Smart Positioning Controller SPC200 - Festo...Electronics/ pneumaticsmanual System manual Smart Positioning Controller type SPC200 Handbuch 170 246 en 0304b [655255] Smart Positioning

Electronics/pneumatics�manual

System manual

Smart PositioningControllertype SPC200

Handbuch170 246en 0304b[655�255]

Smart Positioning Controller SPC200

Contents and general instructions

IFesto P.BE−SPC200−EN en 0304b

Author S. Breuer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Editor M. Holder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Original de. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Translation transline Deutschland. . . . . . . . . . . . . . . . . . . . .

Layout Festo AG & Co. KG, Dept. KG−GD. . . . . . . . . . . . . . . .

Type setting DUCOM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Edition en 0304b. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Designation P.BE−SPC200−EN. . . . . . . . . . . . . . . . . . . . . . . . .

Order no. 170 246. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

E (Festo AG�&�Co.�KG, D�73726 Esslingen, Federal Republicof Germany, 2003)Internet:http://www.festo.comE−Mail: [email protected]

The copying, distribution and utilization of this documentas well as the communication of its contents to others with�out expressed authorization is prohibited. Offenders will beheld liable for the payment of damages. All rights reserved,in particular the right to carry out patent, utility model orornamental design registrations.


II Festo P.BE−SPC200−EN en 0304b

IBM registered trade mark of International Business Machines Corporation

Microsoft Windows registered trade mark of Microsoft Corporation

Temposonics registered trade mark of MTS Sensortechnologie GmbH & Co


IIIFesto P.BE−SPC200−EN en 0304b

Contents

Designated use VII . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safety regulations VIII . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Target group IX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Service IX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Important user instructions X . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Product−specific terms and abbreviations XII . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Manuals for the SPC200 Smart Positioning Controller XIII . . . . . . . . . . . . . . . . . . . . . . . . .

Information on operating system version 4.6 XIV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1. System summary 1−1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.1 Positioning systems with the SPC200 1−4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.1.1 The range of devices for the SPC200 1−8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.1.2 Structure of the SPC200 1−11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.2 Connecting pneumatic axes 1−15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.3 Structure of the axis interface string 1−20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.4 Operating modes of the SPC200 1−25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.5 Multi−axis applications with the SPC200 1−26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.6 Commissioning and programming possibilities 1−27 . . . . . . . . . . . . . . . . . . . . . . .

1.7 I/O address range of the SPC200 1−31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2. Fitting 2−1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.1 Fitting and removing components 2−5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.2 Fit the basic unit 2−9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.3 Fit the control panel into position 2−12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.4 Fitting the axis interface and the I/O function module 2−16 . . . . . . . . . . . . . . . . . .

2.5 Notes on fitting the pneumatic axis 2−21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3. Installation 3−1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.1 General instructions on installation 3−4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.2 General instructions on installing the pneumatic components 3−5 . . . . . . . . . . .

3.2.1 Compressed air supply 3−5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.2.2 Service unit 3−6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


IV Festo P.BE−SPC200−EN en 0304b

3.2.3 Compressed air reservoir (optional) 3−7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.2.4 Proportional directional control valve type MPYE−... 3−8 . . . . . . . . . . . . . . . . . . .

3.2.5 Compressed air tubing and screw connectors 3−10 . . . . . . . . . . . . . . . . . . . . . . . .

3.2.6 Drives 3−11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.2.7 General instructions on measuring systems 3−11 . . . . . . . . . . . . . . . . . . . . . . . . . .

3.2.8 Requirements of the mechanism 3−12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.2.9 Permitted mass load 3−12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.2.10 Pneumatic Emergency Stop circuit 3−15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3 Installing the SPC200 3−22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3.1 Selecting the power unit 3−23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3.2 Connectoins on the supply module 3−25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3.3 Connectoins on the diagnostic module 3−31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3.4 Connections of the I/O module type SPC200−DIO−... 3−34 . . . . . . . . . . . . . . . . . . .

3.3.5 Connections of the analogue input module type SPC200−2AI−U 3−43 . . . . . . . . . .

3.3.6 Connections of the sub−controller module type SPC200−SCU−AIF 3−46 . . . . . . . . .

3.4 Installing the modules on the axis interface string 3−48 . . . . . . . . . . . . . . . . . . . . .

3.4.1 Installing the axis interface type SPC−AIF−... 3−52 . . . . . . . . . . . . . . . . . . . . . . . . . .

3.4.2 Installation I/O function module type SPC−FIO−2E/2A−M8 3−57 . . . . . . . . . . . . . . .

3.4.3 Installing control panel SPC200−MMI−1F 3−61 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4. Commissioning 4−1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.1 Commissioning procedure 4−5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.2 Connecting a single−axis system for the first commissioning 4−9 . . . . . . . . . . . .

4.3 Commissioning with the control panel 4−17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.3.1 Save the hardware configuration 4−17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.3.2 Commissioning pneumatic axes 4−21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.3.3 Notes on commissioning multi−axis systems 4−36 . . . . . . . . . . . . . . . . . . . . . . . . .

5. Controlling the SPC200 5−1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.1 General notes on operation 5−4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.2 Start/stop mode 5−9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.2.1 Explanation of all I/O signals in Start/stop mode 5−11 . . . . . . . . . . . . . . . . . . . . .

5.3 Record Select mode 5−18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.3.1 Explanation of all I/O signals in Record Select mode 5−23 . . . . . . . . . . . . . . . . . . .


VFesto P.BE−SPC200−EN en 0304b

6. Operating the SPC200 with the control panel 6−1 . . . . . . . . . . . . . . . . . . . . . . .

6.4 Structure and functions of the control panel 6−4 . . . . . . . . . . . . . . . . . . . . . . . . .

6.4.1 Moving in the menu system 6−7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.5 Setting project−specific parameters 6−13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.6 Edit programs 6−27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.6.1 Create new program 6−28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.6.2 Instructions on editing 6−33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.6.3 Store of commands on the control panel 6−35 . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.6.4 Edit existing program 6−39 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.6.5 Delete program 6−41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.7 Edit position register 6−42 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.8 Controlling the program sequence 6−46 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.9 Displaying operands and system states 6−48 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.10 Set controller factors 6−50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.11 Test and diagnostic functions of the control panel 6−52 . . . . . . . . . . . . . . . . . . . . .

7. Description of the commands 7−1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.1 General instructions on programming 7−4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.1.1 Parallel program processing 7−5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.1.2 Organisation of the programs 7−10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.1.3 Presettings for positioning 7−11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.1.4 Addressing 7−12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.1.5 New NC syntax and new NC commands 7−14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.2 Command syntax 7−16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.3 Explanation of the NC commands 7−22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8. Diagnosis and error treatment 8−1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.1 On−the−spot diagnosis 8−4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.2 Fault messages on the control panel 8−9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.3 Eliminating faults on the system 8−30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.3.1 Faults when switching on 8−30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.3.2 Faults when positioning 8−31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


VI Festo P.BE−SPC200−EN en 0304b

A. Notes on installing the pneumatic components A−1 . . . . . . . . . . . . . . . . . . . . .

A.1 Axis structure with drive type DGP(L)−... and type DGPI(L)... A−3 . . . . . . . . . . . .

A.2 Axis structure with standard cylinder type DNC−... A−10 . . . . . . . . . . . . . . . . . . . .

A.3 Axis structure with standard cylinder type DNCM−... A−17 . . . . . . . . . . . . . . . . . . .

A.4 Axis structure with rotary module type DSMI−... A−23 . . . . . . . . . . . . . . . . . . . . . .

B. Optimizing the positioning behaviour B−1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

B.1 Basic information on control B−3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

B.2 Description of the controller factors B−7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

B.3 Optimize positioning behaviour B−10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

B.3.1 Proceed as follows if the compressed air supply is unstable B−16 . . . . . . . . . . . .

