Kollmorgen AKD EtherCAT User manual

AKD™
EtherCAT Communication
Edition December 2009
Valid for Hardware Revision A
Original Documentation
Keep all manuals as a product component
during the life span of the product.
Pass all manuals to future users / owners
of the product.

Record of Document Revisions:
Revision Remarks
11/2009 Beta launch version
12/2009 Minor formatting changes
Hardware Revision (HR)
Hardware Revision Firmware WorkBench Remarks
A 1.1.0 1.1.0 launch version
EnDat is a registered trademark of Dr. Johannes Heidenhain GmbH
EtherCAT is a registered trademark of EtherCAT Technology Group
HIPERFACE is a registered trademark of Max Stegmann GmbH
WINDOWS is a registered trademark of Microsoft Corporation
AKD is a registered trademark of Kollmorgen Corporation
Current patents:
US Patent 5,646,496 (used in control card R/D and 1 Vp-p feedback interface)
US Patent 5,162,798 (used in control card R/D)
US Patent 6,118,241 (used in control card simple dynamic braking)
Technical changes which improve the performance of the device may be made without prior notice!
Printed in the United States of America
This document is the intellectual property of Kollmorgen™. All rights reserved. No part of this work may be
reproduced in any form (by photocopying, microfilm or any other method) or stored, processed, copied or dis-
tributed by electronic means without the written permission of Kollmorgen™.
2 Kollmorgen | December 2009

Table of Contents
1 General 5
1.1 About this Manual 6
1.2 Target Group 6
1.3 Warning Symbols 7
1.4 Abbreviations used 8
2 Safety 9
2.1 Safety Instructions 10
2.2 Use as directed 11
2.3 Prohibited use 11
3 Installation and Setup 12
3.1 Safety Instructions 13
3.2 EtherCAT Onboard 14
3.2.1 LED functions 14
3.2.2 Connection technology 14
3.2.3 Network Connection Example 14
3.3 Guide to Setup 15
3.4 Setup via TwinCAT NC/PTP System Manager 15
3.4.1 Scan devices 15
3.4.2 Select the device 17
3.4.3 Scan for boxes 17
3.4.4 Add Slaves to NC tasks 18
3.4.5 Enable the network configuration 19
3.4.6 Enable the axis and move the axis 20
4 EtherCAT Profile 21
4.1 Slave Register 22
4.2 AL Event (Interrupt Event) and Interrupt Enable 23
4.2.1 Interrupt Enable Register (Address 0x0204:0x0205) 23
4.2.2 AL Event Request (Address 0x0220:0x0221) 24
4.3 Phase Run-Up 25
AKD EtherCAT |
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4.3.1 AL Control (Address 0x0120:0x0121) 25
4.3.2 AL Status (Address 0x0130:0x0131) 25
4.3.3 AL Status Code (Address 0x0134:0x0135) 26
4.3.4 EtherCAT communication phases 26
4.4 CANopen over EtherCAT (CoE) Status Machine 27
4.4.1 Status Description 27
4.4.2 Commands in the Control Word 28
4.4.3 Status Machine Bits (status word) 29
4.5 Fixed PDO Mappings 30
4.6 Supported Cyclical Setpoint- and Actual Values 30
4.7 Supported Operation Modes 30
4.8 Adjusting EtherCAT Cycle Time 31
4.9 Maximum Cycle Times depending on operation mode 31
4.10 Synchronization 31
4.11 Latch Control Word and Latch Status Word 32
4.12 Mailbox Handling 33
4.12.1 Mailbox Output 34
4.12.2 Mailbox Input 35
4.12.3 Example: Mailbox Access 36
4.13 Fieldbus Parameters 37
5 Index 39
AKD EtherCAT |
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1 General
1.1 About this Manual 6
1.2 Target Group 6
1.3 Warning Symbols 7
1.4 Abbreviations used 8
AKD EtherCAT | 1 General
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AKD EtherCAT | 1 General
1.1 About this Manual
This manual, AKD EtherCAT Communication, describes the installation, setup, range of functions, and soft-
ware protocol for the EtherCAT AKD product series. All AKD EtherCAT drives have built-in EtherCAT func-
tionality; therefore an additional option card is not required.
A digital version of this manual (pdf format) is available on the CD-ROM included with your drive. Manual
updates can be downloaded from the Kollmorgen website.
