Estun TRIO Flex-6 Nano User manual

USER MANUAL
Flex-6 Nano
EtherCAT 64 AXIS MOTION COORDINATOR

Flex-6 Nano
Document Version: 1.00
© 2023 All rights reserved.
1
About this Manual
Purpose
This manual provides the information required for the Selection, Wiring, Connection, Setup,
Operation and Functions of the FLEX-6 NANO Motion Coordinator.
Please read and understand this manual to ensure correct usage of the product.
Terms
Terms that may be used in this manual are defined as follows.
Term
Meaning
Axis
A software control that operates a Servo or Stepper Motor.
Drive
A Servo or Stepper Drive, which is used for controlling the Motor.
Servo System
A Servo Control System that includes a Motor, a Drive, a host controller (Motion
Coordinator) and peripheral devices.
WDOG ON
Setting the control word on EtherCAT to signal that the Drives may be Enabled.
WDOG OFF
Clear the control word to signal that the Drives must be Disabled.
Motion Perfect
The PC Tool for commissioning and programming the Trio product suite.
Pulse+Direction
An electronic output from the Motion Coordinator that produces one pulse per step
of the motor position, with a second output to signal the direction of motion.
Motion-iX
The motion-centric programming language, an extension of BASIC.
EtherCAT
Ethernet based fieldbus for synchronised control of slave devices in real-time.

Flex-6 Nano
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Revision History
Date
Version
Revised Contents
29 Jun 2021
1.00
Initial release
31 Jan 2023
1.01
Updated specification table

Flex-6 Nano
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All goods supplied by Trio are subject to Trio’s standard terms and conditions of sale.
This manual applies to systems based on the Motion Coordinator FLEX-6 NANO.
The material in this manual is subject to change without notice. Despite every effort, in a
manual of this scope errors and omissions may occur. Therefore, Trio Motion Technology Ltd.
cannot be held responsible for any malfunctions or loss of data as a result.
Copyright (C) 2023 Trio Motion Technology Ltd.
All Rights Reserved
UK
Trio Motion Technology Ltd.
Phone: [phone]
USA
Trio Motion Technology LLC.
Phone: + 1 724 472 4100
CHINA
Trio Shanghai
Tel: [phone]
INDIA
Trio India
Phone: [phone]

Flex-6 Nano
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Safety Warning
During the installation or use of a control system, users of Trio products must ensure there is
no possibility of injury to any person, or damage to machinery.
Control systems, especially during installation, can malfunction or behave unexpectedly.
Users must ensure that in all cases of normal operation, controller malfunction, or
unexpected behaviour, the safety of operators, programmers or any other person is totally
ensured.

Flex-6 Nano
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Contents
Revision History ............................................................................................2
User Manual FLEX-6 NANO ................................................................................6
Overview .................................................................................................6
Programming.............................................................................................6
I/O Capability............................................................................................7
Communications.........................................................................................7
IP Address reset .........................................................................................7
Removable storage......................................................................................7
Axis positioning functions ..............................................................................7
LED indicators ...........................................................................................8
Connections to the FLEX-6 NANO .....................................................................8
Registration ...........................................................................................9
Expanding the system ..................................................................................9
Support Software...................................................................................... 10
Motion Perfect version 5 .......................................................................... 11
Software functions .................................................................................... 12
Firmware recovery .................................................................................... 13
Dimensions ............................................................................................. 14
Mounting................................................................................................ 14
Specifications .......................................................................................... 15
Electromagnetic Compatibility...................................................................... 16
Intended conditions of use ........................................................................ 16
EMC Considerations ................................................................................ 17
Product specific requirements ................................................................... 17
Recommended Installation........................................................................ 18
Surge Protection.................................................................................... 19
Surge protection device ........................................................................... 20
Cable Shields ........................................................................................ 20

Flex-6 Nano
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User Manual FLEX-6 NANO
Overview
The Motion Coordinator FLEX-6 NANO is based on Trio’s high-
performance ARM Cortex-A7 double-precision technology and
provides up to 64 axes of coordinated motion using the
EtherCAT bus system to connect to Drives and I/O. The
FLEX-6 NANO is housed in a rugged plastic case with
integrated earth chassis and incorporates two screened RJ45
Ethernet ports, a 24V dc power connector and micro SD card
slot. The upper RJ45 connector is for a standard Ethernet
connection to the PC for programming and the lower
connector is for the EtherCAT Fieldbus. Filtered power
supplies (DC/DC converters) are included so that it can be
powered from the 24V d.c. logic supply present in most
industrial cabinets.
It is designed to be configured and programmed for the
application using a PC running Trio’s Motion Perfect
application software, and then may be set to run
“standalone” if an external computer is not required for the
final system. Programs and data are stored directly to FLASH
memory, thus eliminating the need for battery backed
storage.
The Multi-tasking version of Motion-iX for the FLEX-6 NANO
allows up to 22 Motion-iX programs to be run simultaneously
on the controller using pre-emptive multi-tasking. In
addition, the operating system software includes the IEC
61131-3 standard run-time environment that has access to
the full library of motion functions.
Programming
The Multi-tasking ability of the FLEX-6 NANO allows parts of a complex application to be
developed, tested and run independently, although the tasks can share data and motion
control hardware. The 22 available processes can be used for Motion-iX or IEC 61131-3
programs, or a combination of both can be run at the same time, thus allowing the
programmer to select the best features of each.
The Flex-6 Nano is fully compatible with Trio’s Robot Programming System (RPS) and the
user can decide to write programs using the powerful Motion iX functions or the RPS motion
suit which is tailored to Scara and other industrial robot systems. Both RPS and Motion iX /
IEC programs may be run on the same Motion Coordinator thus allowing the powerful Flex-6
Nano to control many auxilliary motors as well as the robot arm(s).

