SICK EtherCAT AFS60 User manual

OPERATING INSTRUCTIONS
AFS/AFM60 EtherCAT®
Absolut-Encoder

Described product
AFS/AFM60 EtherCAT®
Manufacturer
SICK AG
Erwin-Sick-Str. 1
79183 Waldkirch
Germany
Legal information
This work is protected by copyright. Any rights derived from the copyright shall be
reserved for SICK AG. Reproduction of this document or parts of this document is
only permissible within the limits of the legal determination of Copyright Law. Any modi‐
fication, abridgment or translation of this document is prohibited without the express
written permission of SICK AG.
The trademarks stated in this document are the property of their respective owner.
© SICK AG. All rights reserved.
Original document
This document is an original document of SICK AG.
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Contents
1 About this document........................................................................ 5
1.1 Scope......................................................................................................... 5
1.2 Purpose of this document........................................................................ 5
1.3 Target group.............................................................................................. 5
1.4 Information depth..................................................................................... 5
1.5 Symbols used............................................................................................ 6
1.6 Abbreviations used................................................................................... 6
2 Safety information............................................................................ 8
2.1 General notes............................................................................................ 8
2.2 Intended use............................................................................................. 8
2.3 Requirements for the qualification of personnel.................................... 9
2.4 Environmental protection......................................................................... 9
3 Product description........................................................................... 10
3.1 Product description.................................................................................. 10
3.2 Specific features....................................................................................... 10
3.3 Operating principle of the encoder.......................................................... 11
3.3.1 Scalable resolution.................................................................. 11
3.3.2 Preset function......................................................................... 11
3.3.3 Round axis functionality.......................................................... 12
3.3.4 Electronic cam mechanism..................................................... 14
3.4 Integration in EtherCAT®........................................................................... 15
3.4.1 EtherCAT® topology.................................................................. 15
3.4.2 EtherCAT® telegram in the Ethernet frame............................ 16
3.4.3 CANopen over EtherCAT® (CoE).............................................. 17
3.4.4 ESI file....................................................................................... 18
3.5 Configurable functions............................................................................. 19
3.5.1 Scaling parameters................................................................. 19
3.5.2 Preset function......................................................................... 21
3.5.3 Cyclic process data.................................................................. 23
3.5.4 Synchronization........................................................................ 24
3.5.5 Speed measurement............................................................... 24
3.5.6 Round axis functionality.......................................................... 25
3.5.7 Electronic cam mechanism..................................................... 25
3.6 Operating modes and synchronization.................................................... 26
3.6.1 EtherCAT® state machine........................................................ 26
3.6.2 Operating modes..................................................................... 27
3.6.3 Synchronous operating modes............................................... 27
3.6.4 Cycle times............................................................................... 28
3.7 Object library............................................................................................. 29
3.7.1 Nomenclature.......................................................................... 29
3.7.2 Overview of the standard objects........................................... 29
3.7.3 Detailed information on the standard objects....................... 30
CONTENTS
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3.7.4 PDO mapping objects.............................................................. 33
3.7.5 Overview of the encoder profile-specific objects................... 38
3.7.6 Detailed information on the encoder parameters................. 39
3.7.7 Detailed information on the electronic cam mechanism
(CAM)........................................................................................ 40
3.7.8 Detailed information on the diagnostics................................ 44
3.7.9 Overview of the manufacturer-specific objects..................... 47
3.7.10 Detailed information on objects for the encoder configura‐
tion............................................................................................ 48
3.7.11 Detailed information on objects that provide status infor‐
mation...................................................................................... 51
3.8 Controls and status indicators................................................................. 58
4 Commissioning.................................................................................. 59
4.1 Electrical installation................................................................................ 59
4.1.1 Connections of the AFS60/AFM60 EtherCAT®...................... 59
4.2 Settings on the hardware......................................................................... 60
4.3 Configuration............................................................................................. 62
4.3.1 Default delivery status............................................................. 62
4.3.2 System configuration............................................................... 62
4.4 Test notes.................................................................................................. 66
5 Troubleshooting................................................................................. 67
5.1 Response to errors................................................................................... 67
5.2 Support...................................................................................................... 67
5.3 Error and status indications on the LEDs................................................ 67
5.3.1 Identification of the encoder................................................... 67
5.3.2 NMOD, STAT and Encoder status LEDs.................................. 67
5.3.3 Ethernet Link LEDs L/A1 and L/A2........................................ 68
5.4 Diagnostics via EtherCAT®........................................................................ 69
5.4.1 Error types................................................................................ 69
5.4.2 Encoder specific errors............................................................ 69
5.4.3 CoE specific errors................................................................... 69
5.4.4 EtherCAT® specific errors........................................................ 70
5.4.5 Error messages........................................................................ 74
6 Annex.................................................................................................. 77
6.1 Conformities and certificates................................................................... 77
6.1.1 Compliance with EU directives................................................ 77
6.1.2 Compliance with UK statutory instruments........................... 77
CONTENTS
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1 About this document
Please read this chapter carefully before working with this documentation and the
AFS60/AFM60 EtherCAT® Absolute Encoder.
