Lika RD5 User manual

User's guide
RD5
RD53
RS-485 version
Smart encoders & actuators

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Electronic s.r.l. reserves the right to make all modifications at any moments and without forewarning.
This manual is periodically reviewed and revised. As required we suggest checking if a new or updated edition of this document is
available at Lika Electronic s.r.l.'s website. Lika Electronic s.r.l. assumes no responsibility for any errors or omissions in this document.
Critical evaluation of this manual by the user is welcomed. Your comments assist us in preparation of future documentation, in order
to make it as clear and complete as possible. Please send an e-mail to the following address [email protected] for submitting your
comments, suggestions and criticisms.

General contents
User's guide...............................................................................................................................................................................................1
General contents................................................................................................................................................................................3
Subject Index.......................................................................................................................................................................................6
Typographic and iconographic conventions..........................................................................................................................7
Preliminary information..................................................................................................................................................................8
1 Safety summary 9
1.1 Safety.............................................................................................................................................................................9
1.2 Electrical safety.........................................................................................................................................................9
1.3 Mechanical safety..................................................................................................................................................10
2 Identification 11
3 Mounting instructions 12
4 Electrical connections 15
4.1 Ground connection (Figure 2)..........................................................................................................................15
4.2 M12 connectors (Figure 2).................................................................................................................................16
4.3 Dip-Switches and diagnostic LEDs (Figure 3)............................................................................................18
4.3.1 Diagnostic LEDs (Figure 3).........................................................................................................................19
4.3.2 Setting the address node: Node ID (Figure 3)...................................................................................21
4.3.3 Setting data transmission rate: Baud rate and Parity bit (Figure 3).......................................22
4.3.4 RT bus termination (Figure 3)...................................................................................................................23
5 Quick reference 24
5.1 Configuring the device using Lika setting up software........................................................................24
5.2 “Serial configuration” page...............................................................................................................................25
5.3 “Operative mode” page.......................................................................................................................................29
5.4 “Machine data” page............................................................................................................................................33
5.5 “Message monitor” page....................................................................................................................................35
5.6 “Test Lika” page.......................................................................................................................................................36
5.7 “Upgrade Firmware” page..................................................................................................................................36
5.7.1 If there is an installation issue.................................................................................................................39
5.8 Getting started.......................................................................................................................................................40
6 Functions 41
6.1 Working principle..................................................................................................................................................41
6.2 Movements: jog and positioning....................................................................................................................42
6.3 Distance per revolution [00 hex], Jog speed [0C hex], Work speed [0D hex], Preset [16-17
hex], Positive delta [08-09 hex] and Negative delta [0A-0B hex].......................................................43
7 Modbus® interface 47
7.1 Modbus Master / Slaves protocol principle................................................................................................47
7.2 Modbus frame description.................................................................................................................................48
7.3 Transmission modes..............................................................................................................................................49
7.3.1 RTU transmission mode..............................................................................................................................50
7.4 Function codes........................................................................................................................................................52
7.4.1 Implemented function codes...................................................................................................................52
03 Read Holding Registers.................................................................................................................................................52
04 Read Input Register........................................................................................................................................................54
06 Write Single Register......................................................................................................................................................56
16 Write Multiple Registers...............................................................................................................................................58
8 Programming parameters 62
8.1 Parameters available............................................................................................................................................62

