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EtherCAT Application Manual

EtherCAT Application

Manual

November 2012 (Ver. 1.401)

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Notice

This guide is delivered subject to the following conditions and restrictions:

?This guide contains proprietary information belonging to Elmo Motion Control Ltd. Such information is supplied solely for the purpose of assisting users of the EtherCAT

Application Manual in its installation.

?The text and graphics included in this manual are for the purpose of illustration and reference only. The specifications on which they are based are subject to change without notice.

?Information in this document is subject to change without notice.

Elmo Motion Control and the Elmo Motion Control logo are

registered trademarks of Elmo Motion Control Ltd.

EtherCAT Conformance Tested. EtherCAT? is a registered

trademark and patented technology, licensed by Beckhoff

Automation GmbH, Germany.

Document no. G-ETHERCATAM (Ver. 1.401)

Elmo Motion Control Ltd.

Version Writer Details Date

1.40 Rafi Sity

Gershon L

Document completely revised. Initial new

document

21/05/2012

1.401 Gershon L Updated to include EtherCAT and CAN

Object tables

12/11/2012

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EtherCAT Application Manual

4 G-ETHERCATAM (Ver. 1.401)

Table of Contents

Chapter 1:Introduction (6)

1.1. What is EtherCAT? (6)

1.2. Elmo EtherCAT (8)

1.3. Elmo Slave Drives (9)

1.3.1. CTT (Conformance Test Tool) (10)

1.4. Elmo G-MAS Master (11)

1.4.1.1. For EAS (13)

1.4.2. G-MAS Operation Modes (13)

1.4.2.1. NC Axes Motions (13)

1.4.2.2. Distributed / Standard DS-402 (stand-alone) Drive (14)

1.4.2.3. G-MAS to Servo Drive Interfaces (14)

1.5. ELMO Application Studio (EAS) – Configuration Tool (15)

Chapter 2:Elmo EtherCAT Slave Device (16)

2.1. Indicators (16)

2.1.1. Drive status LED Indicator (16)

2.1.2. EtherCAT Link/Activity Indicators (16)

2.1.3. EtherCAT Status Indicator (17)

2.2. CoE – CANopen Over EtherCAT (19)

2.2.1. PDO (Process Data Object) (19)

2.2.1.1. Receive PDO Mapping (Outputs) (20)

2.2.1.2. Transmit PDO Mapping (Inputs) (22)

2.2.2. Emergency Requests (24)

2.3. Synchronization Modes (25)

2.3.1. Free Run (25)

2.3.2. Distributed Clocks - Synchronous with SYNC0 (26)

2.4. EoE – Ethernet Over EtherCAT (28)

2.4.1. EoE Extensions (29)

2.4.1.1. MAC Address Info (29)

2.4.1.2. IP Address Info (29)

2.5. FoE – File Access over EtherCAT (30)

2.6. EEPROM (31)

2.7. ESI (xml format) (33)

Chapter 3:G-MAS Communication (34)

3.1. EAS EtherCAT Quick Configuration (34)

3.2. Downloading Firmware to G-MAS using FoE (43)

3.3. G-MAS EoE Configuration (43)

Chapter 4:TwinCAT Communication (46)

4.1. Architecture (46)

4.2. Using TwinCAT Master (46)

EtherCAT Application Manual Table of Contents

5 G-ETHERCATAM (Ver. 1.401)

4.3. Using a Switch Port (47)

4.4. Download Firmware using FoE (via TwinCAT) (48)

4.4.1. Setup Using the TwinCAT NC/PTP System Manager (48)

4.4.2. Setup Procedure (48)

4.4.3. The Firmware Download Procedure (57)

Chapter 5:Gold Drive Object list (60)

5.1. Complete Object List (60)

5.2. CAN Only Object List (66)

5.3. EtherCAT Only Object List (67)

5.4. EtherCAT CoE - PDO Objects list (68)

5.4.1. Transmit PDOs object list (68)

5.4.2. Receive PDOs object list (70)

Chapter 6:Elmo Emergency Error and Abort List (72)

6.1. Emergency Error Description (72)

6.2. Abort SDO Transfer Protocol (76)

Chapter 1:Introduction

The ELMO EtherCAT environment is extensive and abounding in features. ELMO provides a comprehensive solution for the EtherCAT system, which includes the G-MAS Network Motion Controller EtherCAT Master, Servo Drives, EtherCAT Slaves and EtherCAT configuration tools. ELMO EtherCAT is standard compliant and is successfully EtherCAT conformance tested.