1.1 Scope
NOTE
These operating instructions apply to the AFS60/AFM60 EtherCAT® Absolute Encoder
with the following type codes:
•Singleturn Encoder Advanced = AFS60A-xxEx262144
•Multiturn Encoder Advanced = AFM60A-xxEx018x10
1.2 Purpose of this document
These operating instructions instruct the technical personnel of the machine manufac‐
turer or machine operator in:
•Electrical installation
•Commissioning
•Parameterization
•Operation
•Maintenance
These operating instructions must be made available to all persons who work with the
encoder.
The official and legal regulations for operating the encoder must always be complied
with.
1.3 Target group
These operating instructions are intended for planning engineers, developers, and
operators of plants and systems into which one or more AFS/AFM60 EtherCAT® Abso‐
lut-Encoder are to be integrated. They are also intended for people who put the encoder
into operation for the first time or who are in charge of maintenance.
These instructions are written for trained persons who are responsible for the installa‐
tion, mounting and operation of the encoder in an industrial environment.
Only trained electricians are permitted to carry out work on the electrical system or
electrical assemblies.
NOTICE
bRead the operating instructions carefully and ensure that you have understood the
contents completely before you work with the encoder.
1.4 Information depth
These operating instructions contain information on the AFS60/AFM60 EtherCAT®
Absolute Encoder on the following subjects:
•product features
•electrical installation
•commissioning and configuration
•fault diagnosis and troubleshooting
•conformity
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These operating instructions do not contain any information on the mounting of the
AFS60/AFM60 EtherCAT®. You will find this information in the mounting instructions
included with the device.
They also do not contain any information on technical specifications, dimensional
drawings, ordering information or accessories. You will find this information in the data
sheet for the AFS60/AFM60 EtherCAT®.
Planning and using measurement systems such as the AFS60/AFM60 EtherCAT® also
requires specific technical skills beyond the information in the operating instructions
and mounting instructions. The information required to acquire these specific skills is
not contained in this document.
When operating the AFS60/AFM60 EtherCAT®, the national, local and statutory rules
and regulations must be observed.
Additional information
•www.ethercat.org
•ETG.1000, 2 … 6: Layer protocol & service definitions
•ETG.1020, EtherCAT® Guidelines and Protocol Enhancements
•ETG.1300, EtherCAT® Indicator & Labeling specification (as per IEC 61784-2)
•ETG.2000, EtherCAT® Slave Information
•ETG.2200, EtherCAT® Slave Implementation Guide
•CiA DS-406, Profile Encoder for CANopen
•CiA DS-301, CANopen communication profile
•ET1810/1812, Slave Controller IP Core for Altera FPGA
1.5 Symbols used
NOTE
Refer to notes for special features of the device.
LED symbols describe the state of a diagnostics LED. Examples:
O Red The red LED is illuminated constantly.
Ö Yellow The yellow LED is flashing.
o Green The green LED is off.
bTake action …
Instructions for taking action are shown by an arrow. Read carefully and follow the
instructions for action.
