Pilz PMCtendo DD5 User manual

EtherCAT for
PMCtendo DD5 and PMCprotego D
Operating Manual-1002906-EN-02
}Servo amplifiers

Preface
This document is the original document.
All rights to this documentation are reserved by Pilz GmbH & Co. KG. Copies may be made
for the user's internal purposes. Suggestions and comments for improving this documenta-
tion will be gratefully received.
Source code from third-party manufacturers or open source software has been used for
some components. The relevant licence information is available on the Internet on the Pilz
homepage.
Pilz®, PIT®, PMI®, PNOZ®, Primo®, PSEN®, PSS®, PVIS®, SafetyBUS p®,
SafetyEYE®, SafetyNET p®, the spirit of safety® are registered and protected trademarks
of Pilz GmbH & Co. KG in some countries.
SD means Secure Digital

Contents
Operating Manual EtherCAT for, PMCtendo DD5 and PMCprotego D
1002906-EN-02 3
Section 1 General information 4
1.1 About this manual 4
1.2 Target group 4
1.3 Definition of symbols 5
1.4 Abbreviations used 6
Section 2 Safety 8
2.1 Intended use 8
2.2 Notes on the online edition (PDF format) 9
Section 3 Installation/commissioning 10
3.1 Assembly/installation 10
3.1.1 Connection technology 11
3.1.2 Commissioning 11
3.1.2.1 Guide to commissioning 11
3.1.2.2 EtherCAT commissioning 12
Section 4 EtherCAT 13
4.1 Slave Register 13
4.2 AL event (interrupt event) and interrupt enable 14
4.2.1 Interrupt enable register (address 0x0204:0205) 14
4.2.2 AL Event (address 0x220:0221) 14
4.3 Phase runup 15
4.3.1 AL Control (address 0x0120:0x0121) 15
4.3.2 AL Status (address 0x0130:0x0131) 16
4.3.3 AL Status Code (address 0x0134:0x0135) 16
4.3.4 EtherCAT communication phases 17
4.4 CANopen over EtherCAT (CoE) state machine 18
4.4.1 Description of states 19
4.4.2 Commands in the control word 20
4.4.3 Bits of the status machine (status word) 21
4.5 Implemented operating modes 22
4.6 Setting the EtherCAT cycle time 22
4.7 Recommended cycle time based on the operating modes 23
4.8 Synchronisation based on the cycle time 23
4.9 Latch- control word and latch status word 24
4.10 Mailbox Handling 25
4.10.1 Mailbox Output 26
4.10.2 Mail Input 27
4.10.3 Example of a mailbox access 28

General information
Operating Manual EtherCAT for, PMCtendo DD5 and PMCprotego D
1002906-EN-02 4
1 General information
1.1 About this manual
This manual describes the assembly, installation and commissioning of the "Expansion
card EtherCAT" for servo amplifiers of the PMCprotego D series and a reference of the
commands that are supported by these servo amplifiers.
The "Expansion card EtherCAT" provides an EtherCAT interface to this servo amplifier. The
operating manual describes the card and its installation at a later stage.
In PMCprotego D the EtherCAT functionality is already integrated. The servo amplifier has
an onboard Ethernet- interface that has been configured in the standard version for the Eth-
erCAT protocols. This manual is a component of the overall documentation of the digital
servo amplifiers. Installation and commissioning of the servo amplifiers and all the standard
functions are described in the relevant operating manual.
1.2 Target group
This manual is aimed at qualified personnel with the following requirements:
Transport Only by personnel with knowledge of managing electrostatically
sensitive assemblies
Unpacking Only by specialists with electrotechnical qualification
Installation Only by specialists with electrotechnical qualification
Commissioning Only by specialists with extensive knowledge of electrical engineer-
ing and drive technology
Programming Software developer, EtherCAT design engineers
The qualified staff must know and observe the following standards:
}IEC 60364 and IEC 60664
}National accident prevention regulations

General information
Operating Manual EtherCAT for, PMCtendo DD5 and PMCprotego D
1002906-EN-02 5
1.3 Definition of symbols
Information that is particularly important is identified as follows:
DANGER!
This warning must be heeded! It warns of a hazardous situation that poses
an immediate threat of serious injury and death and indicates preventive
measures that can be taken.
WARNING!
This warning must be heeded! It warns of a hazardous situation that could
lead to serious injury and death and indicates preventive measures that can
be taken.
CAUTION!
This refers to a hazard that can lead to a less serious or minor injury plus
material damage, and also provides information on preventive measures
that can be taken.
NOTICE
This describes a situation in which the product or devices could be dam-
aged and also provides information on preventive measures that can be
taken. It also highlights areas within the text that are of particular import-
ance.
INFORMATION
This gives advice on applications and provides information on special fea-
tures.

