ABB MotiFlex e180 Application Manual
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ABB MotiFlex e180 Application Manual

Ethercat
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Summary of Contents for ABB MotiFlex e180

  • Page 1 ABB motion control Application guide MotiFlex e180 EtherCAT...

  • Page 2: List Of Related Manuals

    MotiFlex e180 Quick Installation Guide 3AXD50000017336 MotiFlex e180 User’s Manual 3AXD50000019946 MotiFlex e180 Wall chart 3AXD50000019945 MotiFlex e180 Common DC Application Guide 3AXD50000019947 MotiFlex e180 CE Declaration of Conformity 3AXD10000371048 MotiFlex e180 STO Certificate 3AXD10000391362 You can find manuals and other product documents in PDF format on the Internet. See section Document library on the Internet on the inside of the back cover.
  • Page 3 Application guide MotiFlex e180 EtherCAT Table of contents 1. Safety 4. Mechanical installation 6. Electrical installation: AC input, motor and brake 4. Start-up  2017 ABB UK. 3AXD50000048672 Rev B All Rights Reserved. EFFECTIVE: 2017-01-30...

  • Page 5: Table Of Contents

    Connect the MotiFlex e180 to the PC ........
  • Page 6 Providing feedback on ABB Drives manuals ........

  • Page 7: Safety

    Safety 7 Safety What this chapter contains This chapter contains the safety instructions which you must obey when installing, operating and servicing the drive. If ignored, physical injury or death may follow, or damage may occur to the drive, motor or driven equipment. Read the safety instructions before you work on the unit.

  • Page 8: Safety In Installation And Maintenance

    8 Safety Safety in installation and maintenance These warnings are intended for all who work on the drive, motor cable or motor.  Electrical safety WARNING! Ignoring the following instructions can cause physical injury or death, or damage to the equipment. •...

  • Page 9: Grounding

    Safety 9 • The DC terminals (UDC+, UDC-) carry a dangerous DC voltage (over 500 V) when internally connected to the intermediate DC circuit. • Depending on the external wiring, dangerous voltages (115 V, 220 V or 230 V) may be present on the terminals of relay outputs (NC, NO, COM). •...

  • Page 10: Permanent Magnet Motor Drives

    10 Safety  Permanent magnet motor drives These are additional warnings concerning permanent magnet motor drives. WARNING! Ignoring the following instructions can cause physical injury or death, increased electromagnetic interference and equipment malfunction: • Do not work on the drive when the permanent magnet motor is rotating. Also, when the supply power is switched off and the inverter is stopped, a rotating permanent magnet motor feeds power to the intermediate circuit of the drive and the supply connections become live.

  • Page 11: General Safety

    Electrically conductive debris inside the unit may cause damage or malfunction. • Ensure sufficient cooling. • Do not attach the drive by riveting or welding. • The MotiFlex e180 must be installed where the pollution degree according to EN61800-5-1 shall not exceed 2.  Printed circuit boards...

  • Page 12: Safe Start-Up And Operation

    • When operating a rotary motor with no load coupled to its shaft, remove the shaft key to prevent it flying out when the shaft rotates. • Operating the MotiFlex e180 in torque mode with no load attached to the motor can cause the motor to accelerate rapidly to excessive speed.

  • Page 13: Network Security

    ABB Motion Ltd and its affiliates are not liable for damages and/or losses related to such security breaches, any unauthorized access,...
  • Page 14 14 Safety...

  • Page 15: Introduction To The Manual

    This chapter describes the manual. Target audience This manual is intended for people who wish to connect the MotiFlex e180 to an EtherCAT network. Basic information about EtherCAT connection can be found in the MotiFlex e180 User’s manual. Read the manual before working on the drive. You are expected to know the fundamentals of electricity, wiring, electrical components and electrical schematic symbols.

  • Page 16: Related Documents

    Beckhoff Automation GmbH, Germany. TwinCAT® is a registered trademark of Beckhoff Automation GmbH. Windows 7 and Windows 8 are registered trademarks of the Microsoft Corporation. Mint™ and MotiFlex® are registered trademarks of Baldor, a member of the ABB group.