Related documents for the AKD series include:
lAKD Quick Start (also provided in hard copy). This guide provides instructions for basic drive setup
and connection to a network.
lAKD Installation Manual (also provided in hard copy). This manual provides instructions for installation
and drive setup.
lAKD Parameter and Command Reference Guide. This guide provides documentation for the param-
eters and commands used to program the AKD.
lAKD Accessories Manual. This manual includes technical data and dimensional drawings of acces-
sories such as cables, brake resistors, and mains supplies.
lAKD CANopen Communication. This manual includes setup information for the CAN interface and
describes the CANopen profile.
1.2 Target Group
This manual addresses personnel with the following qualifications:
lInstallation: only by electrically qualified personnel.
lSetup : only by qualified personnel with extensive knowledge of electrical engineering
and drive technology
lProgramming:Software developers, project-planners
The qualified personnel must know and observe the following standards:
lISO 12100, IEC 60364 and IEC 60664
lNational accident prevention regulations
During operation there are deadly hazards, with the possibility of death, severe
injury or material damage. The operator must ensure that the safety instructions
in this manual are followed. The operator must ensure that all personnel respon-
sible for working with the servo drive have read and understand the manual.
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1.3 Warning Symbols
Symbol Indication
Indicates a hazardous situation which, if not avoided, will result in
death or serious injury.
Indicates a hazardous situation which, if not avoided, could result in
death or serious injury.
Indicates a hazardous situation which, if not avoided, could result in
minor or moderate injury.
Indicates situations which, if not avoided, could result in property
damage.
This is not a safety symbol.
This symbol indicates important notes.
Drawing symbols
Symbol Description Symbol Description
Signal ground Diode
Chassis ground Relays
Protective earth Relays switch off
delayed
Resistor Normal open contact
Fuse Normal closed contact
AKD EtherCAT | 1 General
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AKD EtherCAT | 1 General
1.4 Abbreviations used
Abbreviation Meaning
AL Application Layer: the protocol that directly used by the process entities.
Cat Category – classification for cables that is also used in Ethernet.
DC Distributed Clocks Mechanism to synchronize EtherCAT slaves and master
DL Data Link(=Layer 2). EtherCAT uses Ethernet, which is standardized as IEEE 802.3.
FPGA Field Programmable Gate Array
FTP File Transfer Protocol
HW Hardware
ICMP Internet Control Message Protocol: Mechanisms for signaling IP errors.
IEC International Electrotechnical Commission: The international standards
IEEE Institute of Electrical and Electronics Engineers, Inc.
LLDP Lower Layer Discovery Protocol
MAC Media Access Control
MII Media Independent Interface: Standardized interface Ethernet controller <-> routing equipment.
MDI Media Dependant Interface: Use of connector Pins and Signaling.
MDI-X Media Dependant Interface (crossed): Use of connector Pins and Signaling with crossed lines.
OSI Open System Interconnect
OUI Organizationally Unique Identifier – the first 3 Bytes of an Ethernet-Address, that will be assign
to companies or organizations and can be used for protocoll identifiers as well (e.g. LLDP)
PDI Physical Device Interface: set of elements that allows access to ESC from the process side.
PDO Process Data Object
PDU Protocol Data Unit: Contains protocol information transferred from a protocol instance of trans-
parent data to a subordinate level
PHY Physical interface that converts data from the Ethernet controller to electric or optical signals.
PLL Phase Locked Loop
PTP Precision Time Protocol in accordance with IEEE 1588
RSTP Rapid Spanning Tree Protocol
RT Real-time, can be run in Ethernet controllers without special support.
RX Receive
RXPDO Receive PDO
SNMP Simple Network Management Protocol
SPI Serial Peripheral Interface
Src Addr Source Address: Source address of a message.
STP Shielded Twisted Pair
TCP Transmission Control Protocol
TX Transmit
TXPDO Transmit PDO
UDP User Datagram Protocol: Non-secure multicast/broadcast frame.
UTP Unshielded Twisted Pair
ZA ECAT Access mode EtherCAT
ZA Drive Acces mode Drive
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2 Safety
2.1 Safety Instructions 10
2.2 Use as directed 11
2.3 Prohibited use 11
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AKD EtherCAT | 2 Safety
2.1 Safety Instructions
During operation there are deadly hazards, with the possibility of death, severe
injury or material damage. Do not open or touch the equipment during operation.
Keep all covers and cabinet doors closed during operation. Touching the equip-
ment is allowed during installation and commissioning for properly qualified per-
sons only.
lDuring operation, drives may have uncovered live components, depend-
ing on their level of enclosure protection.
lControl and power connections may be live, even though the motor is not
rotating.
lDrives may have hot surfaces during operation. Heat sink can reach tem-
peratures above 80°C.
