halstrup-walcher HIPERDRIVE User manual

Document 7100.004854 07/2018
Instruction Manual
HIPERDRIVE with
EtherCAT
halstrup-walcher GmbH
Stegener Straße 10
D-79199 Kirchzarten, Germany
Tel.: [phone]
Fax: [phone]
E-Mail: [e-mail]
Internet: www.halstrup-walcher.de

Instruction Manual HIPERDRIVE with EtherCAT
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Table of Contents
1Safety precautions...................................................................................................................5
1.1 Appropriate use..............................................................................................................5
1.2 Shipping, assembly, electrical connections and start-up.................................................5
1.3 Troubleshooting, maintenance, repairs, disposal ...........................................................5
1.4 Symbols.........................................................................................................................6
2The HIPERDRIVE concept......................................................................................................6
3Device description: HIPERDRIVE Hub ....................................................................................7
3.1 Pin assignment HIPERDRIVE Hub ................................................................................7
3.2 Setting the device address.............................................................................................8
3.3 LEDs and jog keys for the HIPERDRIVE Hub................................................................8
3.4 Meaning of the LED statuses of LED “RS485” .............................................................10
3.5 Start-up: HIPERDRIVE Hub.........................................................................................11
4Device description: HIPERDRIVE bus adapter......................................................................12
4.1 Assembly of the HIPERDRIVE drives with bus adapter................................................12
4.2 Pin assignment: HIPERDRIVE bus adapter.................................................................12
4.3 Setting the device address...........................................................................................13
4.4 LEDs for the HIPERDRIVE bus adapter.......................................................................14
4.5 Meaning of the LED statuses of LED “RS485” .............................................................15
4.6 Start-up: HIPERDRIVE bus adapter.............................................................................15
5The EtherCAT interface.........................................................................................................16
5.1 EtherCAT interface with CoE protocol (CANopen over EtherCAT)...............................16
5.2 Table of entries implemented from object dictionary.....................................................17
5.3 PDO format..................................................................................................................27
5.4 Detailed description of status bits.................................................................................27
5.5 Detailed description of control bits................................................................................29
5.6 Flow chart....................................................................................................................32
6Jog function...........................................................................................................................33
6.1 Jog function with jog keys on the drive.........................................................................33
6.2 Jog function with jog keys in the HIPERDRIVE Hub.....................................................33
7Special features.....................................................................................................................34
7.1 Target speed (r.p.m.) and torque..................................................................................34
7.2 Response of the drive in case of block.........................................................................34
7.3 Response of the drive if it is turned manually (readjustment function)..........................34
7.4 Using actual value assessment factors to set the spindle pitch ....................................34
7.5 Aborted run when the master fails................................................................................35

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8Technical data.......................................................................................................................36
8.1 HIPERDRIVE Hub........................................................................................................36
8.2 Drives with HIPERDRIVE bus adapter.........................................................................37
9Certificate of Conformity ........................................................................................................39

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Purpose of instruction manual
This instruction manual describes the features of the HIPERDRIVE positioning
system and provides guidelines for its use.
Improper use of these devices or failure to follow these instructions may cause injury
or damage equipment. Every person who uses the devices must therefore read the
manual and understand the possible risks. The instruction manual, and in particular
the safety precautions contained therein, must be followed carefully. Contact the
manufacturer if you do not understand any part of this instruction manual.
Handle this manual with care:
It must be readily available throughout the lifecycle of the devices.
It must be provided to any individuals who assume responsibility for operating the
device at a later date.
It must include any supplementary materials provided by the manufacturer.
The manufacturer reserves the right to continue developing this device model without
documenting such development in each individual case. The manufacturer will be
happy to determine whether this manual is up-to-date.
Conformity
This device is state of the art. It complies with the legal requirements of EC directives.
This is shown by the CE mark.
© 2017, 2018
The manufacturer owns the copyright to this instruction manual. It contains technical
data, instructions and drawings detailing the devices’ features and how to use them. It
must not be copied either wholly or in part or made available to third parties.
EtherCAT® is a registered trademark and patented technology, licensed by Beckhoff
Automation GmbH, Germany.