This manual describes the installation, setup, range of functions and EtherCAT protocols for Elmo’s EtherCAT-ready products.

1.1.What is EtherCAT?

Ethernet for Control Automation Technology (EtherCAT) is an open high performance Ethernet-based fieldbus system, which uses the family of industrial computer network protocols used for real-time distributed control, now standardized as IEC 61158. It is a highly flexible Ethernet network protocol, running over a fast real time Master–Slave network.

The EtherCAT communication speed is up to 100 Mbps full duplex and can include a maximum of 65,535 stations in a single network configuration such as Ethernet star, line or tree without using switches.

Figure 1 describes a network of EtherCAT slaves in a ring topology. The Master controls the traffic in the network by initiating the transactions.

Figure 1: EtherCAT Network Configuration

Usually, a control system requires the following in periodic time intervals:

?Inputs

Messages from the ECAT device to the Master latches data such as Positions, Velocities,

Currents, System Status, IO’s etc,

?Outputs

Messages from the ECAT Master to the device with data or commands such as Control word commands, Trajectory Information (set point), or Higher Drive Level Commands.

The specific nature of the data transferred via the network depends on the operation mode of the slave drive. The Device Profile describes the application parameters and the functional behavior of the devices including the device class-specific state machines. A common standard for the Servo

Drive is the DS-402 for Drive and Motion Control device Profile, which can be addressed via CoE (Can Over EtherCAT).

The EtherCAT protocol is optimized for process data and is transported directly within the standard IEEE 802.3 Ethernet frame. Each Ethernet frame can include several EtherCAT frames, each serving another slave.

EtherCAT network uses a processing on the fly, whereby the Ethernet frame is received and processed, while the telegram passes through the device. The frames only delay by a fraction of a microsecond in each node. Using EtherCAT, the entire network can be addressed with just one frame.

The data sequence is independent of the physical order of the nodes in the network; addressing can be in any order. Broadcast, multicast and communication between slaves are possible and must be performed by the master device.

The EtherCAT protocol can be inserted into UDP/IP datagrams. This also enables any control with an Ethernet protocol stack to address EtherCAT systems.

Using the Master configuration tool, the Master scans the EtherCAT network and uses the EtherCAT Slave library (ESI: EtherCAT Slave Information in XML format) to compare the slave memory area that includes information about the slave such as Vendor ID, Product Code, and Slave Configuration.

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1.2.Elmo EtherCAT

For a complete motion solution, the ELMO environment comprises of three levels:

?EAS; EtherCAT configuration tools

?G-MAS; EtherCAT G-MAS master

?Gold Servo Drive; Elmo EtherCAT slave drives

Figure 2: EtherCAT Environment

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1.3. Elmo Slave Drives

The following diagram describes the EtherCAT communication of the drive.

Physical Layer (PHY)

Data Link Layer (DL)

Application Layer (AL)

Figure 3: Layered Communication protocol in EtherCAT

Physical Layer

The Physical layer of the EtherCAT is a 100Mbits/sec Ethernet port over twisted per cable. Data Link Layer

Supports two mechanisms of data transfer:

? Process data

Allows writing and reading data simultaneously. This mode is used to transfer the Process data objects (PDO). The PDO transfers via SYNC Manager 2 (rPDO) and SYNC Manager 3 (tPDO) ? Mailbox

The mailbox mechanism assures that the data will reach to the target without overlapping

previous data. The mailbox is used to transfer the SDOs. The SDO transfers via SYNC Manager 0 (MailboxOut) and SYNC Manager 1 (MailboxIn). SDO objects are used for user triggered access.

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With SDO services, all of the OD’s entries can be accessed. The SDO transport works in asynchronous mode.

The Elmo drive supports the following communication protocols: CoE

(CANopen over EtherCAT) Defines a standard way to access the CANopen

protocol and includes an object dictionary, SDO, PDO and emergency messages.

EoE

(Ethernet over EtherCAT)

Fully Ethernet compatible, defines a standard way to exchange or tunnel standard Ethernet frames. This is typically used to address the drive inherent parameters such as control parameters

FoE

(File over EtherCAT)

Similar to TFTP, defines a standard way to download firmware to the servo drive.

