltage: 10-3 0 VDC. Dimensions and Clearan ces Funct ion Electrical Charact eristics Inputs ON State V oltage 10-30 VDC ON State Current 2mA-6.5mA OFF State V oltage 0-3VDC OFF State Current 0-400µ A Outputs Max.
250 FM-3 Progr amming M odule Referen ce Manual AX4-CEN CDRO.
251 Specif ications Cable Diagrams.
252 FM-3 Progr amming M odule Referen ce Manual SNCE-XXX Cable SNCDD-001.5 Cable.
253 Specif ications SNCO-003 Cable SNCI-003 Cable.
254 FM-3 Progr amming M odule Referen ce Manual SNCLI-003 Cable.
255 Specif ications CMDX-XXX Cable Note Some CMDX cables may ha ve White/Yellow and Yell ow/White wires in place of the White /Orange and Oran ge/White shown in the fig ure above (pin s 6 and 21).
256 FM-3 Progr amming M odule Referen ce Manual CMDO-XXX Cable Note Some CMDO cables may ha ve White/Yellow and Yell ow/White wires in place of th e White/Orange and Oran ge/White shown in the fig ure above (pin s 6 and 21).
257 Specif ications 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.
258 FM-3 Progr amming M odule Referen ce Manual TIA-XXX Cable DDS-XXX Cable.
259 Specif ications TERM-H (Head) T erminator TERM-T (Tail) Termi nator Note See the "Multi-drop Commu nications" section for r esistor values.
260 FM-3 Progr amming M odule Referen ce Manual CMDS-XXX Cable CMMS-XXX Cable.
261 Specif ications CFCS-XXX Cable.
262 FM-3 Progr amming M odule Referen ce Manual CFCO-XXX Cab le.
263 Specif ications CFOS-XXX Cabl e.
264 FM-3 Progr amming M odule Referen ce Manual.
265 Glossary µs Microsecond, which is 0.0 00001 seco nds. A Amps. Amplifier Servo Drive. ARMS Amps Root Me a n Squa r ed (R MS). Axis The full system to contro l in a s ingle motor shaft. A single FM-3 mo dule with EN Dr ive can denote an axis. AWG American Wire Gauge.
266 FM-3 Progr amming M odule Referen ce Manual Configuration The user-cr eated application. It can b e saved as a disk file or downl oaded to con figure the FM-3. It includes all the user-defined setup, as signments and p rograms. CRC Cyclical Redundancy Check, the data transfer erro r checking mechanism.
267 Glossary Firmware The term f irmware r efers t o sof tware (i.e., comp u t er p rogr ams) that ar e sto red in some fix ed form, su ch as read-on ly memory (ROM). Flash Another ty pe of EEPROM. Flash File In the FM-3, this file loads the firmware into th e driv e and funct ion m odu le.
268 FM-3 Progr amming M odule Referen ce Manual Input Function See destination. A function (i.e., Stop, Preset ) that may be assigned to an input line. In FM- 3, the in put function is connected to th e action throu gh click and drag oper ations in PowerTools Software on the Assignm ent View .
269 Glossary NVM Non-Volatile Memory. NVM stores sp ecifically defined variables as the variables dynamically chang e. It is used to sto re changes throug h a power loss.
270 FM-3 Progr amming M odule Referen ce Manual PowerTools Pro PowerTools Pro is a Windows® b ased softwar e to interf ace with the EN or MDS drive with an attached FM-3 or FM-4 module. Radio Button Also known as the Option Button. In a dialog box, rad io buttons are small circles only one of which can be ch osen at a time.
271 Glossary Uploading The transfer of a complete set of parameters from a drive to an FM. User Units Ability of program to allow user to sp ecify which type of units will measure and specify motion and time. VAC Volts, Alternating Current . Vari able A labeled value that encompasses numeric bo o lean, input fu nction, and output fu nctions.
272 FM-3 Progr amming M odule Referen ce Manual.
273 Index Symbol s +/- Limit, 230 A Add Pro gram Bu tton, 1 31 Adding a Progr am, 131 Adding Ind e xes , 105 Analog Output, 236 Assign ment Polar ity, 75 B Book Mark , 116 Brake Operation and Wi ring .
274 FM-3 Progr amming M odule Referen ce Manual For Count/Next, 120 Formula, 123 G Gear Stop, 130 Gear.Initiate, 130 GoTo, 125 H High DC B us Fault , 229 Home.Initiate, 128 I If/Then/ Endif, 119 Index.CompoundInitiate, 127 Index.Initiate, 126 Installation N otes, 183 Introd uction, 1 Invalid C onfigurat ion, 229 J Jog.
275 Index S Safety Consideratio ns, vii Safety of Machinery , vii Safety Precautions, vii Setup, 31 Setup , Comm issio ning a nd Main tenan ce, vii status codes decimal poi nt, 225 Ready, 225 Ready to.
276 FM-3 Progr amming M odule Referen ce Manual.
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Since 1979 , the “Motion Mad e Easy” product s, designed and manufactured i n Minnesota U.S.A., are r enowned in the mo tion control industry f or their ease of use, reli ability and hi gh perform ance.
An important point after buying a device Emerson FM-3 (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought Emerson FM-3 yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data Emerson FM-3 - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Emerson FM-3 you will learn all the available features of the product, as well as information on its operation. The information that you get Emerson FM-3 will certainly help you make a decision on the purchase.
If you already are a holder of Emerson FM-3, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Emerson FM-3.
However, one of the most important roles played by the user manual is to help in solving problems with Emerson FM-3. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Emerson FM-3 along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
