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Kollmorgen EtherCat November 10, 2018
Carroll Wontrop – System Engineer
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EtherCAT - Topics Why Use Kollmorgen Ethercat ? Basic Principles and Capabilities Communication Overview AKD Implementation PDMM Implementation
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Why Use Kollmorgen Ethercat ?
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EtherCAT – Overview What is Ethercat? Why would I use EtherCAT? Why would I use EtherCAT verses other networks
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High performance Ethernet based Fieldbus Network
Ethercat – What is it ? High performance Ethernet based Fieldbus Network Allows transferring information quickly and deterministically between Controller and Drive between Controller and I/O Uses standard Ethernet components to keep implementation cost low Open Standard (non proprietary), Designed for the Factory
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Why would I use EtherCAT ?
Improve Machine Performance Higher Production Rates Higher Quality Parts and products Gets information quickly across the network Accuracy - Low jitter and distributed clocks node synchronization Fast Communication times Now: down to 250 usec (with Kollmorgen product) Future: ability to go to 10 usec Supported in all Kollmorgen Servo Drive Lines
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Why would I use EtherCAT
Real-time Information Allows monitoring of many drive parameters Machine Diagnostic - know when a machine problem is about to occur Get information if the machine faults Allows changing many drive and I/O parameters Change parameters on the fly Can have Remote I/O on the same network Analog and Digital I/O, Thermocouple Third party modules
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Why would I use EtherCAT
Reliability Transport information reliably, Proven in thousands of applications Interface Flexibility Supports many different drive opmode and interface types to fit many different customer machine control schemes and the available interfaces on other products
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Why would I use EtherCAT
Easy Integration into the Network Easy integration of third party products Easy learning curve and product implementation Special hardware chips not require as with some Networks COE – Can Over Ethercat use COE utilizing the well known CanOpen Protocol Less Wiring – More reliable, less wiring cost Processing on the fly – Faster communications Strong users group. Wide industry acceptance
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Why would I use EtherCAT verses other networks
More Component Vendor Options Not tied to a particular vendor Wide I/O support Many Vendors Support Not a separate SW to configure - Setup is integrated right into the KAS IDE No need for expensive Ethernet switches Comes with Kollmorgen’ s excellent tech support (usually not needed) Includes a distributed clock mechanism Low jitter that meets IEEE 1588 (Precision Time Protocol standard) without additional hardware May be the only bus needed
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The Kollmorgen Ethercat Advantage
Combines precision transfer of information w/ Kollmorgen’ s: Precision servo loops High performance motors Easy to use controllers Tight integration between motion and machine control Result: Industry Setting Machine Performance
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Ethercat Basic Principles and Capabilities
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EtherCAT – Capabilities
Processing on the fly Deterministic for high performance motion control Digital control – not susceptible to noise Precise motion control between axis (Master slaving, gearing coordinated motion) Quick sensor pickup in registration applications Lower installation cost by eliminating both Ethernet start topology and all switches routers and hubs.
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EtherCAT – Design Goals
Ethernet for Control Automation Technology First developed in early 2000’s Design Goals Apply Ethernet to applications with quick update times Cycle times down to 100usec Precise Synchronization – low jitter Low HW cost Fast deterministic update One cable for many signals
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Governing Standard IEC – Defines how Ethercat adapts the OSI seven layer communication model Ethercat FieldBus Network IEC (Industrial communication network spec IEEE standards for 100Base-TX, the physical layer of Ethernet.
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Fit in 7 Layer communication Model
Ethernet communication optimized for Precision machine control The EtherCAT Frame replaces the Ethernet standard stack Data portion of an Ethernet Packet
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Ethercat Protocol Overview
Physical layer is based on IEEE standards for 100Base-TX, the physical layer of Ethernet. Data link and application layers are specifically designed for motion control applications. The 100BASE-TX media system is based on specifications published in the ANSI TP-PMD physical media standard. The 100BASE-TX system operates over two pairs of wires, one pair for 'receive' data signals and the other pair for 'transmit' data signals.
