BONFIGLIOLI Vectron ACTIVE CUBE Series User manual

ACTIVE CUBE
EtherCAT
Communication module CM-EtherCAT
Frequency inverter 230 V / 400 V

Contents
1General Information about the Documentation ............................................................ 8
1.1 This document ......................................................................................................... 9
1.2 Warranty and liability.............................................................................................. 9
1.3 Obligation .............................................................................................................. 10
1.4 Copyright ............................................................................................................... 10
1.5 Storage .................................................................................................................. 10
2General safety instructions and information on use.................................................... 11
2.1 Terminology........................................................................................................... 11
2.2 Designated use ...................................................................................................... 12
2.3 Misuse.................................................................................................................... 12
2.3.1 Explosion protection .................................................................................................12
2.4 Residual risks......................................................................................................... 12
2.5 Safety and warning signs at frequency inverter ................................................... 12
2.6 Warning information and symbols used in the user manual................................. 13
2.6.1 Hazard classes .........................................................................................................13
2.6.2 Hazard symbols........................................................................................................13
2.6.3 Prohibition signs.......................................................................................................13
2.6.4 Personal safety equipment........................................................................................13
2.6.5 Recycling.................................................................................................................14
2.6.6 Grounding symbol ....................................................................................................14
2.6.7 ESD symbol .............................................................................................................14
2.6.8 Information signs.....................................................................................................14
2.7 Directives and guidelines to be adhered to by the operator................................. 15
2.8 Operator's general plant documentation .............................................................. 15
2.9 Operator's/operating staff's responsibilities ........................................................ 15
2.9.1 Selection and qualification of staff.............................................................................15
2.9.2 General work safety..................................................................................................15
2.10 Organizational measures.................................................................................... 15
2.10.1 General....................................................................................................................15
2.10.2 Use in combination with third-party products .............................................................16
2.10.3 Transport and Storage..............................................................................................16
2.10.4 Handling and installation...........................................................................................16
2.10.5 Electrical connections ...............................................................................................16
2.10.5.1 The five safety rules ..........................................................................................17
2.10.6 Safe operation..........................................................................................................17
2.10.7 Maintenance and service/troubleshooting ..................................................................18
2.10.8 Final decommissioning..............................................................................................18
3Introduction................................................................................................................. 19
3.1 Supported Configurations...................................................................................... 21
3.2 Initialization time.................................................................................................. 22
4First Commissioning..................................................................................................... 22
5Installation/Disassembly of the communication module............................................ 23
5.1 Installation ............................................................................................................ 23
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5.2 Disassembly........................................................................................................... 24
6Connector assignment ................................................................................................. 25
7RUN-LED....................................................................................................................... 26
8Cable lengths................................................................................................................ 26
9Setting the node address ............................................................................................. 26
10 Operational behaviour on bus failure .......................................................................... 26
11 EtherCAT®overview..................................................................................................... 27
11.1 Communication Objects ..................................................................................... 27
11.2 Application Objects ............................................................................................ 27
11.3 Function SDO...................................................................................................... 28
11.3.1 Error code table .......................................................................................................28
11.4 PDO Function...................................................................................................... 29
11.5 Emergency Function........................................................................................... 29
11.6 Synchronization (Distributed Clocks)................................................................. 29
11.7 NMT Functions.................................................................................................... 30
11.7.1 NMT Statemachine...................................................................................................30
11.8 OS Synchronization ............................................................................................ 31
11.9 Fault Reset.......................................................................................................... 32
12 Objects ......................................................................................................................... 33
12.1 Objects tabular overview ................................................................................... 33
12.1.1 Communication objects.............................................................................................33
12.1.2 Manufacturer objects................................................................................................35
12.1.3 Device profile objects ...............................................................................................37
12.2 Communication Objects (0x1nnn) ..................................................................... 41
12.2.1 0x1000/0 Device Type..............................................................................................41
12.2.2 0x1001/0 Error Register............................................................................................42
12.2.3 0x1008/0 Manufacturer Device Name........................................................................43
