Page 1 FM-3 Programming Module Reference Manual P/N 400508-01 Revision: B1 Date: March 26, 2009 © Control Techniques Drives, Inc. 2001-2009...
Page 3 Information furnished by Control Techniques Americas LLC (Control Techniques) is believed to be accurate and reliable. However, no responsibility is assumed by Control Techniques for its use. Control Techniques reserves the right to change the design or operation of the equipment described herein and any associated motion products without notice. Control Techniques also assumes no responsibility for any errors that may appear in this document.
Page 4 Control Techniques. The following are trademarks of Control Techniques and may not be reproduced in any fashion without written approval of Control Techniques: AXIMA, “Motion Made Easy.”...
Page 5: Customer Support
That is why we offer you so many ways to get the support you need. Whether it’s by phone, fax or modem, you can access Control Techniques support information 24 hours a day, seven days a week.
Page 6 Customer Service (Sales) (952) 995-8000 or (800) 893-2321 Email: customer.service@emersonct.com Authorized Control Techniques distributors may place orders directly with our Customer Service department. Contact the Customer Service department at this number for the distributor nearest you. 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®...
Page 7: Safety Instructions
The following related reference and installation manuals may be useful with your particular system. • Function Module Installation Manual (P/N 400506-03) • Epsilon Eb and EN Drives Reference Manual (P/N 400501-01) • Modular Drive System (MDS) Reference Manual (P/N 400525-01) • FM-3 and FM-4 Connectivity Reference Manual (P/N 400508-04)
Page 9: Safety Considerations
Safety Considerations Safety Precautions This product is intended for professional integration 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 injury.
Page 10 Isolation of control circuits The installer must ensure that the external control circuits are isolated from human contact by at least one layer of insulation rated for use at the applied AC supply voltage. viii...
Page 11: Table Of Contents
Table of Contents Customer Support ................. . iii Document Conventions .
Page 12 Output Lines View ................. 96 Analog Inputs View .
Page 13 Glossary ............239 Index .
Page 15: Introduction
Introduction The FM-3 module is a compact and rugged function module that attaches to the front of the 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 drive.
Page 16 FM-3 Programming Module Reference Manual Fastening Latch 3 Row by 12 Character Display Soft Keys Direction Arrow Keys Programming Module 100-Pin Connector Inputs 485 + Expanded I/O 485 - SHLD (not used at this time) Sync. Input Outputs MODEL FM-3...
Page 17: Operational Overview
The FM-3 module allows the user to set up 55 different Indexes, Jog functions and a Home. It also provides eight digital input lines and four digital output lines in addition to the four input and three output lines available on the drive.
Page 18: Keypad Interface
Keypad Interface The keypad and character display on the front of the FM-3 module provides navigation through a menu of common parameters and displays current functions. Navigation through the menu is accomplished with the six keys located below the display.
Page 19 After selecting a group using one of the soft keys, the FM-3 module will display a Parameter screen for that group. This screen could be either the first screen in the group or the last screen that was used in that group. The FM-3 module keeps track of the last Parameter screen viewed in each group and returns to that screen when returning come back to that group.
Page 20: How Motion Works
Online tab. A Home or Define Home is required to set the Absolute Position Valid so that any index to absolute position can work. The FM-3 module can home the motor to an external sensor, the motor’s encoder marker pulse, or to a sensor and then to the encoder marker pulse.
Page 21 Operational Overview Gear Reducer External Home Sensor NT Motor with Encoder Carriage Sensor Point Home Offset Distance Figure 6: Basic Home Function, Example The figure above show a basic home function using a ball screw. This example uses most of the setup features in the PowerTools Pro Home view.
Page 22 FM-3 Programming Module Reference Manual Marker Selecting Marker means the rising edge of the motor’s encoder marker channel is used to establish the reference position. Figure 8: Marker Home Reference Position Sensor then Marker Selecting Sensor then Marker means the reference position is established using the first marker rising edge after the device sees the rising edge of the Home Sensor input function.
Page 23 Operational Overview >800 µsec Sensor Marker Direction of Travel Figure 10: Sensor then Marker Home Reference Position Example 2 The Home Sensor must be “On” for at least 800 μsec to guarantee that it will be recognized. Sensor Min. On Time Sensor 800 µsec Figure 11:...
Page 24 FM-3 Programming Module Reference Manual Figure 12: Calculated Home Offset, Peak Velocity Not Reached If the Home Reference is detected after the axis has reached its peak velocity, the axis will decelerate to the precise offset position. Calculated Home Offset...
Page 25 Position. This is the most accurate and most common way to home. Gaer Recuder External Home Sensor Motor Figure 16: Home to Sensor and Marker, Example When the FM-3 module sees the Home Initiate, it accelerates the motor to the Home Velocity.
Page 26 FM-3 Programming Module Reference Manual The motor continues at that velocity until it first senses the Home Sensor input. It continues at the same velocity until the motor’s encoder marker channel is sensed. The rising edge of the motor’s encoder marker channel is used to establish the reference position.
Page 27: How Indexes Work
Operational Overview Figure 19: Home Sensor and Marker then Offset, Example When the device sees the rising edge of the Home Initiate function, it accelerates the motor to the Home Velocity. The motor continues at that velocity until it first senses the Home Sensor input. The motor continues on at the home velocity until the marker is activated.
Page 28 Absolute indexes are used in applications where the motor must travel to a specific position, regardless of where the motor is when the index is initiated. The FM-3 module calculates the distance required to move to the specified position from the current position.
Page 29 In the example above, the motor starts at 1 rev, travels a distance of 2 revs and stops at 3 revs. If the same index is initiated a second time, the FM-3 module would move the motor another 2 revs to a position of 5 revs. If initiated a third time, the...
Page 30 This can be set to a automatic refresh using the Analog Input view Posn Tracker Cont and Posn Tracker Once Indexes - FM-3 Only Posn Tracker Cont and Posn Tracker Once are indexes which expect their position values to be dynamically changed while executing.
Page 31: How Communications Work
Before attempting to upload or download a configuration file using PowerTool Pro, the software must be configured to the correct communication settings for the intended communication connection. The FM-3, FM-3DN and FM-3PB support a serial communication connection, either RS-232 or RS-485. The FM-3E supports both serial and Ethernet communication connections.
Page 32 Downloading Downloading is the process of sending the configuration created with PowerTools Pro from the PC to the FM-3 module. Changes made in PowerTools Pro will not take effect until the information has been downloaded or the Update to RAM button has been clicked.
Page 33 Operational Overview Figure 28: Download to Device ID 1 Dialog Box Select the device to download to and click OK. Change Path Connection This function allows the user to change the drive and Ip address/Com port used for download and upload. It is used when the user has already selected one Ip address.Com port and wishes to change to another.
Page 34 Uploading When uploading from a FM-3 module, the values that were last downloaded are uploaded and put into a PowerTools Pro configuration file. At the completion of the upload, the user will be asked if they wish to upload the NVM values. This dialog box is shown below.
Page 35 Operational Overview Update – This option will upload the current NVM parameter values from the FM-3 module and enter them into the user configuration (PowerTools Pro file). Once the NVM values have been stored in the file, the file is fully downloaded.
Page 36 FM-3 Programming Module Reference Manual If the user modifies parameters, and disconnects, the update button will be disabled, and the changes will not be sent. Options/Preferences/Ptools Operation Communications Tab This tab allows the user to set-up the serial communication baud rate. The drive baud rate and PowerTools Pro baud rate must match, default drive baud rate = 19200.
Page 37 Overwrite – Reset the NVM configuration. When this option is selected the “Overwrite” function will default on every download to the module. This function will overwrite the entire FM-3 configuration including user defined NVM parameters as set in the NVM setup area of PowerTools Pro.
Page 38 The Motor DDF tab controls which .ddf files PowerTools Pro will use when working in the configuration file. The standard ddf files contain a list of motors that can be purchased from Control Techniques and their parameters. This tab gives the advanced user the capability to create their own standard motor ddf file.
Page 39: Secure Downloading
Operational Overview Standard Motor DDF Name The name of the standard motor ddf file is entered in the text box, the information in this file will be used to setup the configuration file, the default is stdmotor.ddf. User Motor DDF Name When a custom motor is created this is the name of the motor ddf file where the information is stored, default is motor.ddf.
Page 40: Brake Operation
FM-3 Programming Module Reference Manual A dialog box will then open asking the user to select the secure file that they wish to download. Select the secure file that was just saved, then click Open. This will download the secure file to the target device.
Page 41: How Data Capture Works
For Data Capture, the update rate for EN drives is 100 usec. For MDS drive modules the update rate is 100 usec for switch- ing frequency of 10 kHz and is 200 usec for 5 kHz. The FM-3 module passes data to the drive at the user selectable trajec- tory update rate of 800, 1200 or 1600 usec.