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Ethercat Protocol Overview
Automatic network configuration and integrity check Cabling over 100 Meters between each node Electrical isolation for robust noise immunity Motion bus - Deterministic Data update rates down to 250 usec Bus connection and bus Medium: 100BASE-T media system Transmission Rate: 100 mhz, Connector and Cables: RJ-45 Physical Media: CAT5 cable Topology: Line
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Network Operation - On the fly
Process data is extracted and inserted on the fly Slave Device AKD 1 Slave Device EtherCAT Slave Controller EtherCAT Slave Controller A single message with data for all nodes Each node reads its inputs and adds its outputs to the message Without messages targeted to specific devices, maximum bandwidth is achieved An EtherCAT network is like a railway and at each train cars are unloaded and loaded while the train moves
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Network Operation – Distributed Clocks
Packet Routing provides precision motion command synchronization Each receiving node uses advanced digital time-correction techniques to minimize skew and jitter to provide precise control EtherCAT Node measures time difference between leaving and returning frame Propagation delays between any nodes can be computed Precise Synchronisation (<< 1 µs!) by exact adjustment of distributed clocks EtherCAT Frame vom Master
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Communication Overview
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EtherCAT Type Kollmorgen Supports
COE (CanOverEthercat) It is the CanOpen Network run over a Ethernet foundation Supported by Kollmorgen KAS, S700, and AKD product lines Parameters Supported for Standards: CiA301 - CanOpen Communication Profile for Industrial Systems CiA402 – Drive Profile Interface
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Ethercat COE Communication
Process Data (PDO) Communication Deterministic, Real Time Communication - FAST Limited parameter set Mailbox Communication Non-Deterministic Service Data Objects (SDO) and ACSII Communication Fuller parameter set Network Startup (COE Init) Sent once during Ethercat Network Initialization Service Data Objects (SDO) setup by the Ethercat Master Device
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Information Passed over EtherCAT
Setup up parameters Diagnostics parameters Operation parameters Status parameters Motion command parameters (Servo Drives) Servo Tuning and limit parameters (Servo Drives) Other Operational Parameters Ethercat Master
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Ethercat Communication – Initialization
Steps up to full Synchronization
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Network Operation - Ethercat Telegram
Efficient Transmission of Data Low overhead Ethernet Header ECAT EtherCAT Telegram Ethernet DA SA Type Frame HDR EtherCAT HDR Data Pad. FCS CTR (6) (6) (2) (2) (10) (0….1486) (2) (0…32) (4) constant Header completely sorted (mapped) process data Working Counter: constant Padding Bytes and CRC generated by Ethernet Controller (MAC)
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Network Operation - Slave Implementation
Definitions ESC = Ethercat slave controller Trafo = Transformer PHY = Physical Layer (Layer 1 in OSI model) EtherCAT Slave structure parts: EtherCAT Master Not part of the Slave. EtherCAT is a master-slave system. An EtherCAT master needs as only hardware a standard NIC. It can use all information provided by the Electronic data sheet of all slaves. Electronic Data Sheet Every EtherCAT device shall be delivered with Electronic Data Sheet in XML format. It describes the identity and all features of the device. Slave Hardware The slave hardware describes the following parts: • Standard Ethernet Physical Layer Components • EtherCAT Slave Controller (ESC) and EEPROM (ESC Configuration Data) • For intelligent slaves with an application controller: Host CPU Standard Ethernet Physical Layer Components The physical layer is based on the standards defined by standard Ethernet according to IEEE802.3. This means: • Standard Ethernet plugs (RJ45 or M12) • Magnetics • PHYs In order to maximize the EtherCAT performance, it is required to select the PHYs according to the criteria listed in the ESC data sheets. For EtherCAT devices connected to an internal backbone connection LVDS can be used as Phyical Layer. This Physical Layer is also called “E-Bus”. Then the Magnetics and the PHYs are no longer required, the connectors are vendor specific. EtherCAT Slave Controller (ESC) The ESC can either be implemented as FPGA or ASIC. This hardware handles the EtherCAT protocol in real time. Thus, the performance of the EtherCAT communication does not depend