12.2.4 0x1009/0 Manufacturer Hardware Version .................................................................43
12.2.5 0x100A/0 Manufacturer Software Version ..................................................................43
12.2.6 0x1010/n Store Parameters.......................................................................................43
12.2.7 0x1011/n Restore default Parameters........................................................................44
12.2.8 0x1018/n Identity Object..........................................................................................44
12.2.9 0x1600/n, 0x1601/n, 0x1602/n, RxPDO Mapping Parameter.......................................45
12.2.10 0x1A00/n, 0x1A01/n, 0x1A02/n, TxPDO Mapping Parameter ...................................46
12.3 Manufacturer objects (0x2nnn) – Parameter access......................................... 47
12.3.1 Handling of data sets/cyclic writing of the parameters................................................47
12.3.2 Handling of index parameters/cyclic writing ...............................................................48
12.3.2.1 Example Writing an index parameter ..................................................................49
12.3.2.2 Example Reading an index parameter.................................................................49
12.4 Manufacturer objects (0x3000 … 0x5FFF)......................................................... 50
12.4.1 0x3001/0 Digital In actual value................................................................................50
12.4.2 0x3002/0 Digital Out actual value..............................................................................50
12.4.3 0x3003/0 Digital Out set values.................................................................................51
12.4.4 0x3004/0 Boolean Mux.............................................................................................52
12.4.5 0x3005/0 Boolean DeMux.........................................................................................53
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12.4.6 0x3006/0 Percentage set value .................................................................................54
12.4.7 0x3007/0 Percentage Actual Value Source 1 ..............................................................55
12.4.8 0x3008/0 Percentage Actual Value Source 2 ..............................................................55
12.4.9 0x3011/0 Actual Value Word 1..................................................................................56
12.4.10 0x3012/0 Actual Value Word 2...............................................................................56
12.4.11 0x3021/0 Actual Value Long 1 ...............................................................................57
12.4.12 0x3022/0 Actual Value Long 2 ...............................................................................57
12.4.13 0x3111/0 Ref. Value Word 1..................................................................................58
12.4.14 0x3112/0 Ref. Value Word 2..................................................................................58
12.4.15 0x3121/0 Ref. Value Long 1...................................................................................59
12.4.16 0x3122/0 Ref. Value Long 2...................................................................................59
12.4.17 0x5F10/n Gear factor ............................................................................................60
12.4.18 0x5F11/n…0x5F14/n Phasing 1…4 .........................................................................61
12.4.19 0x5F15/0 In Gear Threshold..................................................................................63
12.4.20 0x5F16/0 In Gear Time .........................................................................................64
12.4.21 0x5F17/n Position Controller..................................................................................65
12.4.22 0x5F18/0 M/S Synchronization Offset.....................................................................67
12.4.23 0x5FF0/0 Active motion block................................................................................68
12.4.24 0x5FF1/0 Motion block to resume ..........................................................................68
12.5 Device Profile Objects (0x6nnn) ........................................................................ 69
12.5.1 0x6007/0 Abort Connection option code ....................................................................69
12.5.20x603F/0 Error code.................................................................................................71
12.5.3 0x6040/0 Control word.............................................................................................72
12.5.4 0x6041/0 Status word ..............................................................................................73
12.5.5 0x6042/0 Target velocity [rpm].................................................................................74
12.5.6 0x6043/0 Target velocity demand [rpm]....................................................................75
12.5.7 0x6044/0 Control effort ............................................................................................75
12.5.8 0x6046/n Velocity min max amount...........................................................................75
12.5.9 0x6048/n Velocity acceleration..................................................................................77
12.5.10 0x6049/n Velocity deceleration ..............................................................................78
12.5.11 0x604A/n Velocity quick stop.................................................................................79
12.5.12 0x6060/0 Modes of operation ................................................................................80
12.5.13 0x6061/0 Modes of operation display .....................................................................81
12.5.14 0x6064/0 Position actual value...............................................................................81
12.5.15 0x6065/0 Following error window ..........................................................................82
12.5.16 0x6066/0 Following error time out .........................................................................83
12.5.17 0x6067/0 Position window.....................................................................................84
12.5.18 0x6068/0 Position window time .............................................................................85
12.5.19 0x606C/0 Velocity actual value [u/s]......................................................................85
12.5.20 0x606D/0 Velocity Window....................................................................................86
12.5.21 0x606E/0 Velocity Window Time............................................................................87
12.5.22 0x606F/0 Velocity Threshold..................................................................................88
12.5.23 0x6070/0 Velocity Threshold Time .........................................................................89
12.5.24 0x6071/0 Target Torque........................................................................................90
12.5.25 0x6077/0 Torque actual value................................................................................90
12.5.26 0x6078/0 Current actual value...............................................................................90
12.5.27 0x6079/0 DClink circuit voltage..............................................................................91
12.5.28 0x607A/0 Target position ......................................................................................91
12.5.29 0x607C/0 Home offset...........................................................................................92
12.5.30 0x6081/0 Profile velocity [u/s]...............................................................................93
12.5.31 0x6083/0 Profile acceleration.................................................................................94
12.5.32 0x6084/0 Profile deceleration.................................................................................94
12.5.33 0x6085/0 Quick stop deceleration ..........................................................................95
12.5.34 0x6086/0 Motion profile type.................................................................................96
12.5.35 0x6091/n Gear ratio..............................................................................................97