  • Page 17: Physical Connection

    The chapter briefly describes how to connect the MotiFlex e180 to an EtherCAT network. Product overview The MotiFlex e180 is an IP20 drive module for controlling AC motors. All models support EtherCAT ‘slave’ operation under the control of an EtherCAT ‘master’ device or application.

  • Page 18: Ethercat Ports

    18 Physical connection EtherCAT ports The E1 and E2 Ethernet ports on the top panel of the MotiFlex e180 are used for Ethernet fieldbus connections such as EtherCAT®. Pin 1 (NC) (NC) (NC) Link (NC) Activity In an EtherCAT network the E1 (IN) port must be connected to the master side of the network.

  • Page 19: E1 / E2: Ethernet Port Configuration

     E1 / E2: Ethernet port configuration The rotary switches are situated on the front panel of the MotiFlex e180. The rotary switches are read once at startup. They select the mode of operation for the Ethernet fieldbus connectors E1 and E2 on the top panel of the drive.
  • Page 20 20 Physical connection...

  • Page 21: Start-Up

    Connect the MotiFlex e180 to the PC Connect a CAT5e or CAT 6 Ethernet cable between the PC and the MotiFlex e180 E3 Ethernet port on the front panel. Do not connect the cable to the E1 or E2 ports on the top of the drive.

  • Page 22: Configure The Pc Ethernet Adapter

    9. Click Close to close the Local Area Connection Status dialogue. Install Mint WorkBench If you do not wish to install Mint WorkBench, the MotiFlex e180’s ESI file can be downloaded using an ordinary web browser; see page 25. The Windows user account requires administrative user rights to install Mint WorkBench.

  • Page 23: Enable The Ethernet Adapter For Mint Workbench

    “MotiFlex e180 on 192.168.0.1”. Note: If the MotiFlex e180 is not listed, check the Ethernet cable is connected to the E3 port on the front panel of the drive, not E1 or E2 on the top panel. Check that the...

  • Page 24: Ethercat Tool

    EtherCAT master, although it must be completed before the MotiFlex e180 can drive a motor. Commissioning can be performed at a later time by reconnecting to the MotiFlex e180 and selecting the Launch Commissioning Wizard check box. Commissioning is described in the MotiFlex e180 User Manual (3AXD50000019946).

  • Page 25: Downloading The Esi File Using A Web Browser

    3. In the Fieldbus description files area, click the link to download the ESI file. If the web browser cannot find the MotiFlex e180 it may be due to your network using an HTTP proxy, causing all requests entered in the browser to be forwarded to the proxy.

  • Page 26: File Access Over Ethercat (Foe)

    26 Start-up File Access over EtherCAT (FoE) The MotiFlex e180 supports file access over EtherCAT (FoE). This is useful if you do not wish to install Mint WorkBench to transfer files. The following file types can be uploaded and downloaded using FoE:...
  • Page 27 Start-up 27 7. Now select the drive by double-clicking its node in the tree (double-click 'Drive 1' if the tabbed window is not displayed). 8. Activate the 'Run' mode.
  • Page 28 28 Start-up 9. Under File Access over EtherCAT, click Upload… to upload one of the firmware components from the drive. 10. In this example, the file name has been customised by adding a '_123' suffix. This is acceptable as a file name, but the prefix must be omitted when entering the string name for the file.

  • Page 29: Downloading A File To The Drive Using Foe In Twincat

    Start-up 29 ®  Downloading a file to the drive using FoE in TwinCAT 1. To download a file (e.g. new firmware) to the drive, access the File Access over EtherCAT options as described in steps 1. to 8. above. 2.

  • Page 30: Writing Object Values

    30 Start-up Writing object values The drive’s object dictionary contains 4 different types of objects: • Constant objects: static values. • Live objects: PDO mapped, cyclically updated, e.g. axis position value. • Configuration objects: SDO device configuration during operation. • Configuration objects valid on reset: most objects, applied only on reset. Most objects are valid on reset because there are cases where related objects must always be written in a particular order.

