CMMS-AS-...

-G2 Intended use

The motor controller CMMS-AS-...-G2. is a digital positioning controller for servo
motors for
– supply and activation of the motor
– regulation of speed (current), torque and position.
The motor controller supports the following safety function:
– “Safe Torque Off ” (STO)
Category 3 / PL d in accordance with EN ISO 13849-1.
Festo AG & Co. KG Use exclusively:
Postfach – in an excellent technical status
73726 Esslingen – in original status, without unauthorised modifications
Germany – within the limits of the product defined through the technical data
+49 711 347-0 – for the safety function within the specified service life of the switching elements
www.festo.com  Section 9
– in an industrial environment
– as an installed device in a control cabinet.
Brief description 8026148
Foreseeable misuse of the safety function
1310NH
– use outside or in a non-industrial area (residential area),
[8031346]
– use in applications where switching off can result in hazardous movements or
conditions.

Note
Original: de
– The STO function is insufficient as the sole safety function for drives subject to
Motor controller CMMS-AS-...-G2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . English permanent torque or force (e.g. suspended loads).
– Bypassing of safety equipment is impermissible.
Translation of the original instructions
– Repairs to the motor controller are impermissible!
You can find the complete documentation for the motor controller
CMMS-AS-...-G2 in PDF format on the CD-ROM accompanying the motor The STO (Safe Torque Off ) function does not provide protection against
controller or via the support portal  www.festo.com/sp. electric shock, only against hazardous movements!
User documentation on the motor controller CMMS-AS-...-G2
In applications with extremely high requirement rates, the service life of the
Hardware description, Assembly, installation, pin allocations and error messages
GDCP-CMMS-AS-G2-HW-...
switching elements must be taken into account in the design (replacement interval
Description of the safety function Functional safety engineering for the motor controller with for the motor controller)  Section 9.
STO, GDCP-CMMS-AS-G2-S1-... the STO safety function Attainable safety level in accordance with EN ISO 13849-1
Description of function, Functional description and commissioning with FCT The motor controller can be used in applications up to Cat. 3 / PL d in accordance
GDCP-CMMS-AS-G2-FW-... Control interfaces and device profiles
with EN ISO 13849-1. The achievable safety level depends on the other compon-
Description of device profile FHPP, Control and parameterisation of the motor controller via
ents used to achieve a safety function.
P.BE-CMM-FHPP-SW-... the device profile FHPP from Festo.
Description of device profile CiA 402, Description of the CAN interface of the motor controller.
P.BE-CMMS-FHPP-CO-SW-... Control and parameterisation via device profile CiA 402. 1.2 Requirements for product use
PROFIBUS description, Description of PROFIBUS interface of the motor controller For correct and safe use of the product:
P.BE-CMM-FHPP-PB-SW-... • Comply with the connection and ambient conditions of the product and all con-
DeviceNet description, Description of DeviceNet interface of the motor controller nected components specified in the technical data. Compliance with the limit
P.BE-CMMS-FHPP-DN-SW-...
values and load limits permits operation of the product in compliance with the
Help on the FCT plug-in CMMS-AS User interface and functions of the CMMS-AS plug-in for
relevant safety regulations.
the Festo Configuration Tool  www.festo.com
• Observe the instructions and warnings in the documentation.
• For the safety function: For emergency stop applications, protection against
1 Safety and requirements for product use automatic restart must be achieved corresponding to the required safety cat-
1.1 Safety egory, e.g. through an external safety switching device.

Warning Qualification of the specialized personnel (requirements for the personnel)