Page 42 FM-3 Programming Module Reference Manual...
Page 43: Setting Up Parameters
Motor Velocity Group Velocity Command The Velocity Command (VelCommand) is the velocity that the FM-3 module is commanding the motor to run at. This command is generated by the drive velocity control loop and position loop. It is displayed in user units.
Page 44 This parameter shows the lowest measured time difference (in microseconds) between the Trajectory Update Rate and the time taken to process the control loop since the last reset. Certain features in the FM-3 require more time to process (i.e. PLS, Capture, Compound Indexes), and therefore will cause lower limits.
Page 45: Information Tab
FM-3 module. Module Information Group Firmware Part Number Displays the part number of the FM-3 firmware. Firmware Revision Displays the revision of the firmware in the FM-3 module. Serial Number Displays the serial number of the FM-3 module.
Page 46: Graph View
Power Tools data set to match the module's data structure. In this way Power Tools can support different releases of the FM-3 Flash files. For the most part the user does not need to be concerned over interface revisions.
Page 47 Setting Up Parameters Automatically Re-trigger and Plot Check Box Select the check box and the Automatically Re-trigger and Plot tells PowerTools to monitor the graph state for the triggered condition. When this condition occurs, it automatically initiates the UploadPlot command, waits for a brief time then initiates the Run button to repeat the cycle.
Page 48: Setup View
Figure 35: Setup View-FM-3E Identification Group The identification group consists of the Device Name and the Target Drive Address for all non-Ethernet FM-3/4 modules. The Ethernet modules will also have IP Address, Subnet and Gateway. Name This is a 12-character alpha/numeric user-configured name for this axis. Enter this name for the device currently being set up.
Page 49 Subnet, the message must go through this gateway to reach it’s destination. For a detailed description of the Gateway address refer to the Industrial Ethernet Overview section in the FM-3 and FM-4 Connectivity Modules Reference Manual (P/N 400508-04). This parameter is configured via the LCD keypad display or through PowerTools Pro.
Page 50 Messages are Modbus data, DeviceNet data, Keypad/Display information, and are only processed if a message is waiting. If no device is querying data from the FM-3 or sending data to the FM-3, then messages do not take up any time.
Page 51: Motor View
Use Motor Data From .ddf File Check box When selecting a motor for use with the drive and FM-3 module, the user has two basic options: Use a motor that already exists in the standard motor definition file (StdMotor.ddf) or custom motor definition file...
Page 52 FM-3 Programming Module Reference Manual Create a custom motor that has not been used before. When selecting option 1 from above (use an existing motor), the user simply selects one of the motors from the Motor Type list at the top of the Motor view. Once the user selects a motor from the Motor Type list, the data for that motor is read from the pertinent .ddf file and then is displayed in the Motor Parameters column on the Motor view (see Figure 36).
Page 53 Setting Up Parameters Phase Resistance Specifies the phase-to-phase resistance of the motor. This value is determined by measuring the resistance between any two motor stator terminals with an ohm meter. The range is.1 to 50 ohms. Phase Inductance Specifies the phase-to-phase inductance of the motor. Max Operating Speed This parameter specifies the maximum speed of the motor when used with a variable speed drive to achieve velocities over the rated base speed of the motor.
Page 54 The values in the Values from Drive column are not saved as part of the configuration file. To save these values, the user must use the “Apply to Config” button to save them. This column is only functional when online with the drive/FM-3 module. When offline, the values in the Values from Drive column will all read zero.
Page 55 Setting Up Parameters Figure 37: Auto-Tune Dialog Box - Auto-Tune Mode 3 After the Auto-Tune Mode has been selected, click Proceed, to start the Auto-Tune. When the Auto-Tune is completed the results will be in the Values from Drive column on the Motor view. Save .ddf Values Button Once the user has entered the data for the motor they are using, they may or may not wish to save the motor data to the Motor.ddf file so it can be easily recalled at a later time.
Page 56 FM-3 Programming Module Reference Manual Figure 38: The User Defined Motor Name Conflict Dialog Box The User Defined Motor Name Conflict dialog box presents the user with four options on how to proceed with saving the motor data. Those four options are: Create new motor entry In .ddf File...
Page 57: User Units View
When the number of decimal places are changed in an existing configuration file the Index accel and decel parameters need to be checked. Scaling A Characteristic Distance and Length must be established to allow the FM-3 module to scale user units back to actual motor revolutions. This scaling factor is as follows:...
Page 58 If a configuration is downloaded to the FM-3 with a red background on the “User Unit Limited Speed”, the drive will obtain a trajectory fault at speeds near this velocity.
Page 59: Master Units View
Setting Up Parameters Separate Distance Units Example: A user has an application using a leadscrew with a 0.5"/turn lead. The user wants to have Distance Units of Inches, but wants Velocity Units of Feet so motion can be programmed in feet/minute. Distance Units Name —...
Page 60 Select Drive to use the 44-pin Command connector on the front of the drive. Select Module to use the Sync input connector on the FM-3 module. FM-3E Only, select Virtual Master.Counts to use the Virtual Master as the Master Source.
Page 61 Output Source determines which signal will be sent to the Sync Output connector on the FM-3 module. If Motor Encoder (default) is selected, then the encoder signals from the motor that the FM-3/drive is controlling will be sent out the FM-3 Sync Output connector.
Page 62: Virtual Master View - Fm-3E Only
Filters inherently introduce phase shift (or delay) in the followers response to the master position, velocity and acceleration. The FM-3 provides Feedforward compensation to correct for these delays introduced by the filter. The user may set the number of filter samples to be used to “smooth” the master encoder velocity. The more samples used by the filter, the smoother the master velocity signal, however, the more positional delay introduced by the filter.
Page 63 Setting Up Parameters It can also be transmitted to other drives through the Sync Encoder Output connector and into their Master Sync Input connector. Figure 41: Virtual Master View - FM-3E Only Virtual Master View Enabled Enable Virtual Master Check Box Enable Virtual Master check box (VirtualMaster.VirtualMasterEnable) by default is clear.
Page 64: Position View
FM-3 Programming Module Reference Manual Virtual Master Conversion Ratio Group Scaling Converts the user units distance into virtual counts. VirtCnts The numerator (top value of the scaling fraction) is the VirtualMaster.CharacteristicLength. The characteristic length is the number of virtual counts that will be generated per the distance, in user units, defined by the denominator (bottom number of the scaling fraction).
Page 65 Setting Up Parameters Figure 42: Position View Settings Group Define Home Position This is the value to which the position command will be set when the Define Home destination is activated. This is used in applications which do not use a home routine, but require a known reference point. The units are defined on the User Units View.
Page 66 Units Decimal Places parameter on the User Units view in the PowerTools Pro software. If an absolute index is used with a non-zero rotary rollover point, the FM-3 module will calculate the shortest path to its destination and move in the required direction.
Page 67: Velocity View
Setting Up Parameters Motor Position Group Position Command This is the commanded position in user units generated by the FM-3 module. Position Feedback This is the feedback position of the motor in user units. Following Error The Following Error is the difference (in user units) between the Position Command and the Position Feedback. It is positive when the Position Command is greater than the Position Feedback.
Page 68: Ramps View
If online, this view will show the limits group and the velocity group. Velocity Group Velocity Command The Velocity Command is the actual command generated by the FM-3 module to the motor in user units. Velocity Feedback This parameter is the actual feedback motor velocity in user units.
Page 69 Setting Up Parameters Settings Group Acceleration Type The Acceleration Type list box display the various acceleration types: 5/8 S-Curve, 1/4 S-Curve, Linear, and S-Curve. This is used to select the acceleration/deceleration type for all motion (homes, jogs and indexes). The “S-Curve” ramps offer the smoothest motion, but lead to higher peak acceleration/deceleration rates.
Page 70 FM-3 Programming Module Reference Manual = Index 0 = Index 1 1250 Compound Index Blended Index Compound Index Blended Index User Ramps User Ramps Auto Ramps Auto Ramps Index.1.Accel specified by user is used to decelerate from Index.0.Vel, to Index.1.Vel, but overshoots since ramp is not aggressive enough to reach Index.1.Vel within Index.1.Dist of 3 Revs.
Page 71 Setting Up Parameters Distance Velocity Accel Decel (Revs) (RPM) (RPM/sec) (RPM/sec) Index 0 1000 1000 Index 1 1250 2000 2000 = Index 0 = Index 1 1250 Compound Index Blended Index Compound Index Blended Index User Ramps User Ramps Auto Ramps Auto Ramps Index.0.Accel specified by user is used to accelerate up to Index.0.Vel.
Page 72: Torque View
FM-3 Programming Module Reference Manual example, if the motor is running at 50 revs/second and feedhold is activated with 2 seconds specified in the FeedholdDecelTime parameter, then the motor will actually slow and stop in 2 seconds as measured time (on a time/velocity profile) goes from 100% to 0%.
Page 73: Distance Recovery View - Fm-3E Only