  • Page 31: Immediate Apply Mode

    Start-up 31  Immediate apply mode It is possible to override the normal behavior for valid on reset objects to allow objects that are linked to parameters (keywords) to be written with immediate effect. This provides improved usability in PLC programs since it allows parameter access via objects.

  • Page 32: Further Configuration

    Using TwinCAT with the MicroFlex e150 describes how to use the Beckhoff® TwinCAT® System Manager to configure a PLC or PC as the EtherCAT master. AN205 EtherCAT Quick Start Guide describes how to use an ABB AC500 PLC as the EtherCAT master. AN220 AC500 and MicroFlex e150 - EtherCAT Homing Methods describes how to use an ABB AC500 PLC to home the drive.

  • Page 33: Fault Tracing

    Problem diagnosis If you have followed all the instructions in this manual in sequence, you should have few problems installing the MotiFlex e180. If you do have a problem, read this section first. • In Mint WorkBench, use the Error Log tool to view recent errors and then check the help file.

  • Page 34: Power-Cycling The Motiflex E180

    Power-cycling the MotiFlex e180 The term ‘power-cycle the MotiFlex e180’ is used in the Troubleshooting sections. Remove the 24 V supply, wait for the MotiFlex e180 to power down completely (the Status LED turns off), then re-apply the 24 V supply.

  • Page 35: Motiflex E180 Indicators

    Fault tracing 35 MotiFlex e180 indicators  EtherCAT® mode The Ethernet LEDs display the overall condition of the Ethernet interface once the startup sequence has completed. The LED codes conform to the EtherCAT Technology Group (ETG) standard at the time of production.

  • Page 36: Led Flash Periods

    36 Fault tracing NET RUN (Green) Off: INITIALISATION state (or not powered). Blinking: PRE-OPERATIONAL state. 1 flash: SAFE-OPERATIONAL state. 3 flashes: Device identification. This state can be set from the master to locate the device. Continuously illuminated, not flashing: Node in OPERATIONAL state. EtherCAT is operating normally.

  • Page 37: Drive Status Display

    Drive status display The drive status display indicates errors and general MotiFlex e180 status information. When an error occurs the drive displays a sequence starting with the symbol E, followed by the five digit error code. For example, error code 10015 is...
  • Page 38 38 Fault tracing Symbol Description Dwell. A dwell (wait) ‘move’ is in progress. See the Mint keyword MOVEDWELL. Flying shear. A flying shear is in progress. See the Mint keyword FLY. Follow move. The drive is in follow mode. See the Mint keyword FOLLOW. Homing.

  • Page 39: Power

    • Check that the 24 V DC control circuit supply is correctly connected at X9, and is switched on. Drive status display shows ‘r’: • The MotiFlex e180 is in firmware recovery mode. This means that it does not boot fully, and allows Mint WorkBench to download firmware from the Choose Firmware dialogue.

  • Page 40: Ethernet

    Configure the PC Ethernet adapter on page 22. How do I configure my EtherCAT manager to operate with the MotiFlex e180? • An EtherCAT ESI file (.xml) that describes the drive to the EtherCAT manager can be uploaded from the controller using the Mint WorkBench EtherCAT tool. See...

  • Page 41: Reference

    Reference 41 Reference What this chapter contains This chapter contains reference information about the MotiFlex e180 EtherCAT implementation.

  • Page 42: Introduction

    Standard Ethernet switches can be used in EtherCAT networks. The MotiFlex e180 has passed the formal EtherCAT conformance test, which is performed using a network with a wide range of EtherCAT devices. It has also been tested with many different types of master device to ensure interoperability, including: •...

  • Page 43: Setting The Control Reference Source

    Reference 43 SM (SyncManager) synchronisation • SM synchronisation can be used for all applications with less critical timing requirements. Any network topology is converted into a daisy chain structure, so even a star topology is logically a chain. This creates a network where the hop delay is equal to the number of nodes * 500 ns.