General information
Operating Manual EtherCAT for, PMCtendo DD5 and PMCprotego D
1002906-EN-02 6
1.4 Abbreviations used
Abbreviation Meaning
AL Application Layer: The protocol used dir-
ectly by the process instances.
Cat Category - Classification also for the cables
used for Ethernet communication. EtherCAT
cables must be classified at least in cat-
egory 5.
DC Distributed Clocks Mechanism (Distributed
Clock procedure) to sychronise EtherCAT-
Slaves and Masters.
DL Data Link, also Layer 2. EtherCAT used in
accordance with IEEE 802.3 standardised
Ethernet communication.
EtherCAT (ECAT) RT standard for industrial Ethernet Control
Automation Technology
FPGA Field Programmable Gate Array (logic block
that can be modified on-site)
FTP File Transfer Protocol
HW Hardware
ICMP Internet Control Message Protocol: Protocol
to display IP errors.
IEC International Electrotechnical Commission:
International standardisation committee
IEEE Institute of Electrical and Electronics Engin-
eers, Inc.
IOS/OSI Model ISO Open Systems Interconnection Basic
Reference Model (ISO 7498) (ISO-OSI layer
model): Describes the dividing of the com-
munication in seven layers.
LLDP Lower Layer Discovery Protocol
MAC Media Access Control
MII Media Independent Interface: Standard in-
terface between Ethernet Controller and the
routers.
MDI Media-independent interface:
Signal transmission using pins.
MDI-X Media-dependent interface (crossover):
Crossed wiring
OSI Open System Interconnect
OUI Organizationally Unique Identifier - the first
3 Bits of an Ethernet address. They are as-
signed to companies or organisation and
the can also be used for Protocol Identifiers
(e.g.LLDP).

General information
Operating Manual EtherCAT for, PMCtendo DD5 and PMCprotego D
1002906-EN-02 7
Abbreviation Meaning
PDI Physical Device Interface: A set of physical
elements that enable access from the pro-
cess side.
PDO Process Data Object
PDU Protocol Data Unit: Includes protocol inform-
ation from a protocol instance via transpar-
ent data to a subordinate layer.
Ping Program for checking the accessibility of the
partner device.
PHY Physical interface, data conversion in elec-
trical or optical signals.
PLL Phase Locked Loop
PTP Precision Time Protocol in accordance with
IEEE 1588
RSTP Rapid Spanning Tree Protocol
RT Real-time, possible in Ethernet Controller
without additional support.
RT Frames EtherCAT transmission with EtherType
0x88A4.
RX Receive
RXPDO Receive PDO
SNMP Simple Network Management Protocol
SPI Serial Peripheral Interface
Src Addr. Source Address: Source address of a trans-
mission.
STP Shielded Twisted Pair
TCP Transmission Control Protocol
TX Transmit
TXPDO Transmit PDO
UDP User Datagram Protocol: Unsafe Multicast-
Broadcast protocol
UTP Unshielded Twisted Pair
XML Extensible Markup Language
XML Parser Program for checking XML structures
ZA ECAT Access type EtherCAT
ZA Drive Access type amplifier

Safety
Operating Manual EtherCAT for, PMCtendo DD5 and PMCprotego D
1002906-EN-02 8
2 Safety
WARNING!
Risk of death or serious injury and material damage during operation
The operator must ensure that the safety guidelines in this manual are
taken into account. The operator must ensure that every person entrusted
with work at the servo amplifier have read and understood this operating
manual.
We offer training and induction courses on request.
2.1 Intended use
Please note the chapters "Intended use" and "Improper use" in the operating manual of the
servo amplifier.
The sole purpose of the EtherCAT interface is to connect the servo amplifier to a Master
with EtherCAT connection.
The servo amplifiers are installed as components in electrical apparatus or machinery and
can only be commissioned as integrated plant components.
INFORMATION
We guarantee compliance of the servo amplifier with the following
standards in the industrial sector only when using the components
named by us and when complying with the installation manual:
EU EMC Directive 2004/42/EG
EU Low Voltage Directive 2006/95/EG