The Object Dictionary (OD) contains parameters, application data and the mapping information between the Process Data Interface (PDI) and application data. Its entries can be accessed via the

Service Data Object (SDO).

An Object Dictionary is a naming system that provides a unique identifier to each data item or “object” communicated over the CoE protocol. An object is identified by an index and sub-index. It contains variables, arrays and complex objects. CoE and EoE protocols require a set of mandatory objects. Elmo's OD is compliant with the DS402 V3 object list for Drive and Motion control device. The DS402 defines standard objects for the following motion modes; Profile Position, Profile Velocity, Profile Torque, Homing mode, Synchronous Cyclic Position, Synchronous Cyclic Velocity and Synchronous Cyclic Torque.

Elmo drive supports distributed clock in order to synchronize between the Master and Slaves on the EtherCAT network. Refer to the chapter 2.3 Synchronization Modes.

1.3.1. CTT (Conformance Test Tool)

The CTT (Conformance Test Tool) is the official tool used by the EtherCAT Technology Group (ETG) for EtherCAT conformance certification. The CTT includes thousands of tests to verify that the

device complies with the EtherCAT definition, requirements and standard. The Gold drive firmware version has passed the CTT in several quality assurance (QA) stations, making sure that the ETG Certificate given to Elmo is valid.

1.4.Elmo G-MAS Master

While a single servo drive can run as a stand-alone drive using its inner profiler and filter, in order to perform synchronized multi axis motions in the system (such as circle, line etc.), a real time communication protocol must be used, and all drives must be synchronized to a specific SYNC signal in the system. The Gold Maestro Network Motion Controller (G-MAS) performs this task and operates as a master, independent of any host system. In operational mode, it periodically sends data to the slaves that may override the data that a user sends from a host system. Therefore, for

example, the user cannot tune an axis if the axis is in operational mode. Figure

two types of communication mechanisms:

?Inter-process communication (IPC) which is a set of techniques to exchange data among multiple threads in one or more processes. C Programs located on the GMAS use the IPC

mechanism to communicate, and the GDS can communicate directly with the G-MAS via C programs.

? A remote procedure call (RPC) is an inter-process communication allowing a program to initiate

a subroutine or procedure to execute in another address space (the G-MAS server) without the

programmer explicitly coding the details for this remote interaction. The EAS application uses RPC to communicate with the GMAS.

Both these mechanisms allow the GDS and Elmo Application Studio (EAS) to communicate using TCP/IP and EtherCAT over TCP/IP, with the G-MAS to perform master operations.

It should be noted that connecting to the G-MAS is only allowed using one user problems to the G-MAS library. When performing multiple IPC connections to the G-MAS, the multiple connections must be opened from the same user application.

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EtherCAT, specific API functions are called to change the G-MAS operation and allow these applications to function.

1.4.1.1.For EAS

For the EAS application to monitor and perform motions, the G-MAS cannot operate in the background. A special API function changes the EtherCAT and CANbus communication from the

G-MAS to Pre-Operation mode, causing the following:

EtherCAT No process cycle operates

CANbus No outputs via CAN, and no state machines run

These API functions change the GMAS mode so that the GMAS operation is transparent and no messages transfer between the GMAS and the drives.

In order to configure the EtherCAT network (EtherCAT Configuration Mode) via the EAS application, the G-MAS must be set to EtherCAT Configuration mode. The user is then able to perform the operations. The API then employs the specific functions to change the G-MAS back to operational mode.

1.4.

2.G-MAS Operation Modes

To optimize the device network usage, the G-MAS supports two modes of operating axes present on the Device Network:

?NC Axes – for Numeric Control Axes

?Distributed – for axes not under strict numeric control

The main difference between these modes is the way the motion profile is calculated, and as a result, the synchronization level achieved.

In general, for axes not requiring low level (network) motion synchronization, the Distributed mode should be used, allowing the servo drives to generate their own motion trajectory, thus reducing network load. In this case, synchronized motions like ECAM, based on an external master encoder can still be exe cuted. For highly synchronized motions, generated by the Master controller (referred to under the PLCopen definitions as group vector motions), the NC mode should be used.

1.4.