The product may only be placed in operation by a qualified electrotechnician who
Danger of electric shock
is familiar with:
Touching live parts causes severe injuries and can lead to death: – the installation and operation of electrical control systems,
– when the module or cover plate is not mounted on the card slot [EXT] – the applicable regulations for operating safety-engineering systems,
– when cables are not mounted to the plugs [X6] and [X9] – the applicable regulations for accident protection and occupational safety, and
– when connecting cables are disconnected when powered. – the documentation for the product.
The product must be installed in a control cabinet and may only be used if all
Diagnostic coverage (DC) for the safety function
safeguarding has been initiated. Diagnostic coverage depends on the interconnection of the motor controller with
Before touching live parts during maintenance, repair and cleaning work and
the control loop system as well as the implemented diagnostics measures.
when there have been long service interruptions: If a potentially dangerous malfunction is recognised during the diagnostics, appro-
1. Switch off power to the electrical equipment via the mains switch and secure
priate measures must be taken to maintain the safety level.
it against being switched on again.
2. After switch-off, wait at least 5 minutes discharge time and check that power Note
is turned off before accessing the controller.
Check whether a fault exclusion of cross circuits in the input circuit and connec-
tion wiring is possible in your application.
Caution If necessary, use a safety switching device with short-circuit detection.
Danger of burns from hot surfaces
Dependent on the load, housing temperatures > 80° C are possible in operation. Range of application and certifications
• Protect hot surfaces from contact in operation. The motor controller with integrated STO safety function is a safety-related part of
• Touch them only in a switched-off, cooled-off status. the control systems. The motor controller carries the CE mark.
Certificates and the declaration of conformity for this product can be
Note found  www.festo.com.
Danger from unexpected movement of the motor or axis
• Make sure that the movement does not endanger anyone.
• Perform a risk assessment in accordance with the EC Machinery Directive.
• Based on this risk assessment, design the safety system for the entire ma-
chine, taking into account all integrated components.
2 Product overview For vertical mounting onto a control cabinet mounting plate:
2.1 Device view • Mount the accompanying mounting bracket to the motor controller.
• Use the motor controller exclusively in a control cabinet:
1 2 3 – The mounting position is vertical with the power supply lines [X9] leading
upwards.
4 – Mounting to the mounting brackets with M5 screws.

5 4 Electrical installation
Caution
6 aB Danger from unexpected movement
aF
7 Faulty pre-assembled lines may destroy the electronics and trigger unexpected
aC
movements of the motor.
aG
8 • When wiring the system, use only the supplied plug connectors and preferably
aD the cables listed in the catalogue as accessories.
9 aH  www.festo.com/catalogue
• Lay all flexible lines so that they are free of kinks and free of mechanical
aJ aE
stress; if necessary use chain link trunking.

aA

Note
aE ESD (electrostatic discharge) can cause damage to the device or other system
parts at plug connectors that are not used.
1 Front view aJ [X4]: CAN bus • Before installation: Earth the system parts and use appropriate ESD equip-
2 Bottom view aA [M1]: SD memory card ment (e.g. shoes, earthing straps etc.).
3 Top view aB [X3] STO interface • After installation: Seal unassigned D-sub plug connectors with protective caps
4 Earthing screw (central PE aC [X2] Encoder (available at authorized dealers).
connection) aD [X6] Motor • Observe the handling specifications for electrostatically sensitive devices.
5 LED status display aE Shield connection terminal
6 7-segments display aF [X9] Power supply
7 [S1]: DIP switch aG [X10] Master/Slave Warning
8 [X5]: RS232/RS485 aH [X1] I/O interface Danger of electric shock
9 [EXT]: Slot for CAMC-... Motor controllers are devices with increased leakage current (> 10 mA). If wiring
Fig. 1 Motor controller CMMS-AS-...-G2 is incorrect or the device is defective, high voltage can occur on the housing,
which can result in serious injury or even death if the housing is touched.
• Before commissioning, also for brief measuring and test purposes, connect
2.2 Display and control elements
the PE protective conductor:
7-segments display1) – to the earthing screw of the controller housing,
Rotating outside Speed mode (speed adjustment): – to pin PE [X9.5], power supply. The cross section of the protective conduct-
segments Display changes corresponding to rotor position and speed. or at PE [X9.5] must correspond at least to the cross section of the external
Middle segment Controller enable active (motor is energised). conductor L [X9.1].
I Force mode (current control). • Observe the regulations of EN 50178 and IEC 60204-1.

Pxxx Positioning mode, record number x x x Observe the information on safe and EMC-suitable installation and on
PHx Homing phase x protective earthing in the Hardware description GDCP-CMMS-AS-G2-HW-...
H Two-channel safety function requested (DIN4 [X1.21] and Rel [X3.2]).

