Stober MDS 5000 User manual

EtherCAT®
Operation manual Fundamentals
Communication
Parameters
V 5.6-H or later
09/2013 en

Table of contents
ID 441896.05
Operation manual
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Table of contents
1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.1 Purpose of the manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.2 Other manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.3 Further support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2 Notes on Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.1 Component part of the product . . . . . . . . . . . . . . . . . . . . . . 6
2.2 Operation in accordance with its intended use . . . . . . . . . . 6
2.3 Qualified personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.4 Transportation and storage . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.5 Installation and connection . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.6 Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.7 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.8 Presentation of notes on safety . . . . . . . . . . . . . . . . . . . . . . 9
3 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.1 Install in MDS 5000 or SDS 5000 . . . . . . . . . . . . . . . . . . . . 10
3.2 Installation in the FDS 5000. . . . . . . . . . . . . . . . . . . . . . . . . 13
4 Electrical installation . . . . . . . . . . . . . . . . . . . . . . . . . 15
4.1 IN and OUT sockets. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4.2 Connection Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
5 Fundamentals of EtherCAT. . . . . . . . . . . . . . . . . . . . 17
5.1 How it functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
5.2 State machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
6 User interface of the ECS 5000 . . . . . . . . . . . . . . . . 21
7 Data transmission with PDO and SDO . . . . . . . . . . . 23
7.1 Process data transmission with PDO service . . . . . . . . . . . 24
7.1.1 Process data mapping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
7.1.2 Process data - example of fast reference values. . . . . . . . . 25
7.2 Parameter Transmission with SDO Service. . . . . . . . . . . . . 30

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7.2.1 Preselection of the axis . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
7.2.2 Expedited Transfer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
7.2.3 Error codes for SDO services . . . . . . . . . . . . . . . . . . . . . . . 33
7.2.4 List of the drive parameters . . . . . . . . . . . . . . . . . . . . . . . . . 35
8 Emergency messages . . . . . . . . . . . . . . . . . . . . . . . 37
8.1 Error Device State . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
8.2 State Changes of the EtherCAT® State Machine . . . . . . . . 40
9 Synchronization with distributed clocks . . . . . . . . . . 42
10 Monitoring and diagnosis on the inverter . . . . . . . . . 47
10.1 Diagnostic Parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
11 Commissioning with TwinCAT® . . . . . . . . . . . . . . . . 68
11.1 Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
11.2 Device description file . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
11.3 Installing the driver for EtherCAT . . . . . . . . . . . . . . . . . . . . . 69
11.4 Startup of the device on EtherCAT® . . . . . . . . . . . . . . . . . . 69
11.5 Monitoring the process data connection to TwinCAT® . . . . 73
11.6 Activation of the synchronization with TwinCAT® . . . . . . . . 75
12 POSITool over EtherCAT . . . . . . . . . . . . . . . . . . . . . 78
12.1 Prerequisites . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
12.2 Activating mailbox gateway . . . . . . . . . . . . . . . . . . . . . . . . . 80
12.3 Reading and sending data using POSITool over EtherCAT. 82
12.3.1Reading inverter data from the EtherCAT® network (reverse
documentation) 82
12.3.2Sending inverter data to EtherCAT® . . . . . . . . . . . . . . . . . . 86
12.4 Management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
12.5 Principle of operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
13 List of literature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

1
Introduction
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1Introduction
1.1 Purpose of the manual
This manual gives you information on the connection of devices of the 5th
generation of STÖBER inverters to the EtherCAT®1 fieldbus system. The
structure of EtherCAT and the principal procedures are also discussed.
Goals of the manual:
• Provide you with a basic knowledge of EtherCAT communication.
• Offer you support when you design an application and configure
communication.
Target readers of this manual are users who are familiar with the control of drive
systems and who have a basic knowledge of EtherCAT.
1.2 Other manuals
The documentation of the MDS 5000 includes the following manuals:
The documentation of the FDS 5000 includes the following manuals:
The documentation of the SDS 5000 includes the following manuals:
You can find information on the POSITool software in the following manuals:
1 EtherCAT®is registered trademark and patented technology, licensed by
Beckhoff Automation GmbH, Germany.
Manual Contents ID Latest versiona)
Commissioning Instructions Reinstallation, replacement, function test 442297 V 5.6-H
Projecting manual Installation and connection 442273 V 5.6-H
Operating manual Set up the inverter 442285 V 5.6-H
a) At the time of publication. You can find all versions at www.stoeber.de > Products > Doc Center.
Manual Contents ID Latest versiona)
Commissioning Instructions Reinstallation, replacement, function test 442293 V 5.6-H
Projecting manual Installation and connection 442269 V 5.6-H
Operating manual Set up the inverter 442281 V 5.6-H
a) At the time of publication. You can find all versions at www.stoeber.de > Products > Doc Center.
Manual Contents ID Latest versiona)
Commissioning Instructions Reinstallation, replacement, function test 442301 V 5.6-H
Projecting manual Installation and connection 442277 V 5.6-H
Operating manual Set up the inverter 442289 V 5.6-H
a) At the time of publication. You can find all versions at www.stoeber.de > Products > Doc Center.