C. Technical appendix C−1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

C.1 Sequence plans for the programmer C−3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

C.1.1 Creating readiness to operate C−3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

C.1.2 Start NC record in Record Select mode C−7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

C.1.3 Start program or NC record C−9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

C.1.4 Carry out fault quitting C−10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

C.2 Cable length and cross−sectional area C−14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

C.3 Internal layout of the inputs/outputs C−18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

C.4 Technical specifications C−22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

C.4.1 Technical specifications for the SPC200 C−22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

C.4.2 Technical specifications of axis interface type SPC−AIF−... C−28 . . . . . . . . . . . . . . .

C.4.3 Technical specifications of the I/O function module type SPC−FIO−... C−30 . . . . . .

C.4.4 Technical specifications of control panel type SPC200−MMI−1 C−32 . . . . . . . . . . .

C.4.5 Technical specifications of control panel type SPC200−MMI−1F C−33 . . . . . . . . . .

D. Index D−1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

D.1 Index D−3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


VIIFesto P.BE−SPC200−EN en 0304b

Designated use

The SPC200 Smart Positioning Controller is designed for fit�ting into a control caabinet. It serves as a closed−loop posi�tioning controller for pneumatic axes and as positioning con�troller for stepping motor axes. Basic components andmodules for the SPC200 are described in this �documenta�tion. Special extension modules are described in separatemanuals.

It is absolutely necessary to observe the safety instructionsas well as the designated use of the relevant components andmodules. Observe also the safety regulations listed in theoperating instructions for the pneumatic and electric compo�nents used.

The SPC200 and the modules and cables to be connectedmust only be used as follows:

� in accordance with designated use

� only for industrial usage

� without any modifications by the user. Only the conver�

sions or modifications described in the documentationsupplied with the product are permitted.

� in faultless technical condition.

If used together with additional commercially available com�ponents, such as sensors and actuators, the specified limitsfor pressures, temperatures, electrical data, torques etc.must be observed.

Observe also the standards specified in the relevant chapters,as well as national and local laws and technical regulations.


VIII Festo P.BE−SPC200−EN en 0304b

Safety regulations

When commissioning and programming positioning systems,the safety regulations listed in this manual as well as in theoperating instructions for the other components used, mustalways be observed.

The user must ensure that nobody has access to the position�ing range of the connected actuators or axis system. Thedanger area must be made inaccessible by means of suitablemeasures such as protective screening and warning signs.

WarningPneumatic and electric axes move at high speed and withhigh force.

Collisions can lead to serious injury to human beings anddamage to components.

Make sure that nobody can place his/her hand in the posi�tioning range of the axes or other connected actuators andthat no objects lie in the positioning path whilst the syss�tem is connected to sourcess of energy (compressed air,supply voltage).

WarningFaults in parametrizing can cause injury to human beingsand damage to property, if the controller is enabled with a1−signal at the ENABLE input.

Only enable the controller if the axis system has been in�stalled and parametrized by technically qualified staff.


IXFesto P.BE−SPC200−EN en 0304b

WarningIf the tubing of your axis system is incorrectly connectedand you enable the controller, the drive will move, depend�ing on the level of the supply pressure, at high speed andwith high acceleration into one of the end positions (con�trol direction reversed). This can lead to serious injury tohuman beings and damage to components.

Always check the tubing before enabling the controllerwith a 1−signal at the ENABLE input.

Target group

This manual is intended exclusively for technicians trained incontrol and automation technology who have experience ininstalling, commissioning, programming and diagnosing posi�tioning systems.

Service

Please consult your local Festo repair service if you have anytechnical problems.


X Festo P.BE−SPC200−EN en 0304b

Important user instructions

Danger categories

This manual contains instructions on the possible dangerswhich may occur if the product is not used correctly. Theseinstructions are marked (Warning, Caution, etc.), printed on ashaded background and marked additionally with a picto�gram. A distinction is made between the following dangerwarnings:

WarningThis means that failure to observe this instruction mayresult in serious personal injury or damage to property.

CautionThis means that failure to observe this instruction mayresult in personal injury or damage to property.

Please noteThis means that failure to observe this instruction mayresult in damage to property.

The following pictogram marks passages in the text whichdescribe activities with electrostatically sensitive compo�nents.

Electrostatically sensitive components may be damaged ifthey are not handled correctly.


XIFesto P.BE−SPC200−EN en 0304b

Marking special information

The following pictograms mark passages in the text contain�ing special information.

Pictograms

Information:Recommendations, tips and references to other sources ofinformation.

Accessories:Information on necessary or sensible accessories for theFesto product.

Environment:Information on environment−friendly use of Festo products.

Text markings

S The bullet indicates activities which may be carried out inany order.

1. Figures denote activities which must be carried out in thenumerical order specified.

� Hyphens indicate general activities.


XII Festo P.BE−SPC200−EN en 0304b

Product−specific terms and abbreviations

The following product−specific terms and abbreviations areused in this manual:

Term/abbreviation Meaning

0−signal Input or output supplies 0 V

1−signal Input or output supplies 24 V

Application parameters Configuration data which describe the conditions of use specified by theapplication.

Axis data Configuration data which describe the structure, the features and thecomponents of the axis used.

Axis interface The measuring system and the proportional directional control valve areconnected to the SPC200 via the axis interface.

Axis interface string All the modules and cables which are connected together to the axisinterface connection of the SPC200.

Components Function cards which are inserted in the rack of the SPC200.

CP cable Special cable for connecting the various modules to the axis interfacestring.

F Flags

I Digital input

I/O modules Common term for the modules which provide digital inputs and outputson the axis interface string.

I/Os Digital inputs and outputs

PLC/IPC Programmable logic controller/industrial PC

Q Digital output

R Register

String All the modules which are connected together on the axis interface string.


XIIIFesto P.BE−SPC200−EN en 0304b

Manuals for the SPC200 Smart Positioning Controller

This manual contains general basic information on fitting,installing and commissioning pneumatic axes with theSPC200 as well as on their functioning.

Extension modules are available for coupling to field bussystems and for connecting electric axes. Detailed informa�tion on this can be found in the manual for the relevant mod�ule.

Information on commissioning, programming and diagnosingthe SPC200 with the WinPISA software package can be foundin the relevant manual for WinPISA.

Type Title Content

System manual SPC200 Smart PositioningController, manualtype�P.BE−SPC200−...

Installation, commissioning anddiagnosing pneumatic axes withthe SPC200; standardcomponents and modules

Software manual WinPISA software packagetype�P.SW−WIN−PISA−...

Functions of the WinPISAsoftware package

Help system WinPISA help system (contained in WinPISA)

WinPISA help system

Manuals Field bus moduletype�P.BE−SPC200−...−...

Installing, commissioning anddiagnosing the relevant field busmodule

Stepping motor moduletype�P.BE−SPC200−SMX−1−...

Installing, commissioning anddiagnosing with a stepping motor

Electric positioning systemtype�P.BE−ATP−...

Further information on electricpositioning systems

Information on the pneumatic components can be found inthe operating instructions supplied with the product.


XIV Festo P.BE−SPC200−EN en 0304b

Information on operating system version 4.6

As from operating systemversion 4.6, the SPC200 also sup�ports in addition to the DGP(I)(L)−... the following drives(see�also appendix A):

Type Description

DNC−... Standard cylinderThe constant−run variant S10 (slow speed) and thelight−run variant S11 (low friction) are not permitted.Temperature−resistant variant S6 only on demand.

DNCM−... Standard cylinder with built−on measuring system

DSMI−... 1) Rotary module 1)

1) Only in conjunction with WinPISA as from version 4.3

As from version 4.6, the operating system of the SPC200offers, in conjunction with WinPISA as from version 4.3, anextended scope of functions due to the support of new NCcommands and extended NC syntax (see chapter 7.1.5).

Please notePrograms which use the new NC commands and theextended NC syntax of operating system version 4.6 orhigher cannot be displayed and cannot be edited withcontrol panel type SPC200−MMI−1... .

Operating system version 4.6 is downwards compatible andcan be operated with WinPISA as from version 3.0.

