AMCI SD4840EK User manual

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ICRO CONTROLS INC.
ADVANCED
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Manual #: 940-0S310

ADVANCED MICRO CONTROLS INC.
GENERAL INFORMATION
Important User Information
The products and application data described in this manual are useful in a wide variety of different applica-
tions. Therefore, the user and others responsible for applying these products described herein are responsible
for determining the acceptability for each application. While efforts have been made to provide accurate infor-
mation within this manual, AMCI assumes no responsibility for the application or the completeness of the
information contained herein.
UNDER NO CIRCUMSTANCES WILL ADVANCED MICRO CONTROLS, INC. BE RESPONSIBLE OR
LIABLE FOR ANY DAMAGES OR LOSSES, INCLUDING INDIRECT OR CONSEQUENTIAL DAM-
AGES OR LOSSES, ARISING FROM THE USE OF ANY INFORMATION CONTAINED WITHIN THIS
MANUAL, OR THE USE OF ANY PRODUCTS OR SERVICES REFERENCED HEREIN.
No patent liability is assumed by AMCI, with respect to use of information, circuits, equipment, or software
described in this manual.
The information contained within this manual is subject to change without notice.
This manual is copyright 2020 by Advanced Micro Controls Inc. Y
ou may reproduce this manual, in whole or
in part, for your personal use, provided that this copyright notice is included. You may distribute copies of this
complete manual in electronic format provided that they are unaltered from the version posted by Advanced
Micro Controls Inc. on our official website: www.amci.com. You may incorporate portions of this documents
in other literature for your own personal use provided that you include the notice “Portions of this document
copyright 2020 by Advanced Micro Controls Inc.” You may not alter the contents of this document or charge a
fee for reproducing or distributing it.
Standard Warranty
ADVANCED MICRO CONTROLS, INC. warrants that all equipment manufactured by it will be free from
defects, under normal use, in materials and workmanship for a period of [18] months. Within this warranty
period, AMCI shall, at its option, repair or replace, free of charge, any equipment covered by this warranty
which is returned, shipping charges prepaid, within eighteen months from date of invoice, and which upon
examination proves to be defective in material or workmanship and not caused by accident, misuse, neglect,
alteration, improper installation or improper testing.
The provisions of the "STANDARD WARRANTY" are the sole obligations of AMCI and excludes all other
warranties expressed or implied. In no event shall AMCI be liable for incidental or consequential damages or
for delay in performance of this warranty.
Returns Policy
All equipment being returned to AMCI for repair or replacement, regardless of warranty status, must have a
Return Merchandise Authorization number issued by AMCI. Call [phone] with the model number and
serial number (if applicable) along with a description of the problem during regular business hours, Monday
through Friday, 8AM - 5PM Eastern. An "RMA" number will be issued. Equipment must be shipped to AMCI
with transportation charges prepaid. Title and risk of loss or damage remains with the customer until shipment
is received by AMCI.
24 Hour Technical Support Number
24 Hour technical support is available on this product. If you have internet access, start at www.amci.com.
Product documentation and FAQ’s are available on the site that answer most common questions.
If you require additional technical support, call [phone]. Your call will be answered by the factory dur-
ing regular business hours, Monday through Friday, 8AM - 5PM Eastern. During non-business hours an auto-
mated system will ask you to enter the telephone number you can be reached at. Please remember to include
your area code. The system will page an engineer on call. Please have your product model number and a
description of the problem ready before you call.
Waste Electrical and Electronic Equipment (WEEE)
At the end of life, this equipment should be collected separately from any unsorted municipal waste.