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1 Safety precautions
1.1 Appropriate use
Positioning systems are especially suitable for automatically setting tools, stops or
spindles for wood-processing equipment, packing lines, printing equipment, filling
units and other types of special machines.
HIPERDRIVE positioning systems are not stand-alone devices and may only be
used if coupled to another machine.
Always observe the operating requirements –particularly the permissible supply
voltage –indicated on the rating plate and in the “Technical data” section of this
manual.
The device may only be handled as indicated in this manual. Modifications to the
device are prohibited. The manufacturer is not liable for damages caused by improper
use or failure to follow these instructions. Violations of this type render all warranty
claims null and void.
1.2 Shipping, assembly, electrical connections and start-up
Assembly and the electrical connections should only be handled by professionals.
They should be given proper training and be authorised by the operator of the facility.
The device may only be operated by appropriately trained individuals who have been
authorized by the operator of the facility.
Specific safety precautions are given in individual sections of this manual.
1.3 Troubleshooting, maintenance, repairs, disposal
The individual responsible for the electrical connections must be notified immediately
if the device is damaged or if errors occur.
This individual must take the device out of service until the error has been corrected
and ensure that it cannot be used unintentionally.
This device requires no maintenance.
Only the manufacturer may perform repairs that require the housing to be opened.
The electronic components of the device contain environmentally hazardous
materials and materials that can be reused. The device must therefore be sent to a
recycling plant when you no longer wish to use it. The environment codes of your
particular country must be complied with.

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1.4 Symbols
The symbols given below are used throughout this manual to indicate instances when
improper operation could result in the following hazards:
WARNING! This warns you of a potential hazard that could lead to bodily injury up to
and including death if the corresponding instructions are not followed.
CAUTION! This warns you of a potential hazard that could lead to significant
property damage if corresponding instructions are not followed.
INFORMATION: This indicates that the corresponding information is important
for operating the device properly.
2 The HIPERDRIVE concept
The HIPERDRIVE positioning system, an intelligent, compact, complete solution for
positioning auxiliary and positioning axes, consists of an EC motor, gear, power
amplifier, control electronics, absolute measuring system and EtherCAT interface.
The integrated absolute measuring system eliminates the need for time-consuming
reference runs. Connecting to a bus system simplifies the wiring. The positioning
system is especially suitable for automatically setting tools, stops or spindles for
wood-processing equipment, packing lines, printing equipment, filling units and other
types of special machines.
There are two options for the EtherCAT connection:
1) The HIPERDRIVE units are connected to a central connecting station. This
connecting station is called the “HIPERDRIVE Hub”. Up to eight drives can be
connected to a hub, all drives are used via the same bus address.
In addition, the HIPERDRIVE Hub distributes the operating voltage for the drives.
This means that only one cable is required to connect a drive. Both data and
power for the drives are transmitted via the same cable. For the HIPERDRIVE
Hub itself, apart from the fieldbus and 24V motor supply voltage, only a 24V
auxiliary voltage is required for the hub electronics.
2) The HIPERDRIVE drives are equipped with a bus adapter. The bus adapter has a
fixed connection to the drive. Each drive unit therefore has its own bus address
and its own fieldbus connection.
In the same way, each adapter has an input for the 24V power supply to the bus
adapter and the 24V power supply to the drive.

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3 Device description: HIPERDRIVE Hub
3.1 Pin assignment HIPERDRIVE Hub
A round, 5-pin plug, series 713/763 (A-coded) manufactured by Binder for the supply
voltage is located on the housing cover of the HIPERDRIVE Hub.
Two round 4-pin sockets, series 825 (D-coded) are provided for connection to the
bus.
Round plug for the power supply of the control unit:
(External top view)
1 +24V control unit
2 NC
3 Ground (control unit)
4 NC
5 NC
Supply for the drives connected to the HIPERDRIVE Hub:
The motor power supply (24VDC and GND) is connected using two screw
connections for cable lugs M6. These are concealed under a cover on the front side
of the hub.
Screw terminal for each of the drives connected to the HIPERDRIVE Hub:
For each drive to be connected to the HIPERDRIVE Hub, there is a flange adapter
containing a screw terminal with the following pin assignment:
Pin
Signal
Wire colour
1
RS485 data +
white
2
RS485 data -
green
3
+24V
orange
4
GND
black
5
+24V
red
6
GND
blue
Terminals 3 and 5 are connected internally in the hub, as are terminals 4 and 6.