Please noteProjects and files created with WinPISA 4.3, which do notcontain any new NC commands, or extended NC syntax orrotary module type DSMI−... , can also be processed withWinPISA version 4.1a.

System summary

1−1Festo P.BE−SPC200−EN en 0304b

Chapter 1

1. System summary

1−2 Festo P.BE−SPC200−EN en 0304b

Contents

1. System summary 1−1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.1 Positioning systems with the SPC200 1−4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.1.1 The range of devices for the SPC200 1−8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.1.2 Structure of the SPC200 1−11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.2 Connecting pneumatic axes 1−15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.3 Structure of the axis interface string 1−20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.4 Operating modes of the SPC200 1−25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.5 Multi−axis applications with the SPC200 1−26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.6 Commissioning and programming possibilities 1−27 . . . . . . . . . . . . . . . . . . . . . . .

1.7 I/O address range of the SPC200 1−31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1. System summary


Contents of this chapter This chapter provides an overview of the extension possibi�lities for positioning systems with SPC200 as well the rangeof devicies and the structure of the SPC200. �This chapteralso �contains basic information on:

� connecting pneumatic axes to the axis interface string

� the operating modes, commissioning and programmingpossibilities of the SPC200

� the I/O address range of the SPC200.

Further information Coupling to field bus systems is made possible by specialfield bus modules. Detailed information on this can befound in the manual for the relevant field bus module.

The coupling of electric axes is made possible with specialmodules. Detailed information on this can be found in themanual for the relevant module.

1. System summary


1.1 Positioning systems with the SPC200

Festo assists you with your positioning tasks with theSPC200 Smart Positioning Controller. The SPC200 is a univer�sal, modular−based controller which supports the coupling ofpneumatic and electric axes with connection to field bus sys�tems.

Up to 4 axes can be connected depending on the equipmentfitted on the controller. Pneumatic and electric axes can beoperated in mixed mode.

1. System summary


1

2

3

4

5

6

7

8

1 Field bus connection (optional)

2 SPC200 Smart Positioning Controller

3 Control cabinet

4 Stepping motor controller

5 Further field bus slaves

6 Stepping motor axis

7 Pneumatic axis (here type DGPL−...)

8 Axis interface string (max. 2 axes)

Fig.�1/1: Extension possibilities for positioning systems with the SPC200

1. System summary


The components of the pneumatic axes, in some cases alsoexternal I/O modules, are connected via maximum two axisinterface strings with one cable each to the SPC200.

POWERDIAG OUTPUT

PNP

0 1

INPUT/OUTPUT

INPUT0 1

1

2

3

4

3

3

1

2

1 First axis interface string

2 Second axis interface string (optional)

3 Axis interface

4 External I/O modules

Fig.�1/2: Connecting pneumatic axes and external I/O modules

1. System summary


The SPC200 can be operated independently as well as in con�junction with a higher−order PLC/IPC. Within certain limits, itcan also manage control functions. For this purpose I/O mod�ules with digital inputs/outputs can be incorporated in theSPC200 or external I/O modules can be conneccted to theaxis interface string.

Coupling to a higher−order PLC/IPC can be made via digitalinputs/outputs or via special field bus modules (e.g. Inter�bus; PROFIBUS−DP etc.).

1. System summary


1.1.1 The range of devices for the SPC200

The range of devices for the SPC 200 includes the followingcomponents:

Components Function

SPC200 type SPC200−...−...

The SPC200 is housed in a rack. Depend�ing on the requirement of the positioningtask you can install the necessary compo�nents in the rack.

Control panel type SPC200−MMI−1...

The control panel has six buttons withwhich all functions can be accessed bymenu.Control panel type SPC200−MMI−1 can beplaced directly on the SPC200.Control panel type SPC200−MMI−1F isintended for mounting in a front plate.

Axis interfacetype SPC−AIF−...

The axis interface provides the connectionbetween the components on the pneu�matic axis and the SPC200. It receives thevalues supplied by the measuring system,passes them onto the SPC200 and pro�vides the positioning signal for the pro�portional directional control valve.

I/O function module(optional) typeSPC−FIO−2E/2A−M8

This module provides 2 inputs/outputs forconnecting sensors and actuators directlyon the axis. Additional functions, such ase.g. gripping, lifting, lowering and turningcan be implemented with these sensorsand actuators.

1. System summary


If required, the following CP I/O modules and CPV valve ter�minals can be connected to the end of the axis interfacestring.

CP modules (optional)

Function

CPV valve terminalstype CPV...−...−...

Provides via valve plates different valvefunctions for controlling pneumatic actua�tors. Relay plates, pressure zone separ�ation plates and blanking plates can alsobe fitted.

Input module type CP−E16...−M...

Special designs are available for variousconnection variants. Provide inputs forconnecting sensors and enable e.g. cylin�der positions to be scanned.

Output module type CP−A08−M12

Provide universally usuable electric out�puts for controlling low−current consum�ing devices (valves, bulbs etc.).

1. System summary


Supported drives

The SPC200 supports the pneumatic drives listed in the fol�lowing table. Consult Festo if you wish to use other drives.

Drive Description Permittedfittingposition

Positioning drive type DGP(I)(L)−...

Horizontal,vertical ordiagonally

Standard cylinder type DNC−... 1)

Standard cylinder withmeasuring system type DNCM−... 1)

Rotary module withmeasuring system type DSMI−... 1)

Drive shaftverticalupwards ordownwards

1) This drive is supported as from operating system version 4.6.

1. System summary


1.1.2 Structure of the SPC200

The SPC200 is built up on a modular basis and is housed in arack. The host computer and memory of the SPC200 are situ�ated on the rear wall printed circuit board in the rack.

The combination of rack and rear wall printed ciruit board isreferred to as the basic unit. Basic units with 4 and 6 loca�tions are available for implementing variants with differentequipment.

1

23

1 Rack (basic unit)

2 Rear wall printed circuit board (in the rack)

3 Modules

Fig.�1/3: SPC200 Smart Positioning Controller

Depending on the requirement of the positioning task, youcan install the necessary components in the basic unit.

1. System summary


Basic modules With the following modules the SPC200 provides a function�able controller device for penumatic axes:

1

2

3

1 Power supply module type SPC200−PWR−AIF

2 Diagnostic module type SPC200−MMI−DIAG

3 I/O module type SPC200−DIO

Fig.�1/4: Basic modules of the SPC200

Modules Description

Power supplymodule

Enables the power supply and the axis interfacedesigned as a field device to be connected.

Diagnosticmodule

Enables the control panel to be inserted orconnected and a PC to be connected.

I/O module Provides the necessary I/Os for controlling in thevarious operating modes.

1. System summary


A system with the modules mentioned above offers thefollowing scope of performance:

� Up to two pneumatic axes can be controlled

� Various measuring system types can be connected due todifferent variants of the axis interface

� Independent operation or coordination with externalPLC/IPC via I/Os

� Programming and operation via a PC or a control panel

Extension modules The modules listed in the following table are available forextending the system:

Module Description

Analogue inputmodule

With this module you can specify ana�logue nominal position values. The mod�ule has two analogue input channels forthis purpose. The permitted voltage rangeis 0...10 V.

I/O module Provides further freely programmableI/Os. The SPC200 supports maximum4�I/O modules.

Sub−controller module Enables two further pneumatic axes andfurther I/O modules to be connected. The module provides here the necessarycomputer output as well as a connectionfor a further axis interface string.

1. System summary


Module Description

Stepping motorindexer module

Enables a stepping motor controller to beconnected for operating a stepping motor

Field bus module Enables connection to be made to therelevant field bus

Further modules are in preparation.

1. System summary


1.2 Connecting pneumatic axes

With pneumatic axes the SPC200 takes over the control andpositioning of the axes. The measuring system and the pro�portional directional control valve are connected via the axissinterface which is placed directly on the drive.

The axis interface is connected to the SPC200 by only onecable, the axis interface string. The following diagram showsthe basic layout of a pneumatic axis with the SPC200.