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TABLE OF CONTENTS
General Information
Important User Information .... ................. 2
Standard Warranty ................................... 2
Returns Policy .......................................... 2
24 Hour Technical Support Number ........ 2
WEEE Statement ..................................... 2
About this Manual
Audience . ................................................. 7
Applicable Units ...................................... 7
Navigating this Manual ............................ 7
Manual Conventions ................................ 7
Trademark Notices ................................... 7
Revision Record ....................................... 8
Revision History ............................ 8
Where To Go From Here ......................... 8
Reference: Introduction to the
SD4840EK
The SD4840EK ........................................ 9
Conformance Markings ........................... 10
UL .................................................. 10
CE .................................................. 10
RoHS .. ........................................... 10
Specifications ........................................... 11
Indexer Functionality ............................... 12
Synchronizing Moves .................... 13
Encoder Functionality ... ................ 13
Stall Detection .................... 14
Encoder Registration 
Move . ............................... 14
Electronic Gearing ............. 14
Driver Functionality ................................. 15
Idle Current Reduction .................. 15
Current Loop Gain ......................... 15
I/O Connector .......................................... 16
Available Discrete Inputs ......................... 16
Home Input .................................... 16
CW Limit Switch or 
CCW Limit Switch ...................... 16
Start Indexer Move Input ............... 16
Emergency Stop Input ................... 16
Stop Jog or 
Registration Move Input .............. 17
Capture Encoder Position Input ..... 17
General Purpose Input ................... 17
Available Discrete Output ....................... 17
Reference: Introduction to the
SD4840EK (continued)
Ethernet Ports ........................................... 17
Motor Connector ...................................... 18
Front Panel ............................................... 18
Status LED .................................... 18
EtherCAT Run LED ........... 18
EtherCAT ERR LED .......... 18
Reference: Move Profiles
Definitions ................................................ 19
Units of Measure ........................... 19
Distance .... .......................... 19
Speed ... ............................... 19
Acceleration ........................ 19
Motor Position .............................. 19
Home Position ............................... 19
Count Direction ............................. 19
Starting Speed ............................... 20
Target Position .............................. 20
Relative Coordinates .......... 20
Absolute Coordinates ......... 20
Definition of Acceleration Types ............. 20
What is jerk? ................................. 20
Constant Acceleration ................... 21
S-Curve Accelerations .................. 21
Trapezoidal S-Curve 
Acceleration .... ................. 21
Triangular S-Curve 
Acceleration .... ................. 22
A Simple Move ........................................ 22
Controlled and Immediate Stops .............. 23
Host Control .................................. 23
Hardware Control ......................... 23
Basic Move Types .................................... 24
Relative Move ............................... 24
Controlled Stops ................. 24
Immediate Stops ................. 24
Absolute Move .............................. 25
Controlled Stops ................. 25
Immediate Stops ................. 25
CW/CCW Jog Move ..................... 26
Controlled Stops ................. 26
Immediate Stops ................. 27
CW/CCW Registration Move ....... 27
Controlled Stops ................. 28
Immediate Stops ................. 28

TABLE OF CONTENTS SD4840EK User Manual
ADVANCED MICRO CONTROLS INC.
4
Reference: Move Profiles 
(continued)
Encoder Registration Moves .................... 29
Controlled Stops ........................... 29
Immediate Stops ........................... 29
Assembled Moves .................................... 29
Blend Move ................................... 30
Controlled Stops ................. 31
Immediate Stops ................. 31
Dwell Move .................................. 31
Controlled Stops ................. 32
Immediate Stops ................. 32
Assembled Move Programming ............... 33
Control Bits – Output Data ........... 33
Control Bits – Input Data .............. 33
Programming Routine ................... 33
Saving an Assembled 
Move in Flash ............................. 33
Indexed Moves ......................................... 34
Controlling Moves In Progress ................ 35
Jog Moves ..................................... 35
Registration Moves ....................... 35
Absolute, Relative and 
Encoder Registration Moves ....... 35
Assembled Moves ......................... 35
Electronic Gearing .................................... 36
Motor Steps/Turn .......................... 36
ELGearing Multiplier 
and Divisor .................................. 36
How It Works ................................ 36
Controlled Stops ........................... 36
Immediate Stops ........................... 36
Advanced Ratio Control ............... 37
Reference: Calculating Move 
Profiles
Constant Acceleration Equations ............. 39
Variable Definitions ...................... 39
Total Time Equations .................... 41
S-Curve Acceleration Equations .............. 42
Triangular S-Curve 
Acceleration ................................ 42
Trapezoidal S-Curve 
Acceleration ................................ 44
Determining Waveforms 
by Values .................................... 46
Chapter 4: Homing the SD4840EK
Definition of Home Position .................... 49
Position Preset .......................................... 49
CW/CCW Find Home Commands ........... 49
Homing Inputs .......................................... 49
Physical Inputs .............................. 49
Backplane Inputs ........................... 49
Homing Configurations ............................ 50
Homing Profiles ........................................ 50
Home Input Only Profile ............... 50
Profile with Proximity Input ......... 51
Profile with Overtravel Limit ........ 52
Reference: Configuration Data 
Format
CoE Registers ........................................... 53
Output Data Format .................................. 53
CFG_Word_0 Format ............................... 53
CFG_Word_1 Format ............................... 56
Current Loop Gain .................................... 57
Determining Current Loop Gain ... 58
Notes on Other Configuration Words ....... 58
Invalid Configurations .............................. 58
Reference: Command Data Format
Command Bits Must Transition ............... 59
Output Data Format .................................. 59
CMD_word0 ............................................. 60
CMD_word1 ............................................. 62
Command Blocks ..................................... 64
Absolute Move .............................. 64
Relative Move ............................... 64
Hold Move .................................... 65
Resume Move ................................ 65
Immediate Stop ............................. 66
Find Home CW ............................. 66
Find Home CCW ........................... 67
Jog CW .......................................... 67
Registration Move CW ................. 68
Jog CCW ....................................... 68
Registration Move CCW ............... 69
Encoder Follower Move ................ 70
Preset Position ............................... 70
Reset Errors ................................... 71
Run Assembled Move ................... 71
Preset Encoder Position ................. 72