8.1.1 Machine data parameters..........................................................................................................................62
Distance per revolution [00 hex].....................................................................................................................................62
Position window [01 hex]...................................................................................................................................................63
Position window time [02 hex]........................................................................................................................................63
Max following error [03 hex]............................................................................................................................................63
Kp position loop [04 hex]....................................................................................................................................................64
Ki position loop [05 hex].....................................................................................................................................................64
Acceleration [06 hex]............................................................................................................................................................64
Deceleration [07 hex]............................................................................................................................................................64
Positive delta [08-09 hex]...................................................................................................................................................64
Negative delta [0A-0B hex]................................................................................................................................................65
Jog speed [0C hex].................................................................................................................................................................65
Work speed [0D hex].............................................................................................................................................................65
Start torque current time [0E hex].................................................................................................................................66
Code sequence [0F hex].......................................................................................................................................................66
Kp current loop [10 hex].....................................................................................................................................................67
Ki current loop [11 hex].......................................................................................................................................................67
Max current [12 hex]............................................................................................................................................................67
Starting torque current [13 hex].....................................................................................................................................67
Offset [14-15 hex]..................................................................................................................................................................67
Preset [16-17 hex]..................................................................................................................................................................68
Gear ratio [18 hex].................................................................................................................................................................68
Jog step length [19 hex]......................................................................................................................................................68
Extra commands register [29 hex]..................................................................................................................................69
Absolute reading................................................................................................................................................................69
Control Word [2A hex].........................................................................................................................................................69
Jog +........................................................................................................................................................................................69
Jog -.........................................................................................................................................................................................70
Stop..........................................................................................................................................................................................70
Alarm reset...........................................................................................................................................................................70
Incremental jog..................................................................................................................................................................70
Start.........................................................................................................................................................................................71
Emergency............................................................................................................................................................................71
Watch dog enable..............................................................................................................................................................71
Save parameters.................................................................................................................................................................71
Load default parameters.................................................................................................................................................71
Perform counting preset................................................................................................................................................72
Axis torque............................................................................................................................................................................72
Brake released.....................................................................................................................................................................72
Target position [2B-2C hex]...............................................................................................................................................72
8.1.2 Input Register parameters.........................................................................................................................74
Alarms register [00 hex]......................................................................................................................................................74
Machine data not valid...................................................................................................................................................74
Flash memory error...........................................................................................................................................................74
Following error....................................................................................................................................................................74
Axis not synchronized......................................................................................................................................................74
Target not valid...................................................................................................................................................................74
Emergency............................................................................................................................................................................74
Overcurrent..........................................................................................................................................................................75
Overtemperature................................................................................................................................................................75
Undervoltage.......................................................................................................................................................................75

Watch dog............................................................................................................................................................................75
Status word [01 hex].............................................................................................................................................................76
Axis in position....................................................................................................................................................................76
Axis enabled.........................................................................................................................................................................76
SW limit switch +..............................................................................................................................................................76
SW limit switch -...............................................................................................................................................................76
Alarm.......................................................................................................................................................................................76
Axis running.........................................................................................................................................................................76
Executing a command.....................................................................................................................................................77
Target position reached..................................................................................................................................................77
DAC saturation....................................................................................................................................................................77
Current position [02-03 hex]............................................................................................................................................77
Current velocity [04 hex]....................................................................................................................................................77
Position following error [05-06 hex].............................................................................................................................77
Current value [07 hex].........................................................................................................................................................78
Temperature value [08 hex]...............................................................................................................................................78
Wrong parameters list [09-0A hex]................................................................................................................................78
I2t [0B hex]................................................................................................................................................................................79
Dip-switch baud rate [0C hex]..........................................................................................................................................79
Dip-switch node ID [0D hex].............................................................................................................................................79
SW Version [0E hex]..............................................................................................................................................................79
HW Version [0F hex]..............................................................................................................................................................80
8.2 Exception codes......................................................................................................................................................82
9 Programming examples 83
9.1 Using the 03 Read Holding Registers function code.............................................................................83
9.2 Using the 04 Read Input Register function code....................................................................................84
9.3 Using the 06 Write Single Register function code.................................................................................86
9.4 Using the 16 Write Multiple Registers function code...........................................................................88
10 Default parameters list 89