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Round sockets for the bus:
(External top view)
1 TD+ (WH/GN, white/green)
2 RD+ (WH/OR, white/orange)
3 TD-(GN, green)
4 RD-(OR, orange)
Due to the use of 4-pin sockets, only four-wire cables should be used.
3.2 Setting the device address
The device address is assigned via the bus of the EtherCAT master. Alternatively, the
“configured station alias” can be defined using the two rotary switches (address
switch value > 0).
3.3 LEDs and jog keys for the HIPERDRIVE Hub
Opening the housing cover on the top side of the hub provides access to the following
operating and observation elements:

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The LEDs are visible through two windows in the housing cover even when it is
closed.
Meaning of the LEDs:
1) Each of the ports (P1/P2) has an associated green LED for the “Link” and “Activity”
states.
For each port the following states are possible:
- off no connection
- on line connection is active, no data activity
- flickering at 10 Hz line connection and data transmission active
2) Red/green EtherCAT status LED
EtherCAT STATUS LED (green/red; see EtherCAT specification)
3) Red/green LED “RS485”
The LED “RS485” signals the status of the RS485 connections to the connected
motors
Switch S3 = 0 displays a collective message,
Switch S3 > 0 Status of the RS485 connection to the motor selected with S3
(see also following section)
Meaning of the rotary switches and keys:
S1/S2: Definition of the “configured station alias” (address switch value 0 means
that the last value saved in the device will be used)
S3: Selection of the drive to be jogged or to identify a faulty drive
S4: Jog the drive selected with S3. Starts a jog step with the parameters
from SDO #2090 (jog 2; default 1/16 rotation backwards)
S5: Jog the drive selected with S3. Starts a jog step with the parameters
from SDO #208F (jog 1; default 1/16 rotation forwards)
Important: Always close the housing cover after completing the
operating and observation task. This will prevent dust and
contaminants from entering the device.
The HIPERDRIVE drives can only be run via the bus if S3 is set to 0.

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3.4 Meaning of the LED statuses of LED “RS485”
The LED RS485 shows a collective message. When switch S3 is set to 0, the
meanings are as follows:
Status
Meaning
off
No power supply to the HIPERDRIVE electronics.
flashes
red+green
alternately
(5 Hz)
Presence test
The hub is detecting the ports to which drive are connected
red on
Communication error for at least one of the drives marked as
“required”
red+green on
Drive error for at least one of the drives marked as “required”
(communication to these drives is functioning correctly)
flashes green
(2 Hz)
All drives marked as “required” are functioning without
communication or drive errors.
At least one further drive exists, which is not marked as
“required”. No drive errors for any “non-required” drive.
flashes
red+green
simultaneously
(2 Hz)
All drives marked as “required” are functioning without
communication or drive errors.
At least one further drive exists, which is not marked as
“required”. At least one of the “non-required” drives has a drive
error.
green on
Only the drives marked as “required” are available and none of
these have a drive error.
When S3 is set to a value > 0, the LED RS485 shows the status of the drive selected
using the switch S3:
Status
Meaning
off
Not available and not required.
red on
Communication error
red+green on
Communication OK, but drive error
green on
Communication OK, no drive error
When the S3 switch is set to 0, it is therefore possible to view the communication
status with the drives and, if a problem arises, identify the specific drive causing the
problem by setting the S3 switch to the next corresponding position.

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3.5 Start-up: HIPERDRIVE Hub
After connecting the supply voltage, the hub automatically performs a presence test.
During this test, the hub detects the ports to which drives are connected. For each
drive, the baud rate is set to the last value saved in the hub for the specific drive. The
“RS485 message complete time” (time after which the drive evaluates a received
message) is set to a value corresponding to the desired baud rate. The RS485
address of the drive is set to 1 (steady-state).
In addition, the hub loads the most recently saved information about the ports at
which drives were most recently required, i.e. were released for issuing run
commands.
If at least one drive requested recently is not found, the LED RS485 is illuminated red.
If precisely the number of drives requested recently is found, the LED RS485 is
illuminated green.
If more drives than last required are found, the LED RS485 flashes green (frequency
2 Hz).
In the delivery state, no drive is marked as “required”.
A drive must first be “required” at the hub in order to execute run
commands. For the drive “n”, this is done by setting SDO
(0x20A4 + (n-1) * 0x80) to 1.
The presence test can also be repeated at any time after switching on the supply
voltage by setting SDO #200D to -3.