WARNING
A warning notice indicates an actual or potential risk or health hazard. They are
designed to help you to prevent accidents.
Read carefully and follow the warning notices.
1.6 Abbreviations used
CMR Counts per Measuring Range
CNR_D Customized Number of Revolutions, Divisor = divisor of the customized number of
revolutions
CNR_N Customized Number of Revolutions, Nominator = nominator of the customized number
of revolutions
CoE CANopen over EtherCAT®
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CPR Counts Per Revolution
DC Distributed Clocks
EEPROM Electrically Erasable Programmable Read-only Memory
EoE Ethernet over EtherCAT
ESC EtherCAT® Slave Controller
ESI EtherCAT® Slave Information = electronic data sheet based on XML
ESM EtherCAT® State Machine = controls the status of the EtherCAT slave
ETG EtherCAT® Technology Group
EtherCAT®EtherCAT® is registered trademark and patented technology, licensed by Beckhoff Auto‐
mation GmbH, Germany
PDO Process Data Object
PLC Programmable Logic Controller
PMR Physical Measuring Range
PRS Physical Resolution Span (per revolution)
SDO Service Data Object
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2 Safety information
This chapter deals with your own safety and the safety of the equipment operators.
bPlease read this chapter carefully before working with the
AFS60/AFM60 EtherCAT® or with the machine or system in which the
AFS60/AFM60 EtherCAT® is used.
2.1 General notes
DANGER
Observe the following to ensure the safe use of the AFS/AFM60 EtherCAT® as intended.
The encoder must be installed and maintained by trained, qualified personnel with
knowledge of electronics, precision engineering, and controller programming. The rele‐
vant technical safety standards must be observed.
All persons entrusted with the installation, operation, or maintenance of the devices
must follow the safety guidelines:
•The operating instructions must always be available and must be followed.
•Unqualified personnel must stay away from the system during installation and
maintenance.
•The system must be installed in accordance with the applicable safety regulations
and mounting instructions.
•The work safety regulations of the employers’ liability insurance associations and
trade associations in the respective country must be observed during installation.
•Failure to observe the relevant work safety regulations may lead to physical injury
or cause damage to the system.
•The current and voltage sources in the encoder are designed in accordance with
the applicable technical guidelines.
2.2 Intended use
The Absolut-Encoder AFS/AFM60 EtherCAT® is a measuring device which is manufac‐
tured according to the recognized industrial regulations and which meets the quality
requirements stipulated in ISO 9001:2008 as well as those relating to environmental
management systems as defined in ISO 14001:2009.
An encoder is designed for mounting and can only be operated according to its
intended function. For this reason, the encoder is not equipped with direct safety
devices.
The system designer must provide measures to ensure the safety of persons and
systems in accordance with the legal guidelines.
Due to its design, the AFS/AFM60 EtherCAT® may only be operated within an EtherCAT
network. It is necessary to comply with the EtherCAT specifications and guidelines for
setting up a EtherCAT network.
In the event of any other usage or modification to the AFS/AFM60 EtherCAT® (e.g., due
to opening the housing during mounting and electrical installation) or in the event of
changes made to the SICK software, any claims against SICK AG under the warranty will
be rendered void.
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2.3 Requirements for the qualification of personnel
The encoder must only be mounted, commissioned, and maintained by authorized
personnel.
NOTE
Repair work on the encoder may only be performed by qualified and authorized service
personnel from SICK AG.
The following qualifications are necessary for the various tasks:
Table 1: Authorized personnel
Task Qualification
Mounting (see mount‐
ing instructions)
•Basic practical technical training
•Knowledge of the current safety regulations in the workplace
Electrical installation
and device replace‐
ment
•Practical electrical training
•Knowledge of current electrical safety regulations
•Knowledge of the operation and control of the devices in their
particular application (e.g., industrial robots, storage and conveyor
systems)
Commissioning, oper‐
ation, and configura‐
tion
•Knowledge of the current safety regulations and of the operation
and control of the devices in their particular application
•Knowledge of automation systems
•Knowledge of EtherCAT®
•Knowledge of automation software
2.4 Environmental protection
Please note the following information on disposal.