Subject Index
A
Absolute reading..............................................................69
Acceleration [06 hex]......................................................64
Alarm.....................................................................................76
Alarm reset..........................................................................70
Alarms register [00 hex]................................................74
Axis enabled.......................................................................76
Axis in position..................................................................76
Axis not synchronized....................................................74
Axis running.......................................................................76
Axis torque..........................................................................72
B
Brake released....................................................................72
C
Code sequence [0F hex].................................................66
Control Word [2A hex]...................................................69
Current position [02-03 hex]......................................77
Current value [07 hex]...................................................78
Current velocity [04 hex]..............................................77
D
DAC saturation..................................................................77
Deceleration [07 hex].....................................................64
Dip-switch baud rate [0C hex]...................................79
Dip-switch node ID [0D hex].......................................79
Distance per revolution [00 hex]...............................62
E
Emergency...................................................................71, 74
Executing a command...................................................77
Extra commands register [29 hex]............................69
F
Flash memory error.........................................................74
Following error..................................................................74
G
Gear ratio [18 hex]...........................................................68
H
HW Version [0F hex]........................................................80
I
I2t [0B hex].........................................................................79
Incremental jog.................................................................70
J
Jog -.......................................................................................70
Jog +......................................................................................69
Jog speed [0C hex]...........................................................65
Jog step length [19 hex]................................................68
K
Ki current loop [11 hex]................................................67
Ki position loop [05 hex]...............................................64
Kp current loop [10 hex]...............................................67
Kp position loop [04 hex].............................................64
L
Load default parameters...............................................71
M
Machine data not valid.................................................74
Max current [12 hex]......................................................67
Max following error [03 hex]......................................63
N
Negative delta [0A-0B hex].........................................65
O
Offset [14-15 hex]...........................................................67
Overcurrent.........................................................................75
Overtemperature..............................................................75
P
Perform counting preset...............................................72
Position following error [05-06 hex].......................77
Position window [01 hex].............................................63
Position window time [02 hex]..................................63
Positive delta [08-09 hex]............................................64
Preset [16-17 hex]...........................................................68
S
Save parameters...............................................................71
Start.......................................................................................71
Start torque current time [0E hex]...........................66
Starting torque current [13 hex]...............................67
Status word [01 hex]......................................................76
Stop........................................................................................70
SW limit switch -.............................................................76
SW limit switch +............................................................76
SW Version [0E hex]........................................................79
T
Target not valid.................................................................74
Target position [2B-2C hex]........................................72
Target position reached.................................................77
Temperature value [08 hex].........................................78
U
Undervoltage.....................................................................75
W
Watch dog...........................................................................75
Watch dog enable............................................................71
Work speed [0D hex].......................................................65
Wrong parameters list [09-0A hex].........................78

Typographic and iconographic conventions
In this guide, to make it easier to understand and read the text the following typographic and
iconographic conventions are used:
•parameters and objects both of Lika device and interface are coloured in ORANGE;
•alarms are coloured in RED;
•states are coloured in FUCSIA.
When scrolling through the text some icons can be found on the side of the page: they are expressly
designed to highlight the parts of the text which are of great interest and significance for the user.
Sometimes they are used to warn against dangers or potential sources of danger arising from the use of
the device. You are advised to follow strictly the instructions given in this guide in order to guarantee
the safety of the user and ensure the performance of the device. In this guide the following symbols are
used:
This icon, followed by the word WARNING, is meant to highlight the parts of the
text where information of great significance for the user can be found: user must
pay the greatest attention to them! Instructions must be followed strictly in order
to guarantee the safety of the user and a correct use of the device. Failure to heed
a warning or comply with instructions could lead to personal injury and/or damage
to the unit or other equipment.
This icon, followed by the word NOTE, is meant to highlight the parts of the text
where important notes needful for a correct and reliable use of the device can be
found. User must pay attention to them! Failure to comply with instructions could
cause the equipment to be set wrongly: hence a faulty and improper working of
the device could be the consequence.
This icon is meant to highlight the parts of the text where suggestions useful for
making it easier to set the device and optimize performance and reliability can be
found. Sometimes this symbol is followed by the word EXAMPLE when instructions
for setting parameters are accompanied by examples to clarify the explanation.

Preliminary information
This guide is designed to provide the most complete information the operator needs to correctly and
safely install and operate the ROTADRIVE positioning units RD5 and RD53 models.
RD5 and RD53 units are positioning devices which integrate into one system a brushless motor fitted
with gearbox, a drive, a multiturn absolute encoder and a position controller. They can be used in a
variety of applications in any industrial sector and are suitable to drive secondary axes such as in mold
changers, mobile stops, tools changers, suction cups motion units, conveyor and spindle positioning
devices on packaging & woodworking machineries, among others.
An integrated brake differentiates RD53 model from RD5 model. The brake is designed to activate as
soon as the motor comes to a stop in order to prevent it from moving even slightly.
The available interfaces for fieldbus communication are: Modbus RTU, Profibus-DP and CANopen DS
301.
In the Modbus version the configuration of the ROTADRIVE unit can be done through a software
expressly developed and released by Lika Electronic in order to allow an easy set up of the device. The
program is supplied for free and can be installed in any PC fitted with a Windows operating system
(Windows XP or later). It allows the operator to set the working parameters of the device; control
manually some movements and functions; and monitor whether the device is running properly.
To make it easier to read the text, this guide can be divided into two main sections.
In the first section general information concerning the safety, the mechanical installation and the
electrical connection as well as tips for setting up and running properly and efficiently the unit are
provided.
While in the second section, entitled Modbus Interface, both general and specific information is given
on the Modbus interface. In this section the interface features and the registers implemented in the unit
are fully described.