1

2

3

4

5

6

7

1 Proportional directional control valvetype MPYE−...

2 Drive

3 Measuring system

4 Axis interface string

5 SPC200 Smart Positioning Controller

6 Axis interface type SPC−AIF−...

7 Service unit with 5 �m filter

Fig.�1/5: Connecting pneumatic axes to the SPC200

1. System summary


Components You will require the following components for setting up apneumatic axis:

� the SPC200 axis controller

� an axis interface type SPC−AIF−...

� a proportional directional control valvetype�MPYE−5−...−010B

� a measuring system type MLO−POT−...−TLF,type�MLO−POT−...−LWG or type MME−MTS−...−TLF−AIF or a drive with integrated measuring system

� a permitted drive

� if necessary, further components for the drive, e.g. amechanical guide, a coupling etc. (see appendix A)

� a service unit with 5 �m filter

� a 24 V DC power supply

� if necessary, components for a pneumatic emergencystop circuit.

The SPC200 Smart Positioning Controller takes control of thefollowing tasks:

� specification of the nominal position by positioningcontrol

� comparison of the nominal and actual positions and posi�tioning control by means of the proportional directionalcontrol valve (status control)

� optimization of the controller behaviour by parameteradaption

� control of the peripherals via digital inputs and outputsand sequence control.

1. System summary


Method of operation

The following diagram shows the basic layout of a position�ing control circuit with the SPC200 Smart Positioning Con�troller.

1

2

3

4

5

6

1 Position of the drive = control variable

2 Actual position value

3 SPC200 positioning controller

4 Axis interface

5 Valve voltage (positioning signal)

6 Proportional directional control valve(positioner)

Fig.�1/6: Positioning control circuit with pneumatic components

The axis interface, valve, drive and measuring system areconnected with each other to form a closed−loop control cir�cuit. In this closed−loop control circuit, the position of thedrive represents the control variable. This control circuit istherefore also called positioning control.

The measuring system registers continuously the position ofthe drive and passes this on to the axis interface in the formof an electric signal.

1. System summary


The measured values are passed on from the axis interface tothe SPC200 Smart Positioning Controller. The SPC200 com�pares the nominal position with current position and calcu�lates from this value the positioning signal for the propor�tional directional control valve.

The proportional directional control valve controls the driveby pressurizing one drive chamber and exhausting the other.In the mid−position the flow is blocked so that the drive stopstypically at the current position.

1. System summary


Notes on planning pneumatic axes

Note that in conjunction with the SPC200, the completestroke of the drive must not be used. On each side of thedrive positioning must not take place in the range of thestroke reduction (see appendix A).

CautionIf the range is exceeded, this can lead to impairment offunction and thereby to operating faults.

Please noteFor faultless operation of the pneumatic axes with theSPC200 the following performance limits must be ob�served.

Performance limits Value

Minimum speed With DGP(I)(L)−... , DNC−... and DNCM−...: 50 mm/sWith rotary modules DSMI−25−... and DSMI−40−...: 40°/s

Minimum positioningstroke

With DGP(I)(L)−... , DNC−... and DNCM−...:� with stroke lengths < 700 mm: 3 % of the stroke length� with stroke lengths � 700 mm: 20 mmWith rotary module type DSMI−...:� 3 % of the max. swivel angle

Usable stroke length orusable swivel angle

For the best possible positioning behaviour max. 80 % of the strokelength or of the max. swivel angle can be used (from 10 % to 90 %) 1)

1) The stroke reduction range must not be used (see appendix A)

1. System summary


1.3 Structure of the axis interface string

The SPC200 is intended for fitting into a control cabinet. Theconnection to the measuring system and the proportionaldirectional control alve is made via the axis interface which isconnected to the SPC200 via the axis interface string.

In its basic design, the SPC200 can take control of the posi�tioning of two pneumatic axes. Two axis interfaces and twopneumatic axes can therefore be connected to the axis inter�face string. The axis interface for the second axis is con�nected here to the axis interface of the first axis.

Axis identifiers The axis identifiers are assigned to the axes automatically.The first axis is addresses as the X−axis; the second axis asthe Y−axis.

1 Axis interface ofthe X−axis

2 Axis interface ofthe Y−axis

3 Axis interfacestring

POWER

ERROROUT

VALVEIN

POWER

ERROROUT

VALVEIN

1

2

3

3

Fig.�1/7: Assignment of axis identifiers (example 1)

1. System summary


Maximum two axis interface strings and therefore up to fourpneumatic axes are possible (X, Y, Z, U) per SPC200. The sec�ond axis interface string is connected via the sub−controllermodule type SPC200−SCU−AIF, which takes control of thepositioning of the further axes. Modules for connecting elec�tric axes can then be installed.

If modules for connecting further pneumatic or electric axesare fitted, the following applies:

� Axis identifiers (X, Y, Z, U) are distributed automatically inascending order without gaps from left to right on theinstalled modules.

� On the axis interface string the first axis receives thelower−value axis identifier, the second axis the higher−value axis identifier.

1. System summary


1

2 3 1 2 3 4

1 Axis interface of the X−axis

2 Axis interface of the Y−axis

3 Axis interface of the Z−axis

4 Stepping motor controller of the U−axis

Fig.�1/8: Assignment of axis identifiers (examples 2 and 3)

1. System summary


Further modules with inputs and outputs can be connectedto the axis interface string. The following diagram shows thepossible configurations on the axis interface string, with theexample of a two−axis system.

POWER

ERROROUT

VALVEIN

POWERDIAG OUTPUT

PNP

0 1

INPUT/OUTPUT

INPUT0 1

POWER

ERROROUT

VALVEIN

POWER

ERROROUT

VALVEIN

POWER

ERROROUT

VALVEIN

POWER

ERROROUT

VALVEIN

POWER

ERROROUT

VALVEIN

1 1 1

2

3

4

5

6

1 Possible alternatives

2 Axis interface of the X−axis

3 Axis interface of the Y−axis

4 Module with outputs/valves

5 Module with inputs

6 Module with inputs and outputs

Fig.�1/9: Configurations on the axis interface string (examples)

1. System summary


If required, the I/O function module 6 or the module withoutputs 4 is connected to the Out connection of axis inter�face 2 or 3. Modules with outputs 4 possess a connectionfor coupling an input module 5.

Input modules can also be connected directly to the axis in�terface.

The individual modules are connected to each other by ca�bles. Information is transmitted between the modules andthe SPC200 via this cable. The operating voltage and the loadvoltage are also provided via this cable. Identification of allconnected modules is carried out automatically by theSPC200.

1. System summary


1.4 Operating modes of the SPC200

The SPC200 offers suitable operating modes for the differentapplications. The functions of the digital inputs and outputsof the SPC200 depend on the operating mode set. The follow�ing operating modes are available:

� Start/stop mode

� Record Select mode

Start/stop mode In Start/stop mode the SPC200 can control simple position�ing tasks independently or together with a higher−orderPLC/IPC. Freely programmable inputs and outputs are avail�able in this operating mode.

You can start and stop positioning programs either with thecontrol panel, a handheld or a higher−order PLC/IPC.

The command Programmed Stop (M00) is available for loosecoupling with a higher−order PLC/IPC. With this commandyou can synchronize the program sequence of the SPC200,e.g. with externally controlled processes.

Record Select mode The Record Select operating mode supports the closecoupling of the SPC200 with a higher−order PLC/IPC. Thecomplete sequence control here is carried out by the con�trolling PLC/IPC. This controller passes positioning tasks inthe form of record numbers via digital I/Os to the SPC200.

When the I/O module is used, the NC records 0...31 of theactive program can be accessed via 5 digital inputs. Theserecords usually contain positioning tasks. The PLC/IPC cantherefore access freely up to 32 positions per axis. The maxi�mum permitted number of NC records (1000 NC records) canbe accessed via field bus modules.