Safety
Operating Manual EtherCAT for, PMCtendo DD5 and PMCprotego D
1002906-EN-02 9
2.2 Notes on the online edition (PDF format)
Bookmarks:
Table of contents and index are active bookmarks.
Table of contents and index in the text:
The lines are active cross-references. Click the required line to display the corresponding
page.
Page number in the text:
Page numbers/chapter numbers with cross references are active. Click on the page num-
ber/chapter number to go to the specified target.

Installation/commissioning
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1002906-EN-02 10
3 Installation/commissioning
3.1 Assembly/installation
WARNING!
Risk of electrocution!
Install and wire the devices always in a voltage-free state. Ensure that there
is a safe enabling of the control cabinet (lock, warning signs etc.). The indi-
vidual voltages are switched on only when commissioning. Residual
charges in the capacitors may still show hazardous values several minutes
after the mains voltage is switched off. Measure the voltage in the interme-
diate circuit and wait until the voltage has dropped below 40VDC. Control
and power connections may still carry voltage, even when the motor is not
rotating.
WARNING!
Possible loss of the safety
Electronic devices are not fail-safe as a matter of principle. The user is re-
sponsible that the drive is led to a safe condition for machinery or personnel
when the servo amplifier fails, e.g. by using a mechanical brake. Drives with
servo amplifiers in EtherCAT networks are remotely operated machines.
They can set in motion at any time without prior notice. Warn the operator
and maintenance personnel by corresponding instructions. Use a relevant
protective measure to ensure that an unintended startup of the machine
does not lead to a hazardous situation for man and machine. Software end
switches do not replace the hardware end switches of the machine.
NOTICE
Wire the servo amplifier as described in the operating manual. The wiring of
the analogue set value input and the position interface after the connection
image of the operating manual may be omitted.

Installation/commissioning
Operating Manual EtherCAT for, PMCtendo DD5 and PMCprotego D
1002906-EN-02 11
INFORMATION
Due to the internal representation of the position control parameters, the po-
sition controller can only be operated if the final speed of the drive does not
exceed the following values:
rotary:
Sinusoidal²-shaped acceleration: max. 7500 U/min
Trapezoidal acceleration: max. 12000 U/min
linear:
Sinusoidal²-shaped acceleration: max. 4 m/s
Trapezoidal acceleration: max. 6.25 m/s
INFORMATION
All the data regarding resolution, incremental value, positioning accuracy
etc. refers to the arithmetic values. Non-linearities in the mechanics (back-
lash, elasticity etc.) are not considered.
If the motor's end speed needs to be changed, all the position control and
motion block parameters that were entered previously will need to be adap-
ted.
3.1.1 Connection technology
Connection to the EtherCAT network via RJ45 connector (IN and OUT interfaces).
3.1.2 Commissioning
3.1.2.1 Guide to commissioning
INFORMATION
The servo amplifier may only be commissioned by qualified personnel with
sound knowledge of control and drive technology.
CAUTION!
Possible loss of the safety
Ensure that no hazard can result for personnel or machinery, even if the
drive should move unintentionally.

Installation/commissioning
Operating Manual EtherCAT for, PMCtendo DD5 and PMCprotego D
1002906-EN-02 12
Procedure:
Step Description
Check assembly/installation Check that all the safety guidelines in this
manual and in the operating manual for the
servo amplifier are respected and imple-
mented.
Connect PC, start commissioning software Use the commissioning software to set the
parameters for the servo amplifier.
Commissioning the basic functions Commission the basic functions of the servo
amplifier and optimise the current, speed
and position controller. This part of the com-
missioning process is described in more de-
tail in the commissioning software's online
help.
Save parameters Once the parameters have been optimised
they should be saved in the servo amplifier.
3.1.2.2 EtherCAT commissioning
To commission with the TwinCAT tool please use the documents in the download area of
the Pilz homepage.
To commission with the motion controller PMCprimo please use the documents in the
download area of the Pilz homepage.

