KEBA FM 299/A fieldbus master module: Sanyo Denki driver bus in K2-200 system

In the field of industrial motion control, high-speed and deterministic communication between controllers and servo drives is key to ensuring multi axis collaborative accuracy. As a mature platform for plastic machinery, metal forming, and complex motion control fields, the KEBA KEMRO K2-200 automation system's FM 299/A fieldbus master module is specifically designed as a dedicated interface module to solve the integration of Sanyo Denki's drive bus. This article is based on the engineering manual "FM 299/A GA1060 Field Bus Master Module Project Engineering Manual V1.1", and provides in-depth technical analysis of the module from five dimensions: functional positioning, system configuration, electrical wiring, status diagnosis, and technical specifications.

Product positioning: Dedicated driver bus master station for K2-200 system

The FM 299/A module is the fieldbus master module in the K2-200 modular control system, with the sole mission of serving as the master controller for the Sanyo Denki GA1060 driver bus. This bus is specifically designed to connect Sanyo Denki QSE series servo drives, enabling real-time issuance of position, speed, and torque commands and upstream acquisition of encoder feedback.

Core features:

Specialization: does not support other fieldbus protocols, specifically optimized for GA1060 physical layer and data link layer;

Dual module support: A single K2-200 CPU can run up to 2 FM 299/A modules simultaneously, managing independent driver networks separately;

Seamless integration: directly connected to the K2-200 backplane bus (K-Bus), configured uniformly by the CPU through cfg files;

Compact design: 22.5mm front panel width, 32.5mm overall width, suitable for high-density cabinet installation.

This module belongs to the category of "Open Type Equipment" and must be installed in a closed control cabinet, complying with UL 508 and IEC 61131-2 standards.

System configuration: from KEMRO.Manager to the underlying cfg file

The configuration process of FM 299/A embodies the engineering philosophy of combining textual configuration with graphical tools in the K2-200 system.

1. Configure graphically through KEMRO.Manager

KEMRO.Manager is an integrated engineering platform for the K2-200 system. After the user adds the FM 299/A module to the hardware configuration tree, the system automatically generates the corresponding GA1060 bus object, which serves as the mounting point for the drive. All parameters of QSE series drivers, such as address, motor code, encoder type, and control mode, can be adjusted through a graphical interface, and the complete cfg configuration file will be generated by the Manager.

2. Manual configuration of underlying cfg files

For advanced users or scenarios that require batch deployment, FM 299/A supports directly editing cfg configuration files in text format. The manual provides typical configuration examples, and its hierarchical structure clearly reflects the hardware topology of K2-200:

text

[IO. ONBOARD. KBUS: 0]//K-Bus main interface

name = "Kbus"

cycleTime = 0.001

[IO. ONBOARD. KBUS: 0. FM299:0]//First FM 299/A module

name = "FM299_Interface"

[IO. ONBOARD. KBUS: 0. FM299:0. GA1060B: 0]//GA1060 bus instance

name = "GA1060B_Bus"

cycleTime = 0.002

[IO. ONBOARD. KBUS: 0. FM299:0. GA1060B: 0. QSE: 0]//Mounted QSE drive

name = "Axis_0"

address = 0

MCODE=16 # 1017//Motor code

ENCODE=16 # 800B//Encoder code

ENTYPE=16 # 8300//Encoder type

DriverMode=3//Drive Mode

positionMode = 1

PosUnitsToCreatments=16.00//Position unit conversion

VelUnitsToRPM=11.777//Speed unit conversion

TorqueUnitsToPercent=13.66//Torque unit conversion

Interpretation of key parameters:

CycleTime: The K-Bus cycle is set to 1ms, and the GA1060 bus cycle is set to 2ms, both of which can run asynchronously;

MCODE/ENCODE/ENTYPE: It must be strictly matched with the firmware and motor model inside the drive, otherwise it may cause communication failure or axis loss of control;

POSUnitsToCreatments, etc.: The conversion coefficient from user units to incremental units inside the driver directly affects the accuracy of position closed-loop;

BANK1/BANK8: Bottom level register configuration section, used to set internal functions of the driver (such as digital input/output mapping, analog calibration, etc.), which ordinary users do not need to modify.

3. Address switch setting

FM 299/A sets the K-Bus address through the rotary encoder switch under the right cover plate. A single CPU system can support up to two FM 299/A blocks, with addresses set to 0 and 1 (or other non repeating values) respectively. The default factory address is 0, and the upper and lower cover plates are in a closed state during transportation. Users must open the upper cover plate to connect the K-Bus plug and adjust the address as needed during installation.

4. Optional configuration options

The cfg file supports optional parameters, which are used to define the system behavior when the module is not ready:

Optional=0 (default): When a module is missing, an error is reported and the CPU stops running;

Option=1: When a module is missing, only a Warning is reported and the CPU continues to run.

This design provides flexibility for degraded operation or temporary debugging with faults.