1. System summary


1.5 Multi−axis applications with the SPC200

The SPC200 axis controller offers the possibility of parallelprogram processing and supports the setting up of multi−axisapplications. An SPC200 can control up to 4 axes. It therebysupports:

� the coordinated mode

� the autonomous mode.

Coordinated mode The possibility of parallel program processing is not nor�mally used in the coordinated mode. Only one program isdefined as the starting program. NC records with positioningtasks for all axes are programmed in this program.

If a positioning task concerns, e.g. all axes, it is not com�pleted until all the axes have reached the target position. Themovement sequence of all axes is thereby synchronized.

Autonomous mode With the implementaton of multi−axis systems, the con�nected axes can be distributed into two asynchronous− func�tioning independent work stations. This permits the low−cost implementation of two independent one or two−axissystems with one SPC200.

In the autonomous mode, the two parallel−running programseach contain positioning tasks for one defined work station.In this way, e.g. a loading and unloading station can be con�trolled with just one SPC200.

1. System summary


1.6 Commissioning and programming possibilities

You can carry out the commissioning and programming of theSPC200 with the:

� control panel type SPC200−MMI−...

� WinPISA software package.

With the control panel you can commission and programsingle and multi−axis systems. Compared with the controlpanel WinPISA offers an extended scope of functions and avery user−friendly user interface. The following table gives abrief overview:

Theme Function Controlpanel

WinPISA

Configuration � Entering axis data� Entering application data� Entering controller data

��

��

Programming � Entering programs� Entering positions� Teach Editor for positions� Project backup functions� New NC syntax and new NC commands

��

�� *)

Commissioning � Test functions for components� Program test in single steps� Extended test functions� Uploading/downloading programs� Starting and stopping programs

��

��

Service � Updating the SPC200 firmware by downloading� Reading out statistic diagnostic data

��

��

Analysis andoptimization

� Graphical representation of measured data� Entering extended system data

��

��

*) Only in conjunction with operating system versions 4.6 and WinPISA as from version 4.3

1. System summary


Control panel Control panel type SPC200−MMI−1... has a two−line LCD dis�play. Up to 16 characters per line can be represented. Thecontrol panel has six buttons with which all functions can beaccessed by menu.

Control panel type SPC200−MMI−1 can be placed directly onthe SPC200. Control panel type SPC200−MMI−1F is intendedfor mounting in a front plate.

1

2 3

1 Display (LCD display with 2 x 16 characters)

2 Touch−sensitive keyboard

3 Interface to the SPC200 on the rear

Fig.�1/10: Control panel type SPC200−MMI−1

The control panel offers all the necessary functions for com�missioning, programming, diagnosing and operating directlyon the SPC200. The control panel provides editor functionsfor editing position registers and programs.

1. System summary


You can enter positions or programs via menus on the key�board. If your positioning system is built−up completely, youcan move to positions very easily and transfer them to theposition register with the Teach functions.

WinPISA The WinPISA software package can run under the operatingsystem Windows® 95, 98, NT 4.0, ME, 2000 or XP. It offers acomfortable user interface.

1

2

3

1 Icon bar

2 Project window

3 Program window

Fig.�1/11: User interface of WinPISA

1. System summary


The WinPISA project window offers fast access to all projectdata. All project components, such as the position list, pro�grams and configuration data are represented graphically inthe project window. A double click suffices for checking set�tings or for undertaking modifications.

WinPISA provides the following functions:

� graphically supported configuration of the current project

� a user−friendly Editor for NC programming based onDIN�66025

� load functions for programs, projects, etc.

� a graphical function for analysing the positioningbehaviour.

WinPISA supports single−axis applications and multi−axisapplications with up to four axes.

Position list As an alternative to direct entry of positions (e.g. X100)when programming, you can also specify position values byposiition register. Specifying the position register. You sim�ply need to enter the desired position in the program regis�ter (e.g. X@1).

100 position registers are availabl per axis.

In WinPISA you can map the position register by means of theposition list. The position registers of all the axes aregrouped together under the same index in the position listand are given a name as a symbolic position. You can thenuse the names of the symbolicc positions in user programsinstead of specifying position registers.

Please noteAs from operating system version 4.6, position registers(@n) can also be used for saving speed and accelerationvalues.

1. System summary


1.7 I/O address range of the SPC200

A complete word (16 bits) for inputs and/or outputs is avail�able for every component and every I/O module, irrespectiveof how many I/Os are integrated.

Configuring the SPC200 Maximum address range

Without field bus module With �field bus module

First I/O module � I0.0�...�I0.9 1) Q0.0 ... Q0.7 1)

I/O module on the first axis interface string I1.0�...�I1.15 Q1.0 ... Q1.15

Second I/O module First I/O module I2.0�...�I2.9 Q2.0 ... Q2.7

I/O modules on the second axis interface string I3.0�...�I3.15 Q3.0 ... Q3.15

Third I/O module Second I/O module I4.0�...�I4.9 Q4.0 ... Q4.7

Fourth I/O module Third I/O module I5.0�...�I5.9 Q5.0 ... Q5.7

� Field bus module I10.0�...�I13.15 2) Q10.0 ... Q13.15 2)

1) Address range is not available if a field bus module is used 2) Address range is not available without a field bus module

1. System summary


The following diagram shows an example.

I0.0�...�I0.9�

Q0.0�...�Q0.7

I2.0�..�I2.9

Q2.0�...�Q2.7I4.0�..�I4.9

Q4.0�...�Q4.7

Q1.0�...�Q1.11

I1.0�...�I1.15

Q3.0�...�Q3.15

I3.0�...�I3.15

1

1 These I/Os are partly reserved bypre−assigned functions (control inputs and outputs)

Q = outputI = input

Fig.�1/12: Address assignment without field bus module (example)

Fitting


Chapter 2

2. Fitting


Contents

2. Fitting 2−1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.1 Fitting and removing components 2−5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.2 Fit the basic unit 2−9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.3 Fit the control panel into position 2−12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.4 Fitting the axis interface and the I/O function module 2−16 . . . . . . . . . . . . . . . . . .

2.5 Notes on fitting the pneumatic axis 2−21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2. Fitting


Contents of this chapter This chapter explains how to fit and remove SPC200modules as well as how to fit the following components:

� the SPC200 basic unit

� the control panel

� the axis interface

� the I/O function module

This chapter also contains instructions on how to fit thepneumatic axis.

Further information Instructions on fitting electromechanical axes, power con�trollers and sensors can be found in the documentation forthe relevant component.

Detailed information can also be found in the instructionssupplied with the product. Further information on the electricaxis can be found in the manual for the relevant module.

2. Fitting


WarningBefore carrying out installation and/or maintenance work,switch off the following in the sequence specified:

1. the compressed air supply

2. the load and operating voltage supplies on the SPC200and, if applicable, the load voltage supply on the axisinterface string.

You will thereby avoid:

� uncontrolled movements of the connected actuators

� uncontrolled movements of loose tubing

� undefined switching states.

2. Fitting


2.1 Fitting and removing components

CautionComponents may be damaged if they are not handledcorrectly.

S Do not touch the electrical contacts of the modules.

S Observe the regulations for handling electrostaticallysensitive components.

S Protecting the components against discharges of staticelectricity Discharge yourself of static electricity beforefitting or removing the modules.

The rack type SPC200−CPU−... serves as a housing for thecomponents of the SPC200. The processor and memory ofthe SPC200 are situated on the integrated rear−wall printedcircuit board. The components inserted are connected witheach other via this rear−wall printed circuit board.

The components are fastened with the aid of a locking leveron the rack. A tool is not therefore required for fitting orremoving the components.

Locations The locations are marked from left to right with 1 to 4 or 6.Location 1 is reserved for the power supply module(type�SPC−200−PWR−AIF). Other components can be fitted asdesired in locations 2 to 4 or 6. Individual identification of allinserted components is carried out automatically.