12.5.36 0x6092/n Feed constant........................................................................................98
12.5.37 0x6098/0 Homing method.....................................................................................99
12.5.38 0x6099/n Homing speeds....................................................................................101
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12.5.39 0x609A/0 Homing acceleration.............................................................................102
12.5.40 0x60C1/1 Interpolation data record......................................................................103
12.5.41 0x60F4/0 Following error actual value..................................................................105
12.5.42 0x60F8/0 Max Slippage [u/s]...............................................................................106
12.5.43 0x60FF/0 Target Velocity [u/s].............................................................................106
13 Motion Control Interface (MCI)................................................................................. 107
13.1 Parameter dependencies in Motion Control..................................................... 108
13.2 Reference system............................................................................................. 113
13.3 Homing ............................................................................................................. 114
13.3.1 Start position after homing .....................................................................................114
13.3.2 Flying homing ........................................................................................................114
13.4 Position Controller............................................................................................ 114
13.5 Move away from Hardware limit switches....................................................... 115
13.6 Motion Control Interface for Experts ............................................................... 116
13.7 Motion Control Override................................................................................... 117
14 Inverter Control ......................................................................................................... 118
14.1 Control via digital inputs/remote digital inputs............................................... 119
14.1.1 Device State machine.............................................................................................121
14.2 Control via state machine................................................................................. 122
14.2.1 Statemachine diagram............................................................................................124
14.3 Non motion control configurations .................................................................. 127
14.3.1 Behaviour in quick stop...........................................................................................127
14.3.2 Behaviour in transition 5 (Disable operation)............................................................128
14.3.3 Reference value / actual value ................................................................................129
14.3.4 Example Sequence .................................................................................................130
14.4 Motion control configurations.......................................................................... 131
14.4.1 Velocity mode [rpm]...............................................................................................132
14.4.1.1 Example Sequence...........................................................................................135
14.4.2 Profile Velocity mode [u/s]......................................................................................137
14.4.2.1 Example Sequence...........................................................................................140
14.4.3 Profile position mode..............................................................................................141
14.4.3.1 Example Sequence...........................................................................................147
14.4.4 Interpolated position mode.....................................................................................149
14.4.4.1 Example Sequence...........................................................................................153
14.4.5 Homing mode ........................................................................................................154
14.4.5.1 Example Sequence...........................................................................................156
14.4.6 Cyclic Synchronous position mode...........................................................................157
14.4.6.1 Example Sequence...........................................................................................159
14.4.7 Cyclic Synchronous Velocity mode...........................................................................160
14.4.7.1 Example Sequence...........................................................................................162
14.4.8 Table travel record.................................................................................................163
14.4.8.1 Example Sequence...........................................................................................170
14.4.9 Move away from Limit switches...............................................................................171
14.4.9.1 Example Sequence...........................................................................................174
14.4.10 Electronic Gear: Slave .........................................................................................175
14.4.10.1 Master/Slave Position Correction......................................................................182
14.4.10.2 Sequence Example..........................................................................................184
15 Parameter list............................................................................................................. 186
15.1 Actual values .................................................................................................... 186
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15.2 Parameter......................................................................................................... 187
16 Annex ......................................................................................................................... 188
16.1 Control Word/Status word Overview............................................................... 189
16.1.1 Control Word overview (without Sync Modes) ..........................................................189
16.1.2 Status Word overview (without Sync modes) ...........................................................190
16.1.3 Control Word overview for Sync Modes....................................................................191
16.1.4 Status Word overview for Sync modes.....................................................................191
16.2 Warning messages ........................................................................................... 192
16.3 Warning Messages Application......................................................................... 193
16.4 Fault messages................................................................................................. 194
16.5 Conversions...................................................................................................... 195
16.5.1 Speed [rpm] to Frequency [Hz]...............................................................................195
16.5.2 Frequency [Hz] to Speed [rpm]...............................................................................195
16.5.3 Speed in user units [u/s] to Frequency [Hz].............................................................195
16.5.4 Frequency [Hz] to Speed in user units [u/s].............................................................195
16.5.5 Speed in user units [u/s] to Speed [rpm].................................................................195
16.5.6 Speed [rpm] to Speed in user units [u/s].................................................................195
16.6 Object support in the Software versions and XML files ................................... 196
Index................................................................................................................................ 198
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1General Information about the Documentation
For better clarity, the documentation of the frequency inverter is structured according to the custom-
er-specific requirements.