Electrical connection and wiring specifications: fully shielded, short distance, terminal matching

The GA1060 driver bus is based on the RS-485 differential signal physical layer, with a transmission rate of up to 10 Mbit/s, and imposes strict requirements on signal integrity and anti-interference ability. The FM 299/A engineering manual provides detailed specifications for this.

1. Interface and connector

Connector type: 9-pin D-Sub female socket, fully conductive metal shell, ensuring 360 ° shielding continuity;

Pin definition:

Pin1：GA1060 Bus +

Pin2：GA1060 Bus -

Pin3-8: GND (Signal Ground)

Pin9: Vacant

2. Cable selection

Type: Shielded twisted pair, characteristic impedance 100-120 Ω;

Structure: One pair of twisted pair cables carries GA1060 Bus+/-, while the remaining core wires carry GND;

Taboo: It is strictly prohibited to place non system signals (such as PLC digital inputs, third-party device communication lines) and GA1060 bus in the same multi-core cable.

3. Wiring topology

Bus topology: All nodes (FM 299/A master station+QSE driver slave station) are connected to the same bus;

Terminal matching: A 120 Ω terminal resistor must be installed at each end of the bus;

Total length: not exceeding 10 meters, with arbitrary spacing between nodes;

Module position: FM 299/A can be located at any position on the bus (endpoint or middle). If it is located at the endpoint, the other endpoint must be connected to a terminal resistor; If located in the middle, both sides need to be matched with terminals.

4. Shielding grounding

360 ° ring connection: The cable shielding layer must be fully crimped through the metal shell of the connector, and the use of "pigtail" single point grounding is strictly prohibited;

Equipotential: Both ends of the shielding layer need to be grounded, and low impedance equipotential connections should be maintained between the devices inside the control cabinet.

5. Bus terminal board

The manual recommends using a dedicated bus terminal board. If there is no stock available, a 120 Ω resistor can be soldered inside the D-Sub plug and bridged between Pin1 and Pin2.

Diagnosis and Status Indication: Tri color LED and Bus Activity Monitoring

The FM 299/A front panel provides rich visual diagnostic information, divided into two categories:

1. Module status LED

LED color function description

Orange system startup (self-test/initialization)

Green communication is normal with no errors

Red light stays on after power on: module hardware failure;

Lights up after loop operation: communication interruption/bus error

2. GA1060 bus active LED

LED color label function

Yellow TX sends activity, flashing when the main station issues instructions to the driver

Green RX receiving activity, flashing when the main station receives feedback from the driver

Diagnostic logic:

During normal operation, TX/RX should flash according to the control cycle pattern;

If TX is constantly on or off and RX is inactive, it usually indicates a bus physical layer fault (cable breakage, missing terminal resistance, address conflict);

The red status LED combined with TX/RX status can quickly locate the fault area.

Technical specifications: Industrial grade compact design

1. Electrical parameters

Logic power supply: 5V DC, powered through K-Bus backplane;

Maximum power consumption: 1.0W;

Safety level: Level III (EN 61131-2);

Overvoltage category: II.

2. Mechanical dimensions

Front panel width: 22.5 mm;

Module total width (including K-Bus plug): 32.5 mm;

Module height: 120mm;

Installation depth: 100mm;

Weight: 130 grams.

3. Environmental conditions

Meets the requirements of EN 61131-2 for industrial environments;

Working temperature: 0 ° C~+55 ° C (refer to K2-200 system specification);

Storage temperature: -40 ° C~+70 ° C.

4. Certification and Standards

UL 508: Industrial Control Equipment Certification;

UL - listed: fully listed;

IEC 61131-1/-2: Programmable Logic Controller Products and Hardware Standards.

Application scenarios and historical value

The FM 299/A module was born around 2006, during a critical period when servo drive technology was transitioning from pulse direction control to high-speed dedicated buses. Sanyo Denki's GA1060 bus belongs to the manufacturer's proprietary real-time Ethernet/serial bus predecessor, with a 10 Mbit/s rate and deterministic periodic communication capability.

This module has played a central role in the following scenarios:

Fully electric injection molding machine: multi axis servo drive synchronous control (injection, mold opening and closing, ejection, mold adjustment);

Die casting machine picking robot: servo walking axis and joint axis cooperate;

High speed packaging equipment: fly shear, chase shear electronic cam synchronization.

With the comprehensive migration of industrial communication to general open buses such as EtherCAT and PROFINET IRT, the FM 299/A and GA1060 buses have gradually been replaced by KEBA's new generation KeDrive D3 and KeControl C5 with EtherCAT solutions. However, in the market for the renovation and spare parts maintenance of a large number of existing K2-200 old equipment, this module still plays an irreplaceable role.

Engineering insights:

The design philosophy of FM 299/A reflects two eternal propositions in the field of industrial automation: the ultimate performance of dedicated buses and the ecological advantages of general-purpose buses. The strict regulations on shielding wiring, terminal matching, unit conversion and other details in its engineering manual are still a must read textbook for motion control system designers today.