Table 2: Disposal of the assemblies
Assembly Material Disposal
Packaging Cardboard Waste paper
Shaft Stainless steel Scrap metal
Flange Aluminium Scrap metal
Housing Aluminium die cast Scrap metal
Electronic assemblies Various Electronic waste
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3 Product description
3.1 Product description
This chapter provides information on the special features and properties of the Abso‐
lute Encoder AFS60/AFM60 EtherCAT®. It describes the construction and the operating
principle of the device.
bPlease read this chapter before mounting, installing and commissioning the
device.
3.2 Specific features
Table 3: Special features of the encoder variants
Features Singleturn encoder Multiturn encoder
Absolute encoder in 60 mm design X X
Rugged nickel code disk for harsh ambient
conditions
X X
High accuracy and availability X X
Large ball bearing distance of 30 mm X X
High vibration resistance X X
Optimum concentricity X X
Compact design X X
Face mount flange, servo flange and blind hol‐
low shaft
X X
18 bit singleturn resolution (1 to
262,144 steps)
X X
30 bit total resolution X
12-bit multiturn resolution (1 to 4,096 revolu‐
tions)
X
Round axis functionality X
Interface (according to IEC 61784-1) X X
Supports the encoder profile CiA DS-406 X X
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3.3 Operating principle of the encoder
Die Sensorik des Absolut-Encoders AFS60/AFM60 EtherCAT beruht auf absoluter
Umdrehungserfassung ohne externe Versorgung und ohne Batterie. Dadurch kann der
Encoder nach dem Ausschalten und anschließenden Wiedereinschalten sofort seine
absolute Position ausgeben.
The Absolut-Encoder detects the position and speed of rotary axes and outputs the
position in the form of a unique digital numerical value. Optical detection takes place
via an internal code disk.
The AFS60 is a singleturn encoder
Singleturn encoders are used when one shaft revolution must be detected absolutely.
The AFM60 is a multiturn encoder
Multiturn encoders are used when more than one shaft revolution must be detected
absolutely.
3.3.1 Scalable resolution
The steps per revolution or the total resolution can be scaled and adapted to the
respective application.
The steps per revolution are scalable from 1 ... 262,144 in whole numbers. The total
resolution of the AFM60 must be 2ⁿ-fold the steps per revolution. This restriction is not
relevant if the round axis functionality is activated.
3.3.2 Preset function
A preset value can be used to set the position value of the encoder. I. e. the encoder
can be set to any position within the measuring range. This allows, for example, the zero
position of the encoder to be aligned with the machine zero point.
2
3
5
44
6
1
Figure 1: Setting a preset value
1Setting a preset value
2When switching on again
3Actual position value
4Offset
5Position value after preset
6Position value after switching on again
When the encoder is switched off, the offset – the delta between the real position
value and the value specified by preset – is saved. When switching on again, the
new calculated position value is formed from the new real position value and the
offset. Even if the encoder was turned further during the switched-off state, the correct
position value is output as a result.
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3.3.3 Round axis functionality
The encoder supports the gear function for round axes. Here, the steps per revolution
are set as a fraction (see "Preset function", page 11). This allows a number that is not
2ⁿ-fold the steps per revolution or/and a decimal number (e.g. 12.5) to be configured
as the total resolution.
NOTE
The output position value is calculated with a zero point correction, the set code
sequence and the entered gear parameters.
Example with transmission ratio
A rotating table for filling bottles is to be controlled. The steps per revolution are
specified by the number of fillers. There are nine fillers available. 1000 steps are
required for precise measurement of the distance between two fillers.
1
2
3
4
Figure 2: Example of position measurement on a rotating table with transmission ratio
1Rotating table with nine fillers
2Diameter of round table: 125 cm
3Encoder mounted on an axis together with the drive wheel.
4Diameter of drive wheel: 10 cm
The number of revolutions is given by the transmission ratio of the rotating table drive
(125/10 = 12.5).
The total resolution is thus 9 × 1000 = 9000 steps, to be realized in 12.5 revolutions
of the encoder. This ratio cannot be realized via the steps per revolution and the total
resolution, since the total resolution is not 2ⁿ-fold the steps per revolution.