2. Fitting


Module Type designation Maximumnumber

Power supply module SPC200−PWR−AIF 1

Diagnostic module SPC200−MMI−DIAG 1

Sub−controller module SPC200−SCU−AIF 1

Field bus module SPC200−COM−... 1

Nominal value module SPC200−2AI−U 2

Stepping motor indexer modules SPC200−SMX 3

I/O modules SPC200−DIO 3 or 4 1)

1) Maximum four I/O modules if a field bus module is not installed.

Recommendation:

� If a sub−controller or stepping motor module is installed:Check to see if the modules must be fitted in a certainsequence. Axis identifiers (X...U) are assigned automati�cally to these modules in ascending order without gapsfrom left to right (see chapter 1.3).

� Mount the sub−controller module if possible in the outer�most right−hand location. The cable screening/shield canthen be fitted easily to the earth connection on the right−hand side.

� Mount the stepping motor indexer module and the fieldbus module with a gap of at least one location from thediagnostic module, if you are using a control panel.

2. Fitting


WarningActuators can be activated unintentionally and the SPC200can be damaged if modules are fitted or removed whenthe power supply is switched on. Before carrying out in�stallation and/or maintenance work, switch off the follow�ing in the sequence specified:


2. the load voltage and operating voltage supplies of theSPC200.

Fitting modules Fit the modules into the rack as follows:

1. Switch off the compressed air supply and the operatingvoltage supply.

2. If necessary, remove the blanking plate.

3. Hold the module by the front plate and push it into theguide rail. Make sure that the modules are not tiltedwhen they are pushed in and that the components on theprinted circuit board are not damaged.

4. Make sure that the plugs on the contact strips are cor�rectly aligned. Then gently push the module in complete�ly. The locking levers will then engage automatically(see�Fig.�2/1).

2. Fitting


1 Locksautomatically

2 Direction forunlocking

3 Guide rail

4 Contact strip

5 Front plate of themodule

6 Locking lever

1

2

34

5

6

Fig.�2/1: Installing the modules

Removing modules Proceed as follows when removing a module:

1. Switch off the compressed air supply and the operatingvoltage supply.

2. Disconnect and remove the connecting cable from thefront of the module.

3. Unlock both locking levers (see Fig.�2/1) and carefullyremove the module.

4. If necessary, seal the unused connections with blankingplates.

2. Fitting


2.2 Fit the basic unit

You can fit the SPC200 into a control cabinet in one of twoways:

� by screwing it directly to the wall of the control cabinet

� by means of a hat rail.

Please noteFit the SPC200 or the hat rail so that there is sufficientspace above or below for heat dissipation (at least40�mm).

Screwing the SPC200 to the wall

You will require:

� a mounting surface of approximately 126 x 120 mm.

� four threaded holes for screw size M4 (dimensions seefollowing diagram).

94 mm

1

1 SPC200−CPU−4: 117 mmSPC200−CPU−6: 158 mm

Fig.�2/2: Screwing the SPC200 to the wall

2. Fitting


Fitting with a hat rail

In order to fit the rack onto a hat rail, you will require mount�ing kit CPV10/14−VI−BG−NRH. This kit consists of 2 brackets,4�M4x10 screws and 2 clamping elements with spring(see�Fig.�2/3).

Proceed as follows when fitting the SPC200 onto a hat rail:

1. Make sure that the mounting surface can support theweight of the SPC200.

2. Fit a hat rail (support rail EN 50022 � 35x7.5;width�35�mm, height 7.5 mm).

3. Fasten the hat rail at least every 100 mm to the fasteningsurface.

4. Screw the two brackets 2 with the M4x10 screws sup�plied 1 to the fastening bracket of the rack (see follow�ing diagram). Make sure that the fixing bolts 5 of thebracket grip into the groove of the rack.

5. Hang the rack onto the hat rail. Fasten the rack with theclamping elements 4 so that it cannot tilt or slide down.

2. Fitting


1 M4*10 screw

2 Bracket

3 Hat rail

4 Clampingelement

5 Fixing bolts

12

3

45

Fig.�2/3: Fitting the rack onto a hat rail

Dismantle the rack as follows:

1. Remove the clamping elements.

2. Lift up the rack.

2. Fitting


2.3 Fit the control panel into position

Control panel type SPC200−MMI−1

Control panel type SPC200−MMI−1 can be inserted directlyinto the diagnostic module type SPC200−MMI−DIAG of theSPC200 (see Fig.�2/4).

WarningActuators can be activated unintentionally and the SPC200can be damaged if modules are fitted or removed whenthe power supply is switched on. Before carrying out in�stallation and/or maintenance work, switch off the follow�ing in the sequence specified:



Proceed with fitting as follows:

Control panel type SPC200−MMI−1 can be inserted directlyinto the diagnostic module type SPC200−MMI−DIAG of theSPC200 (see Fig.�2/4).

1. Switch off the compressed air supply.

2. Switch off the load voltage and operating voltagesupplies on the SPC200.

3. Carefully place the control panel onto the diagnosticmodule type SPC200−MMI−DIAG of the SPC200. Makesure that plug 3 and socket 5 are correctly alignedbefore fully inserting the control panel.

4. Make sure that locking pins�2�snap into position.

2. Fitting


1 Control panel(side view)

2 Locking pin

3 Locking pins onthe control panel

4 Diagnosticmodule

5 Socket for controlpanel (X3)

6 Groove for lockingpins

ÎÎÎ

1

2 3

4

5

6

2

Fig.�2/4: Fitting the control panel

Proceed as follows:

1. Switch off the compressed air supply.

2. Switch off the operating voltage and load voltage sup�plies for the SPC200.

3. Carefully lift up the control panel from diagnostic moduletype SPC200−MMI−DIAG.

2. Fitting


Control panel type SPC200−MMI−1F

Control panel type SPC200−MMI−1F is intended for mountingin a front plate. For fastening the control panel you require aspace of approx. 114 x 102 x 70 mm and a cut−out area ofapprox. 92 x 92 mm. The front plate must not be thicker than4 mm.

1 Display (LCDdisplay with 2 x 16characters)

2 Fastening clamps

1

2

Fig.�2/5: Control panel type SPC200−MMI−1F

The following diagram shows appropriate dimensions.

1 2 3

1 Control panel (side view)

2 Control panel (rear view)

3 Fastening clamps (included in delivery)

Fig.�2/6: Dimensions of type SPC200−MMI−1F

2. Fitting



1. Push the control panel into the cut−out in the front plate.

2. Hang the fastening clamps from the rear into theappropriate cut−outs.

3. Screw the control panel to the front plate.

1 Control panel

2 Front plate

3 Fastening clamps

4 Fastening screws

1.

2.3.

1

2

3

4

Fig.�2/7: Fitting control panel type SPC200−MMI−1F

2. Fitting


2.4 Fitting the axis interface and the I/O function module

This section explains how to fit the I/O function module typeSPC−FIO−... and the axis interface type SPC−AIF−...�.

Fitting the axis interface

Fit the axis interface as close as possible to the relevantdrive. The length of the cable to the measuring systemshould be approx. 500 mm.

With the aid of the support brackets supplied, the axis inter�face type SPC−AIF−... can be fitted either vertically or horizon�tally on a flat surface. The following mounting surface is re�quired, depending on the method of fastening:

Method of fastening Mounting surface

Horizontal Approx. 66 mm x 70 mm

Vertical Approx. 66 mm x 30 mm

The following diagram shows the dimensions for the fourthreaded holes of screw size M4 as well as how to fit thesupport brackets.

2. Fitting


85.8 mm

1

2

3

8.45 m

m

16.9 mm

66 m

m

34 mm

81 mm

30 mm

72 m

m

95 mm

1 Fitting the support brackets with horizontal mounting

2 Angled plug

3 Fitting the support brackets with vertical mounting

Fig.�2/8: Fitting the axis interface type SPC−AIF−...

S Fasten the axis interface with at least 3 screws.

2. Fitting


Fitting the I/O function module

I/O function modules are intended for fitting onto a flatsurface and for hat rails.

Fitting onto a wall For fastening to a flat surface you will require a mountingarea of approx. 70 x 80 mm. The following diagram showsthe dimensions for the four threaded holes of screw sizeM4.