4.1 I/O interface [X1]

Point Start program (Bootloader) active. Pin Value Assignment in 0 mode – positioning
Flashing point – Firmware file (memory card) is being read. 1 SGND 0V Screening for analogue signals
– Display of errors through the start program.
2 DIN12/AIN0 – Mode bit 0/setpoint input 0 2)
Exxy Error (E = error)
3 DIN 10 – Record selection bit 4 (high active)
Number: Two-position main index (x x), single-position subindex (y)
Example: E 0 1 0  section 7. 4 +VREF +10 V ±4 % Reference output for setpoint value potentiometer
–xxy– Warning 5 – – –
Number: Two-position main index (x x), single-position subindex (y). 6 GND24 – Reference potential for digital I/O modules
Example: - 1 7 0 -  section 7. 7 DIN 1 – Record selection bit 1 (high active)
1) Several characters are displayed one after the other. 8 DIN 3 – Record selection bit 3 (high active)
9 DIN 5 – Controller enable (high active)
LED display 10 DIN 7 – Limit switch 1

Ready Green Operating status/controller enable 11 DIN 9 – Mode bit 1

Flashing green Parameter file (memory card) is being red/written 12 DOUT1 24 V 100 mA Motion complete (high active) 1)

CAN Yellow Status display: CAN bus active 13 DOUT3 24 V 100 mA Common error (low active) 1)
14 AGND 0V Reference potential for analogue signals
15 DIN13/#AIN0 –/Ri = 20 kΩ Stop (low active)/reference potential AIN0 2)
DIP switch 16 DIN 11 – Record selection bit 5 (high active) 2)
S1.1 … 7 CAN bus address or MAC-ID 17 AMON0 0 … 10 V ±4 % Output: analogue monitor 0
S1.8 Automatic loading of new firmware and parameter files from memory card 18 + 24 V DC 24 V 100 mA Output: 24 V DC, looped through from [X9.6]
S1.9 … 10 Setting the CAN-bus transmission rate 19 DIN 0 – Record selection bit 0 (high active)
S1.11 Activation of the CAN-bus interface 20 DIN 2 – Record selection bit 2 (high active)
S1.12 Terminating resistor for CAN-bus 21 DIN 4 – Output stage enable (high active)
22 DIN 6 – Limit switch 0
23 DIN 8 – Start for the positioning procedure (high active)
3 Mechanical installation
24 DOUT0 24 V 100 mA Output: Controller ready for operation (high active)
3.1 Assembly 25 DOUT2 24 V 100 mA Start acknowledged (low active) 1)
Observe the information on the installation dimensions and free spaces in 1) Default setting, configurable in the Festo Configuration Tool (FCT).
the  hardware description GDCP-CMMS-AS-G2-HW-... 2) Pin allocation with control via analogue input
4.2 Encoder [X2] 4.5 Serial interface RS232/RS485 [X5]
[X2] Pin Value Description [X5] RS232 Pin1) Value Description
1 MT+ +3.3 V / 3 mA Temperature sensor, motor temperature. 2 RS232_RxD 10 V, Ri > 2 kΩ Receive signal
2 –U_SENS 0V Connected internally with pin 3 9 5 3 RS232_TxD 10 V, Ra < 2 kΩ Transmission signal
8 4
8
15 3 GND 0V Reference potential US and MT+ 3 4 RS485_A Positive transmission and receive signal
7 7
14 2
6 5 #DATA USS = 5 V RS485 data transmission line (differential) 6 5 GND 0V Reference potential 0 V DC
13 1
5
12 6 #SCLK USS = 5 V Cycle output RS485 EnDat interface 9 RS485_B Negative transmission and receive signal
4
11 3 9 +U_SENS 5 V (–0 % … +5 %) Connected internally with pin 10 1) Connect only the pins for RS232 or RS485, dependent on the interface used!
10 2
9 10 US 5 V (–0 % … +5 %) Operating voltage for EnDat encoder
1
12 DATA USS = 5 V RS485 data transmission line (differential)
4.6 Motor [X6]
13 SCLK USS = 5 V Cycle output RS485 EnDat interface
[X6] Pin1) Value Description
1 BR– 0V For motors EMMS-AS-…- TSB/TMB:
4.3 STO interface [X3] 1 2 BR+ 24 V holding brake (motor)
Interface [X3] (Circuitry without use of the STO safety function) 2
3 MT– 0V Temperature sensor (N/C contact, N/O
[X3] Pin Value Description 3 contact, PTC or KTY)
4 4 MT+ + 3.3 V, 5 mA
1 24 V 24 V DC 24 V DC supply carried out 5 5 PE – PE connection of the motor cable
1 2 REL 0 V/24 V DC Setting and resetting the relay for 6 6 W  Hardware Connection of the three motor phases
2 interrupting the driver supply 7 7 V description
3 3 0V 0 V (GND 24 V DC) Reference potential for PLC (24 V DC) 8
4 8 U
5
4 – – –
1) In the motor and connecting cable, reliable separation of the motor temperature sensore from the motor
6 5 NC1 Max. 25 V AC, Potential-free feedback contact for driver
circuit must be ensured.
6 NC2 30 V DC, 2 A supply, NC contact