RD5 – RD53 Modbus®
1 Safety summary
1 1 Safety
•Always adhere to the professional safety and accident prevention
regulations applicable to your country during device installation and
operation;
•installation and maintenance operations have to be carried out by
qualified personnel only, with power supply disconnected and stationary
mechanical parts;
•device must be used only for the purpose appropriate to its design: use for
purposes other than those for which it has been designed could result in
serious personal and/or the environment damage;
•high current, voltage and moving mechanical parts can cause serious or
fatal injury;
•warning ! Do not use in explosive or flammable areas;
•failure to comply with these precautions or with specific warnings
elsewhere in this manual violates safety standards of design, manufacture,
and intended use of the equipment;
•Lika Electronic s.r.l. assumes no liability for the customer's failure to
comply with these requirements.
1 2 Electrical safety
•Turn OFF power supply before connecting the device;
•connect according to explanation in section ”Electrical connections”;
•a safety push-button for emergency power off has to be installed to shut
off motor power supply in case of emergency situations;
•in compliance with 2004/108/EC norm on electromagnetic
compatibility, following precautions must be taken:
- before handling and installing the equipment, discharge
electrical charge from your body and tools which may come in touch
with the device;
- power supply must be stabilized without noise; install EMC filters on
device power supply if needed;
- always use shielded cables (twisted pair cables whenever possible);
- avoid cables runs longer than necessary;
- avoid running the signal cable near high voltage power cables;
- mount the device as far as possible from any capacitive or inductive
noise source; shield the device from noise source if needed;
- to guarantee a correct working of the device, avoid using strong magnets
on or near by the unit
MAN RD5 RD53 MB E 1.1 Safety summary 9 of 92

RD5 – RD53 Modbus®
- minimize noise by connecting the shield and/or the connector housing
and/or the frame to ground. Make sure that ground is not affected by
noise. The connection point to ground can be situated both on the device
side and on user’s side. The best solution to minimize the interference
must be carried out by the user.
1 3 Mechanical safety
•Install the device following strictly the information in the section
“Mounting instructions”;
•mechanical installation has to be carried out with stationary mechanical
parts;
•do not disassemble the unit;
•do not tool the unit or its shaft;
•delicate electronic equipment: handle with care; do not subject the device
and the shaft to knocks or shocks;
•respect the environmental characteristics of the product;
•unit with hollow shaft: ROTADRIVE can be mounted directly onto a shaft
whose diameter has to respect the technical characteristics specified in the
purchase order and clamped by means of the collar and the hole into
which an anti-rotation pin has to be inserted.
WARNING
The unit has been adjusted by performing a no-load mechanical running test;
thence default values which has been set refer to an idle device, i.e. running
disengaged from the load. Furthermore they are intended to ensure a standard
and safe operation which not necessarily results in smooth running and
optimum performance. Thus to suit the specific application requirements it may
be advisable and even necessary to enter new parameters instead of the factory
default settings; in particular it may be necessary to change velocity,
acceleration, deceleration and gain values.
WARNING
The counter-electromotive force (back EMF) generated by the motor in case the
shaft is forced to rotate due to a manual external force can cause irreparable
damages to the internal circuitry.
MAN RD5 RD53 MB E 1.1 Safety summary 10 of 92

RD5 – RD53 Modbus®
2 Identification
Device can be identified through the order code and the serial number printed
on the label applied to its body. Information is listed in the delivery document
too. Please always quote the order code and the serial number when reaching
Lika Electronic s.r.l. for purchasing spare parts or needing assistance. For any
information on the technical characteristics of the product refer to the
technical catalogue.
MAN RD5 RD53 MB E 1.1 Identification 11 of 92