Setting Up Parameters Distance Recovery View - FM-3E Only When initiating gear or cam using the Master Axis to provide synchronization, distance is lost as we must follow the acceleration limitations. This distance can be recovered when at velocity by adding a distance recovery index on top of the gear operation or cam.
Page 74 FM-3 Programming Module Reference Manual Figure 49: Tuning View Load Group Inertia Ratio Inertia Ratio specifies the load to motor inertia ratio and has a range of 0.0 to 50.0. If the exact inertia is unknown, a conservative approximate value should be used. If you enter an inertia value higher than the actual inertia, the resultant motor response will tend to be more oscillatory.
Page 75: Faults View
Setting Up Parameters Enable Feedforwards Check Box When feedforwards are enabled, the accuracy of the Inertia and Friction parameters is very important. If the Inertia parameter is larger than the actual inertia, the result could be a significant overshoot during ramping. If the Inertia parameter is smaller than the actual inertia, following error during ramping will be reduced but not eliminated.
Page 76 These parameters will be active when online with the drive. Power Up Count This parameter shows the numbers of times the drive that the FM-3 is attached to has been powered up since the last reset be the factory. Power Up Time...
Page 77 Setting Up Parameters Total Power Up This parameter shows the total time that the drive has been powered up since reset by the factory. Fault Log Tab The Fault Log tab is visible when online and consists of a list of the ten most recent faults detected by the drive or module. These are saved in non-volatile memory to be preserved during power down.
Page 78 FM-3 Programming Module Reference Manual Fault Counts Tab Figure 53: Fault View - Fault Counts Tab The Fault Counts tab is visible when online and consists of a list of all supported faults and the number of times each fault has been detected.
Page 79: Setup Nvm View
Setting Up Parameters Drive Fault Log Tab Figure 54: Faults View - Drive Fault Log Tab The Drive Fault Log tab is visible when online and consists of a list of the ten most recent faults detected by the drive. These are saved in the drive’s non-volatile memory to be preserved during power cycles.
Page 80: Devices / Vars Group
NVM is given to the module whenever a parameter on the list changes value (via a program or a communications network). Currently the NVM in the FM-3 is rated at a minimum, 1 million writes.
Page 81 (MasterPosnFeedback). The FM-3E can also use the real time clock from the drive’s built- in microprocessor (FreeRunTime). The term motor axis refers to the motor being controlled by the FM-3/drive combination. The source list box is used to select the source for the individual PLS.
Page 82: Timers View - Fm-3E Only
FM-3 Programming Module Reference Manual PLS.#.Status will be active if:PLS.#.OnPosn < Feedback Position ≤ PLS.#.OffPosn If using negative values for your OnPosn and OffPosn, the most negative value should go in the OnPosn parameter, and the least negative value should go in the OffPosn.
Page 83 Setting Up Parameters There are several different types of Timers available to the user based on the task they are trying to achieve. Figure 57: Timers View - FM-3E Only Number of Timers This parameter determines the number of Timer objects that are available in the configuration. Use the spin control to change the number of Timers from 1 to 8.
Page 84 FM-3 Programming Module Reference Manual In the case of the Edge type timer, once the rising-edge occurs on the Input, it doesn't matter what happens to the state of the Input after that. The Output will always turn ON when the Preset Time is reached (unless the Reset activates before the Preset Time is reached).
Page 85 Setting Up Parameters Note that if the Input is already ON when the Reset activates, the Output will not automatically activate at that point. The timer controller must see a rising edge on the Input to activate the Output. Figure 60: Edge Off Timer - Timing Diagram Level OFF Timer With this type of timer, when the Input of the timer activates, the Output turns ON automatically.
Page 86 FM-3 Programming Module Reference Manual being ON reaches the Preset time, the Output turns ON. Figure 6 below shows an example timing diagram of the Cumulative On Timer. Figure 62: Cumulative ON Timer, No Reset - Timing Diagram Additionally, a Reset signal can be used to clear the cumulative timer and restart it at zero. The figure below shows an example of this.
Page 87 Setting Up Parameters the Output of the timer turns OFF. If the Input turns ON again before the Preset time is reached, the clock resets to zero and waits again for the Input to turn OFF before resuming the count again. Figure 64: Cumulative OFF Timer - Timing Diagram Additionally, a Reset signal can be used to clear the cumulative timer and restart it at zero.
Page 88 FM-3 Programming Module Reference Manual reaches Preset time, the Output turns ON. The Output will remain ON until the Timer Reset is activated. If a rising edge is seen on the Input while the Output is ON, it will be ignored and the Elapsed Time will NOT be reset.
Page 89 Setting Up Parameters However, if you wanted to hold that same output active for ten revolutions of the Master Encoder instead of ten seconds, you set the Timebase to Synchronized. This means that you are using the master encoder position to control the duration of the Timer rather than actual Time.
Page 90 FM-3 Programming Module Reference Manual When the TimerEnable is deactivated, all output events associated with that Timer object will also deactivate and Elapsed Time will be set to zero. All timer types use the Enable even though it is not shown in the individual timing diagrams. See examples of how TimerEnable affects timer functionality in Figure 77 and Figure 78.
Page 91: Variables View
Setting Up Parameters Timer.#.TimerOutput The Timer Output state is controlled by the Timer Input, the Timer Type, and the other configuration settings of the Timer object. See the various timing diagrams in Figures 2 through 10 to see how Timer Output functions. The Timer Output can be assigned to multiple Destinations on the Assignments view just as any other Output Event.
Page 92 User variables are all of a Global type, meaning that they can be accessed from any program. Online Tab (not shown) While online with the FM-3, an online tab will be shown on the lower half of the User Variables view. This online tab will show the current value of each of the user variables.
Page 93: Bits View
Setting Up Parameters Bits View Bits act just like Variables except that they allow the user to store bit level parameters rather than 32-bit parameters. The user may customize each Bit by giving it a Name and an Initial Value. The Name for each bit may be up to 12 characters in length, and must start in an alpha character (non-numeric character).
Page 94 When using different communications protocols (i.e. DeviceNet, Profibus, Modbus), it is often desirable to access groups of Bits in a single parameter, rather than having to access them individually. In the FM-3 module it is possible to access 32 Bits in a single parameter.
Page 95 Setting Up Parameters FM-3/4 Write Network Master Read Mask Value Written data is AND’ed with the Mask and then written into 32-bit Value. Read data is read directly from the 32-bit Value and bypasses the Mask. Figure 74: User Bits Read/Write Process...
Page 96: Packed Bits - Fm-3E Only
FM-3 Programming Module Reference Manual Figure 75: Bits Mask View To configure the mask in a user program, the parameter named BitRegisiter.#.ValueMask is written to. The mask can be written to using Hexadecimal based values or decimal based values. To write a hexadecimal value to the parameter, the hex value must be preceded with the characters "0x".
Page 97 Setting Up Parameters a user program, Bit0 of the Control Word in the Figure 84 below would not automatically change to 1. Bit0 will only be 1 if the master device sets that bit when writing to the Control Word. ControlWord.0 Value Bit0...
Page 98 FM-3 Programming Module Reference Manual Packed Bits Control Words View Control Words handle data being written to the user defined drive bit-level parameters. The user configures the Control Word(s) by dragging-and-dropping the desired bit-level parameters they wish to write into the Control Word mapping. Figure 86 below shows the Packed Bits Control Words view onto which the user has dragged several motion initiate parameters.
Page 99 Setting Up Parameters Figure 86 above) should become enabled. Simply click the Add button and the highlighted parameter will be assigned to the highlighted bit on the Control Word. To delete parameters from the Control Word, simply drag and drop the parameter off the control word (see explanation above), or highlight the desired parameter to delete, and click the Delete button on the right side of the view.
Page 100 FM-3 Programming Module Reference Manual Using Pack Bits Control Words Once the Control Word(s) have been configured by the user, they can be utilized by fieldbus communications (i.e. Modbus, EtherNet I/P, Profibus, DeviceNet, etc.) or within a user program. Figure 88 shows an example in which the user will write to the Control Word 0 and 1 via Ethernet I/P.
Page 101 Setting Up Parameters Word mapping. Figure 89 below shows the Packed Bits Status Words view onto which the user has dragged several status parameters. Figure 81: Pack Bits Status Words View Enable Packed Bits Control and Status Words In order to use the Pack Bits Control Word and Status Word mapping, the function must be enabled by activating the Enable Packed Bits Control and Status Words checkbox.
Page 102 FM-3 Programming Module Reference Manual Online Status Tab (Available Online Only) While online with the device, the user can monitor the Status Word value (see Figure 90). The data is displayed in binary form for each individual bit of the Status Word(s), as well as hexidecimal and decimal format for each Status Word.
Page 103: I/O Setup Group
These functions directly correspond to any input or output line on the drive or the FM-3 module. External controllers, such as a PLC or other motion controllers, may be connected to affect or monitor the device’s operation.
Page 104 FM-3 Programming Module Reference Manual To make an assignment in the FM-3 module occur, you must tie a source to a destination. Any source can be tied to any destination to create the desired system operation. Creating An Assignment: Various methods can be used to tie a source (such as DriveInput.1) to a destination, such as Index.0.Initiate.