on the implementation of the application software in the host CPU. Neither does the communication speed has impact on the performance of the application controller. To connect the ESC to an application controller or just digital I/Os the following Process Data Interfaces (PDI) are available depending on the ESC type: • 32 Bit digital I/O • Serial Peripheral Interface (SPI) Used for small process data • 8/16 bit synchronous/ asynchronous microcontroller interface Usually used for larger process data Process data and parameter data are exchanged via a DPRAM while the ESC behaves like a memory. Appropriate mechanisms are provided by the ESC hardware (defined by the EtherCAT protocol) to ensure data consistency. ESC Configuration Data (EEPROM) During start-up the ESC needs to load configuration data (e.g. PDI type) from an external NVRAM. Most ESC support an I²C interface to connect an EEPROM. Application Layer/ Host CPU In a complex slave the application layer services are implemented on an application controller here named as Host CPU. The Host CPU has to support the following tasks: - EtherCAT State Machine handling - Process data – Exchange with the application - Mailbox protocols (CoE, EoE etc.) - Object Dictionary Handling - Handling of Application Parameter (Communication Parameter are handled by ESC) - Optional TCP/IP Stack Handling – if device supports EoE - CC-Performance is determined by device application, not by EtherCAT Communication In many cases an 8bit CC/ PIC is sufficient.
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Product Configuration File
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ESI Vendor Files Also called Ethercat XML Device Description Defines the communications and what objects will be passed through Cyclicly Required by the Master to setup the ECAT Network
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AKD Implementation
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Network Operation - AKD Ethercat Connection
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Velocity / Torque Control
Architecture Typical Ethercat Configuration 1 Path Generation in Controller PLC PLC or PAC PLC or PC PLC or PC Machine Control I/O Field Bus Motion Programming Standalone Multi Axis Control Single Axis Controller PDMM Field Bus Path Generation Digital Drive AKD or S700 Motion Bus Position Control Digital Drive AKD or S700 +/- 10V Velocity / Torque Control Analog Drive
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Velocity / Torque Control
Architecture Typical Ethercat Configuration 2 Path Generation in Drive PLC PLC or PAC PLC or PC PLC or PC Machine Control I/O Field Bus Motion Programming Standalone Multi Axis Control Single Axis Controller PDMM Field Bus Path Generation Digital Drive Motion Bus Position Control Digital Drive +/- 10V Velocity / Torque Control AKD or S700 Analog Drive
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Network Operation -Drive Addressing
No drive manual address setting required Addresses assigned automatically Addresses can be kept – no new addressing if nodes are added
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AKD drive models that support Ethercat
AKD Drive Modes AKD drive models that support Ethercat AKD-P00xxx-NAEC-0000: Ethercat bus only AKD-P00606-NACC-0000: Configurable to Ethercat or CanOpen bus
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Network Startup (COE Init)
AKD COE Communication Network Startup (COE Init) Non-Deterministic – Initial Setup ( related to initial drive setup) Sent only one time during Ethercat Network Initialization Service Data Objects (SDO) setup by the Ethercat Master Device Process Data (PDO) Communication Deterministic - Operational (Realtime) Limited parameter set Mailbox Communication Non-Deterministic - Operational (Non-realtime) Service Data (SDO) and ACSII Communication Fuller parameter set
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AKD Opmodes supported Set by Object 0x6060
1 to 8 : ECAT Standard Opmodes -1 to -3 : Additional Kollmorgen specific Opmodes
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AKD Support Parameters
Most AKD Parameters are linked to Ethercat Objects Example: Velocity Loop Proportional Gain is linked to object 0x3548
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Control and Status Objects
Bit Wise Objects not connected to a specific AKD Parameter Drive Control Word: 0x6040 (Master Controller to AKD) Drive Status Word: 0x6041 (AKD to Master Controller) Control Word Status Word
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Network Startup (COE Init) Communications
Sent by master to the AKD during ECAT network startup Used to configure the drive for ECAT communications. Can in parameters to set up: opmode, high speed capture engine, network synchronization, Units scaling, Enable/Disable coordination with tthe controller, and others: Example : Beckhodff TwinCat (Ethercat Master) ECAT Startup