2.1.NC Axes Motions

In this mode, the G-MAS controls the motion, handling the axis (and motion) State (as defined by the PLCopen Standard), and calculating the motion profile as part of its real-time loop process (NC Cycle). Servo drives operating with a G-MAS master under this mode will run under the DS-402 motion modes e.g.; Interpolated position, or one of the Cyclic Sync modes (Position/Velocity).

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1.4.

2.2.Distributed / Standard DS-402 (stand-alone) Drive

In this mode, the G-MAS uses the servo drives own DS-402 operation modes, where the drive itself controls its own profiling as part of its Real Time process. The G-MAS only synchronizes start/stop and general activation functions, but is not responsible to the low-level real-time profile generation.

The G-MAS can mix NC and Distributed axes in the same network configuration, thus optimizing usage of network and processor resources. The definition of the axis type (NC or Distributed), can be changed during operation using an operation mode command.

1.4.

3.G-MAS to Servo Drive Interfaces

The G-MAS manages all motion commands sent to the servo drives, via the CANopen DS-402 standard (Refer to Figure 4). This is relevant to the G-MAS CAN hardware interface, and to the EtherCAT protocol implementing CoE (CAN Over EtherCAT).

For axes (Nodes) that operate in NC mode, G-MAS uses the DS-402 motion modes: Interpolated position, or one of the Cyclic Sync modes (Position/Vel).

For axes (Nodes) operating in Distributed mode, where the servo drive manages its own profiler and real-time motion execution, it is assumed that the servo drive supports the relevant requested motion modes.

Motion Modes that are part of the PLC Motion API definition, but are not supported by the DS-402 interface, will not be available in standard DS-402 servo drives when working in Distributed mode (unless specific Vendor Types objects are defined, e.g. ECAM in drive level, etc. as implemented for example in Elmo servo drives).

The G-MAS uses the EtherCAT communication protocol to enable synchronized motion of all the controllers to the same SYNC signal. Thus, all drives in the system are synchronized to the master clock, and all generate an interrupt at exactly the same time.

A profiler can run in the G-MAS, on the condition that the axis (axes) is defined as a vector axis (axes). A vector axis may consist of 1 - 16 axes. The Multi Axis Indexer (MAI) is the profiler that runs within the G-MAS, which sends (via a high priority interrupt routine) a calculated set point to the axes in the system and can perform vector calculations for up to 16 axes. The profiler EtherCAT outputs are points that are to be sent to the specific drives belonging to the vector. Therefore, a number of combination options are available:

? 1 x 16 axes (One vector profiler performing profiles for 16 axes),

?16 x 1 axes (16 profilers for 16 vector axes), or,

?Any combination of M x N axes – as long as M x N < 16

The SYNC interrupt signal to the drives is based on the ET1100 component in the servo drive. The master G-MAS does not receive this signal, but can calculate when the SYNC signal is generated. This is because the master EtherCAT in the G-MAS is responsible for updating the SYNC cycle time

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in the servo drives, and therefore knows when the SYNC is generated. The MAI can operate at varying cycle times, dependent on a number of parameters, such as the:

?Desired response from the system

?Number of axes participating in the MAI. The more axes, the higher the cycle rate

1.5.ELMO Application Studio (EAS) – Configuration Tool

The EtherCAT configuration tools enable configuration and monitoring of the network from the EAS application.

Using the Master configuration tool, the Master scans the EtherCAT network and uses the EtherCAT Slave library to compare the slave memory area that includes information about the slave such as Vendor ID, Product Code, and Slave Configuration.

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Chapter 2: Elmo EtherCAT Slave Device

2.1. Indicators

This section describes the drive and EtherCAT indicators used to support visual inspection and troubleshooting of the drive and networks.

2.1.1. Drive status LED Indicator

This LED is used for immediate indication of the drive status. The LED color varies between green or red. The LED states are defined in the table below. Indicator state/color

Definition

Off

No power supply to drive

Temporary blinking red and then Off The drive is in BOOT state . Fi rmware download is required and should be performed now. Red The drive is in fault state e.g. Safety switches or Low bus

voltage) Green

Drive is ready

2.1.2. EtherCAT Link/Activity Indicators

Each EtherCAT slave device includes two RJ-45 connectors; EtherCAT IN and EtherCAT OUT as shown in Figure 4:

Figure 5: EtherCAT ports

Figure 5 describes the two status LEDs for each RJ-45 connector. The link/activity indicators show the state of the physical link and activity on this link.