Page 105 Setting Up Parameters Drag and Drop Method Figure 85: Tying a Source to a Destination Assignment Polarity The active state of an assignment can be programmed to be Active Off, Active On, or Custom using PowerTools Pro. Making an assignment “Active On” means that the destination will be active when the source it is assigned to becomes active, and is inactive when the source is inactive.
Page 106: Selector View
Certain assignments (Sources or Destinations) automatically generate position capture data internally for greater performance and accuracy. This captured data is used by the FM-3 module, but is not directly available to the user. Following is a list of assignments that automatically generate or use captured data.
Page 107 Setting Up Parameters Figure 86: Selector View The selector allows conservation of the number of input lines by using a binary input conversion to decimal. The binary select lines are set up by assigning sources to the Selector.Select destinations on the Assignments view. In most cases, hardware inputs are assigned to the Selector.Select functions (see Figure 87).
Page 108 FM-3 Programming Module Reference Manual Figure 87: Assignment View For example, if we entered 3 for the number of Selector Input Destinations, we would have 8 selection lines (Selector.Selection0 through Selector.Selection7). The Selector.Selection number that is activated is determined by the status of the Selector.Select lines when the Selector.Selector Initiate bit is activated.
Page 109: Input Lines View
Setting Up Parameters Total Binary Value = 0 + 2 + 1 Total Binary Value = 3 Therefore, Selector.Selection3 would activate. The Selector.Select lines can change without any action until the Selector.SelectorInitiate destination is activated. Selector.Selection sources can be tied to any destination in the Assignments view. Figure 87 shows the four selection lines being tied to Index 0 through Index 3 initiates.
Page 110: Output Lines View
Analog Inputs View The drive has one Analog input channel. The FM-3 module is able to use the analog input located on the drive. The analog input accepts a +10 to -10 V signal. The drive has a 12-bit over sampled to 14-bit analog to digital converter (A/D), which is used to transform the analog voltage to a usable parameter in the FM-3 module.
Page 111 Setting Up Parameters Figure 91: Analog Inputs View Enable Channel Check Box By default, the analog input channel is not enabled meaning that the drive is not reading the A/D value read by the analog circuit. If the check box is clear, the channel is not enabled and the configuration parameters for the analog input are unavailable and therefore have no effect.
Page 112: Analog Outputs View
This parameter is visible while online. This is the results of the analog value scaled to the user unit value. Read Max/Min Voltage Settings This button is not functional for the FM-3 module. Analog Outputs View The drive has two 10-bit Analog Outputs that may be used for diagnostics, monitoring or control purposes. These outputs are referred to as Channel 1 and Channel 2.
Page 113 Setting Up Parameters Figure 92: Analog Outputs View Enable Channel Check Box By default, the analog output channels are not enabled meaning that a value is not being sent to the analog circuit. When the channel is disabled (check box is clear), the configuration parameters for that analog output are unavailable and therefore have no effect.
Page 114: Jog View
FM-3 Programming Module Reference Manual Minimum Value The analog output is a linear interpolation of the selected module variable between the minimum and maximum specified end points. Each end point is specified as the user value and the corresponding output value at that point. The number of decimal places for both values is taken from the selected module variable.
Page 115 Setting Up Parameters Jog Name This is a descriptive character string which can be assigned to the specific jog. Giving a name to a jog can make the motion setup easier to follow. Time Base This list box allows the user to select between a jog that is based on time (Realtime) as defined by user units, normally in seconds, or a time based on Master position via an external encoder (Synchronized) set in the Master Units View.
Page 116 FM-3 Programming Module Reference Manual Jog.MinusActivate When this destination is activated, jogging motion will begin in the negative direction. The jog velocity is determined by which jog (Jog0 or Jog1) is active or not. A jog stops when this destination is deactivated. If the jog velocity is negative, Jog.MinusActivate will cause the motor to jog in the positive direction.
Page 117 Setting Up Parameters Figure 95: Jog Select Details If the Jog direction is reversed, the Jog.#.Decel value 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. Note The Jog destinations cannot be initiated when any other motion type (homing, indexing, or programs) is in progress.
Page 118: Home View
FM-3 Programming Module Reference Manual Home View The Home is used in applications in which the axis must be precisely aligned with some part of the machine. The Home is initiated with the Home.#.Initiate Destination or from a program. Figure 96:...
Page 119 Setting Up Parameters If on sensor... Group These radio buttons determine how the system reacts if the Home.#.SensorTrigger is already active when the home is initiated. ’Back off before homing’ Radio Button If this radio button is selected, the drive will back off the sensor before beginning the home. It does this by moving the direction opposite to that specified by the sign of the home velocity.
Page 120 FM-3 Programming Module Reference Manual Below is a diagram of a home using the "Back off before homing" radio box, a Home Reference of "Sensor", and using a "Calculated Offset". Home Sensor Input Velocity Back off Sensor Move Time Start of Normal...
Page 121 Setting Up Parameters Home.#.LimitDistHit This source is activated when the home reference is not found before the Home Limit Distance is traveled. It will remain active until the home is initiated again. Destinations Home.#.Initiate The Home.#.Initiate destination is used to initiate the home function. The Home 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 destination is active or if a travel limit is active.
Page 122: Index View
FM-3 Programming Module Reference Manual Index View An index is a complete motion sequence that moves the motor a specific incremental distance or to an absolute position. The index is initiated with the Index.#.Initiate destination or from a program. Figure 98:...
Page 123 A Timed Index allows the user to specify the amount of time in which to perform an index rather than specifying the Velocity, Acceleration, and Deceleration. The processor in the FM-3 will automatically calculate the necessary velocity, accel, and decel in order to achieve the programmed distance in the specified time. A Timed Index can not be compounded into or out of.
Page 124 FM-3 Programming Module Reference Manual Deceleration. When the Time check box is enabled, these parameters automatically become maximums for use in the calculations. Figure 99: Time Check Box Enabled If the values for Max.Velocity, Max.Acceleration, and Max.Deceleration are such that the distance cannot be covered in the specified time, the Index.ProfileLimited flag will activate when the index is initiated, indicating the index cannot be...
Page 125 Setting Up Parameters Max Velocity Max Decel Max Accel Trapezoidal Move Index.ProfileLimited activates for this profile Triangle Move Time Figure 100: Timed Index Profiles Enable Index PLS This check box enables (when checked) or disables the Index PLS function. An Index PLS is similar to a global PLS (explained in the PLS View section), but is incremental in nature. The Index PLS has On and Off points just like a global PLS, but the On and Off points are specified as an incremental distance from the start of the index, instead of absolute positions.
Page 126 FM-3 Programming Module Reference Manual Registration Tab Parameters The following parameters are only used if Registration is selected as the Index Type. ’Analog’ or ’Sensor’ Radio Buttons Select one of these radio buttons to determine what signal will be used as your registration trigger.
Page 127 Setting Up Parameters If the Registration Offset distance is in the opposite direction from the move, or is so short that the motor cannot stop in the specified distance at the programmed deceleration rate, the motor will decelerate with the programmed ramp, and then back- up to the specified position (registration point + the Registration Offset).
Page 128 FM-3 Programming Module Reference Manual Index.#.Initiate The Index.#.Initiate destination is used to initiate the specific index. 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 destination or if a travel limit is active.
Page 129: Gearing View
Setting Up Parameters Gearing View Figure 101: Gearing View - FM-3, FM-3DN, and FM-3PB Figure 102: Gearing View - FM-3E Use Scale Check Box - FM-3E Only Select this check box (Gear.UseScaleEnable) to enable the Scaling feature and disable Gear Ratio. Scaling allows the user to use irrational ratios such as 1.0/7.0 that were not possible with the single parameter ratio (Gear.Ratio).
Page 130 FM-3 Programming Module Reference Manual By default, gearing does not use acceleration or deceleration ramps with respect to the master encoder. This means that once gearing is activated, peak torque is available to try to achieve the specified gear ratio. Therefore, if the master axis is already in motion when gearing is activated, the control loop will attempt to accelerate the motor to the programmed ratio within one update (800µsec <...
Page 131: Torque Mode View - Fm-3E Only
Setting Up Parameters The GearRatio can be changed on the fly (while in motion), but acceleration or deceleration must be enabled to use ramps to achieve the new ratio. If gearing accel and/or decel ramps are not enabled, the motor will attempt to achieve the new ratio in one trajectory update (800<t<16000 microseconds).
Page 132: Stopping Motion
FM-3 Programming Module Reference Manual Torque Mode Settings Group Torque Command This parameter (TorqueMode.TorqueCommand) value is the torque level that will be applied when Torque mode is activated. Peak Torque This is a read only parameter displays the peak torque available from the selected drive and motor combination.