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AKD PDO Communications (Fixed)
Parameters transmitted at the ECAT update rate The following are standard (Fixed) options Some combination of the PDO‘s below is possible Options: Controller to AKD Options: AKD to Controller
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AKD PDO Communications (Other options- Flexible PDOs)
Some other AKD parameters can be mapped into the PDO communication (Requires removing some Fixed PDOs) Check the Appendix to the AKD Ethercat Manual to determine PDO mappable objects
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AKD Mailbox communications
Non time critical transmission of Parameters. Example: Change Tuning gains, Limits, Scalings Many AKD parameters can be mapped into the PDO communication (Requires removing some Fixed PDOs) See the Appendix to the AKD Ethercat Manual for complete list
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AKD Ethercat Notes Position Feedback Object PDO mapping
0x6064 is for interpolated position 0x6063 is for everything else. PDO mapping When free mapping PDO , turn off the PDOs you don’t intend to use. Individual PDOs limited to 8 bytes. Some masters only will map one TX-PDO and one RX-PDO. Ethercat Network Run-up Often when Starting up Ethercat network via the Control Word (0x6040), will need to monitor the status word (0x6041) for the step completion before using the control Word to move on to the next step. Monitor the bus voltage bit in the status word, plus 300mS, for the bus voltage to be present before starting the run up. Resetting Home AKD firmware 1.10.x.x and up: homing will reset 0x6064 and 0x6063. Set HOME.MODE to 13 and set FB1.OFFSET.
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AKD Ethercat Notes Over Travel Limit Position Jump AKD XML file
May need to defeat Over travel limit setup in AKD to work with certain master Position Jump If position “jump” occurs in interpolated position mode, caused by the position update arriving at the drive when the drive is calculating the next set of position points set FBUS.PARAM02 and FBUS.PARAM04 = 1 AKD XML file Use new XML file for TwinCat3 and other controllers There are some clerical errors in the “optional” parts of the AKD’s XML files and some Ethercat masters don’t like it. Will not allow configuration. (Delta Tau, Omron).
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KAS PDMM/PCMM Implementation
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Velocity / Torque Control
Architecture Default KAS Ethercat Configuration PLC PLC or PAC PLC or PC PLC or PC Machine Control I/O Field Bus Motion Programming Standalone Multi Axis Control Single Axis Controller Field Bus Path Generation Digital Drive AKD or S700 Motion Bus Position Control Digital Drive AKD or S700 +/- 10V Velocity / Torque Control Analog Drive
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KAS Ethercat Configuration
Architecture KAS Ethercat Configuration Machine Controller PCMM or PDMM Servo Drive (AKD or S700) Machine I/O Motor Position Control Velocity Control Current Control Application Program Profile Generator Feedback Network Interface HMI Interface Feedback Interface EtherCAT HMI
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Network Operation - Drive Addressing
No drive manual address setting required Addresses assigned automatically Addresses can be kept – no new addressing if nodes are added
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PDO Execution Time Each Ethercat cycle 250, 500, 1000 or 2000 microsecond
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EtherCAT System ENI file
Defines component parameters for Ethercat Network Stored in KAS Project (for particular ones used in a project) <?xml version="1.0" ?> - <!-- edited with XML Spy v4.4 U ( by name (company) --> <EtherCATInfo xmlns:xsi=" xsi:noNamespaceSchemaLocation="EtherCATInfo.xsd" Version="1.2">- <Vendor> <Id>106</Id> <Name>Danaher Motion GmbH</Name> <ImageData16x14>424de e c40e0000c40e c0c0c ff0000ff000000ffff00ff000000ff00ff00ffff0000ffffff00cccccccccccccccccfffffffffffffffcfcccccccccccccccfcffccfcfcfcfcccfcfcfcfcfcfcfcccfcfcfcfcfcfcfcccfcfcfcfcfcfcfcccfcfcfcfffcffccccfcfcfcfcfcfcfcccfcfcfcfcfcfcfcccfcfcfcfcfcfcfcccfcffccfcfcffccccfcccccccccccccccfcccccccccccccc</ImageData16x14> </Vendor>- <Descriptions>- <Groups>- <Group SortOrder="520"> <Type>Drive</Type> <Name LcId="1033">Drives</Name> <Image16x14>DRIVE</Image16x14
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Process Data (PDO) Communication