EtherCAT
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4 EtherCAT
4.1 Slave Register
The following table displays the addresses of individual registers in the FPGA memory. The
data exist in little endian format, the "least significant byte" is on the lower address. A de-
tailed description of all registers and FPGA locations can be seen from the "EtherCAT
Slave Controller" description of the EtherCAT user organisation (www.ethercat.org).
Address
Lengt
h
(Byte) Description
ZA
ECAT
ZA
Drive
0x0120 2 AL Control r/w r/-
0x0130 2 AL Status r/- r/w
0x0134 2 AL Status Code r/- r/w
0x0204 2 Interrupt enable register r/- r/w
0x0220 2 AL Event (IRQ Event) r/w r/-
0x0800 8 AL Manager 0 (Mail Out control register) r/w r/-
0x0808 8 AL Manager 1 (Mail Out control register) r/w r/-
0x0810 8 AL Manager 2 (Process data Output Control
Register)
r/w r/-
0x0818 8 AL Manager 3 (Process data Input Control Re-
gister)
r/w r/-
0x0820 8 AL Manager 4 r/w r/-
0x0828 8 AL Manager 5 r/w r/-
0x0830 8 AL Manager 6 r/w r/-
0x0838 8 AL Manager 7 r/w r/-
0x0840 8 AL Manager 8 r/w r/-
0x1100 64 ProOut Buffer (process data output, set values
ECAT)
r/w r/-
0x1140 72 ProIn (process data input, actual values of
ECAT)
r/- r/w
0x1800 512 Mail Out Buffer (Object channel buffer of ECAT) r/w r/-
0x1C00 512 Mail In Buffer (Object channel buffer of serve
amplifier)
r/- r/w
*:ZA ECAT = Access type EtherCAT
ZA Drive = Access type amplifier

EtherCAT
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4.2 AL event (interrupt event) and interrupt enable
The communication between the drive and EtherCAT FPGA is completely interrupt-con-
trolled. The Interrupt enable register and the Al event register are responsible for the inter-
rupt functionality of the EtherCAT interface. With a 1 in the corresponding Bit of the Inter-
rupt enable register the servo amplifier activates the individual events of the EtherCAT in-
terface, with a 0 the events are deactivated.
4.2.1 Interrupt enable register (address 0x0204:0205)
Parameter Address Bit
ZA
Drive
ZA
ECAT Description
AL Control
Event
0x204 0 r/w r Activating the AL Control
Events for phase runup
-- 0x204 1 r/w r Reserved
DC Distributed
Clock
0x204 2 r/w r Activating the Distributed Clock
(DC) Interrupts for the complete
communication
-- 0x204 3 … 7 r/w r Reserved
Mail Out Event 0x205 0 r/w r Activating the Mailbox Output
Event (SDO, Sync Manager 0)
for the object channel
Mail In Event 0x205 1 r/w r Activating the Mailbox Input
Event (SDO, Sync Manager 1)
for the object channel
Pro Out Event 0x205 2 r/w r Activating the process data
Output Event (PDO, cyclical set
values of the card)
Pro In Event 0x205 3 r/w r Activating the process data In-
put Event (PDO, cyclical actual
values of the servo amplifier)
-- 0x205 4 … 7 r/w r Reserved
With a 1 in the relevant Bit of the AL Event register the EtherCAT interfaces signals to the
servo amplifier in the Interrupt routine which event is to be processes by the servo amplifier.
4.2.2 AL Event (address 0x220:0221)
Parameter Address Bit
ZA
Drive
ZA
ECAT Description
AL Control Event 0x220 0 r r/w Editing the AL Control Events for
phase runup
Sync Manager
Watchdog Event
0x220 1 r r/w Editing a Sync Manager Watch-
dog Event
Distributed Clock
(DC) Event
0x220 2 r r/w Editing a Distributed Clock (DC)
Event
-- 0x220 3 … 7 r r/w Reserved