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4 Device description: HIPERDRIVE bus adapter
4.1 Assembly of the HIPERDRIVE drives with bus adapter
The drives are fixed in position using 4x M5 screws via the centring spigot flush on
the mounting surface. Please ensure that the screw depth in the mounting surface is
at least 10mm.
The mounting flange is symmetrical, i.e. the drives can be mounted in four different
angle positions on the mounting surface depending on the cable outlet.
The shaft connection with the feather key shows a positive engagement. When
installing mechanical coupling elements, please take note of the permitted axial and
radial forces stated in the “Technical data” section. If necessary, use a suitable
coupling element to balance the axial and radial tolerances.
To prevent damage to electromechanical components, please avoid
banging or knocking the output shaft.
4.2 Pin assignment: HIPERDRIVE bus adapter
A 4-pin screw terminal for connecting the supply voltage is located in the housing
cover of the HIPERDRIVE bus adapter. A PG threaded connection through which the
screw terminal can be accessed is provided as standard. Optionally, these terminals
are already factory-wired to the pins of a 7/8″plug (manufacturer: Lumberg;
designation RSF 50/11-04). In this case, the PG threaded connection is omitted.
Two round 4-pin sockets, series 825 (D-coded) are provided for connection to the
bus.
Screw terminal for the power supply of the HIPERDRIVE drive unit with bus
adapter:
1 GND drive
2 +24V drive
3 GND bus adapter
4 +24V bus adapter
The bus adapter electronics can either be powered via separate connection points
(terminals 3/4) or be interconnected with the motor power supply via the jumpers J1
and J2 in the adapter:

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The former is generally selected if the motor power supply is run in a safety circuit
with the EMERGENCY STOP and the databus has to remain active during an
EMERGENCY STOP, or if the motor power supply does not permit correct operation
of the bus adapter due to inadequate voltage stability or high interference voltages.
The jumper J1 for the connection between the two GND potentials
always must be closed, because otherwise the differences in the
potential between the two GND could become unacceptable high. In
addition, the two GND potentials should be connected outside the device
(e.g. directly at the power supplys which provide the two supply
voltages) so that potential compensating currents will not flow through
the device.
Round plug for power supply
(optional):
(External top view)
1 +24V Motor
2 Ground (motor)
3 Housing
4 Ground (control unit)
5 +24V control unit
Round socket for the bus:
(External top view)
1 TD+ (WH/GR, white/green)
2 RD+ (WH/OG, white/orange)
3 TD- (GR, green)
4 RD- (OR, orange)
Due to the use of 4-pin
sockets, only four-wire
cables should be used.
4.3 Setting the device address
The device address is assigned via the bus of the EtherCAT master. Alternatively, the
“configured station alias” can be defined using the two rotary switches (address
switch value > 0).

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4.4 LEDs for the HIPERDRIVE bus adapter
Opening the cover of the bus adapter provides access to the following operating and
observation elements:
The LEDs are visible through two windows even when the bus adapter cover is
closed.
Meaning of the LEDs:
1) Each of the ports (P1/P2) has an associated green LED for the “Link” and “Activity”
states.
For each port the following states are possible:
- off no connection
- on line connection is active, no data activity
- flickering at 10 Hz line connection and data transmission active
2) Red/green EtherCAT status LED
EtherCAT STATUS LED (green/red; see EtherCAT specification)
3) Red/green LED “RS485”
The LED “RS485” signals the status of the RS485 connection to the connected motor
(collective message, see also following section).