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SD4840EK User Manual TABLE OF CONTENTS
5
Reference: Command Data Format
Programming Blocks ............................... 73
First Block ..................................... 73
Segment Block ............................... 73
Input Data Format .................................... 74
STATUS_word0 Format ............... 74
STATUS_word1 Format ............... 76
Notes on Clearing a Driver Fault ............. 77
Reset Driver Fault .......................... 77
Task 1: Motor and Power Supply 
Sizing
Sizing Your Motor 79
Determining Your Motor 
Current Setting ....................................... 79
A Note on Microstepping .............. 79
Torque and Power Curves ........................ 80
Power Supply Sizing ................................ 82
Regeneration Effects ..................... 82
Task 2: Installing the SD4840EK
Safe Handling Guidelines ........................ 83
Prevent Electrostatic Damage ........ 83
Prevent Debris From 
Entering the Module .................... 83
Remove Power Before 
Servicing ...................................... 83
Mounting .................................................. 83
Dimensions .................................... 83
Minimum Spacing ......................... 84
Mounting the SD4840EK 
Module .. ...................................... 84
I/O Connector Pin Out ............................. 85
Power Wiring ........................................... 85
Input Wiring ............................................. 87
Cable Shields ................................. 87
Output Wiring .......................................... 87
Encoder Wiring ........................................ 88
Differential Wiring ........................ 88
Single Ended Wiring ..................... 89
Installing the Stepper Motor .................... 89
Outline Drawings ........................... 89
Mounting the Motor ...................... 90
Connecting the Load ...................... 90
Extending the Motor Cable ........... 90
Installing the Motor Cable ............. 90
Connecting the Motor .............................. 91
Motor Connector ........................... 91
Motor Wiring ................................. 91
Ethernet Connections ............................... 93
Task 3: EtherCAT System 
Configuration
Install the ESI file ..................................... 95
Obtain the ESI file ........................ 95
Install the ESI file ......................... 95
Restart the Programming 
System If Needed ........................ 95
Add the SD4840EK to the Project ........... 95
Scan for the SD4840EK ................ 95
Rename the Device ....................... 95
Configure the SD4840EK ............. 96
Create a DUT ........................................... 97
Create Variables Based on the DUT ........ 97
Link Variable Names to I/O Words ......... 97
Task 4: Distributed Clock - SYNC0
Setup
Verify Main PLC Task Timing ................ 99
Create New PLC Task .............................. 100
Set Operational Mode .............................. 102
Set CFG_word1 Value to 
Enable SYNC0 ....................................... 103