Introduction
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Note that the programming functionality of POSITool can only be used after
training by STÖBER ANTRIEBSTECHNIK. You can find information on training at
www. stoeber.de
1.3 Further support
If you have technical questions that are not answered by this document, please
contact:
• Phone: [phone]
• E-mail: [e-mail]
If you have questions about the documentation, please contact:
• E-mail: [e-mail]
If you have questions about training sessions, please contact:
• E-mail: [e-mail]
Manual Contents ID Latest versiona)
POSITool operating manual Information on the
basic functions of
POSITool
442233 V 5.6-H
Programming manual Information on
programming with
POSITool
441693 V 5.6-H
a) At the time of publication. You can find all versions at www.stoeber.de > Products > Doc Center.

2
Notes on Safety
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2 Notes on Safety
The devices may cause risks. For these reasons, comply with the following:
• The safety notes listed in the following sections and points
• The technical rules and regulations.
In addition, always read the appropriate documentation. STÖBER
ANTRIEBSTECHNIK GmbH + Co. KG accepts no liability for damages caused by
non-adherence to the instructions or applicable regulations. Subject to technical
changes to improve the devices without prior notice. This documentation is purely
a product description. It does not represent promised properties in the sense of
warranty law.
2.1 Component part of the product
The technical documentation is a component part of a product.
• Since the technical documentation contains important information, always
keep it handy in the vicinity of the device until the machine is disposed of.
• If the product is sold, disposed of, or rented out, always include the technical
documentation with the product.
2.2 Operation in accordance with its intended use
The ECS 5000 accessory is only intended for establishing communication
between devices from the 5th generation of STÖBER inverters and a EtherCAT®
network.
Improper use includes integration in other communication networks.

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2.3 Qualified personnel
Since the devices may harbor residual risks, all configuration, transportation,
installation and commissioning tasks including operation and disposal may only
be performed by trained personnel who are aware of the possible risks.
Personnel must have the qualifications required for the job. The following table
lists examples of occupational qualifications for the jobs:
Tab. 2-1: examples of occupational qualifications
In addition, the valid regulations, the legal requirements, the reference books, this
technical documentation and, in particular, the safety information contained
therein must be carefully
•read
• understood and
• complied with
2.4 Transportation and storage
Inspect the delivery for any transport damage immediately after you receive it.
Notify any damage to the transport company immediately. Do not operate the
product if damaged. Store the device in a dry and dust-free room if you do not
install it immediately
Activity Possible occupational qualifications
Transportation and storage Worker skilled in storage logistics or comparable
training
Configuration - Graduate engineer (electro-technology or
electrical power technology)
- Technician (m/f) (electro-technology)
Installation and connection Electronics technician (m/f)
Commissioning 
(of a standard application)
- Technician (m/f) (electro-technology)
- Master electro technician (m/f)
Programming Graduate engineer (electro-technology or
electrical power technology)
Operation - Technician (m/f) (electro-technology)
- Master electro technician (m/f)
Disposal Electronics technician (m/f)

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2.5 Installation and connection
The accessory installation instructions allow the following actions during the
installation of accessories:
• The housing in the upper slot can be opened.
Opening the housing in another place or for other purposes is not permitted.
Installation and connection work are only permitted after the device has been
isolated from the power!
Apply the 5 safety rules in the order stated before performing any work on the
machine:
1. Enable. Also enable the auxiliary circuits.
2. Secure against restart.
3. Check that voltage is not present.
4. Earth and short circuit.
5. Cover adjacent live parts.
Afterwards you can carry out the work.
2.6 Service
Repairs must only be performed by STÖBER ANTRIEBSTECHNIK GmbH + Co.
KG. Send faulty devices with a fault description to:
STÖBER ANTRIEBSTECHNIK GmbH + Co. KG
Abteilung VS-EL
Kieselbronner Str.12
75177 Pforzheim, Germany
GERMANY
2.7 Disposal
Please comply with the latest national and regional regulations! Dispose of the
individual parts separately depending on their nature and currently valid
regulations such as, for example:
• Electronic scrap (PCBs)
• Plastic
• Sheet metal
• Copper
•Aluminum
Information
Note that the discharge time of the DC link capacitors is 5 minutes. You
can only determine the absence of voltage after this time period.