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Meaning of the rotary switches:
The two rotary switches are used to define the “configured station alias” (address
switch value 0 means that the last value saved in the device will be used). These can
be accessed by opening the cover of the bus adapter.
Important: Always close the cover of the bus adapter after completing
the operating and observation task. This will prevent dust and
contaminants from entering the device.
4.5 Meaning of the LED statuses of LED “RS485”
LED-RS485 shows a collective message.
Status
Meaning
off
No power supply to the HIPERDRIVE electronics.
flashes
red+green
alternately
(5 Hz)
Presence test
The bus adapter determines whether communication with the
basic unit has been established.
red on
Communication error to the drive, if this is marked as “required”
red+green on
Drive error (communication to the drive is functioning correctly)
flashes green
(2 Hz)
The drive is not marked as “required”, no drive error.
flashes
red+green
simultaneously
(2 Hz)
The drive is not marked as “required”, the drive has a drive
error.
green on
Communication to the drive is functioning correctly, the drive
has no drive error.
4.6 Start-up: HIPERDRIVE bus adapter
After connecting the supply voltage, the bus adapter automatically performs a
presence test:
During this test, the adapter determines whether a drive is connected to the adapter.
If so, the transfer rate is set to the last value saved in the adapter. The “RS485
message complete time” (time after which the drive evaluates a received message) is
set to the value corresponding to the desired baud rate. The RS485 address of the
drive is set to 1 (steady-state).
If no drive is found, the LED RS485 is illuminated red.
If the drive is found, the LED RS485 is illuminated green.

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5 The EtherCAT interface
5.1 EtherCAT interface with CoE protocol (CANopen over
EtherCAT)
The EtherCAT interface uses the CANopen over EtherCAT protocol in accordance
with ETG1000.6 Section 5.6:
one send and one receive SDO per device
one asynchronous send and receive PDO, active by default
Meaning of the LEDs:
1) Each of the ports (P1/P2) has an associated green LED for the “Link” and
“Activity” states.
For each port the following states are possible:
- off no line connection
- flickering at 10 Hz line connection; data transmission active
- on line connection; data transmission inactive
2) The green “Run” LED signals the ESM status:
- off INIT
- flashes at 2.5Hz PRE-OPERATIONAL
- single flashes at 1Hz SAFE-OPERATIONAL
- on OPERATIONAL
3) The red “Error” LED signals an error:
- off no error
- single flashes at 1Hz local fault, application is changing ESM status
- double flashes at 1Hz watchdog timeout
- flashes at 2.5Hz configuration fault

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5.2 Table of entries implemented from object dictionary
The area 0x1000 to 0x207F of the object dictionary contains those objects that only
exist once regardless of whether the HIPERDRIVE unit is a drive with a bus adapter
or a hub and independently of the number of drives that can be connected to a hub.
Name,
designation
Index
number
Function
Range of
values
Back
up?
Deliver
y state
R/W
Device type
1000
Returns a “0” when read
0
0
R
Software
description
100A
Identifies the software of the EtherCAT
drives; returns the string “HIPERDRIVE /
ECAT” when read
R
Identity
1018
Sub index 0: No. of indices (= 4)
Sub 1: Vendor-ID (= 0x000002D8)
Sub 2: Product code
Sub 3: Revision number (= 0x00010000)
Sub 4: Serial number
8 bit
32 bit
32 bit
32 bit
32 bit
4
R
R
R
R
R
Receive PDO
1 mapping
1600
Sub index 0: No. of indices
(Adapter 4; Hub-4 16; Hub-8 32)
Sub 1: 0x20800010
Sub 2: 0x20810008
Sub 3: 0x20820008
Sub 4: 0x20830032
In addition, for Hub-4 and Hub-8:
Sub 5: 0x21000010
Sub 6: 0x21010008
Sub 7: 0x21020008
Sub 8: 0x21030032
Sub 9: 0x21800010
Sub 10: 0x21810008
Sub 11: 0x21820008
Sub 12: 0x21830032
Sub 13: 0x22000010
Sub 14: 0x22010008
Sub 15: 0x22020008
Sub 16: 0x22030032
In addition, for Hub-8:
Sub 17: 0x22800010
…
Sub 32: 0x24030032
8 bit
32 bit
32 bit
32 bit
32 bit
32 bit
32 bit
32 bit
32 bit
32 bit
32 bit
32 bit
32 bit
32 bit
32 bit
32 bit
32 bit
32 bit
…
32 bit
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
…
R