The problem of the application can be solved with the round axis functionality. Here, the
steps per revolution are disregarded. The total resolution and numerator and denomi‐
nator of the number of revolutions are configured.
9000 steps are configured as the total resolution. The numerator of the number of
revolutions is configured as 125, the denominator as 10 (125/10 = 12.5).
After 12.5 revolutions (i.e. after one complete revolution of the rotating table), the
encoder reaches the total resolution of 9000.
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Example without transmission ratio
1
2
3
Figure 3: Example of position measurement on a rotating table without transmission ratio
1Rotating table with nine fillers
21000 steps
3Encoder
The encoder is mounted directly on the shaft of the rotating table. The transmission
ratio is 1:1.
The rotating table has 9 fillers. The encoder is to be configured so that it starts counting
with 0 at a filler position and counts up to 999 until the next filler position.
1000 steps are configured as the total resolution.
1 is configured as the numerator of the number of revolutions, 9 as the denominator
(1/9 revolutions = 1000).
After 1/9 revolutions of the encoder shaft there are 1000 steps, then the encoder
starts counting again at 0.
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3.3.4 Electronic cam mechanism
An electronic cam mechanism can be configured using the encoder. Two so-called CAM
channels with up to eight cam switching positions are supported (1). This is a limit
switch for the position.
Figure 4: Example electronic cam mechanism
Among other parameters, each cam has parameters for the lower switching point
(2) and the upper switching point (3), which can be configured via EtherCAT (see
"Electronic cam mechanism", page 25).
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3.4 Integration in EtherCAT®
3.4.1 EtherCAT® topology
EtherCAT supports a large variety of topologies such as line, tree, ring, star and their
combinations.
Figure 5: EtherCAT topology
For this reason the AFS60/AFM60 EtherCAT® has two Ethernet interfaces for integra‐
tion in an EtherCAT topology.
Figure 6: Two Ethernet interfaces on the encoder
An EtherCAT connection comprises to a large extent standardized Ethernet compo‐
nents. The slaves (e.g. the AFS60/AFM60 EtherCAT®) have an EtherCAT® Slave Control‐
ler for the communication with the master.
The EtherCAT® Slave Controller in the AFS60/AFM60 EtherCAT® reads the output data
for the encoder and writes the input data for the PLC while the telegram is passing
through. The process is implemented in hardware in the EtherCAT® Slave Controller
and is therefore independent of the software cycle times of the protocol stack or the
processor’s performance.
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Figure 7: Passage of the EtherCAT telegram
The last EtherCAT slave in the segment sends back the already completely processed
telegram so that it is sent to the controller — as a quasi reply telegram.
Figure 8: Returning the EtherCAT telegram
3.4.2 EtherCAT® telegram in the Ethernet frame
EtherCAT is based on the standard Ethernet frame. This contains the Ethernet header,
the Ethernet data and the Ethernet trailer. The EtherCAT telegram is transported directly
in the Ethernet data using a specially standardized EtherCAT frame.
Figure 9: EtherCAT frame in the Ethernet frame
Data in the form of process data are exchanged between the master and slaves in the
Ethernet frame. Each telegram has an address that refers to a specific slave or several
slaves. The combination of data and address form an EtherCAT telegram.
•An Ethernet frame can contain several EtherCAT telegrams.
•Several Ethernet frames may be necessary for all the EtherCAT telegrams for a
control cycle.
Each bus user has an addressable memory area of 64 kbyte in the telegram; data can
be read, written or read and written simultaneously.
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3.4.3 CANopen over EtherCAT® (CoE)
EtherCAT only defines a new protocol for the transport layer. It does not define its own
user or device protocol. EtherCAT is able to transmit various already existing, tried and
tested user protocols and device protocols via the EtherCAT protocol (tunneling).