Figure 6: Status LEDs

Table 1 displays the LEDs’ link and activity.

LED State Definition

Link and/or Activity Off No Connection Green color, defines the state of

the physical link/activity of the

link.

On Connection Established (Link)

Flashing Data transmission active (Act)

Speed On 100Mbps Connection

(default) otherwise there is

no EtherCAT connection Orange color, define the speed of the EtherCAT line.

Off 10Mbps connection

Table 1: LED Functionality

2.1.

3.EtherCAT Status Indicator

This indicator is one bi-colored led that combines the green RUN indicator (Table 2: RUN Indicator States) and the red ERROR indicator(Table 3: ERROR Indicator States) of the EtherCAT state machine. The LED indicator signals are based on ETG1300 of which Elmo drives are fully certified. Indicator State ESC State Description

Off Initialization Elmo drive is in state INIT

Blinking Pre-Operational Elmo drive is in state Pre-OP

Single Flash Safe-Operational Elmo drive is in state Safe-OP

On Operational Elmo drive is in state OP

Flickering Initialization or Bootstrap Elmo device is booting and has not yet

entered the INIT state,

or Elmo device is in state Bootstrap.

Firmware download operation in

progress

Triple Flash Device Identification User sets this state from the master to

locate the specific slave

Table 2: RUN Indicator States

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Error State Error Name Description

On Application controller failure An critical communication or

application controller error has

occurred

Double Flash Process data watchdog timeout /

EtherCAT watchdog timeout An application watchdog timeout occurred

Single Flash Local error Elmo device application has

changed the EtherCAT state

autonomously, due to local

error.

Blinking Invalid configuration General configuration error Flickering Booting error Booting error was detected

Off No error The EtherCAT communication of

the device is in working

condition.

Table 3: ERROR Indicator States

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2.2.CoE – CANopen Over EtherCAT

Defines a standard way to access the CANopen protocol and includes an object dictionary, SDO, PDO Emergency and Abort messages.

2.2.1.PDO (Process Data Object)

The PDO protocol is used for communication with SYNC Manager 2 for RxPDO, and SYNC Manager 3 for TxPDO.

Each PDO consist of objects in the object dictionary, which is PDO map able. The PDO mapping objects describes how these objects are related to a PDO.

Figure 7: PDO Mapping

Each sync manager channel object describes a consistent area inside the EtherCAT process data and consists of several process data objects.

All PDO mappings are located in the object dictionary from index 0x1C10 to 0x1C2f.

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2.2.1.1.Receive PDO Mapping (Outputs)

This defines a list of objects that include data from the master to the slave. All RPDOs are located in the object dictionary from index 0x1600 to 0x17FF.

Sub-index Description Data Type Access PDO

Mapping

Value

0 Number of

objects in

this PDO Unsigned8 RW,

Mandatory

No 0-254

Writable if variable

mapping is supported

1 First output

object to be

mapped Ubsgined32 R, depends

upon setting

No Bit 0-7: length of the

mapped objects in

bits.

Bit 8-15: sub index of

the mapped object.

Bit 16-31: index of the

mapped object

……..

N Last output

object to be

mapped Unsigned32 R, depends

upon setting

Table 4 : Receive PDO Mapping Configuration The following table describes Elmo RxPdo’s objects:

PDO Index Default

Value

Bit

Len

Description Function

Group

Exclude

0x1600 0x607A

0x60FE:1

0x6040 32

Target Position

Digital Inputs

Control Word

Position 0x1601-0x1606

0x1601 0x60FF

0x6040 32

Target Velocity

Control Word

Velocity 0x1600,

0x1602-0x1606

0x1602 0x6071

0x6040 16

Target Torque

Control Word

Torque 0x1600-0x1601

0x1603-0x1606

0x1603 0x607A

0x60FE:1

0x60B1

0x6040 32

Target Position

Digital Outputs

Velocity Offset

Control Word

Position 0x1600-0x1602

0x1604-0x1606

0x1604 0x607A

0x60FF

0x6072

0x6040 32

Target Position

Target Velocity

Max. Torque

Control Word

Position,

Velocity

0x1600-0x1603

0x1605-0x1606

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