This documentation was written in German language. The German documentation is the original one.
Other language versions are translated.
Quick Start Guide
The “Quick Start Guide” describes the basic steps required for mechanical and electrical installation of
the frequency inverter. The guided commissioning supports you in the selection of necessary parame-
ters and the configuration of the software of the frequency inverter.
User manual
The user manual documents the complete functionality of the frequency inverter. The parameters
required for special purposes, for adjustment to the application and the numerous additional functions
are described in detail.
Separate user manuals are supplied for optional components for the frequency inverter. These manu-
als complement the operating instructions and the “Quick Start Guide” for the frequency inverter.
Application manual
The application manual complements the documentation to ensure goal-directed installation and
commissioning of the frequency inverter. Information on various topics in connection with the use of
the frequency inverter are described in context with the specific application.
Installation instructions
The installation manual describes the installation and use of devices, complementing the “Quick Start
Guide” and the user manual.
8 CM-EtherCAT 07/13

1.1 This document
The present user manual of the CM-EtherCAT®communication module complements the user manual
and the “Quick Start Guide” for the frequency inverters of the ACU 201 and ACU 401 device series.
The user manual contains important information on the installation and use of the EtherCAT®com-
munication module CM-EtherCAT®in its specified application range. Compliance with this user manual
contributes to avoiding risks, minimizing repair cost and downtimes and increasing the reliability and
service live of the frequency inverter.
For this reason, make sure you read the user manual carefully.
EtherCAT®is a registered trademark and patented technology,
licensed by Beckhoff Automation GmbH, Germany.
WARNING
Compliance with the documentation is required to ensure safe operation of the frequen-
cy inverter. BONFIGLIOLI VECTRON GmbH shall not be held liable for any damage
caused by any non-compliance with the documentation.
In case any problems occur which are not covered by the documentation sufficiently,
please contact the manufacturer.
1.2 Warranty and liability
BONFIGLIOLI VECTRON GmbH would like to point out that the contents of this user manual do not
form part of any previous or existing agreement, assurance or legal relationship. Neither are they
intended to supplement or replace such agreements, assurances or legal relationships. Any obligations
of the manufacturer shall solely be based on the relevant purchase agreement which also includes the
complete and solely valid warranty stipulations. These contractual warranty provisions are neither
extended nor limited by the specifications contained in this documentation.
The manufacturer reserves the right to correct or amend the specifications, product information and
omissions in these operating instructions without notice. The manufacturer shall not be liable for any
damage, injuries or costs which may be caused by the aforementioned reasons.
In addition to that, BONFIGLIOLI VECTRON GmbH excludes any warranty/liability claims for any per-
sonal and/or material damage if such damage is due to one or more of the following causes:
•inappropriate use of the frequency inverter,
•non-compliance with the instructions, warnings and prohibitions contained in the documentation,
•unauthorized modifications of the solar inverter,
•insufficient monitoring of parts of the machine/plant which are subject to wear,
•repair work at the machine/plant not carried out properly or in time,
•catastrophes by external impact and Force Majeure.