Page 133: Network Group
The MotionStop as explained above can also be initiated from an Assignment. MotionStop can be found in the Ramps group of Destinations. Network Group For information on the DeviceNet, Ethernet and Profibus Views, please refer to the FM-3 and FM-4 Connectivity Reference Manual (P/N 400508-04).
Page 134: Modbus View
FM-3 Programming Module Reference Manual Modbus View The Modbus View or Modbus RTU/TCP View is used to assign Modbus addresses to individual parameters. By selecting Modbus or Modbus RTU/TCP in the Hierarchy Tree, the Modbus or Modbus RTU/TCP View will appear on the right.
Page 135 An external device such as a Human Machine Interface (HMI) or PLC can be used to monitor or edit individual module parameters. The FM-3 module and drives use a 32-bit Modbus RTU communications protocol. In order to view or modify a parameter, a Modbus address must be assigned to the specific parameter. To do this, locate the parameter you wish to read/write to or from in the variables list in the middle of the view.
Page 136: Devicenet View - Fm-3Dn Only
400001 in this software is equal to 40001 in Control Techniques Modbus RTU. DeviceNet View - FM-3DN Only For those modules that have the DeviceNet option, please refer to the FM-3 and FM-4 Connectivity Reference Manual, P/N 400508-04, which can be found on the Control Techniques MME Power CD.
Page 137: Programming
Multiple programs can be created using PowerTools Pro software and stored in the FM-3. The FM-3 module is capable of storing up to 55 indexes, 99 motion programs, and a maximum of 1024 program steps in the FM-3 Flash Memory. The amount of available Flash Memory determines how many programs, program steps, indexes, etc.
Page 138 This list will easily allow you to find any of the available pre-defined variables in the FM-3. The available parameters shown in the window depends on the selected Program User Level.
Page 139: Program Instruction Types
Programming Program Where Am I? Clicking on this button will show the line of the program that is currently being executed. A blue arrow will point to the line in the program that was executing when the button was clicked. The arrow will not continue to follow program flow. If the program is not currently running, then the arrow will point to the top of the program, or to the last line of the program that was processed before it was stopped.
Page 140 FM-3 Programming Module Reference Manual Endif If (ModuleInput.3=ON) Then ‘Jog- when ModuleInput.3=ON Jog.0.MinusInitiate ‘Vel=20in/s Wait For ModuleInput.3=OFF ‘Stop when the input goes OFF Jog.Stop ‘Decelerate to a stop Endif Else This program flow instruction is used in conjunction with the If/Then/Endif instruction. If the If/Then test condition evaluates to true the code after the If/Then and before the Else is executed.
Page 141 Programming ‘ModuleInput.2=OFF. Index.1.Initiate ‘Incremental,Dist=5.250in,Vel=10.0in/s Dwell For Time 1.000 ‘seconds Loop Do While (TRUE) ‘Repeat until the program is halted Index.1.Initiate ‘Incremental,Dist=5.250in,Vel=10.0in/s Dwell For Time 1.000 ‘seconds Loop Wait For This program flow instruction is used to halt program execution until an expression becomes true. Once the expression becomes true the program continues on with the next line of code.
Page 142 Formula This program instruction can be used to enter a formula or assignment into a program. All FM-3 parameters are available for use in a formula. They may be dragged and dropped into a formula, but the program User Level will determine how many appear for dragging and dropping (see the section on User Level in the Setting Up Parameters chapter).
Page 143 Programming var.var2 = var.var0 bitor var.var1 For example: if var.var0 = 1000 and var.var1 = -10000 var.var0 = 0000000000000000000001111101000b var.var1 = 1111111111111111101100011110000b var.var2 = 1111111111111111101101111111000b Label: The Label: instruction is used in conjunction with the GoTo instruction to cause program flow to transfer to a specified location within a program.
Page 144 FM-3 Programming Module Reference Manual This trig function can be used in formulas from within a program. Example: var.var0 = Sin(var.var1). Returns the trigonometric sine in degrees. Sin(x) x is in degrees and accurate to 6 decimal places. This trig function can be used in formulas from within a program. Example: var.var0 =Tan(var.var1). Returns the trigonometric tangent in degrees.
Page 145 Programming Index.0.Initiate ‘Incremetal,Dist=25.000in,Vel=25in/s Dwell For Time 1.000 ‘Seconds Index.1.Initiate ‘Incremental,Dist=15.000in,Vel=25in/s Dwell For Time 0.500 ‘Seconds Loop Dwell for Master Dist This motion instruction is used to pause program execution for a precise change in distance on the master encoder signal. This is typically used in synchronized motion applications.
Page 146 FM-3 Programming Module Reference Manual Example: Gear.Initiate Wait for DriveInput.2=ON Gear.Stop Home.Initiate This program instruction is used to initiate the home. A comment is automatically inserted after the Home.Initiate instruction which shows key data about the particular home. The comment starts with the apostrophe " character.
Page 147 Programming Examples: Complex Velocity Profile Index 0 Index 1 Index 2 Time Index.0.CompoundInitiate ‘Incremental,Dist=5.000in,Vel=50in/s Index.1.CompoundInitiate ‘Incremental,Dist=20.000in,Vel=75in/s Index.2.Initiate ‘Incremental,Dist=10.000in,Vel=30in/s Wait For Index.AnyCommandComplete Figure 108: Index Velocity Profile Complex Velocity Profile Drive Output 3 ON Drive Output 2 Drive Output 1 Index 0 Index 1 Index 2 Time...
Page 148 Prior to A7 firmware in the FM-3 module the user had no control over the timeline. If a motion initiate command was seen within 5 milliseconds from the last time a motion profile was completed, the processor assumed that the user wanted to initiate the motion from the exact ending point of the last profile.
Page 149: Adding And Deleting Programs
Run Anytime Programs The FM-3 programming environment has been designed to automatically stop all programs when a fault occurs (regardless of what type of fault). Some applications require the ability to run a program as soon as a fault occurs of continue running a program even through a fault condition.
Page 150: Example Programs
FM-3 Programming Module Reference Manual Figure 110: Program View (FM-3E) with “Run Anytime” Check Box Enabled When a fault occurs, the drive will still be disabled, and no motion will be possible. For this reason, it may be necessary to reset the fault in the “Run Anytime”...
Page 151 Programming Out and Return – More Complex Description: Home, Wait For an input, Move out to an absolute position, set an output, dwell for 1 second, clear the output, return to home position, repeat the out and return sequence until the stop input halts the program. Home.0.Initiate ‘Sensor,Offset=0.000in,Vel=-10.0in/s ModuleOutput.1=ON...
Page 152 FM-3 Programming Module Reference Manual Simple Jogging within a Program Jog+ when DriveInput.2 goes ON and stop when it goes off. Jog- when DriveInput.3 goes ON and stop when it goes off. This could also be accomplished using the Jog input functions when there is no program running.
Page 153 Programming Endif Wait For PLS.0.Status=ON ‘Start the Index when PLS.0 goes on ‘(every 100 inches). Index.1.Initiate ‘Incremental,Sync,Dist=20.0in,Vel=1.0in/in Index.0.Initiate ‘Absolute,Sync,Dist=0.0in,Vel=2.0in/in Wait For Index.AnyCommandComplete Loop Synchronized Jog with Manual Phase Adjustment The motor controls a lugged conveyor belt which is synchronized to another lugged conveyor belt. Jog.0 is configured as a “Synchronized”...
Page 154 FM-3 Programming Module Reference Manual If((ModuleInput.3=OFF) AND (ModuleOutput.3=ON)) Then ModuleOutput.3=OFF Endif ‘Decrease the fill amount once every time ModuleInput.4 is pressed. If ((ModuleInput.4=ON) AND (ModuleOutput.4=OFF)) Then Index.1.Dist = Index.1.Dist - 0.10 ‘ounces ModuleOutput.4=ON ‘ModuleOutput.4 is used to make sure that the distance is ‘incremented only once each time ModuleInput.4 is pressed.
Page 155 Programming ‘input is on Index.3.Dist = PosnCommand ‘Read the Position Command into Index.3’s ‘absolute position. Endif Wait For ModuleInput.1=OFF ‘Wait until the “Learn” input goes off Wait For ModuleInput.2=OFF ‘Wait until the “Skip” input goes off Subroutine for Jogging the Axis into the Desired Position (Program 1) ‘Allow jogging until either the “Learn”...
Page 156 FM-3 Programming Module Reference Manual...
Page 157: Parameter Descriptions
Accelerating Accelerating This source is active when the FM-3 module is executing an acceleration ramp. A normal index consists of 3 segments: Accelerating, At Velocity, and Decelerating. The Accelerating source will be set (active) during this acceleration segment regardless of whether the motor is speeding up or slowing down. Therefore, this source can sometimes be active when the motor is decelerating.
Page 158 This read/write bit may be used in a program as an intermediary variable bit controlled by the user. Bit.B# is one of 32 bits that make up the BitRegister parameter. Assigned to communication networks such as DeviceNet, Profibus and Modbus, Bit.B# may be used to transfer events that have occurred in a PLC to the FM-3/4 program. Note When the value of Bit.B# is changed, the value of BitRegister.#.Value is changed as well.
Page 159 Decelerating Decelerating This source is active when the FM-3 module is decelerating. A normal index consists of 3 segments: Accelerating, At Velocity, and Decelerating. Decelerating follows the accelerating segment and the At Velocity segment. When indexes are compounded to create a complex motion profile, only the last index may contain a decelerating segment.
Page 160 FM-3 Programming Module Reference Manual Characteristic Distance DistUnits.CharacteristicDist This parameter is the distance the load travels (in user units) when the motor travels the characteristic length (in motor revolutions). This parameter is used along with the DistUnits.CharacteristicLength to establish the relationship between user distance and actual motor travel distance.