Electronic equipment is basically not failure-proof. The user is responsible for
ensuring that, in the event of a failure of the servo amplifier, the drive is set to a
state that is safe for both machinery and personnel, for instance with the aid of a
mechanical brake.
Drives with servo amplifiers and EtherCAT expansion cards are remote-con-
trolled machines. They can start to move at any time without previous warning.
Take appropriate measures to ensure that the operating and service personnel
is aware of this danger.
Implement appropriate protective measures to ensure that any unintended start-
up of the machines cannot result in dangerous situations for personnel or
machinery. Software limit-switches are not a substitute for the hardware limit-
switches in the machine.
Install the drive as described in the Installation Manual. The wiring for the
analog setpoint input and the positioning interface, as shown in the wiring dia-
gram in the Installation Manual, is not required. Never break any of the electrical
connections to the drive while it is live. This action can result in destruction of
the electronics
Do not connect the Ethernet line for the PC with the set up software to the Ether-
CAT interface X5/X6. The set up Ethernet cable must be connected to the serv-
ice interface on X11
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2.2 Use as directed
Drives are components that are built into electrical plants or machines and can only be operated as integral
components of these plants or machines. The manufacturer of the machine used with a drive must generate a
hazard analysis for the machine and take appropriate measures to ensure that unforeseen movements cannot
cause personnel injury or property damage.
Please observe the chapters "Use as directed” and "Prohibited use" in the AKD Installation Manual.
The EtherCAT interface serves only for the connection of the AKD Drive to a master with EtherCAT con-
nectivity.
2.3 Prohibited use
Other use than that described in chapter “Use as directed” is not intended and can lead to personnel injuries
and equipment damage. The drive may not be used with a machine that does not comply with appropriate
national directives or standards. The use of the drive in the following environments is also prohibited:
lpotentially explosive areas
lenvironments with corrosive and/or electrically conductive acids, alkaline solutions, oils, vapors, dusts
lships or offshore applications
The connectors X5 and X6 of the AKD EtherCAT drive may not be used for any ethernet protocol except Ether-
CAT (CoE, Can over EtherCAT).
AKD EtherCAT | 2 Safety
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AKD EtherCAT | 3 Installation and Setup
3 Installation and Setup
3.1 Safety Instructions 13
3.2 EtherCAT Onboard 14
3.3 Guide to Setup 15
3.4 Setup via TwinCAT NC/PTP System Manager 15
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3.1 Safety Instructions
Never undo any electrical connections to the drive while it is live. There is a danger of
electrical arcing with damage to contacts and serious personal injury. Wait at least
seven minutes after disconnecting the drive from the main supply power before touching
potentially live sections of the equipment (e.g. contacts) or undoing any connections.
Capacitors can still have dangerous voltages present up to 7 minutes after switching off
the supply power. To be sure, measure the voltage in the DC Bus link and wait until it
has fallen below 40 V.
Control and power connections can still be live, even if the motor is not rotating.
Electronic equipment is basically not failure-proof. The user is responsible for ensuring
that, in the event of a failure of the servo amplifier, the drive is set to a state that is safe
for both machinery and personnel, for instance with the aid of a mechanical brake.
Drives with servo amplifiers and EtherCAT are remote-controlled machines. They can
start to move at any time without previous warning. Take appropriate measures to
ensure that the operating and service personnel is aware of this danger.
Implement appropriate protective measures to ensure that any unintended start-up of the
machines cannot result in dangerous situations for personnel or machinery. Software
limit-switches are not a substitute for the hardware limit-switches in the machine.
Install the drive as described in the Installation Manual. The wiring for the analog setpoint
input and the positioning interface, as shown in the wiring diagram in the Installation Man-
ual, is not required. Never break any of the electrical connections to the drive while it is
live. This action can result in destruction of the electronics.
The drive's status must be monitored by the PLC to acknowledge critical situations.
Wire the FAULT contact in series into the emergency stop circuit of the installation. The
emergency stop circuit must operate the supply contactor.
It is permissible to use WorkBench to alter the settings of the drive. Any other alterations
will invalidate the warranty.
Because of the internal representation of the position-control parameters, the position
controller can only be operated if the final limit speed of the drive does not exceed:
rotatory
at sinusoidal² commutation: 7500 rpm
at trapezoidal commutation: 12000 rpm.
linear
at sinusoidal² commutation: 4 m/s
at trapezoidal commutation: 6.25 m/s
All the data on resolution, step size, positioning accuracy etc. refer to calculatory values.