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Name,
designation
Index
number
Function
Range of
values
Back
up?
Deliver
y state
R/W
Transmit
PDO 1
mapping
1A00
Sub index 0: No. of indices
(Adapter 3; Hub-4 12; Hub-8 24)
Sub 1: 0x20840010
Sub 2: 0x20850010
Sub 3: 0x20860020
In addition, for Hub-4 and Hub-8:
Sub 4: 0x21040010
Sub 5: 0x21050010
Sub 6: 0x21060020
Sub 7: 0x21840010
Sub 8: 0x21850010
Sub 9: 0x21860020
Sub 10: 0x22040010
Sub 11: 0x22050010
Sub 12: 0x22060020
In addition, for Hub-8:
Sub 13: 0x22840010
…
Sub 24: 0x24060032
8 bit
32 bit
32 bit
32 bit
32 bit
32 bit
32 bit
32 bit
32 bit
32 bit
32 bit
32 bit
32 bit
32 bit
…
32 bit
R
R
R
R
R
R
R
R
R
R
R
R
R
R
…
R
SM Comm
Types
1C00
Sub index 0: No. of indices (= 4)
Sub 1: SM0 (= 1)
Sub 2: SM1 (= 2)
Sub 3: SM2 (= 3)
Sub 4: SM3 (= 4)
8 bit
8 bit
8 bit
8 bit
8 bit
4
R
R
R
R
R
SM0 PDO
Assignment
1C10
Sub index 0: No. of indices (= 0)
8 bit
0
R
SM1 PDO
Assignment
1C11
Sub index 0: No. of indices (= 0)
8 bit
0
R
SM2 PDO
Assignment
1C12
Sub index 0: No. of indices (= 1)
Sub 1: 0x1600 (1. RxPDO)
8 bit
16 bit
1
R
SM3 PDO
Assignment
1C13
Sub index 0: No. of indices (= 1)
Sub 1: 0x1A00 (1. TxPDO)
8 bit
16 bit
1
R

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Name,
designation
Index
number
Function
Range of
values
Back
up?
Delivery
state
R/W
general
purpose
register
2000
10 general purpose registers
Sub index 0: No. of indices (= 10)
Sub 1..10: Free register
8 bit
32 bit
yes
10
0
R
R/W
Address
2001
Configured Station Alias
Write:
When writing the address via SDO, the
new address will only be taken over into
the ESC and the Sll after saving the
parameters in the EEPROM (see SDO
#200D) and restart.
If the value is written directly to the SII by
the master (i.e. not via SDO), it will be
saved automatically by the HIPERDRIVE
Hub or adapter.
16 bit
yes
0
R/W
HIPERDRIVE
category
2002
Adapter “HIPERDRIVE SINGLE”
4-port hub “HIPERDRIVE HUB-4”
8-port hub “HIPERDRIVE HUB-8”
R
HIPERDRIVE
name
2004
Type designation as string
R
Item number
2005
halstrup-walcher article number as string
(format xxxx.xxxx)
R
Serial
number
2006
Serial device number of the hub or
adapter
0…
65535
16 bit
R
Production
date
2007
Year and week of manufacture as string
(format WW/YYYY)
R
Version
2008
Software version number as string (format
x.xx)
R
U control
2009
Current supply voltage to control unit, in
0.1 V
16 bit
R
Device
temperature
200B
Internal device temperature in °C
16 bit
R

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Name,
designation
Index
number
Function
Range of
values
Back
up?
Delivery
state
R/W
Delivery state
200D
Writing a “-3”:
resets all the connected drives and sets
the desired baud rate
The execution of this command may take
up to 2 sec for the HIPERDRIVE bus
adapter and up to 8 sec for the
HIPERDRIVE Hub Watch
acknowledgement of drive (receiving of
SDO response).
Writing a “-2”:
sets the values of all the parameters that
can be saved in the hub or adapter to the
last values saved by the user, without
saving the parameters in EEPROM
Writing a “-1”:
sets the values of all the parameters that
can be saved in the hub or adapter to the
delivery state, without saving the
parameters in EEPROM
Writing a “1”:
saves the parameters in EEPROM
Reading after booting:
0 Memory content correct
≠ 0 Memory content incorrect
Reading after saving:
0 Saving successfully completed
≠ 0 Saving not yet completed or
completed incorrectly
(saving can take up to 200ms)
-3, -2, -1
or 1
(during
writing)
0..3
(during
reading)
15 bit
no
R/W