Page 161 Parameter Descriptions Bandwidth DriveAnalogInput.LowPassFilterFrequency This parameter sets the low-pass filter cutoff frequency applied to the analog input. Signals exceeding this frequency will be filtered at a rate of 20 db per decade. Maximum Value DriveAnalogInput.MaxUserValue Enter the maximum value in analog user units that the maximum analog voltage should correspond to. Set Maximums Group. Maximum Voltage DriveAnalogInput.MaxVoltageValue Enter the maximum voltage that will be seen on the analog input terminals.
Page 162 FM-3 Programming Module Reference Manual Custom Variable DriveAnalogOutput.#.CustomSourceVariable The Custom Variable parameter is only available once the user has selected Custom Variable from the Source list box. The field is used to define what parameter will control the Analog Output. This means that the selected variable parameter will directly determine the value of the analog output based on the Max and Min scaling values entered on this view.
Page 163 The Drive Input Debounce Time parameter is the minimum time a digital input must be steady in order to be recognized by the FM-3 module. This feature helps prevent false triggering in applications in electrically noisy environments. Drive Input Force DriveInput.#.Force...
Page 164 When on, this parameter enables the use of the drive encoder output scaling feature. Drive Serial Number DriveSerialNumber This displays the serial number of the Drive to which the FM-3 module is attached. Active Fault Fault.#.Active The specified fault is active. See the help index for more information on faults and recovery from them.
Page 165 This is the fault identifier for the current fault log entry. It is a read only parameter for the logged fault. It may hold a value for any fault supported by the device. They are the same as the faults listed on the Assignments View for Faults. Code FM-3 EncoderStates EncoderHardware PowerModule...
Page 166 FM-3 Programming Module Reference Manual Code FM-3 HighDCBus IsrOverrun TrajectoryFault Synchronization WatchdogTimer OverSpeed InvalidConfiguration PowerUpSelfTest RMSShuntPower MotorOverTemperature OverTemperature Auto-Tune WatchdogTimer InvalidConfiguration NVMInvalid PowerUpTest FollowingError TraveLimitPlus TraveLimitMinus ProgramFault NoProgram DevicenetConnTimeout DevicenetBusOffInt DevicenetDupMacId TrajectoryFault ProfibusParameterizationFlt ProfibusWatchdogFault ProfibusConfigurationFault Fault Log - Power Up Count FaultLog.#.PowerUpCount...
Page 167 Parameter Descriptions Enable Feedforwards FeedforwardsEnable This parameter may be setup on the Tuning view or through a program, and enables feedforward compensation. When feedforwards are enabled, the accuracy of the Inertia and Friction settings are very important. If the Inertia setting is larger than the actual inertia, the result could be a significant overshoot during ramping.
Page 168 FM-3 Programming Module Reference Manual Following Error FollowingError Following Error displays the difference between the Position Command and the Position Feedback. Enable Following Error FollowingErrorEnable This parameter can be setup from the Position view or from a program. When enabled, a following error fault will be generated if the absolute value of the Following Error exceeds the Following Error Limit.
Page 169 Parameter Descriptions Gear Command Complete Gear.CommandComplete This source will activate when gearing has been stopped, and will remain active until the gear is initiated again. Gearing does not use a deceleration ramp, so this source will activate immediately after a Gear.Activate destination is deactivated. Gear Command In Progress Gear.CommandInProgrees This source will activate when Gearing is initiated either from a program or through an assignment.
Page 170 FM-3 Programming Module Reference Manual Graph.TriggerState TriggerState This parameter is used to control the Graph function from within a program. 0 = Filling Buffer: The whole buffer must be filled with selected data before trigger sampling starts 1 = Filled - Waiting Trigger: Continue putting data into the buffer, check back into previous sampled data for the trigger...
Page 171 Parameter Descriptions Command Complete Home.#.CommandComplete This source is active when the specified home command is completed, if a stop is activated before the home has completed the function or if the Home Limit Distance has been exceeded it will not be activated. Inactive when a home command is executed.
Page 172 FM-3 Programming Module Reference Manual Home Offset Type Home.#.OffsetType Selects calculated or specified home offset. Calculated offset is the distance traveled during the deceleration ramp from the home velocity. The specified offset allows the user to choose an exact offset from the Home Reference.
Page 173 Parameter Descriptions Index Profile Limited Index.ProfileLimited For timed indexes, if the values for Max. Velocity, Max. Acceleration and Max. Deceleration are such that the distance cannot be covered in the specified time, the Index.ProfileLimited flag will activate when the index is initiated. The Index.ProfileLimited flag will remain active until cleared using the Index.ResetProfileLimited assignment or program instruction.
Page 174 FM-3 Programming Module Reference Manual Compound Initiate Index.#.CompoundInitiate When activated will initiate the specified Index to compound into the next index in the program. Only allowed in a program. Deceleration Index.#.Decel This parameter is the Average Deceleration rate used during the index. Units are specified on the User Units page.
Page 175 Parameter Descriptions PLS Off Point Index.#.PLSOffDist This an incremental distance from the start of the index to the Index PLS off point. This is an unsigned value and is relative only to starting position of this index. Index direction does not affect this parameter. Index.#.PLSStatus will be active if the distance traveled from the start of the index is greater than the Index.#.PLSOnDist and less than the Index.#.PLSOffDist.
Page 176 Initially Active InitiallyActive This source, when assigned to a destination, will activate the destination on power-up or upon FM-3 module reset. InitiallyActive can be assigned to any destination that does not create motion (i.e. indexes, jogs, homes, programs). In Position...
Page 177 Parameter Descriptions Any Command Complete Jog.AnyCommandComplete The Jog.AnyCommandComplete bit will activate when either Jog 0 or Jog 1 completes its deceleration ramp and reaches zero commanded speed. It deactivates when another jog is initiated. Minus Activate Jog.MinusActivate This destination is used to initiate jogging motion in the negative direction using the jog parameters of the jog selected by the Jog select input function.
Page 178 FM-3 Programming Module Reference Manual Command In Progress Jog.#.CommandInProgress The Jog.#.CommandInProgress source is high throughout an entire jog profile. The bit goes high at the start of a jog acceleration ramp, and turns off at the end of a jog deceleration ramp.
Page 179 The Module Input Debounce Time parameter is the minimum time a digital input must be on in order to be recognized by the FM-3 module. This feature helps prevent false triggering in applications in electrically noisy environments. Module Input Force ModuleInput.#.Force...
Page 180 This destination sets the current state of an output line. Module Serial Number ModuleSerialNumber This is the FM-3 module serial number. Motion Stop MotionStop This destination is used to stop all motion operating without stopping programs. MotionStop can be activated through an assignment, or in a user program.
Page 181 Parameter Descriptions Name Name User name for this FM-3 axis can have a length up to 12 characters. This can be used to help differentiate setup files. Packed Bits Control Word Value PackedBits.ControlWord.#.Value When accessing the Packed Bits Control Words for network mapping or use in a program, the Value parameter is what holds the data.
Page 182 This bit is used to select which direction of motor rotation is considered motion in the positive direction. Select from CW or CCW. Position Command PosnCommand Position command sent to the EN drive by the FM-3 module. This parameter does not take following error into account. See also PosnFeedback and FollowingError. Units are in user units.
Page 183 Parameter Descriptions Position Error Integral Enable PosnErrorIntegralEnable This parameter is used to enable the position error integral compensation. See also Position Error Integral Time Constant. Position Error Integral Time Constant PosnErrorIntegralTimeConstant Position Error Integral parameter is a control term, which can be used in Pulse mode to compensate for the continuous torque required to hold a vertical load against gravity or to minimize following error.
Page 184 FM-3 Programming Module Reference Manual Name Program.#.Name This is a character string which the user can assign to an individual program. It allows the user to give a descriptive name to programs for ease of use. Program Complete Program.#.ProgramComplete This source is activated when a specific program ends normally. If the program ends due to a fault or the stop destination, this source does not activate.
Page 185 StartUp This source can be used to trigger an event to occur on startup (when the FM-3 module powers up or is rebooted). This source is typically used to initiate a program or to initiate a home so that a machine will automatically home on power up or reboot.
Page 186 FM-3 Programming Module Reference Manual Stop Stop Activate this destination to stop all motion and programs. If Stop is activated when a Jog, Index, Home or Program is in progress, they will decelerate to zero speed at the Stop Decel ramp. When Stop is active, all Jog, Home, Index and Program initiate destinations will be ignored.
Page 187 TravelLimitDisable can be used from the Assignments view, or through a user program. It can be used to temporarily disable the travel limit fault capability of the FM-3 module. When TravelLimitDisable is activated, the FM-3 module travel limits (hardware or software) are no longer valid. If disabled using a program, the travel limits will automatically be re-enabled when the program ends, if they haven’t already been enabled.
Page 188 Velocity Command VelCommand The Velocity Command is the velocity that the FM-3 module is commanding the motor to run at. This command is generated by the drive velocity control loop. It is displayed in user units. Velocity Feedback VelFeedback This is the feedback (or actual) velocity.