KAS COE Communication Process Data (PDO) Communication Deterministic, Real Time Communication Limited parameter set Mailbox Communication Non-Deterministic Service Data (SDO) and ACSII Communication Fuller parameter set Network Startup (COE Init) Sent once during Ethercat Network Initialization Service Data Objects (SDO) setup by the Ethercat Master Device
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Mailbox Execution time
SDO Execution Time ASCII Execution Time Sending multiple commands to a single drive: Only one command can be sent at a time. The time to execute multiple commands is: Number of commands x Execution time of a single command Commands sent to different AKD drives at the same time the requests do not interfere with each other. You can be confident the function finishes execution in the same max time as to one drive 250 microsecond Update 1000 microsecond Update Mean 9 milliseconds Min 3 milliseconds MAx 16 milliseconds 250 microsecond Update 1000 microsecond Update Mean 20 milliseconds 11 milliseconds Min 15 milliseconds 9 milliseconds MAx 45 milliseconds 58 milliseconds
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PDO Defaults (with AKD)
Setup in IDE
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PDO / Link to Application Project Variables
Easy connection to Project Variable
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PDO / Mapping Default settings – good for most applications
PDO mapping can be change to meet particular Application Needs
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PDO – Fixed and User definable
PDO Editor tab allows changing Objects (Drive parameters) associated with each PDO PDO mapping When free mapping PDO , turn off the PDOs you don’t intend to use. Individual PDOs limited to 8 bytes. Some masters only will map one TX-PDO and one RX-PDO.
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PDO Mappables To meet individual Application needs , Additional PDO mappings can be selected in the PDO Selection/Mapping tab
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PDO / Drive parameter/ KAS FB Cross Reference
Ethercat Object From Controller to Drive
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PDO / Drive parameter/ KAS FB Cross Reference
From Drive to Controller
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Network Startup (COE Init)
Sent by the PDMM/PCMM to the AKD or S700 during ECAT network startup Used to configure the drive for ECAT communications. Can in parameters to set up: opmode, high speed capture engine, network synchronization, Units scaling, Enable/Disable coordination with tthe controller, and others Use the Add and Edit buttons to make changes to this list
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Communication in KAS Program
Ethercat Specific Function Blocks Mailbox Communication Provides access to drive parameters not included in the ML and MC motion libraries Examples: Tuning parameter Limit parameter Opmode change Use in all IEC Languages: ST, FFLD,FBD, and IL languages
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Communication in KAS Program
Function Block Support for Drive/Motor Control Enable/Disable Drive Make Motion Get Motion Status Other Contain in these sections of the Function Block Library
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Communication in KAS Program
Mailbox Communications: DriveParamRead and DriveParamWrite FB Enter parameter name directly : KL.KP
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number associated with a drive Parameter
Drive Object Numbers Determining Object number associated with a drive Parameter 16#3480
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MailBox Communications
ECATReadSDO and ECATReadSDO Enter object number, size (bytes), and sub index number
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KAS System - AKD Opmode support
Position (Default) - Good for most applications Object 6060 = 7 (Interpolated position mode) Velocity (configure through Mailbox object 6060 or Special Map PDO) Object 6060 = 3 (Profile velocity mode) Torque Object 6060 = 4 (Profile torque mode)
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Adding Non Kollmorgen Ethercat Devices
Possible Products Safety Module Slice IO Gateway to other network Invertor Drive
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Adding Non Kollmorgen Ethercat Devices
ESI File Also called Ethercat XML Device Description Available from Vendor Defines what PDO objects the Device and standard mappings Required by the Master to setup ECAT Network
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Adding Non Kollmorgen Ethercat Devices
Procedure Locate the device’s ESI file Add to the Project’s listing of ESI files Determine parameters to be send through Ethercat To/from KAS controller Set up PDO mapping Set up COE- Init (if needed)
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