EtherCAT
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Parameter Address Bit
ZA
Drive
ZA
ECAT Description
Sync Manager 0
Event
0x221 0 r r/w Activating the Mailbox Output
Event (SDO, Sync Manager 0)
for the object channel
Sync Manager 1
Event
0x221 1 r r/w Activating the Mailbox Input
Event (SDO, Sync Manager 1)
for the object channel
Sync Manager 2
Event
0x201 2 r r/w Activating the process data Out-
put Event (PDO, cyclical set val-
ues of the card)
Sync Manager 3 0x201 3 r r/w Activating the process data Input
Event (PDO, cyclical actual val-
ues of the servo amplifier)
Sync Manager 4
– Sync Manager
7 Event
0x221 4 … 7 r r/w Reserved
Sync Manager 8
– Sync Manager
15 Event
0x222 0 … 7 r r/w Reserved
4.3 Phase runup
The registers AL Control, AL Status and AL Status Code are responsible for the communic-
ation phase runup (also called EtherCAT change of state) and the display of the current
status and any error messages are the registers AL Control, AL Status und AL Status
Code. Each Transition request of the EtherCAT interface by the AL Control Register and
each AL Control Event (Interrupt) is followed by the servo amplifier with the AL Status Re-
gister. Any error messages are displayed in the AL Status Code Register.
4.3.1 AL Control (address 0x0120:0x0121)
Parameter Address Bit
ZA
Drive
ZA
ECAT Description
Status 0x120 3 … 0 R w 0x01: Init Request
0x02: PreOperational Request
0x03: Bootstrap Mode Request
0x04: Safe Operational Request
0x08: Operational Request
Acknow-
ledgement
0x120 4 R w 0x00: No error reset
0x01: Error reset with positive
pulse edge
Reserved 0x120 7 … 5 R w --
Appl. specific 0x120 15 … 8 R w --

EtherCAT
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4.3.2 AL Status (address 0x0130:0x0131)
Parameter Address Bit
ZA
Drive
ZA
ECAT Description
Status 0x130 3 … 0 w r 0x01: Init
0x02: PreOperational
0x03: Bootstrap Mode
0x04: Safe Operational
0x08: Operational
Change of
state
0x130 4 w r 0x00: Confirmation during change of
state
0x01: Error during change of state,
e.g. with not permitted transition
Reserved 0x130 7 … 5 w r --
Appl. specific 0x130 15 … 8 w r --
4.3.3 AL Status Code (address 0x0134:0x0135)
Parameter Address Bit
ZA
Drive
ZA
ECAT Description
Status 0x134 7 … 0 w r See table below
Status 0x135 7 … 0 w r See table below
Code Description
Current status
(change of state) Resulting status
0x0000 No error All Current status
0x0011 Faulty change of
state request
I -> S, I -> O, P -> O,
O -> B, S -> B, P -> B
Current status + E
0x0017 Incorrect synchron-
isation manager
configuration
P -> S, S -> O Current status + E
0x001A Synchronisation er-
ror
O S -> O S + E
Other codes are not supported.

EtherCAT
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1002906-EN-02 17
4.3.4 EtherCAT communication phases
INIT:
Initialisation, no communication
PRE-OP:
Mailbox active, parametrising
Slave and Startup parameters
SAVE-OP:
Cyclical actual values are trans-
mitted, and the servo amplifier
tries to synchronise itself.
OPERATIONAL:
Cyclical set values are processed,
torque release can be started and
the servo amplifier must be syn-
chronised.
Description of the individual communication transitions
Trans-
ition
AL Control
(Bit 3 … 0) Description
(IB) 0x03 Hardware reset requirement by the control.
(BI) -- Hardware reset on the servo amplifier.
(IP) 0x02 Activation of the mailbox (SyncManager 0 and 1) and activation
of the amplifier synchronisation routine. As the EC interface does
not yet created cyclical interrupts, the warning n17 (no sync.) ap-
pears in the amplifier.
(PI) 0x01 Deactivation of all EtherCAT Events except AL control and stop-
ping of mailbox activities.
(PS) 0x04 The amplifier checks the communication configuration specified
by the Master in status Pre-Op. Non-fatal errors are deleted auto-
matically (no COLDSTART).
Mapping of various set and actual values (PDO mapping). The
mapping can be preset by the mailbox. The ECAT interface pro-
ducers cyclical interrupts and therefore cyclical actual values are
available to the EAT interface. The amplifier starts synchronising
with the cyclical IRQ of the ECAT interface. The Pro_In and
Pro_Out events are activated, which are responsible for the cyc-
lical set (Pro_Out) and actual values (Pro_In) of the amplifier.
(SP) 0x02 The ECAT interface no longer produces cyclical interrupts.
Therefore the warning for lost synchronisation in the amplifier
(in17) and the actual values are not activated further.