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1.3 Obligation
This user manual must be read before commissioning and complied with. Anybody entrusted with
tasks in connection with the
•transport,
•assembly,
•installation of the frequency inverter and
•operation of the frequency inverter
must have read and understood the user manual and, in particular, the safety instructions in order to
prevent personal and material losses.
1.4 Copyright
In accordance with applicable law against unfair competition, this user manual is a certificate. Any
copyrights relating to it shall remain with
BONFIGLIOLI VECTRON GmbH
Europark Fichtenhain B6
47807 Krefeld
Germany
These user manual is intended for the operator of the frequency inverter. Any disclosure or copying of
this document, exploitation and communication of its contents (as hardcopy or electronically) shall be
forbidden, unless permitted expressly.
Any non-compliance will constitute an offense against the copyright law dated 09 September 1965,
the law against unfair competition and the Civil Code and may result in claims for damages. All rights
relating to patent, utility model or design registration reserved.
1.5 Storage
The documentation form an integral part of the frequency inverter. It must be stored such that it is
accessible to operating staff at all times. In case the frequency inverter is sold to other users, this user
manual must also be handed over.
10 CM-EtherCAT 07/13

2General safety instructions and information on use
The chapter "General safety instructions and information on use" contains general safety instructions
for the Operator and the Operating Staff. At the beginning of certain main chapters, some safety in-
structions are included which apply to all work described in the relevant chapter. Special work-specific
safety instructions are provided before each safety-relevant work step.
2.1 Terminology
According to the documentation, different activities must be performed by certain persons with certain
qualifications.
The groups of persons with the required qualification are defined as follows:
Operator
This is the entrepreneur/company who/which operates the frequency inverter and uses it as per the
specifications or has it operated by qualified and instructed staff.
Operating staff
The term Operating Staff covers persons instructed by the Operator of the frequency inverter and
assigned the task of operating the frequency inverter.
Qualified staff
The term Qualified Staff covers staff who is assigned special tasks by the Operator of the frequency
inverter, e.g. installation, maintenance and service/repair and troubleshooting. Based on their qualifi-
cation and/or know-how, qualified staff must be capable of identifying defects and assessing func-
tions.
Qualified electrician
The term Qualified Electrician covers qualified and trained staff who has special technical know-how
and experience with electrical installations. In addition, Qualified Electricians must be familiar with the
applicable standards and regulations, they must be able to assess the assigned tasks properly and
identify and eliminate potential hazards.
Instructed person
The term Instructed Person covers staff who was instructed and trained about/in the assigned tasks
and the potential hazards that might result from inappropriate behavior. In addition, instructed per-
sons must have been instructed in the required protection provisions, protective measures, the appli-
cable directives, accident prevention regulations as well as the operating conditions and verified their
qualification.
Expert
The term Expert covers qualified and trained staff who has special technical know-how and experience
relating to frequency inverter. Experts must be familiar with the applicable government work safety
directives, accident prevention regulations, guidelines and generally accepted rules of technology in
order to assess the operationally safe condition of the frequency inverter.
07/13 CM-EtherCAT 11

2.2 Designated use
The frequency inverter is designed according to the state of the art and recognized safety regulations.
The frequency inverters are electrical drive components intended for installation in industrial plants or
machines. Commissioning and start of operation is not allowed until it has been verified that the ma-
chine meets the requirements of the EC Machinery Directive 2006/42/EC and DIN EN 60204-1.
The frequency inverters meet the requirements of the low voltage directive 2006/95/EEC and DIN
EN 61800-5-1. CE-labeling is based on these standards. Responsibility for compliance with the EMC
Directive 2004/108/EC lies with the operator. Frequency inverters are only available at specialized
dealers and are exclusively intended for commercial use as per EN 61000-3-2.
No capacitive loads may be connected to the frequency inverter.
The technical data, connection specifications and information on ambient conditions are indicated on
the rating plate and in the documentation and must be complied with in any case.
2.3 Misuse
Any use other than that described in "Designated use" shall not be permissible and shall be consid-
ered as misuse.
For example, the machine/plant must not be operated
•by uninstructed staff,
•while it is not in perfect condition,
•without protection enclosure (e.g. covers),
•without safety equipment or with safety equipment deactivated.
The manufacturer shall not be held liable for any damage resulting from such misuse. The sole risk
shall be borne by the operator.