If third-party cables are used: Place the complete screening of the motor-
Circuitry without use of the STO safety function side cable flat on the plug or motor housing. Length ≤ 40 mm.
If you do not need the integrated safety function STO in your application, • Place the complete screening of the motor cable at the screening con-
to operate the motor controller you must bridge Pin 1 and Pin 2 at the X3 nection terminal of the related motor controller so that the leaked cur-
interface. rent can flow back into the controller causing it
This deactivates the integrated safety function! • Do not use the complete screening as strain relief.
With this circuitry, safety in the application must be ensured through other
appropriate measures.
Connection of a holding brake
Holding brakes are not appropriate for braking the motor. They only serve
Use of the STO safety function
functional holding of the motor shaft. Additional measures are required for
For intended use of the safety function STO – “Safe Torque Off ”, observe use in safety-oriented applications.
the information in the STO description  GDCP-CMMS-AS-G2-S1-...

Use the “Safe Torque Off ” function (STO) whenever you have to reliably disconnect 4.7 Power supply [X9]
the energy supply to the motor in your particular application. To ensure the func- Protection against electric shock through protective extra-low voltage (PELV):
tion STO “Safe Torque Off ”, the control ports DIN4 [X1.21] and Rel [X3.2] must be Warning
connected in two channels through parallel wiring. This interface can be part of an Danger of electric shock
emergency stop circuit or a protective door arrangement, for example.
Recommendation for initial start-up without safety equipment: • Only use PELV circuits in accordance with IEC/EN 60204-1 (protective
Minimum circuitry with emergency stop switching device and two-channel switch- extra-low voltage, PELV) for the electrical power supply.
off via the control ports REL [X3.2] and DIN4 [X1.21]. Also observe the general requirements for PELV circuits as per
IEC/EN 60204-1.
Note
• Only use voltage sources which guarantee reliable electrical isolation of the
Loss of the safety function.
operating voltage in accordance with IEC/EN 60204-1.
Lack of the safety function can result in serious, irreversible injuries, e.g. due to
uncontrolled movements of the connected actuator technology. The use of PELV circuits ensures protection from electric shock (protection from
– The STO function request must always run over X3.2 and X1.21 (end stage direct and indirect contact) in accordance with IEC/EN 60204-1 (Electrical equip-
enable). ment of machines, General requirements). A 24 V power supply unit used in the
– If uncontrolled coasting can result in a hazard or damage, additional meas- system must satisfy the requirements of EN 60204-1 for DC power supply (beha-
ures are required. viour during power interruptions, etc.).
– A clamping unit is actuated by the non-safety-relevant firmware of the CMMS- [X9] Pin Value Description
AS-...-G2 motor controller.
1 L1 1-phase Mains voltage connection for intermediate
• Make sure that no jumpers or the like can be inserted parallel to the safety 1
2 N 95 ... 250 V AC circuit voltage
wiring, e.g. through the use of the maximum wire cross section of 1.5 mm² or 2
suitable wire end sleeves with insulating collars. 3 IC + 320 V DC Connection for external braking resistor
3
(max 400 V DC)  Hardware description
• Use twin wire end sleeves for looping through lines between neighbouring 4
4 BR-CH 0 V/400 V, max. 4 A Not short-circuit proof against L1, N, PE
devices. 5
5 PE PE Mains-side PE connection
• Comply with the specified environmental and connection conditions, in partic- 6
ular the input voltage tolerances. 6 24 V +24 V/1.7 A Supply of the control section, DOUT..., etc.
7
• Place the motor controller in operation only if all safeguarding, including the 7 0V GND Common reference potential L1/24 V
safety function, has been installed and checked.
• The safety function must be checked and, prior to the intended use, a corres-
4.8 Master/slave interface [X10]
ponding validation must be carried out.
[X10] Pin Description
1 A/CLK/CW Tracking signal A/pulse CLK/steps CW
4.4 CAN [X4]
2 B/DIR/CCW Tracking signal B/direction DIR/steps CCW
[X4] Pin Value Description
3 N Incremental encoder zero pulse N
5
2 CANL 5 V, Ri = 60 Ω CAN low, signal line
9 4 GND 1) Reference GND for incremental encoder
4
9 5 3 GND – CAN GND, not galvanically isolated 8 3 5 VCC Auxiliary supply, maximum load 100 mA
4
8 7
3 5 Screening – Connection for the cable screening 2 6 #A/#CLK/#CW Tracking signal A/pulse CLK/steps clockwise CW
7 6
2 1
6
1
6 GND – CAN GND, not galvanically isolated 7 #B/#DIR/#CCW Tracking signal B/direction DIR/steps CCW
7 CANH 5 V, Ri = 60 Ω CAN high signal line 8 #N Zero pulse N
9 GND 1) Screening for the connecting cable