EtherCAT
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1002906-EN-02 18
Trans-
ition
AL Control
(Bit 3 … 0) Description
(SI) 0x01 Deactivate all EtherCAT Events except AL Control. In addition,
the ECAT interface does not send any more interrupts, and the
amplifier loses synchronisation (warning n17) and it no longer up-
dates the actual values. Also, all mailbox activities are stopped.
(SO) 0x08 The amplifier finishes this transition only when synchronisation
has been performed, the synchronisation warning (n17) is de-
leted. Otherwise a synchronisation error (F28) is set after a time-
out period. This transition enables the editing of the control word
and therefore the acceptance and processing of the cyclical PDO
set values.
(OS) 0x04 Locking the set value acceptance
(OP) 0x02 The ECAT interface no longer produces cyclical interrupts.
Therefore the warning for lost synchronisation in the amplifier
(in17) and the actual values are not activated further.
(OI) 0x01 Deactivate all EtherCAT Events except AL Control. In addition,
the ECAT interface does no longer send interrupts, and the amp-
lifier loses synchronisation (warning n17) and it no longer up-
dates the actual values. Stopping of a mailbox activities.
4.4 CANopen over EtherCAT (CoE) state machine
The state machine for control word and status word corresponds to the CANopen state ma-
chine according to DA402. Control word and status word can be found in any fixed PDO
mapping.

EtherCAT
Operating Manual EtherCAT for, PMCtendo DD5 and PMCprotego D
1002906-EN-02 19
The status word is updated and
written only in Safe-Op and Opera-
tional states by the amplifier.
The control word is read in only in
Operational state.
4.4.1 Description of states
State Description
Not Ready to Switch
On
Servo amplifier is not ready to switch on; the amplifier has not
signalled operational readiness (BTB). The servo amplifier is still
in the boot phase or in an error state.
Switch On Disable In the ‘Switch On Disable’ state the amplifier cannot be enabled
by the EtherCAT interface, e.g. because there is no power
switched on.
Ready to Switch On In the ’Ready to Switch On’ status the servo amplifier must be
brought to the enable state using the control word.
Switched On In ’Switched On’ status the amplifier is enable, however the set
values of the EtherCAT interface are not yet accepted. The amp-
lifier is in standstill and a positive edge in Bit 3 of the control word
switches on the actual value acceptance (transition to the Opera-
tion Enable state).
Operation Enable In this state the servo amplifier is enabled and set values are ac-
cepted from the EtherCAT interface.
Quick Stop Active The servo amplifier follows a quick stop ramp.
Fault Reaction Active The servo amplifier reacts to a fault with an E-STOP ramp.
Fault A fault is present, the drive has been stopped and locked.

EtherCAT
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1002906-EN-02 20
4.4.2 Commands in the control word
The servo amplifier evaluated the individual Bits of the control word.
Commands in the control word for a change of state:
Transition
Bit 7
Reset
error
Bit 3
General
set value
enable
Bit 2
Enable for
Bit 3 and
display Bit 5 in
the
status word
Bit 1
Cancel
switch on
disable
Bit 0
Switch on
(enable)
when
Bit 1 = 1
0 X X X X X
1 X X X 0 X
2 X X X 1 0
3 X X 1 1 P
4 X P 1 1 1
5 X N 1 1 1
5 X X N 1 1
6 X X X 1 N
7 X X X N X
8 X X X 1 N
9 X X X N X
10 X X X N X
11 X 1 N 1 1
12 X X X N X
13 X 1 1 1 1
14 X 1 1 1 1
15 P X X X X
Legend
X Bits are irrelevant
1/0 Status of the individual bits
P Signalises a positive edge in the Bit
N Signalises a negative edge in the Bit