2.3.1 Explosion protection
The frequency inverter is an IP 20 protection class device. For this reason, use of the device in explo-
sive atmospheres is not permitted.
2.4 Residual risks
Residual risks are special hazards involved in handling of the frequency inverter which cannot be elim-
inated despite the safety-compliant design of the device. Residual risks are not obviously identifiable
and can be a potential source of injury or health hazard.
Typical residual hazards include:
Electrical hazard
Danger of contact with energized components due to a defect, opened covers or enclosures or im-
proper working on electrical equipment.
Danger of contact with energized components inside of the frequency inverter if no external discon-
nection device was installed by the operator.
Electrostatic charging
Touching electronic components bears the risk of electrostatic discharges.
Thermal hazards
Risk of accidents by hot machine/plant surfaces, e.g. heat sink, transformer, fuse or sine filter.
Charged capacitors in DC link
The DC link may have dangerous voltage levels even up to three minutes after shutdown.
Danger of equipment falling down/over, e.g. during transport
Center of gravity is not the middle of the electric cabinet modules.
2.5 Safety and warning signs at frequency inverter
•Comply with all safety instructions and danger information provided on the frequency inverter.
•Safety information and warnings on the frequency inverter must not be removed.
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2.6 Warning information and symbols used in the user manual
2.6.1 Hazard classes
The following hazard identifications and symbols are used to mark particularly important information:
DANGER
Identification of immediate threat holding a high
risk of death or serious injury if not
avoided.
WARNING
Identification of immediate threat holding a medium
risk of death or serious injury if
not avoided.
CAUTION
Identification of immediate threat holding a low risk of minor or moderate physical inju-
ry if not avoided.
NOTE
Identification of a threat holding a risk of material damage if not avoided.
2.6.2 Hazard symbols
Symbol
Meaning
Symbol
Meaning
General hazard Suspended load
Electrical voltage Hot surfaces
2.6.3 Prohibition signs
Symbol
Meaning
No switching; it is forbidden to switch
the machine/plant, assembly on
2.6.4 Personal safety equipment
Symbol
Meaning
Wear body protection
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2.6.5 Recycling
Symbol
Meaning
Recycling, to avoid waste, collect all
materials for reuse
2.6.6 Grounding symbol
Symbol
Meaning
Ground connection
2.6.7 ESD symbol
Symbol
Meaning
ESD: Electrostatic Discharge (can
damage components and assemblies)
2.6.8 Information signs
Symbol
Meaning
Tips and information making using the
frequency inverter easier.
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2.7 Directives and guidelines to be adhered to by the operator
The operator must follow the following directives and regulations:
•Ensure that the applicable workplace-related accident prevention regulations as well as other ap-
plicable national regulation are accessible to the staff.
•An authorized person must ensure, before using the frequency inverter, that the device is used in
compliance with its designated use and that all safety requirements are met.
•Additionally, comply with the applicable laws, regulations and directives of the country in which
the frequency inverter is used.
Any additional guidelines and directives that may be required additionally shall be defined by the op-
erator of the machine/plant considering the operating environment.
2.8 Operator's general plant documentation
•In addition to the user manual, the operator should issue separate internal operating instructions
for the frequency inverter. The user manual of the frequency inverter must be included in the user
manual of the whole plant.
2.9 Operator's/operating staff's responsibilities
2.9.1 Selection and qualification of staff
•Any work on the frequency inverter may only be carried out by qualified technical staff. The staff
must not be under the influence of any drugs. Note the minimum age required by law. Define the
staff's responsibility in connection with all work on the frequency inverter clearly.
•Work on the electrical components may only be performed by a qualified electrician according to
the applicable rules of electrical engineering.
•The operating staff must be trained for the relevant work to be performed.
2.9.2 General work safety
•In addition to the user manual of the machine/plant, any applicable legal or other regulations
relating to accident prevention and environmental protection must be complied with. The staff
must be instructed accordingly.
Such regulations and/or requirements may include, for example, handling of hazardous media and
materials or provision/use of personal protective equipment.
•In addition to this user manual, issue any additional directives that may be required to meet spe-
cific operating requirements, including supervision and reporting requirements, e.g. directives re-
lating to work organization, workflow and employed staff.