1) Pin 4 and pin 9 are connected internally

5 Commissioning No. Message group Cause/measure
Note 42-x Positioning Parameterisation/sequence control, homing?
Danger from unexpected movement of the motor or axis 43-x Limit switch error Check parametrisation, wiring and limit switches.
• Make sure that the movement does not endanger anyone. 45-x STO error Check activation; the error must not recur.
• Parameterise the motor controller with the Festo Configuration Tool (FCT) 64-x DeviceNet error Check configuration and network.
before enabling the controller via DIN5 [X1.9]. 65-x DeviceNet error Check configuration and network.
– Bypassing of safety equipment is impermissible 70-x Operating mode error Check factor group and impermissible change.
Recommendation for first commissioning without safety equipment 79-x RS232 error Check wiring and transferred data.
 section 4.3
8 Repair and disposal
Note
Damage to the motor controller Repair or maintenance of the motor controller is not permissible. If re-
quired, replace the motor controller.
The motor controller is damaged in case of
– excessive operating voltage Observe the local regulations for environmentally friendly disposal of elec-
– polarity reversal of the operating voltage connections tronic components.
– interchange of operating voltage and motor connections
– short circuits in the motor circuit between the motor phases and PE
9 Technical data
• Comply with the specified values for the supply voltage.
• Before switching on, check the connections [X9] and [X6]. The complete technical data on CMMS-AS-...-G2 can be found in the
• Check that no PE short circuit is present in the motor connection circuit.  Hardware description GDCP-CMMS-AS-G2-HW-...
When using the safety function, observe the special technical data and
Before switching on the power supply:
restrictions on environmental conditions in dependence on required out-
Check installation of the motor controller:
put nominal power in the description STO  GDCP-CMMS-AS-G2-S1-...
• Check all connections.
• Connect all PE protective conductors, even for brief measuring and test pur-
poses. General technical data
• Mounted module or cover plate on the card slot [EXT]. Mounted line on [X9] and Approvals
[X6]. CE marking (see declaration of in accordance with EU Machinery Directive 2006/42/EC
Check operating status conformity) in accordance with EU Low Voltage Directive
1. Make sure that the controller enable is switched off (controller enable: DIN 5 in accordance with EU EMC Directive
[X1.9] ). The device is intended for use in an industrial environment. Measures may need to be
2. Switch on the power supplies of all devices. The READY LED on the front of the implemented in residential areas for interference suppression.
device should now light up. Operating and environmental conditions
If the READY LED is not lit, there is a malfunction. If an “E” appears in the 7-seg- Permissible setup altitude above sea level
ments display followed by a sequence of numbers, this is an error message and with nominal power [m] 1000
you must eliminate the cause of the error. with power reduction [m] 1000 … 2000
Additional steps for preparation of commissioning can be found in the Air humidity [%] 0 … 90 (non-condensing)
 Function description GDCP-CMMS-AS-G2-FW- ... Protection class IP20
Degree of contamination 2
6 Obligations of the operator for the safety function Ambient temperature
The operational capability of the safety device is to be checked at adequate inter- with nominal power [°C] 0 … +40
vals. It is the responsibility of the operator to choose the type of check and time with power reduction [°C] +40 … +50