TABLE OF CONTENTS SD4840EK User Manual
ADVANCED MICRO CONTROLS INC.
6
Notes

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ABOUT THIS MANUAL
Audience
This manual explains the set-up, installation, and operation of the SD4840EK Stepper Motor Indexer / Driver
from AMCI. It is written for the engineer responsible for incorporating these modules into a design, as well as
the engineer or technician responsible for its actual installation.
Applicable Units
This manual applies to the SD4840EK Networked Stepper Indexer/Driver with the EtherCAT® network inter-
face.
Navigating this Manual
This manual is designed to be used in both printed and on-line formats. Its on-line form is a PDF document,
which requires Adobe Acrobat Reader version 7.0+ to open it. The manual is laid out with an even number of
pages in each chapter. This makes it easier to print a chapter to a duplex (double sided) printer.
Bookmarks of all the chapter names, section headings, and sub-headings were created in the PDF file to help
navigate it. The bookmarks should have appeared when you opened the file. If they didn’t, press the F5 key
on Windows platforms to bring them up.
The PDF file is password protected to prevent changes to the document. You are allowed to select and copy
sections for use in other documents and you are allowed to add notes and annotations.
Manual Conventions
Three icons are used to highlight important information in the manual:
NOTES highlight important concepts, decisions you must make, or the implications of those
decisions.
CAUTIONS tell you when equipment may be damaged if the procedure is not followed
properly.
WARNINGS tell you when people may be hurt or equipment may be damaged if the pro-
cedure is not followed properly.
The following table shows the text formatting conventions:
Trademark Notices
The AMCI logo is a trademark of Advanced Micro Controls Inc. EtherCAT® is a registered trademark and
patented technology, licensed by Beckhoff Automation GmbH, Germany. “Adobe” and “Acrobat” are regis-
tered trademarks of Adobe Systems Incorporated.
All other trademarks contained herein are the property of their respective holders.
Read this chapter to learn how to navigate through this manual and familiarize
yourself with the conventions used in it.
Format Description
Normal Font Font used throughout this manual.
Emphasis Font Font used the first time a new term is introduced.
Cross Reference When viewing the PDF version of the manual, clicking on
the cross reference text jumps you to referenced section.
HTML Reference When viewing the PDF version of the manual, clicking on
the HTML reference text will open your default web
browser to the referenced web page.

ABOUT THIS MANUAL SD4840EK User Manual
ADVANCED MICRO CONTROLS INC.
8
Revision Record
This manual, 940-0S310, is the first revision of this manual. It was first released December 14th, 2020.
Revision History
940-0S310 Initial Release.
Where To Go From Here
This manual contains information that is of interest to everyone from engineers to operators. The table below
gives a brief description of each chapter’s contents to help you find the information you need to do your job.
Section Title Page # Section Description
Introduction to the
SD4840EK 9Complete specifications for the SD4840EK product.
Move Profiles 19 Reference information on how the SD4840EK can be used to control
motion in your application.
Calculating Move
Profiles 39 Reference information on calculating detailed move profiles.
Homing the SD4840EK 49 Reference information on how to set the home position of the
SD4840EK.
Configuration Data
Format 53 Reference information on the format of the CANopen over Ether-
CAT (CoE) data that is used to configure the units.
Command Data Format 59 Reference information on the format of the network data to and from
the SD4840EK that is used to command it.
Motor and Power
Supply Sizing 79 Reference information and performance data on compatible AMCI
stepper motors and guidelines for using a foreign stepper motor.
Installing the
SD4840EK 83
Task instructions covering how to install an SMD23K or SMD24K
on a machine. Includes information on mounting, grounding, and
wiring specific to the units.
EtherCAT System
Configuration 95 Task instructions that covers how to add an SD4840EK to an 
EtherCAT network.
Distributed Clock -
SYNC0 Setup 99 Task instructions that covers the optional task of using the Distrib-
uted Clock functionality of the EtherCAT protocol with the
SD4840EK.