Page 189 Parameter Descriptions Time Scale VelocityUnits.TimeScale Velocity time scale can be set to user units per second or user units per minute, used for all real-time velocities throughout the PowerTools Pro software. Acceleration - FM-3E Only VirtualMaster.Accel This parameter is the acceleration rate, in user units, that the virtual master will use to accelerate. This parameter is used when in either jog or indexing mode.
Page 190 FM-3 Programming Module Reference Manual FeedRate Deactivate - FM-3E Only VirtualMaster.FeedRateDeactivate When this parameter is activated, from an assignment or a program, virtual master feedrate override is deactivated meaning that the virtual master counts will be 100%. FeedRate Decel/Accel - FM-3E Only VituralMaster.FeedRateDecelerationTime...
Page 191 Parameter Descriptions Posn Command - FM-3E Only VirtualMaster.Stop This parameter when activated stops the Virtual Master using the VirtualMaster.Decel rate. Velocity - FM-3E Only VirtualMaster.Vel This parameter is the maximum virtual velocity that will be attained by the virtual master. This parameter is in user units. Enable Virtual Master - FM-3E Only VirtualMaster.VirtualMasterEnable Enable Virtual Master check box by default is clear.
Page 192 FM-3 Programming Module Reference Manual...
Page 193: Installation
Mechanical Installation The FM-3 module detects and verifies the drive serial number when its attached to an drive. If an FM-3 module is moved from one drive to another, it will detect the difference in serial numbers and generate an Invalid Configuration fault.
Page 194: Electrical Installation
A single power supply can be used to power the I/O on both the drive and the FM-3 module, however, it must be wired to both the drive and the FM-3 module because I/O power is not passed through the connector on the back of the FM-3 module.
Page 195 The drive’s serial communication protocol is Modbus RTU slave with a 32 bit data extension. The Modbus protocol is available on most operator interface panels and PLC’s. Serial Communications Specifications Max baud rate 19.2k (default) Start bit Stop bit Parity none Data Control Techniques’ Motion Interface panels are supplied with a Modbus master communications driver.
Page 196: Software Installation
• Creates a new Windows group called "Control Techniques". • Loads PowerTools Pro into the Control Techniques\PowerTools Pro directory. Note To complete the installation for Windows 98, 200, 2003, 2008, XP and Vista, you may be required to restart Windows.
Page 197: Starting And Exiting Powertools
To start a new file or configuration, select File from the menubar, and then select New. You may also click on the File New button on the toolbar. The New dialog box (see figure 114) will appear prompting the user to select FM-3 then the FM-3 module model depending on the model number.
Page 198 FM-3 Programming Module Reference Manual • Choose a command from the Help menu. • Click the Help button on a dialog box or view. • Click the Help button on the toolbar. • Click the Context Sensitive Help button on the toolbar and then the field on the view.
Page 199: Quick Start
FM-3 Programming Module Reference Manual Quick Start The quick start guide provides information on the basic operation and functions of the FM-3 module. The quick start steps cover only the most basic steps required to setup a FM-3 module for use with a drive.
Page 200 Setup View On this view, you must enter the following parameters before entering other setup views: Drive Type – Select, from the list box, the type of drive to which the FM-3 module is attached. E Series Only Line Voltage – Select, from the list box, the line voltage applied (115 Vac or 230 Vac).
Page 201 If a configuration is downloaded to the FM-3 with a red background on the “User Unit Limited Speed”, the drive will obtain a trajectory fault at speeds near this velocity.
Page 202 FM-3 Programming Module Reference Manual Figure 118: Position View To set up Following Error Limit and Software Travel Limits, fill out the following parameters in the Limits Group: Enable Following Error – This check box enables (when selected) and disables the following error fault capability. If selected, a following error fault is generated whenever following error exceeds the value entered in the parameter text box.
Page 203 Tuning View Control Techniques’ Drives are designed to handle a 10:1 inertia mismatch without a tuning requirement. If you have calculated and know the inertia mismatch, the value can be entered on the Tuning view for ideal drive response and velocity regulation.
Page 204 Name – This 12-character string allows a descriptive name assigned to an input line. This makes the configuration easier to follow. Debounce – This is the minimum time a specific input must be on, for recognition by the drive/FM-3 module. This helps prevent false triggering for applications in electrically noisy environments. The units for this parameter are seconds, with resolution of 0.001 seconds.
Page 205 Quick Start Figure 122: Output Lines View A name can also be given to each hardware output line. Figure 122 shows how to enter a name for an individual output line. Name – This 12-character string allows a descriptive name assignment to an output line. This makes the configuration easier to follow.
Page 206 FM-3 Programming Module Reference Manual Jog Deceleration - Is the average deceleration rate used when decelerating to zero speed or to the new target velocity. Home Setup Next, select the Home view from the Hierarchy Tree. Figure 124 shows the Home view and its associated home parameters.
Page 207 Quick Start Figure 125: Index Setup View (Absolute Type) Indexes use the following parameters: Index Name - Is a 12-character string that gives a descriptive name to an index. Index Type – Selects the desired type of index from the list box. An Absolute index means the load will travel to an exact position with respect to the home reference point.
Page 208 FM-3 Programming Module Reference Manual Figure 126: Index Setup View (Incremental Type) Now that all of the motion parameters are setup, the jogs and indexes can be initiated through assignments to hardware inputs that were made on the Assignment view.
Page 209 Quick Start Drag Drop Figure 127: Program View The window in the middle of the view allows selection from a list of Program Flow and Motion instructions. To insert an instruction into the programming window, you can use the “drag-and-drop” method also used in making assignments. Simply position your mouse pointer over the instruction you wish to use, click the left mouse button and hold it down.
Page 210: Example Application Start Up
FM-3 Programming Module Reference Manual A comment is automatically inserted after the index instruction, which shows key data about the specific index. Notice comments start with the ‘ apostrophe character. A “Wait For Index.AnyCommandComplete” instruction is automatically inserted after each Index.Initiate. This ensures that the index has completed before the program continues on to the next line of code.
Page 211 Quick Start Position View The example wishes to limit the Following Error to 0.25 Inches or one motor revolution, and the Software Travel Limits of +20 and 0 Inches. To setup following error limit and software travel limits, fill out the following parameters in the Limits Group: Enable Following Error –...
Page 212 FM-3 Programming Module Reference Manual Drag and Drop Method Figure 131: Assignments View The Input Lines view shows all of the assignments that have been made to the Inputs group of Sources. After all assignments for the example application have been made, the Input Lines view should look like Figure 132.
Page 213 Quick Start Figure 133: Output Lines View Home Setup The example application calls for setup of the following parameters: Home Reference –The example calls for a Home to Sensor; therefore, “Sensor” is selected as the home reference. Because of this selection, the home profile will travel at its target velocity until the Home.0.SensorTrigger is activated. Figure 131, shows the Home.0.Sensor Trigger has been assigned to ModuleInput.2.
Page 214 FM-3 Programming Module Reference Manual Absolute Index Figure 134: Index Setup View (Absolute Type) Indexes 0 and 1 are both Absolute type indexes and use the following parameters: Index Name - Is a 12-character string that gives a descriptive name to an index.
Page 215 Quick Start Distance – The distance is a signed value that specifies the distance the load will travel from the start position. The sign of this parameter determines direction of travel for the load. The distance of Position C has been set to 2.5 inches. Velocity –...
Page 216 FM-3 Programming Module Reference Manual Wait For – This program instruction halts program execution until the expression becomes True. Once True, the program continues with the next line of code. The example program uses a Wait For DriveInput.1 so that the program will wait until DriveInput.1 is activated, then continue on.
Page 217: Tuning Procedures
Basic Level, then determine if further tuning is needed based on axis performance. The setup procedures explained here assume that you are using PowerTools FM-3 software or an FM-P. Initial settings Set the drive tuning parameters as follows: •...
Page 218 FM-3 Programming Module Reference Manual • Feedforwards = Disabled Tuning steps If your Inertia Ratio is greater than 10 times the motor inertia go directly to the Intermediate Level tuning. No Tuning No tuning will be required in most applications where the load inertia is 10 times the motor inertia or less.
Page 219: Tuning Parameters
Tuning Procedures Tuning Parameters Inertia Ratio Inertia Ratio specifies the load to motor inertia ratio and has a range of 0.0 to 50.0. A value of 1.0 specifies that load inertia equals the motor inertia (1:1 load to motor inertia). The drives can control up to a 10:1 inertia mismatch with the default Inertia Ratio value of 0.0.
Page 220: Determining Tuning Parameter Values
FM-3 Programming Module Reference Manual Feedforwards Feedforward gains are essentially open loop gains that generate torque commands based on the commanded velocity, accel/ decel and the known load parameters (Inertia Ratio and Friction). Using the feedforwards reduces velocity error during steady state and reduces overshoot during ramping.
Page 221 Tuning Procedures If your application has less than a 10:1 inertia mismatch, the default parameter settings will be acceptable. If the inertial mismatch is greater than 10:1, use the following table for initial parameter settings. Parameter Setting Friction 0.00 Inertia Ratio 1/3 to 1/2 Actual Response 500/Inertia Ratio...