1 I/O functionmodule typeSPC−FIO−2E/2A−M8

POWER

DIAGOUTPUT

PNP

0 1

INPUT/OUTPUT

INPUT0 1

67 mm

40 mm

1

Fig.�2/9: Fitting dimensions of the I/O function module

Fitting onto a hat rail In order to fit the I/O function module onto a hat rail, youwill require mounting kit CP−TS−HS35. This kit consists oftwo fastenings, two M4*12 screws and two washers.


1. Fit a hat rail (support rail EN 50022 � 35x15;width�35�mm, height 15 mm).

2. Fasten the hat rail at least every 100 mm to the fasteningsurface.

3. Snap both fastenings into the hat rail (see Fig.�2/10).

2. Fitting


4. Screw the housing to the fastening with the screws andwashers supplied, as shown in the following diagram.

5. Tighten the screws. The fastening and the housing willthen be clamped firmly on the hat rail.

1 Fastening

2 Housing

3 M4x12 screw

4 Washer

5 Hat rail

1 2

3

4

5

Fig.�2/10: Fitting the SPC−FIO−2E/2A−M8 onto a hat rail

2. Fitting


Proceed with dismantling as follows:

1. Loosen the screws.

2. Remove the housing.

3. Use a screwdriver to lift the fastening out of the hat rail.

1 Screwdriver

2 Fastening 1

2

Fig.�2/11: Dismantling the fastening

2. Fitting


2.5 Notes on fitting the pneumatic axis

Please noteFit the drive, the measuring system and the proportionaldirectional control valve in accordance with the relevantoperating instructions.

The following sections contain general rules which are im�portant for the reliable operation of a pneumatic axis.

Proportional directional control valve

� Fit the proportional directional control valve as close aspossible to the drive. Short compressed air tubing willensure the dynamics of the system.

� If you wish to fit the proportional directional control valveonto moving parts, you must fit it at right angles to thedirection of movement. Acceleration forces then have noinfluence on the valve slide setting.

� If the proportional directional control valve is to be usedin an environment subjected to heavy electrical interfer�ence, it should be insulated from the mounting surface.

� Use silencers with a large flow.

2. Fitting


Drives

CautionMount shock absorbers on the drive, also on drives withadjustable cushioning (PPV). In this way you can avoiddamage in the event of operating and system faults.

CautionLimit the positioning range by means of fixed end stops ifthe measuring system is shorter than the positioningrange. In this way you can avoid damage to the measuringsystem in the event of operating and system faults.

Important for positioning accuracy

� The cylinder, guide, measuring system and load must berigid in the direction of movement, have very little playand must be connected flush with each other.

� The play between the drive, guide, mass and measuringsystem must be smaller by the factor 10 than the requiredtolerance (max. 0.1 mm).

Installation


Chapter 3

3. Installation


Contents

3. Installation 3−1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.1 General instructions on installation 3−4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.2 General instructions on installing the pneumatic components 3−5 . . . . . . . . . . .

3.2.1 Compressed air supply 3−5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.2.2 Service unit 3−6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.2.3 Compressed air reservoir (optional) 3−7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.2.4 Proportional directional control valve type MPYE−... 3−8 . . . . . . . . . . . . . . . . . . .

3.2.5 Compressed air tubing and screw connectors 3−10 . . . . . . . . . . . . . . . . . . . . . . . .

3.2.6 Drives 3−11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.2.7 General instructions on measuring systems 3−11 . . . . . . . . . . . . . . . . . . . . . . . . . .

3.2.8 Requirements of the mechanism 3−12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.2.9 Permitted mass load 3−12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.2.10 Pneumatic Emergency Stop circuit 3−15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3 Installing the SPC200 3−22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3.1 Selecting the power unit 3−23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3.2 Connectoins on the supply module 3−25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3.3 Connectoins on the diagnostic module 3−31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3.4 Connections of the I/O module type SPC200−DIO−... 3−34 . . . . . . . . . . . . . . . . . . .

3.3.5 Connections of the analogue input module type SPC200−2AI−U 3−43 . . . . . . . . . .

3.3.6 Connections of the sub−controller module type SPC200−SCU−AIF 3−46 . . . . . . . . .

3.4 Installing the modules on the axis interface string 3−48 . . . . . . . . . . . . . . . . . . . . .

3.4.1 Installing the axis interface type SPC−AIF−... 3−52 . . . . . . . . . . . . . . . . . . . . . . . . . .

3.4.2 Installation I/O function module type SPC−FIO−2E/2A−M8 3−57 . . . . . . . . . . . . . . .

3.4.3 Installing control panel SPC200−MMI−1F 3−61 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3. Installation


Contents of this chapter This chapter contains general instructions on installing thepneumatic axis. It also deals with the installation of theSPC200 basic unit with the following components andmodules:

� power supply module type SPC200−PWR−AIF

� diagnostic module type SPC200−MMI−DIAG

� I/O module type SPC200−DIO

� analogue input module� type SPC200−2AI−U

� sub−controller module type SPC200−SCU−AIF

� axis interface type SPC−AIF−...

� I/O function module type SPC−FIO−2E/2A−M8

This chapter also contains important basic rules on setting upan axis interface string.

Further information Installation instructions on special drives can be found inappendix A.

Installation instructions on field bus modules as well as mod�ules for coupling electric axes can be found in the manual forthe relevant module.

Instructions on fitting electromechanical axes, power con�trollers and sensors can be found in the documentation forthe relevant component.

3. Installation


3.1 General instructions on installation

CautionUse only the special matching components from Festo forsetting up and wiring the system. Only in this way can youguarantee the correct functioning of the system.

WarningBefore carrying out installation and/or maintenance work,switch off the following in the sequence specified:



You will thereby avoid:

� uncontrolled movements of the connected actuators

� uncontrolled movements of loose tubing

� undefined switching states.

3. Installation


3.2 General instructions on installing the pneumatic components

Please noteFaults in the axis set−up can lead to malfunctioning. Ob�serve all the instructions on installing pneumatic compo�nents. Set up the system with great care. Only then canyou guarantee faultless operation.

The following sections contain general instructions on instal�ling pneumatic components. These instructions apply to allthe drives mentioned here. Special installation instructionsrelated to a certain drive can be found in appendix A.

Please noteIt is necessary to carry out identification during the firstcommissioning, when components are replaced, as well aswhen the drive configuration is modified (e.g. mountingposition, tubing or supply pressure) (see section 4.3.2).

3.2.1 Compressed air supply

For protecting the proportional directional control valveagainst damage you will require a service unit with a 5��mfilter.

S Use only dry non−lubricated 5 �m filtered compressed air4...8�bar, tolerance ± 1 bar. Note the permitted pressurerange of the components used.

3. Installation


3.2.2 Service unit

S Use a service unit consisting of a compressed air filterand a regulating valve (e.g. type LFR−...−D−... with 5��mfilter element) as well as a safety start−up valve(e.g.�HEL−...−...):

� without lubricator

� with a 5 �m filter

� with sufficiently large nominal flow corresponding tothe air requirement of the connected cylinder duringpositioning. Reference value: twice the rated flow ofthe valve (type MPYE−5−...).

� Use a microfilter if you cannot avoid slight oil mistfrom the compressed air supply.

3. Installation


3.2.3 Compressed air reservoir (optional)

For good positioning behaviour during operation, fluctuationsin pressure of max. 1 bar are permitted in front of the propor�tional directional control valve. In order to check the stabilityof the supply pressure, you can fit a pressure measuringpoint directly in front of the proportional directional controlvalve.

S Install a compressed air reservoir (e.g. type VZS−...−B)between the service unit and the proportional directionalcontrol valve, if the positioning behaviour does not meetyour requirements and if you ascertain fluctuations inpressure of over 1 bar in front of the proportional direc�tional control valve.

In this way you can reduce fluctuations in pressure duringoperation. You can compensate for slight excesses in thepermitted pressure by using supply tubing with a largerdiameter.