•Unless approved of expressly by the manufacturer, do not modify the frequency inverter in any
way, including addition of attachments or retrofits.
•Only use the frequency inverter if the rated connection and setup values specified by the manu-
facturer are met.
•Provide appropriate tools as may be required for performing all work on the frequency inverter
properly.
2.10 Organizational measures
2.10.1 General
•Train your staff in the handling and use of the frequency inverter and the machine/plant as well
as the risks involved.
•Use of any individual parts or components of the frequency inverter in other parts of the opera-
tor's machine/plant is prohibited.
•Optional components for the frequency inverter must be used in accordance with their designated
use and in compliance with the relevant documentation.
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2.10.2 Use in combination with third-party products
•Please note that BONFIGLIOLI VECTRON GmbH will not accept any responsibility for compatibility
with third-party products (e.g. motors, cables or filters).
•In order to enable optimum system compatibility, BONFIGLIOLI VECTRON GmbH office compo-
nents facilitating commissioning and providing optimum synchronization of the machine/plant
parts in operation.
•If you use the frequency inverter in combination with third-party products, you do this at your
own risk.
2.10.3 Transport and Storage
•The frequency inverters must be transported and stored in an appropriate way. During transport
and storage the devices must remain in their original packaging.
•The units may only be stored in dry rooms which are protected against dust and moisture and are
exposed to little temperature deviations only. The requirements of DIN EN 60721-3-1 for storage,
DIN EN 60721-3-2 for transport and labeling on the packaging must be met.
•The duration of storage without connection to the permissible nominal voltage may not exceed
one year.
2.10.4 Handling and installation
•Do not commission any damaged or destroyed components.
•Prevent any mechanical overloading of the frequency inverter. Do not bend any components and
never change the isolation distances.
•Do not touch any electronic construction elements and contacts. The frequency inverter is
equipped with components which are sensitive to electrostatic energy and can be damaged if
handled improperly. Any use of damaged or destroyed components will endanger the ma-
chine/plant safety and shall be considered as a non-compliance with the applicable standards.
•Only install the frequency inverter in a suitable operating environment. The frequency inverter is
exclusively designed for installation in industrial environments.
•If seals are removed from the case, this can result in the warranty becoming null and void.
2.10.5 Electrical connections
•The five safety rules must be complied with.
•Never touch live terminals. The DC link may have dangerous voltage levels even up to three
minutes after shutdown.
•When performing any work on/with the frequency inverter, always comply with the applicable
national and international regulations/laws on work on electrical equipment/plants of the country
when the frequency inverter is used.
•The cables connected to the frequency inverters may not be subjected to high-voltage insulation
tests unless appropriate circuitry measures are taken before.
•Only connect the frequency inverter to suitable supply mains.
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2.10.5.1 The five safety rules
When working on/in electrical plants, always follow the five safety rules:
1. Isolate
2. Secure to prevent restarting
3. Check isolation
4. Earth and short-circuit,
5. Cover or shield neighboring live parts.
2.10.6 Safe operation
•During operation of the frequency inverter, always comply with the applicable national and inter-
national regulations/laws on work on electrical equipment/plants.
•Before commissioning and the start of the operation, make sure to fix all covers and check the
terminals. Check the additional monitoring and protective devices according to the applicable na-
tional and international safety directives.
•During operation, never open the machine/plant
•Do not connect/disconnect any components/equipment during operation.
•The machine/plant holds high voltage levels during operation, is equipped with rotating parts
(fan) and has hot surfaces. Any unauthorized removal of covers, improper use, wrong installation
or operation may result in serious injuries or material damage.
•Some components, e.g. the heat sink or brake resistor, may be hot even some time after the ma-
chine/plant was shut down. Don't touch any surfaces directly after shutdown. Wear safety gloves
where necessary.
•The frequency inverter may hold dangerous voltage levels until the capacitor in the DC link is dis-
charged. Wait for at least 3 minutes after shutdown before starting electrical or mechanical work
on the frequency inverter. Even after this waiting time, make sure that the equipment is deener-
gized in accordance with the safety rules before starting the work.
•In order to avoid accidents or damage, only qualified staff and electricians may carry out the work
such as installation, commissioning or setup.
•In the case of a defect of terminals and/or cables, immediately disconnect the frequency inverter
from mains supply.