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2.8 Presentation of notes on safety
NOTICE
Notice
means that property damage may occur
if the stated precautionary measures are not taken.
CAUTION!
Caution
with warning triangle means that minor injury may occur
if the stated precautionary measures are not taken.
WARNING!
Warning
means that there may be a serious danger of death
if the stated precautionary measures are not taken.
DANGER!
Danger
means that serious danger of death exists
if the stated precautionary measures are not taken.
Information
indicates important information about the product or a highlighted
portion of the documentation which requires special attention.

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3 Installation
The ECS 5000 fieldbus must first be installed before the inverter of the 5th
generation of STÖBER inverters can be integrated in an EtherCAT system. We
recommend ordering the option card with installation since the card will already
have been installed by STÖBER ANTRIEBSTECHNIK before delivery.
3.1 Install in MDS 5000 or SDS 5000
WARNING!
Danger of injury/death and property damage due to electric shock!
Before installing accessories, turn off all voltage supplies! Then wait 5
minutes for the DC link capacitors to discharge. Never begin with accessory
installation until after this!
CAUTION!
Danger of property damage due to electrostatic discharge, among others!
Provide suitable protective measures while handling open PCBs (e.g., ESD
clothing, environment free of dirt and grease).
Do not touch the contact surfaces.
You will need the following to install the ECS 5000:
• a TX10 Torx screwdriver
• a Phillips screwdriver
• The covering plate shown below which is included with the ECS 5000 as an
accessory:
• The screw with locking disk which is included with the ECS 5000 as an
accessory.

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Installing the ECS 5000 in an MDS 5000 or SDS 5000
1. Unscrew the mounting screws and remove the cover plate:
2. From below, stick the RJ45 plug connector of the PCB through the plate
which is included with the ECS 5000 accessories:
3. Secure the plate to the PCB with the included screw with locking disk:

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4. Insert the option PCB in the inverter so that the gold contacts slide into the
black terminal block:
5. Secure the plate to the inverter with the mounting screws:
You have installed the accessory.

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3.2 Installation in the FDS 5000
WARNING!
Danger of injury/death and property damage due to electric shock!
Before installing accessories, turn off all voltage supplies! Then wait 5
minutes for the DC link capacitors to discharge. Never begin with accessory
installation until after this!
CAUTION!
Danger of property damage due to electrostatic discharge, among others!
Provide suitable protective measures while handling open PCBs (e.g., ESD
clothing, environment free of dirt and grease).
Do not touch the contact surfaces.
You will need the following to install the ECS 5000:
• a TX10 Torx screwdriver
• a Phillips screwdriver
• The cover plate shown below which is included with the accessories of the
ECS 5000:
• The screw with the locking disk which is included with the accessories of the
ECS 5000
Installing the ECS 5000 in an FDS 5000
1. Unscrew the mounting screws and remove the cover plate:
IN OUT

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2. From below, stick the RJ45 plug connector of the PCB through the plate
which is included with the ECS 5000 accessories:
3. Secure the plate to the PCB with the included screw with locking disk:
4. From below, stick the RJ45 plug connector of the PCB through the plate
which is included in the ECS 5000 accessories:
5. Secure the plate to the inverter with the mounting screws:
You have installed the accessory.

Electrical installation
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4 Electrical installation
There is always exactly one EtherCAT master (for example an industrial PC) and
any number of EtherCAT slaves (drive controllers, etc.) connected. All
subscribers are connected together in a line. The master is connected at the
beginning of the line. It is followed by the slaves in any order. The X201 OUT
socket on the last subscriber remains open.
Fig. 4-1 Layout of an EtherCAT network
4.1 IN and OUT sockets
Each EtherCAT slave (e.g., inverter) has an IN (X200) and an OUT (X201) RJ-45
socket. The incoming EtherCAT cable (coming from the direction of the master)
is plugged into the IN socket. The OUT socket is connected to the next station.
CAUTION!
Unexpected movements!
The connection order determines the address of devices in the EtherCAT
network. Connecting devices differently will cause the addressing to change,
resulting in faulty control.
Make certain based on parameter A256 that the connection order of the
devices is unchanged, especially after working on the switch cabinet.
EtherCAT master
(e.g.,industrial PC)
The „OUT“ socket on the last station
is not connected. Protect this „OUT”
socket from dirt with a dust-protective
cover for RJ45.