RD5 – RD53 Modbus®
3 Mounting instructions
WARNING
Installation and maintenance operations have to be carried out by qualified
personnel only, with power supply disconnected. Motor and shaft must be in
stop.
ROTADRIVE unit must be secured firmly only to the user's shaft using the
provided collar. ROTADRIVE unit is supplied with a screw insulation and an anti-
rotation pin; the anti-rotation pin (TE M4 screw) has to be inserted into the
screw insulation. This will provide to the unit both stability and the mobility
needed to absorb the mechanical tensions produced during operation. Do not
fasten firmly the anti-rotation pin to the motor flange or the fixed support on
user's side without using the screw insulation! If this occurs, the mechanical
tensions would be transmitted completely to the motor shaft and this would
lead to bearings damages and mechanical breakdowns!
MAN RD5 RD53 MB E 1.1 Mounting instructions 12 of 92

RD5 – RD53 Modbus®
Figure 1 - Typical installation example of RD5-53 unit on worm screw
To install properly the ROTADRIVE unit please read carefully and follow these
instructions; anyway note that the unit can be installed in several manners and
according to the specific user's application.
•Drill a 9 mm diameter hole in the motor flange or in the fixed support on
user's side in order to insert the screw insulation and the anti-rotation pin.
The distance between the axis of the shaft and the axis of the hole must be
51 ± 0,2 mm.
MAN RD5 RD53 MB E 1.1 Mounting instructions 13 of 92

RD5 – RD53 Modbus®
Make sure that the hole and the shaft are perfectly aligned on the vertical
axis. If installation is not carried out properly, mechanical tensions would be
produced on the motor shaft and this would lead to bearings damages and
mechanical breakdowns!
•insert the screw
insulation in the
hole;
•insert the TE M4
x 30 screw and
the two M4
washers in the
middle hole
designed in the
flange of the
ROTADRIVE
unit; partially
screw the M4
lock nut;
•insert the user's shaft in the hollow shaft of the ROTADRIVE unit; the
maximum depth of the ROTADRIVE shaft is 21 mm; ascertain that the anti-
rotation pin is inserted properly in the
screw insulation; secure the user's shaft
through the collar and the relevant fixing
screw; the minimum distance between the
collar and the fixed support on user's side
must be not less than 1 mm in order to
prevent the fixed parts from coming into
contact;
•tighten the anti-rotation pin on the screw
insulation;
•tighten the M4 lock nut in order to secure
the anti-rotation pin to the flange of the ROTADRIVE unit.
ATTENTION
Never force manually the rotation of the shaft not to cause permanent
damages! The counter-electromotive force (back EMF) generated by the motor
in case the shaft is forced to rotate due to a manual external force can cause
irreparable damages to the internal circuitry.
MAN RD5 RD53 MB E 1.1 Mounting instructions 14 of 92

RD5 – RD53 Modbus®
4 Electrical connections
WARNING
When you send Start, Jog + or Jog - commands, the unit and the shaft start
moving! Make sure there are no risks of personal injury and mechanical
damages.
Each Start routine has to be checked carefully in advance!
Never force manually the rotation of the shaft not to cause permanent
damages!
Figure 2: Electrical connections
Legend
1 Internal housing for dip-switches and diagnostic LEDs
2 M12 4-pin male connector for power supply
3 M12 5-pin female connector for BUS OUT
4 M12 5-pin male connector for BUS IN
5 Connection to earthing
4 1 Ground connection (Figure 2)
To minimize noise connect properly the frame to ground; we suggest using the
ground screw provided in the frame (see Figure above). Connect properly the
cable shield to ground on user's side. Lika's EC- pre-assembled cables are fitted
with shield connection to the connector ring nut in order to allow grounding
through the body of the device. Lika's E- connectors have a plastic gland, thus
grounding is not possible. If metal connectors are used, connect the cable shield
properly as recommended by the manufacturer. See also note in the next
paragraph. Anyway make sure that ground is not affected by noise. It is
recommended to provide the ground connection as close as possible to the
device.
MAN RD5 RD53 MB E 1.1 Electrical connections 15 of 92