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REFERENCE 1
INTRODUCTION TO THE SD4840EK
The SD4840EK
The AMCI SD4840EK is a DC powered, 4.0 Arms, micro-stepping driver with an internal bus voltage equal to
the supply voltage. The drive’s built-in indexer accepts configuration and command data from a host system.
The SD4840EK driver attaches to your Ethernet based network and communicates using the EtherCAT proto-
col.
EtherCAT uses standard Ethernet cabling, but forgoes the full TCP/IP stack typically associated with Ethernet
communications. The EtherCAT protocol transfers data to and from multiple slaves with a single packet of
information. Data for each slave is located at a known position within the packet. EtherCAT slave devices use
a hardware only solution to read and write data to the packet before transmitting the packet to the next slave.
This solution leads to a delay between nodes that is typically 4 microseconds or less. This results in a very fast
and deterministic network.
An EtherCAT Slave Information (ESI) file is available for the SD4840EK. The ESI file is required to add the
device to the network. Configuration of the SD4840EK is accomplished using the CANopen PDO and SDO
objects. EtherCAT supports CANopen through its CANopen over Ethernet (CoE) interface.
Motion commands and status information is transmitted using the output and input variables assigned to the
SD4840EK when the EtherCAT system is configured.
Each unit also supports the Distributed Clock (DC) functionality of the EtherCAT system. This allows you to
synchronize the start of moves across devices using the SYNC0 signal instead of the SyncManager 2 event.
The combination of host and driver gives you several advantages:
Sophisticated I/O processing can be performed in the host (PLC or other controller) before sending
commands to the Networked Indexer/Driver.
All motion logic is programmed in the host, eliminating the need to learn a separate motion control lan-
guage
Eliminating the separate indexer lowers Total System Cost
The SD4840EK is powered by a nominal 24 to 48 Vdc power source, and can accept surge voltages of up to
60Vdc without damage. The output motor current is fully programmable from 0.1 Arms to 4.0 Arms which
makes the SD4840EK compatible with the complete line of size 23 and size 34 stepper motors that are avail-
able from AMCI. In addition to the Motor Current setting, the Motor Steps per Turn, Idle Current Reduction,
and Anti-Resonance Circuit features are also fully programmable. If you have used other stepper indexer
products from AMCI you will find programming to be very similar to these products.
This manual is designed to get you quickly up and running with the SD4840EK
stepper indexer / driver. As such, it assumes you have some basic knowledge of
stepper systems. If stepper systems are new to you, we’re here to help. AMCI has
a great deal of information on our website and we are adding more all the time. If
you can’t find what you’re looking for at http:///www.amci.com, send us an e-mail
or call us. We’re here to support you with all of our knowledge and experience.

INTRODUCTION TO THE SD4840EK SD4840EK User Manual
ADVANCED MICRO CONTROLS INC.
10
The SD4840EK (continued)
The SD4840EK is a true RMS motor current control driver. This means that you will always receive the
motor’s rated torque regardless of the Motor Steps/Turn setting. (Drivers that control the peak current to the
motor experience a 30% decrease in motor torque when microstepping a motor.) The SD4840EK automati-
cally switches from RMS to peak current control when the motor is idle to prevent overheating the motor.
In addition to power and motor hookups, the SD4840EK has three DC inputs and one DC output that are used
by the indexer. Configuration data from the host sets the function of these points. The output can be config-
ured to be a Fault Output or a general purpose output. Inputs accept 5 to 24 Vdc signals and they can be indi-
vidually configured as a:
CW or CCW Limit Switch
Home Limit Switch
Capture Encoder Position Input
Stop Jog or Registration Move Input
Start Indexer Move
Emergency Stop Input
General Purpose Input
Conformance Markings
The SD4840EK meets the requirements for the following conformance markings when installed and operated
in accordance with the instructions contained in their product documentation.
UL
Recognized component in the USA and Canada. UL file number is E231137.
US: UL 61800-5-1 Standard For Safety For Adjustable Speed Electrical Power Drive Systems - Part 
5-1: Safety Requirements - Electrical, Thermal and Energy
Canada: CSA C22.2 No. 274 - Adjustable Speed Drives
CE
Directive 2014/30/EU of the European Parliament and of the Council (EMC), of 26 February 2014 on
the harmonisation of the laws of the Member States relating to electromagnetic compatibility; per EN
61800-3:2004/A1:2012.
Directive 2014/35/EU of the European Parliament and of the Council (Low Voltage), of 26 February
2014 on the harmonisation of the laws of the Member States relating to the making available on the
market of electrical equipment designed for use within certain voltage limits; per EN 61010-1:2010.
RoHS
Directive (EU) 2015/863 (RoHS 3) and Directive 2011/65/EU (RoHS 2)