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I/O Capability
The FLEX-6 NANO has the ability to add up to 16 EtherCAT FLexslice input / output modules
using the EBUS connector on the side. Modules are supported mechanically by a positive
latch system that allows rapid assembly that results in a robust final assembly ready for
clipping on the DIN rail. These may be used for system interaction or may be defined to be
used by the controller for end of travel limits, soft registration, datuming and feedhold
functions if required. The FLEX-6 NANO can have up to 1024 external Input and Output
channels connected using a combination of the local EBUS and remote EtherCAT IO via the
P366 bus coupler module.
Communications
A 100 base-T Ethernet port is fitted as standard and this is the primary communications
connection to the FLEX-6 NANO. Protocols supported include Telnet (Client and Server),
Modbus TCP (Client and Server), Ethernet IP (Slave), Profinet (Slave) and the TrioPCMotion
DLL/ActiveX channel.
IP Address reset
To reset the IP _ ADDRESS, IP _ GATEWAY and IP _ NETMASK to their default values press the
IP reset button, located under the upper ventilation slots, and power cycle the controller
while keeping the button pressed.
The factory default IP
address is 192.168.0.250.
This can be changed using
the ETHERNET or IP_ADDRESS
commands via Motion
Perfect.
IP_ADDRESS and other settings may also be changed by adding the commands to a file called
TRIOINIT.BAS on a micro-SD card and powering up the FLEX-6 NANO with the card inserted in
the SD slot.
Removable storage
The FLEX-6 NANO has a micro-SD Card slot which allows a simple
means of transferring programs, firmware and data without a PC
connection. Offering the OEM easy machine replication and servicing.
The memory slot is compatible with a wide range of micro-SD cards
up to 32 GBytes using the FAT32 compatible file system.
Axis positioning functions
The motion control generation software receives instructions to move an axis or axes from
the Motion-iX or IEC 61131-3 language which is running concurrently on the same processor.
The motion generation software provides control during operation to ensure smooth,
coordinated movements with the velocity profiled as specified by the controlling program.

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Linear interpolation may be performed on groups of axes, and circular, helical or spherical
interpolation in any two/three orthogonal axes. Each axis may run independently, or they
may be linked using interpolation, variable electronic gearboxes and kinematic transform.
Consecutive movements may be merged to produce continuous path motion and the user
may program the motion using programmable units of measurement (e.g. mm, inches, revs
etc.). The module may also be programmed to control only the axis speed. The positioner
checks the status of end of travel limit switches which can be used to cancel moves in
progress and alter program execution.
LED indicators
2 LEDs show the status of the power and the enable circuit.
The enable circuit drives the watchdog relay and activates the
pulse output signals.
Red LED ON shows that the WDOG is off and the axes are
disabled. When the red LED is OFF, the axes are enabled and
ready to move. A flashing red LED indicates that one or more
axes are in error.
RN is the run status of the EtherCAT network and LA show the
EtherCAT network activity.
RN LED
EtherCAT State
OFF
Initial
Uniform flash
Pre-Operational
Brief flash
Safe-Operational
ON
Operational
Connections to the FLEX-6 NANO
Ethernet port connection
RJ45 socket 10/100 base-T
The Ethernet port is the default connection between the Motion Coordinator
and the host PC running the Motion Perfect development application.
In addition, the Ethernet port will provide connection using common Ethernet industrial
protocols such as Modbus, CIP and Profinet.
EtherCAT port connection
RJ45 socket 100 base-T
The Flex-6 Nano acts as an EtherCAT master. EtherCAT drives and I/O devices
are normally connected in a chain.
Ethernet standard pin assignment:

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Pin
Signal
Description
1
TD+
Transmission data +
2
TD-
Transmission data -
3
RD+
Receive data +
6
RD-
Receive data -
Straight through (patch) or cross-over cables can be used between EtherCAT devices.
Minimum cable specification: CAT 5e shielded SF/UTP cable is recommended.
Registration
FLEX-6 NANO requires servo and stepper drives connected by EtherCAT to support the CiA402
Touch Probe system. With the touch probe objects included in the cyclic data PDO, the
Motion Coordinator programs can use the REGIST command to access the registration inputs
and functions in the remote drives. Precise position capture can then be done to enable
operation of many machine types which include printing, cutting and scanning machines.
Expanding the system
The Flexslice system makes available a selection of digital and analogue I/O terminals as
well as motion modules with analogue servo and pulse + direction outputs designed for
precise positioning of stepper and servo motors via suitable drive technology. The digital
I/O modules have high-speed functionality and can sample on each EtherCAT cycle. In
addition, analogue modules and axis modules may be fitted to make a superbly tailored
system that can be placed remotely from the master if needed.
All Flexslice modules support automatic
addressing with the master able to
automatically detect and configure the
modules on startup. The Flex-6 Nano
supports up to 16 input/output modules
which have a positive mechanical lock and
bus connector, making a reliable “back-
bone” style connection (EBUS). The complete
assembly can be DIN rail mounted.