Page 222 FM-3 Programming Module Reference Manual The figure below shows the relationship of Torque Command to the Velocity Feedback. There is increased torque during the Accel ramp (Ta), constant torque (Tc) during the constant velocity portion of the ramp and decreased torque (Td) during the decel ramp.
Page 223 Tuning Procedures For horizontal loads or counterbalanced vertical loads use the following formula: • Td)) − 2000 Where: IR = Inertia Ratio R = ramp in ms/kRPM Ta = (unsigned) percent continuous torque required during acceleration ramping (0 - 300) Td = (unsigned) percent continuous torque required during deceleration ramping (0 - 300) Vm = motor constant value from Table 18 below...
Page 224 FM-3 Programming Module Reference Manual Percent Continuous/volt RPM /volt Scaled Velocity Motor Drive Scaled Torque Command Command Output (default)) Output (default)) NT-320 5.16 NT-330 6.87 NT-345 6.72 NT-355 EN-208 5.97 MG-316 3.17 MG-340 3.14 MG-455 2.44 NT-345 6.72 NT-355 5.97...
Page 225: Diagnostics And Troubleshooting
Diagnostic Display The diagnostic segment display on the front of the drive shows drive status, FM-3 module 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 module provides additional fault information.
Page 226 FM-3 Programming Module Reference 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 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, can only be reset by cycling power “Off”...
Page 227 This fault indicates that the firmware checksum has failed. Use the Tools Program Flash menu item from PowerTools to reprogram/upgrade the firmware stored in flash memory. If this problem persists, call Control Techniques. A common cause would be an interrupted F/W Flash upgrade (cable disconnected during an upgrade process).
Page 228 FM-3 Programming Module Reference Manual Power Module This fault is generated when a power stage over-temperature, over-current or loss of power stage logic supply occurs. This can be the result of a motor short to ground, a short in the motor windings, a motor cable short or the failure of a switching transistor.
Page 229 Diagnostics and Troubleshooting FM-3 Fault A 3 will be displayed on the diagnostic segment display on the drive when the FM-3 module experiences one of the following faults. DvTrjFlt This fault occurs when the drive has received trajectory data from the FM module that indicates a problem or drive following error is extremely large.
Page 230: Drive Faults
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 is a value that represents two states such as On or Off. In the FM-3 there are three variable types that have Boolean values.
Page 231 Syntax error encountered understand your text sequence. To change a Name you assign a quoted text string to that name. In FM-3/FM-4, text strings are fixed Text Strings are limited to 12 at 12 characters. If you use fewer than 12 characters...
Page 232: Online Status Indicators
PowerTools Pro contains a diagnostic utility called the Watch Window. The Watch Window can be used while PowerTools Pro is running and the PC is online with the FM-3 module. The Watch Window allows the user to monitor the status of all...
Page 233 Diagnostics and Troubleshooting To setup the Watch Window, select Tools\Watch Window from the PowerTools Pro menu. If not online with the module, Watch Window will be unavailable on the menu. Upon selecting Watch Window, the following window will appear. Figure 138: Watch Window The Select Drive Parameters window as seen in Figure 139 allows the user to specify which parameters are to be seen in the Watch Window.
Page 234 FM-3 Programming Module Reference Manual Select Defaults The Select Defaults button adds the most commonly used parameters to the Watch Window. Select I/O The Select I/O button will add the Drive and Module digital inputs and outputs to the Watch Window.
Page 235: Diagnostic Analog Output Test Points
Diagnostics and Troubleshooting Diagnostic Analog Output Test Points The drive has two 10 bit Analog Outputs which may be used for diagnostics, monitoring or control purposed. These outputs are referred to as Channel 1 and Channel 2. They can be accessed form the command connector on the drive or from the diagnostic output pins located on the front of the drive.
Page 236 FM-3 Programming Module Reference Manual Black (GND) Yellow Blue 10 Ohm 10 Ohm DGNE Cable Command Connector (J5) DGNE Cable Figure 141: Diagnostic Cable (DGNE) Diagram...
Page 237: Specifications
FM-3 Programming Module Reference Manual Specifications Power consumption: 3 W from drive power supply. I/O Supply Voltage: 10 Vdc-30 Vdc. Function Electrical Characteristics ON State Voltage 10 Vdc-30 Vdc ON State Current 2 mA-6.5 mA Inputs OFF State Voltage 0 Vdc-3 Vdc OFF State Current 0 µA-400 µA...
Page 238 FM-3 Programming Module Reference Manual AX4-CEN CDRO...
Page 239: Cable Diagrams
Specifications Cable Diagrams EN Drive EN Drive w/ FM-3 w/ FM-3 SCSLD-x Encoder EN Drive EN Drive w/ FM-3 w/ FM-3 EN Drive EN Drive w/ FM-3...
Page 240 FM-3 Programming Module Reference Manual SNCE-XXX Cable Pin 1 RED/WHT YEL/WHT BLU/WHT BLK/WHT +5 Vdc +5 Vdc DRAIN WIRE SNCDD-001.5 Cable +5 Vdc Pin removed DRAIN WIRE Completely remove pin 4 CONNECTOR END VIEW CONNECTOR END VIEW...
Page 241 Specifications SNCO-003 Cable Pin 1 Pin removed DRAIN WIRE SNCI-003 Cable .68 MAX. 2.00 MAX. Pin 1 +5 Vdc DRAIN WIRE...
Page 242 FM-3 Programming Module Reference Manual SNCLI-003 Cable +5 Vdc DRAIN WIRE...
Page 243 Specifications CMDX-XXX Cable Pin 1 Pin 1 Note: Inner foil shields are already mechanical connected to outer braid shield by raw cable manufacture. RED/BRN Input I/O 1 BRN/RED Input I/O 2 BLK/BLU Input I/O 3 BLU/BLK Input I/O 4 WHT/ORG RS-485+ Some early shipments of this cable have WHT/YEL ORG/WHT...
Page 244 FM-3 Programming Module Reference Manual CMDO-XXX Cable Pin 1 Note: Inner foil shields are already mechanical connected to outer braid shield by raw cable manufacture. RED/BRN Input I/O 1 BRN/RED Input I/O 2 BLK/BLU Input I/O 3 BLU/BLK Input I/O 4...
Page 245 Specifications CDRO-XXX Cable Pin 1 BLU/PUR Encoder Output A/ PUR/BLU Encoder Output A ORG/PUR Encoder Output B/ PUR/ORG Encoder Output B BRN/PUR Encoder Output Z/ PUR/BRN Encoder Output Z RED/BLU Encoder +5VDC Supply BLU/RED Encoder Supply Common GRN/BLK I/O Supply+ BLK/GRN Drive Enable Input WHT/BLU...
Page 246 FM-3 Programming Module Reference Manual TIA-XXX Cable Pin 1 (Typ) .63" (Typ) 2 1/2" Pin 1 DDS-XXX Cable SHELL DRAIN DB-9 MALE WIRE BLACK WHITE 485+ BLUE 485- 485+ 485- DB-9 FEMALE DB-9 MALE...
Page 247 Specifications TERM-H (Head) Terminator TERM-T (Tail) Terminator Note See the "Multi-drop Communications" section for resistor values.
Page 248 FM-3 Programming Module Reference Manual CMDS-XXX Cable 1 1/2" MAX. 3 3/4" MAX. BRAID SHIELD FORM WIRE GRN/YEL PE/GND CMMS-XXX Cable 1 1/2" MAX. BRAID SHIELD FORM WIRE GRN/YEL PE/GND...
Page 249 Specifications CFCS-XXX Cable 3 3/4" MAX. 1 1/2" MAX. Pin 1 WHT/BRN BRN/WHT WHT/GRY GRY/WHT RED/ORG ORG/RED RED/BLU +5 VDC +5 Vdc BLU/RED RED/GRN MOTOR OVERTEMP MOTOR OVERTEMP GRN/RED NOT USED NOT USED...
Page 250 FM-3 Programming Module Reference Manual CFCO-XXX Cable Pin 1 WHT/BRN BRN/WHT WHT/GRY GRY/WHT RED/ORG ORG/RED RED/BLU +5 Vdc BLU/RED RED/GRN MOTOR OVERTEMP GRN/RED NOT USED...
Page 251 Specifications CFOS-XXX Cable 1 1/2" MAX. 3 3/4" MAX. WHT/BRN BRN/WHT WHT/GRY GRY/WHT RED/ORG ORG/RED RED/BLU +5 Vdc BLU/RED RED/GRN MOTOR OVERTEMP GRN/RED NOT USED...
Page 252 FM-3 Programming Module Reference Manual...
Page 253 Cyclical Redundancy Check, the data transfer error checking mechanism. Destination A function (i.e., Stop, Preset) that may be assigned to an input line. In FM-3, the input function is connected to the action through click and drag operations in PowerTools Software on the Assignment View.
Page 254 Another type of EEPROM. Flash File In the FM-3 module, this file loads the firmware into the drive and function module. Flash files can field upgrade the firmware. Function Module - device which is attached to the front of the drive to provide additional functionality.
Page 255 Glossary Inertia The property of an object to resist changes in rotary velocity unless acted upon by an outside force. Higher inertia objects require larger torque to accelerate and decelerate. Inertia is dependent upon the mass and shape of the object. Input Function See destination.
Page 256 Programmable Logic Controller. Also known as a programmable controller, these devices are used for machine control and sequencing. PowerTools Pro PowerTools Pro is a Windows® based software to interface with the EN or MDS drive with an attached FM-3 or FM-4 module. Radio Button Also known as the Option Button.
Page 257 Glossary Serial Port A digital data communications port configured with a minimum number of signal lines. This is achieved by passing binary information signals as a time series of 1’s and Ø’s on a single line. Source The terminals at which energy is taken from a circuit or device. Travel Limit The distance that is limited by either a travel limit switch or the software.
Page 258 FM-3 Programming Module Reference Manual...
Page 259 FM-3 Programming Module Reference Manual Index Symbols +/- Travel Limit, 214 Else, 126 Encoder Line Fault, 214 Encoder State, 214 End, 128 Error Messages, 216 Example Programs, 136 Add Program Icon, 135 Adding a Program, 135 All "On", 214 Analog Output, 216...
Page 260 FM-3 Programming Module Reference Manual Setup, 34 Setup, Commissioning and Maintenance, vii status codes Label, 129 decimal point, 211 Lock Program, 124 Ready, 211 Low DC Bus Fault, 214 Ready to Run, 211 Stop All, 125 Modbus Communications, 181 Motion Instructions, 130...
Page 262 Minnesota U.S.A., are renowned in the motion control industry for their ease of use, reliability and high performance. For more information about Control Techniques “Motion Made Easy” products and services, call (800) 893-2321 or contact our website at www.emersonct.com.

Control Techniques FM-3 Reference Manual

Safety Considerations

Introduction

Operational Overview

Setting up Parameters

Programming

Parameter Descriptions

Installation

Quick Start

Tuning Procedures

Diagnostics and Troubleshooting

Specifications

Quick Links

Related Manuals for Control Techniques FM-3

Summary of Contents for Control Techniques FM-3

Table of Contents