For drive technology, e.g. CANopen over EtherCAT® (CoE) is relevant. This protocol
is supported by the AFS60/AFM60 EtherCAT®. The CoE protocol makes it possible
to use all CANopen profiles — and as a consequence also to utilize the encoder
profile DS-406. You can see which objects of the encoder profile are implemented
in the AFS60/AFM60 EtherCAT® (see "Overview of the encoder profile-specific objects",
page 38).
Figure 10: CANopen over EtherCAT®
The EtherCAT protocol provides two different transfer rates for the transmission. These
two transfer rates are the mailbox telegram protocol for acyclic data and the process
data protocol for the transmission of cyclic data.
•Mailbox telegram protocol
This transfer type is used to transmit the service data objects (SDO) defined
under CANopen. The objects are transmitted in EtherCAT in SDO frames. The
service data objects form the communication channel for the transmission of
device parameters (e.g. programming the encoder resolution). These parameters
are transmitted acyclically (e.g. only once on starting the network).
•Process data telegram protocol
This type of transfer is used to transmit the process data objects (PDO) defined
under CANopen that are used to exchange cyclic data. The objects are transmitted
in EtherCAT in PDO frames. The process data objects are used for the quick and
efficient exchange of real time data (e.g. I/O data, set or actual values).
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3.4.4 ESI file
To be able to simply interface EtherCAT slave devices to an EtherCAT master, an ESI
file must be available for each EtherCAT slave device. This file is in XML format and
contains information on the following features of the AFS60/AFM60 EtherCAT®.
•information on the manufacturer of the device
•name, type and version number of the device
•type and version number of the protocol used for this device
•default parameters of the AFS60/AFM60 EtherCAT® and default configuration of
the process data
Figure 11: Integration via ESI file
•Copy the ESI file SICK-AFx_vX-xxx in the TwinCAT® folder to the folder Twin‐
CAT\IO\EtherCAT.
•Restart the TwinCAT® system manager.
•Add the encoder in the device tree as a box.
•Then place the TwinCAT® system manager in the configuration mode.
NOTE
A detailed description of the configuration see "System configuration", page 62.
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3.5 Configurable functions
The AFS60/AFM60 EtherCAT® is configured in the configuration tool TwinCAT® using
various objects. The most important objects for the configuration of the functions are
listed in the following. A complete list of the objects see "Object library", page 29.
CAUTION
During the configuration of the encoder, make sure there are no persons in a system’s
hazardous area!
All parameter changes have a direct effect on the operation of the encoder. For this rea‐
son the position value may change during configuration, e.g. due to the implementation
of a preset or change of scale. This change could cause an unexpected movement that
may result in a hazard for persons or damage to the system or other items.
NOTE
All functions described in the following for which parameters can be set can also be
configured in the encoder’s start-up configuration.
3.5.1 Scaling parameters
The scaling parameters are configured by the objects 6000h, 6001h and 6002h.
Figure 12: Objects 6000h, 6001h and 6002h in TwinCAT®
6000h – Operating Parameter
Using the object 6000h (see table 31, page 39 ) the parameters Support additional
error code, Scaling and Code sequence are configured. The object is configured using a
bit sequence 16 bits wide.
Example:
Bit 0 = code sequence ccw = 1
Bit 2 = scaling on = 1
Table 4: Example for binary code
Bit 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0
Value 0 0 0 0 0 0 0 0 0 0 0 0 0 1 0 1
The binary value must be converted into a hexadecimal value and entered in the
configuration dialog box.
101b = 5h
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Figure 13: Example for the parameterization of object 6000h
Scaling
Scaling makes it possible to scale the resolution per revolution and the total resolution.
NOTE
Only if the parameter Scaling is configured to 1 are the values entered for the resolu‐
tion and total resolution applied.
Code sequence
The code sequence defines the direction of rotation, viewed on the shaft, in which the
position value increases.
•clockwise (cw) = increasing position value on clockwise revolution of the shaft
•counterclockwise (ccw) = increasing position value on counter clockwise revolution
of the shaft
6001h – Counts Per Revolution (CPR)
The resolution per revolution is configured using the object 6001h (see table 33,
page 39).
NOTE
The parameter is not used if the round axis functionality is activated.
Figure 14: Example for the parameterization of object 6001h
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