intervals in the specified time period. The check is to be conducted so the flawless
Storage temperature [°C] –25 … +70
functioning of the safety device in interaction with all the components can be veri-
Vibration and shock resistance
fied.
Operation in accordance with EN 61800-5-1, section 5.2.6.4
Recommendation: Carry out a performance test at least every 24 hours.
Transport in accordance with EN 61800-2, section 4.3.3
7 Diagnostics and fault clearance
No. Message group Cause/measure
Power supply/braking resistor [X9]
01-x Internal error – stack overflow Load approved firmware.
Load voltage
02-x Undervoltage in intermediate Check power supply, intermediate circuit voltage,
circuit undervoltage monitoring (threshold value). Input voltage [V AC] 95 … 250 (single-phase)
03-x Temperature monitoring, motor Check parameterisation (current regulator, limits). Input current [A] 4…5
04-x Temperature monitoring, Check installation conditions and cylinder sizing. Mains frequency [Hz] 50 … 60
electronics Logic supply
05-x Internal voltage supply Check 24 V logic supply. If error is present without Nominal voltage [V DC] 24 ± 20 %
connected peripheral equipment  repair. Nominal current (outputs unloaded, without holding [A] 0.35
06-x Intermediate circuit Check motor, cable and motor controller. brake)
(over-current) Max. current (incl. holding brake) [A] 1.7
07-x Intermediate circuit Check design and connection of the braking resistor.
Connection for external braking resistor
(overvoltage)
Braking resistor [Ω] ≥ 100
08-x Angle encoder Check encoder and encoder signals.
Pulse power (for 500 ms) [W] ≤ 1600
11-x Homing Check homing, switch arrangement.
Nominal power [W] ≤ 100
12-x CAN Re-start CAN controller. Check CAN configuration in the
controller. Check wiring. Operating voltage [V] 400
14-x Motor identification Check intermediate circuit voltage, encoder cable.
Motor blocked, e.g. holding brake does not release?
Safety reference data and safety specifications
16-x Initialization Load firmware again. Hardware defective?
17-x Following error monitoring Enlarge error window. Parameterise acceleration to be Safety function STO Safe restart interlock (STO, Safe Torque Off )
less. Motor overloaded? Category 3 Grading in categories as per EN ISO 13849-1
18-x Temperature monitoring Check installation conditions. Performance Level PL d Performance level as per EN ISO 13849-1
19-x I²t monitoring Motor/mechanics blocked or sluggish? T [Years] 20 Proof test interval
21-x Current measurement If the error occurs repeatedly  hardware defective. duration of use as per EN ISO 13849-1
22-x PROFIBUS Check slave address, bus termination, cabling. MTTFd [Years] 528 Mean time to dangerous failure.
25-x Firmware Update the firmware. Due to the service life of the internal switching relay, the safety data for the STO function apply
for an annual actuation rate of Die nop = 500,000 / a (CMMS-AS-…G2 from Rev. 02).
26-x Data flash Load factory setting. Hardware defective?
Type test The functional safety engineering of the product has been
29-x SD card Check SD card.
certified by an independent testing authority in accordance with,
31-x I²t monitoring Check motor and mechanical system. see certificate  www.festo.com
32-x Intermediate circuit Check mains voltage/power supply, braking resistor. Certificate issuing authority MFS 09030
35-x Fast stop Check parameterisation. Reliable component Yes, for the STO safety function
40-x Software end position Check target data and positioning range.
41-x Travel program Check parameterisation.