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4.2 Connection Cable
Ethernet patch or crossover cables in CAT5e quality can be used as the
connection cables. Lengths of 0.2 to 100 m are permitted for an EtherCAT
network.
RJ-45 socket
If you want to make the cables yourself, be sure to select suitable crimp tools and
use great care. Afterwards check the quality with a cable tester to avoid
transmission problems.
The individual contacts of the RJ-45 socket are allocated as per the "T 568-B"
standard as shown in the table below.
Pin Color Cable Core Pair Function
1 white/orange 2 TxData +
2 orange 2 TxData -
3 white/green 3 RecvData +
4 blue 1 Unused
5 white/blue 1 Unused
6 green 3 RecvData -
7 white/brown 4 Unused
8 brown 4 Unused
Information
Since a very large selection of inexpensive Ethernet cables is available
in various lengths, it is easier and quicker to buy Ethernet cables
instead of making them yourself. If you do purchase Ethernet cables,
make sure that they are of CAT5e quality.
1 2 3 4 5 6 7 8
24
3
1

Fundamentals of EtherCAT
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5 Fundamentals of EtherCAT
Fieldbuses have been an established part the world of automation technology for
many years now. Since higher and higher speeds are required but the technical
limits of this technology have already been reached, new solutions needed to be
found.
At least in theory, the Ethernet which is familiar to all of us from the office world,
is very fast with its 100 Mbit/s speed which is available everywhere today.
However, these networks do not offer real-time capability due to the kind of
cabling that they use and the rules governing access rights.
This problem was corrected with EtherCAT. EtherCAT means "Ethernet for
Controller and Automation Technology." It was developed by Beckhoff
Automation GmbH and is now supported by the international organization
EtherCAT Technology Group (ETG). EtherCAT is an open technology which is
standardized by the IEC since 2005.
Various protocols can be transmitted via EtherCAT. STÖBER
ANTRIEBSTECHNIK offers the widely-used communication profile CANopen as
per DS 301 ().
Fig. 5-1 EtherCAT systems
CANopen
Application
®
CANopen
SDO
®
Processdata
Processdata
PDO
ProcessdataMailbox
EtherCAT
®
CoE CoE

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Fundamentals of EtherCAT
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5.1 How it functions
Ethernet transfers data within packets. With other real-time Ethernet systems
each packet is received by the stations, interpreted via a complicated software
system, and the process data then removed. After this a response packet is
generated.
With EtherCAT, the stations on the hardware interface (see ) pick out the data
intended for them from the data stream. Similarly the station's own response data
are added to the telegram. The master sends the telegram to the first station. This
station and all other stations receive the packet, change it as described, and send
it on to the next station.
Fig. 5-2 Data processing, EtherCAT stations
When the packet arrives at the last station, this station determines that no cable
is plugged into a next station. Using a "logical short circuit" it sends the data via
the other core pair through all stations back to the master (full duplex).
Fig. 5-3 Data processing, last EtherCAT station
EtherCAT uses the plug-in sequence together with full duplex technology to
create a logical ring.
Forward
Backward
Input
data
Forward
Output
data
IN OUT
Backward
Input
data
IN
Short
circuit
Forward Forward
Output
data

Fundamentals of EtherCAT
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5.2 State machine
The following state machine is implemented in every EtherCAT slave. Which
communication services are active via EtherCAT are defined for each state. The
EtherCAT master controls the state machine.
Fig. 5-4 EtherCAT state machine
State table:
State transitions:
State Description
Initialising Inverter configuration starts. Stored values are loaded.
Pre-Operational Inverter is ready for parameterization in preparation for
actual operation via SDO.
Safe-Operational EtherCAT master reads actual values from the inverter via
PDO and SDO.
Operational EtherCAT master and inverter exchange reference values
and actual values via PDO and SDO.
Transition Actions
IP Start mailbox communication
PI Stop mailbox communication
PS Start input update
SP Stop input update
SO Start output update
OS Stop output update
OP Stop output update, stop input update
SI Stop input update, stop mailbox communication
Initializing
Pre-
Operational
Operational
Safe-
Operational
Power
on
(PI)
(IP)
(SI)
(OI)
(OP)
(PS)
(SP)
(OS)
(SO)

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A PLC usually performs the startup in this sequence of states:
Initialising - Pre-Operational - Safe-Operational - Operational
If, for example, the TwinCAT®software from Beckhoff Automation GmbH is used,
these steps can be executed automatically by the System Manager or individually
as needed. When a controller program is started on the TwinCAT®PLC, the
startup is executed automatically.
OI Stop output update, stop input update, stop mailbox
communication
Transition Actions