•Persons not familiar with the operation of frequency inverters must not have access to the fre-
quency inverter. Do not bypass nor decommission any protective facilities.
•The frequency inverter may be connected to power supply every 60 s. This must be considered
when operating a mains contactor in jog operation mode. For commissioning or after an emer-
gency stop, a non-recurrent, direct restart is permissible.
•After a failure and restoration of the power supply, the motor may start unexpectedly if the Auto
Start function is activated.
If staff is endangered, a restart of the motor must be prevented by means of external circuitry.
•Before commissioning and the start of the operation, make sure to fix all covers and check the
terminals. Check the additional monitoring and protective devices according to EN 60204 and ap-
plicable the safety directives (e.g. Working Machines Act or Accident Prevention Directives).
07/13 CM-EtherCAT 17

2.10.7 Maintenance and service/troubleshooting
•Visually inspect the frequency inverter when carrying out the required maintenance work and
inspections at the machine/plant.
•Perform the maintenance work and inspections prescribed for the machine carefully, including the
specifications on parts/equipment replacement.
•Work on the electrical components may only be performed by a qualified electrician according to
the applicable rules of electrical engineering. Only use original spare parts.
•Unauthorized opening and improper interventions in the machine/plant can lead to personal injury
or material damage. Repairs on the frequency inverters may only be carried out by the manufac-
turer or persons authorized by the manufacturer. Check protective equipment regularly.
•Before performing any maintenance work, the machine/plant must be disconnected from mains
supply and secured against restarting. The five safety rules must be complied with.
2.10.8 Final decommissioning
Unless separate return or disposal agreements were made, recycle the disassembled frequency in-
verter components:
•Scrap metal materials
•Recycle plastic elements
•Sort and dispose of other component materials
Electric scrap, electronic components, lubricants and other utility materials must be
treated as special waste and may only be disposed of by specialized companies.
In any case, comply with any applicable national disposal regulations as regards envi-
ronmentally compatible disposal of the frequency inverter. For more details, contact
the competent local authorities.
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3Introduction
The present document describes the possibilities and properties of EtherCAT®com-
munication for the frequency inverters of the ACU series of devices.
EtherCAT®
communication (as described in this manual) requires software version
5.3.0 or higher.
“Cyclic Synchronous Positioning” mode and “Cyclic Synchronous Positioning” mode is
Supported with software version 5.4.0 or higher.
Please refer to chapter 16.6 “Object support in the Software versions and XML” for
information on the required objects and XML files.
This manual is not to be understood as providing general/basic information on Ether-
CAT®. It requires basic knowledge of the methods and effects of EtherCAT®
on the
user's side.
In some chapters, setting and display options via the
PC software VPlus are described
as an alternative to the KP500 control unit. Use of a PCs running the VPlus software
requires an optional interface adapter KP232 or EoE modules in the PLC for a direct
Ethernet connection from the PC/VPlus to the frequency inverter.
07/13 CM-EtherCAT 19

In this document, the hardware circuitry, relevant parameters and the available ob-
jects are described.
The available objects are divided by:
Communication objects
(0x1nnn)
Manufacturer objects
(0x2nnn)
Standardized objects
(0x6nnn)
The functions and objects are described in this manual to the extent necessary. For
more information, refer to the standards of EtherCAT Technology Group (ETG).
The standards referred to are available at:
EtherCAT Technology Group
Headquarters
Ostendstr. 196
90482 Nürnberg, Germany
E-Mail: [email protected]
Web: www.ethercat.org
Phone: [phone] - 20
Fax: [phone] - 29
NOTE
With the CM-
EtherCAT communication module, it is possible to access
ALL frequency inverters parameters from a controller. There is no ac-
cess control via the control level as in the case of the KP500 manual
control unit or the VPlus PC software. Changing parameters, the func-
tions of which are not known to the user, can result in unintended
movements and material and/or personal losses as well as inoperative-
ness of the frequency inverter.
NOTE
If values are to be written cyclically, follow the notes in Chapter 12.3.1
“Handling of data sets/cyclic writing of the parameters”.
For operation with a controller, a XML is required. You will find this XML
file in the documentation of the product CD.
Hexadecimal values are marked in the following by a preceding “0x”.
20 CM-EtherCAT 07/13