RD5 – RD53 Modbus®
4 2 M12 connectors (Figure 2)
Power supply
M12 4-pin male connector
A coding
(frontal side)
Pin Description
1+24VDC 10%
Motor power supply
2+24VDC 10%
Controller power supply
30VDC
Power supply
4 n.c.
n.c. = not connected
Modbus interface
M12 5-pin connector
A coding
(frontal side)
male
(BUS IN)
female
(BUS OUT)
Pin Description
1 n.c.
2 n.c.
3 GND (RS-485)
4 Modbus A (RS-485)
5 Modbus B (RS-485)
Case Shielding1
1Lika's EC- pre-assembled cables only.
n.c. = not connected
MAN RD5 RD53 MB E 1.1 Electrical connections 16 of 92

RD5 – RD53 Modbus®
NOTE
We suggest always connecting the cable shield to ground on user's side.
Lika's EC- pre-assembled cables are fitted with shield connection to the
connector ring nut in order to allow grounding through the body of the device.
Lika's E- connectors have a plastic gland, thus grounding is not possible (see
Figure below). If metal connectors are used, connect the cable shield properly as
recommended by the manufacturer.
MAN RD5 RD53 MB E 1.1 Electrical connections 17 of 92

RD5 – RD53 Modbus®
4 3 Dip-Switches and diagnostic LEDs (Figure 3)
WARNING
Power supply must be turned off before performing this operation!
NOTE
When performing this operation be careful not to damage the connection wires.
To access the DIP-Switches and the diagnostic LEDs remove the plastic cover
fitted on one side of the device.
The DIP-switches and the diagnostic LEDs are located just beneath.
Figure 3: Dip-Switches and diagnostic LEDs
MAN RD5 RD53 MB E 1.1 Electrical connections 18 of 92

RD5 – RD53 Modbus®
4 3 1 Diagnostic LEDs (Figure 3)
Four LEDs located in the inside of the device next to the provided switches and
accessible by removing the plastic cover fitted on one side of the housing (see
the previous page) are designed to show visually the operating or fault status of
the Modbus interface and the unit as well. The meaning of each led is explained
in the following table:
LED 1 GREEN Description
ON Indicates the power supply of the controller is
turned on
OFF Indicates the power supply of the controller is
turned off
LED 2 RED Description
ON Active alarms, internal error, for a comprehensive list
of alarms see on page 74
OFF No alarms active
LED 3 GREEN Description
Blinking led Device is sending or receiving a message
OFF No send - receive activity
LED 2 LED 3 Description
GREEN
Blinking led
GREEN
Blinking led
While downloading data to the flash memory for
upgrading the firmware of the unit (see section “5.7
“Upgrade Firmware” page” on page 36), both LEDs 2
& 3 blink green at 5 Hz.
RED
Blinking led
RED
Blinking led
While downloading data to the flash memory for
upgrading the firmware of the unit (see section “5.7
“Upgrade Firmware” page” on page 36), if an error
occurs which stops the upgrading process (for
instance: a voltage drop and/or the switching off of
the ROTADRIVE unit), as soon as the power is turned
on again both LEDs start blinking red at 5 Hz as the
user program is not installed in the flash memory (it
has been deleted previously). For any information on
restoring the unit please refer to the section “5.7
“Upgrade Firmware” page” on page 36.
RED
ON
RED
ON
While downloading data to the flash memory for
upgrading the firmware of the unit (see section “5.7
“Upgrade Firmware” page” on page 36), if data
transmission is cut off (for instance, because of the
disconnection of the serial cable), after 5 seconds
both LEDs come on solidly red. For any information
on restoring the unit please refer to the section “5.7
“Upgrade Firmware” page” on page 36.
MAN RD5 RD53 MB E 1.1 Electrical connections 19 of 92

RD5 – RD53 Modbus®
LED 4 GREEN Description
ON Indicates the motor is enabled (control loop
activated)
OFF Indicates the motor is disabled (control loop
deactivated)
During initialisation, system checks the diagnostic LEDs for proper operation;
therefore they blink for a while.
MAN RD5 RD53 MB E 1.1 Electrical connections 20 of 92