Reservoir volume:

The size of the reservoir volume depends on the cylinder vol�ume of the drive used and should be at least twice as large asthe volume of the cylinder used.

VP = 2 * VZ

VP = buffer volume;VZ = cylinder volume (VZ = r2 * � * LZ )LZ = cylinder stroke length r = cylinder diameter / 2

3. Installation


3.2.4 Proportional directional control valve type MPYE−...

S Fit the proportional directional control valve as close aspossible to the drive. Short compressed air tubing willensure the dynamics of the system.

S If the proportional directional control valve is to be usedin an environment subjected to heavy electrical interfer�ence, it should be insulated from the mounting surface.

S Fitting onto moving parts:If fitted to moving parts, the proportional directional con�trol valve must be mounted at right−angles to the direc�tion of movement. Acceleration forces then have no influ�ence on the valve slide setting.

1 2

3

1 Fitting at right angles to the direction of movement

2 Not permitted

3 Proportional directional control valve type MPYE−...

Fig.�3/1: Fitting to moving parts

S Use silencers with a large rated flow (e.g. U−1/8).

Reducing loud exhaust noises:

S Install larger silencers with the aid of tubing or pass theducted exhaust into a small compressed air reservoir andexhaust this with a large silencer. Make sure that thescrew connectors and tubing provide sufficient flow. Keepthe tubing as short as possible.

3. Installation


1 Ducted exhaust

2 Compressed airreservoir

3 Silencer

1

2

3

Fig.�3/2: Ducted exhaust

3. Installation


3.2.5 Compressed air tubing and screw connectors

S If possible, use screw connectors from the QS or QSMseries. In the case of drives with 3/8 connection,CK�screw connectors of type CK−3/8−PK−13 are alsopermitted.

S Use only straight screw connectors. If angled connectorscannot be avoided, use plug connectors from the FestoQuick Star series.

S Use screw connectors with the largest possible ratedwidth. If the proportional directional control valve and thedrive have connections of different sizes, select thelargest possible rated width of the smaller connectionsize.

S Depending on the screw connectors, always use thelargest possible tubing diameter.

S Avoid installing restrictors or non−return valves in thesupply line.

S Arrange the tubing so that it does not project into thepositioning range.

S Use only clean compressed air tubing and connectors.

S Use tubing as short as possible between the valve(MPYE−5−...) and the drive and arrange the tubingsymmetrically.

The permitted tubing lengths for the relevant drive can befound in appendix A.

Details on permitted temperature and pressure ranges fortubing and connectors can be found in the Pneumatics cata�logue.

3. Installation


3.2.6 Drives

Use only the permitted drives with suitable guide listed inappendix A. Consult Festo if you wish to use other drives.

Installation instructions for the permitted drives can be foundin appendix A.

3.2.7 General instructions on measuring systems

Please noteNote that the positioning accuracy which can be reacheddepends on the type of measuring system used.

The mechanical work path (possible slide path) of themeasuring system can be longer than the electrical work path(usable stroke length of the measuring system).

If analogue measuring systems are used (e.g. type MLO−POT−...), the following also applies: In conjunction with the SPC200, an electrical reserve of��0.3�% of the rated length is also required in both endpositions.

Example:

� Rated length of the measuring system: 1000 [mm]

� Permitted work path: 3 ... 997 [mm]

CautionIf the slide of the measuring system leaves the permittedwork path, the SPC200 will generate an appropriate faultmessage. In order to avoid these fault messages, limit thepositioning range so that the slide of the measuring sys�tem is always within the permitted work path.

3. Installation


Measuring systems with actuator slide

� If you wish to use a measuring system with a slide underdifficult ambient conditions, fit it so that the side with theactuator slide faces downwards. The drip edge on bothsides prevents excessive dirt from forming on the runningsurface.

3.2.8 Requirements of the mechanism

� The drive, guide, measuring system and load must berigid in the direction of movement, have very little playand must be mounted flush with each other.

� If necessary, provide a sufficiently large supply of energyin order to minimize the effects of transverse forces onthe positioning behaviour.

� The play between the drive, guide, mass and measuringsystem must be smaller by the factor 10 than the requiredtolerance (max. 0.1 mm).

3.2.9 Permitted mass load

For good positioning behaviour the drive must be operatedwith a permitted mass load. The mass load represents thecomplete mass to be moved including the weight of the pis�ton and the slide. The mass load comprises the tool load andthe current work load. The permitted mass load depends on:

� the type of drive used

� the diameter of the drive used

� the mounting position

� the operating pressure.

3. Installation


Make sure that:

� the tool load is greater than or equal to the ascertainedminimum mass load. In this way, the minimum mass loadwill always be reached even during positioning withoutwork load (recommendation). If necessary, mount anappropriate basic load.

� the work load together with the tool load does not exceedthe ascertained maximum mass load.

Mass load for linear drives and standard cylinders

Determine the permitted mass load by means of the followingtable:

Mounting position Maximum mass load Minimum mass load

Horizontal (á = 0°) mmax 0.1 * mmax

Vertical (á = 90°) 0.33 * mmax 0.1 * mmax

Diagonal (0° < á < 90°) (1−2/3 sin ) * mmax 0.1 * mmax

á = Mounting position in �[°]mmax = d³ * Psys * 0.008d = Cylinder diameter [mm]Psys = Supply pressure [bar]mmax = Maximum mass load for horizontal mounting position [kg]�

3. Installation


Mass moment of inertia for rotary drives

The mass moment of inertia must not change during themovement. Permitted mass moments of inertia for rotarymodule type DSMI−... in electronically regulated operationwith the SPC200 are shown in the following table:

Rotary module Permitted mass moment of inertia[kgm2 * 10−4]

DSMI−25−... 15 ... 300

DSMI−40−... 60 ... 1200

Festo supports you in calculating the mass moment of inertiawith the MTM calculation program (Internet: http://www.fes�to.com). This program serves for calculating the mass mo�ments of inertia of the 2nd. degree for various basic units andstandard parts from Festo (e.g. clip−on flange for DSMI−...).

3. Installation


3.2.10 Pneumatic Emergency Stop circuit

In order to put the system into a safe state in the event of afault, you will require a pneumatic Emergency Etop circuit.From the types of circuit listed below, select the one whichbest suits the construction and operating characteristics ofyour system:

� drive pressureless during Emergency Stop

� drive clamped during Emergency Stop

� drive moves at reduced speed into the left or right−handend position during Emergency Stop.

Variants of Emergency Stop circuits

The following four diagrams show as an example four variantsof Emergency Stop circuits for a linear drive. In each case theEmergency Stop situation is represented.

Requirements and recommendations concerning the compo�nents used see Fig.�3/7 and Fig.�3/8.

3. Installation


Variant 1: Drive pressureless during Emergency Stop

1 Emergency Stopactuated

1

1A

1V1

1V2

1V3

1V4

1G1

1R1

EMERGENCY STOP

Fig.�3/3: Drive pressureless during Emergency Stop

3. Installation


Variant 2: Drive clamped during Emergency Stop


1

1A

1V1

1V2

1V3

1G1

1R1

EMERGENCY STOP

Fig.�3/4: Drive clamped during Emergency Stop

3. Installation


Variant 3: Drive moves at reduced speed into the right−handend position during Emergency Stop


1

1A

1V2

1V1

1V3

1G1

1R1

1V4EMERGENCY STOP

Fig.�3/5: Drive moves at reduced speed into the right−hand end position duringEmergency Stop

3. Installation


Variant 4: Drive moves at reduced speed into the left−handend position during Emergency Stop


1

1G1

1R1

1A

1V2

1V1

1V3

1V4

EMERGENCY STOP

Fig.�3/6: Drive moves at reduced speed into the left−hand end position duringEmerg

Smart Positioning Controller SPC200 - Festo...Electronics/ pneumaticsmanual System manual Smart Positioning Controller type SPC200 Handbuch 170 246 en 0304b [655255] Smart Positioning

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