Non-linearities in the mechanism (backlash, flexing, etc.) are not taken into account.If
the final limit speed of the motor must be altered, then all the parameters that were pre-
viously entered for position control and motion blocks must be adapted.
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AKD EtherCAT | 3 Installation and Setup
3.2 EtherCAT Onboard
Connection to the EtherCAT Network via X5 (in port) and X6 (out port).
3.2.1 LED functions
The communication status is indicated by the built-in LEDs.
Connector LED# Name Function
X5 LED1 IN port Link ON = active
OFF= not active
LED2 RUN ON = running
OFF = not running
X6 LED3 OUT port Link ON = active
OFF = not active
LED4 - -
3.2.2 Connection technology
You can connect to the EtherCAT network using RJ-45 connectors.
3.2.3 Network Connection Example
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3.3 Guide to Setup
Only professional personnel with extensive knowledge of control and drive
technology are allowed to setup the drive.
Make sure that any unintended movement of the drive cannot endanger
machinery or personnel.
1. Check assembly/installation. Check that all the safety instructions in the product manual for the drive
and this manual have been observed and implemented. Check the setting for the station address and
baud rate.
2. Connect PC,start WorkBench. Use the setup software WorkBench to set the parameters for the drive.
3. Setup basic functions. Start up the basic functions of the drive and optimize the current, speed and
position controllers. This section of the setup is described in the in the online help of the setup soft-
ware.
4. Save parameters. When the parameters have been optimized, save them in the drive.
3.4 Setup via TwinCAT NC/PTP System Manager
Before you set up the drive, make sure the following have been completed:
lThe AKD is configured with WorkBench and the servomotor is able to move
lA correctly configured EtherCAT card is present in the master.
lTwinCAT software from Beckhoff (NC/PTP-Mode setup) is installed.Install first the TwinCAT System
Manager, restart your PC, then install the option package NC/PTP-Mode.
lThe XML description of the Drive is available (the XML file on the CD-ROM or on the Kollmorgen web-
site).
lAn AKD EtherCAT slave is connected to the EtherCAT master PC.
lThe TwinCAT system manager resides in Config-Mode. The current mode of the system manager is
displayed of the bottom right side of the TwinCAT main-screen window.
Copy the XML description of the drive to the TwinCAT system (usually to the folder c:\Tw-
inCAT\IO\EtherCAT) and restart the TwinCAT system since TwinCAT analyzes all device description files
during start-up.
The following example explains the automatic EtherCAT network setup. The network setup can also be done
manually; please refer to the TwinCAT manual for more details.
3.4.1 Scan devices
First ensure that the EtherCAT master is physically connected to the EtherCAT AKD Drive. Create a new
(empty) project. Right click I/O-Devices and scan for the devices. An example is included in the EtherCAT net-
work card, which is plugged into the PC.
AKD EtherCAT | 3 Installation and Setup
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AKD EtherCAT | 3 Installation and Setup
A pop-up window informs you that not all devices can be detected by the TwinCAT software.
Click OK to continue.
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3.4.2 Select the device
TwinCAT must be able to find the EtherCAT network card. An EtherCAT slave must be connected to the network
card; otherwise TwinCAT will find a real-time EtherNET card instead of the EtherCAT card. Press the OK button.
3.4.3 Scan for boxes
Click Yes to allow TwinCat to scan for boxes. A box is an alias for a slave device and is always used in Beck-
hoff software products.
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AKD EtherCAT | 3 Installation and Setup
3.4.4 Add Slaves to NC tasks
TwinCAT should now have identified the AKD according to the Device Description file. TwinCAT next asks if
the slaves should be connected to NC tasks. Click Yes to continue. An NC task can, for example, contain a
PLC program, which can be programmed by the user.
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3.4.5 Enable the network configuration
Confirm that the AKD appears in the device tree. Next, enable the network configuration Press first the
button in order to generate the mappings, afterwards press the button in order to let TwinCAT check the
configuration and use finally the button in order to step into run-mode.
Confirm afterwards that TwinCAT is allowed to jump into run-mode.
AKD EtherCAT | 3 Installation and Setup
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AKD EtherCAT | 3 Installation and Setup
3.4.6 Enable the axis and move the axis
The Axis can be enabled by a mouse-click on the Set button within the Online window inside of each Axis, see
also the next picture.
Afterwards a pop-up window appears.
The following setting enables the drive and allows command values in both directions.
Afterwards the motor should move in positive or negative direction as soon as the clicks on the following yel-
low buttons within the Online window:
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