  • Page 44: Nmt State Machine

    44 Reference NMT state machine The MotiFlex e180’s operating states/modes are defined by an NMT state machine based upon that used by CANopen. The state machine is important because it defines the behavior of the valid on reset objects (see Object dictionary on page 46).
  • Page 45 Reference 45 (NMT_GT1) PowerOn NMT_GS_POWERED (NMT_GT2) Reset NMT_GS_INITIALISATION (NMT_GT8) NMT_SwReset NMT_GS_INITIALISING (NMT_GT10) auto (NMT_GT4) NMT_ResetNode NMT_GS_RESET_APPLICATION (NMT GT13) EtherCAT * to INIT (NMT_GT11) auto (NMT_GT5) NMT_ResetCommunication NMT_GS_RESET_COMMUNICATION (NMT_GT6) Internal Communication error (NMT_GT12) auto (NMT_GT7) NMT_ResetConfiguration NMT_GS_RESET_CONFIGURATION NMT_GS_COMMUNICATING (NMT_GT14) Auto [Error] NMT_GS_CONFIGURATION_ERROR (NMT_CT1) Auto...

  • Page 46: Object Dictionary

    46 Reference Object dictionary The object dictionary contains 4 different types of objects: Constant objects Constant object contain the same value during their entire life time, for example the manufacturer device name object (1008h). The value is set once during firmware boot-up and does not change.
  • Page 47 Reference 47 *The SM threshold increments by 8 for every error and decrements by 1 for every successful operation. The threshold value is 15 to guarantee that 2 consecutive errors trigger the error. Error detection If the drive is in error then the fault bit (bit 3) will be set in the status word object 0x6041.

  • Page 48: Object 4144H: First Error

    48 Reference DS 402 DS 402 description Equivalent Mint/MML description error Mint/MML code error code 0xFF0C Manufacturer specific error 20004 Encoder battery low (warning) 0xFF0D Manufacturer specific error 10040 Hiperface DSL encoder error 0xFF0E Manufacturer specific error 10041 Output frequency over limit 0xFF0F Manufacturer specific error 20005...

  • Page 49: Object Dictionaries

    1000h 0 NMT_DeviceType_U32 UINT32 CONST No 131474 1001h 0 ERR_ErrorRegister_U8 UINT8 Poss. 1008h 0 NMT_ManufactDevName_VS STRING CONST No MotiFlex e180 1009h 0 NMT_ManufactHwVers_VS STRING CONST No 100Ah 0 NMT_ManufactSwVers_VS STRING CONST No MotiFlex e180 Build 581.3.0 (mCard) 1010h 0 NMT_StoreParam_REC UINT8 NMT_StoreParam_REC.AllParam_U32...
  • Page 50 50 Reference Index Sub- Object Name Type Attr. Content ind. mapping example 1A00h 0 ARRAY PDO_TransmitMapping_0_AU32 UINT8 PDO_TransmitMapping_0_AU32[1] UINT32 1614872592 PDO_TransmitMapping_0_AU32[254] UINT32 1C00h 0 ARRAY SM_CommunicationType_AU8 UINT8 SM_CommunicationType_AU8 SM_CommunicationType_AU8 SM_CommunicationType_AU8 SM_CommunicationType_AU8 SM_CommunicationType_AU8 SM_CommunicationType_AU8 SM_CommunicationType_AU8 SM_CommunicationType_AU8 1C12h 0 ARRAY SM_PDOAssignment_2_AU16 UINT8 SM_PDOAssignment_2_AU16[1] UINT16 SM_PDOAssignment_2_AU16[16]...
  • Page 51 Reference 51 and appears on the network as “save”. 1011h must be written with 0x64616F6C which results in “load” on the bus. 10F3h: The diagnosis history is a mapping of the Mint WorkBench error log into objects. 1600h, 1A00h: Two large PDOs are used, as for Powerlink. If the device is simpler then it makes sense to have more PDOs and switch them based on machine demands.

  • Page 52: Manufacturer Specific Objects

    52 Reference  Manufacturer specific objects The following table lists the common manufacturer specific objects applicable to MotiFlex e180 on EtherCAT and Ethernet POWERLINK: Index Sub- Obj. Name Type Attr. Units Description ind. Mapping 2000h Comms array UINT8 Number of comms array elements...
  • Page 53 Reference 53 Index Sub- Obj. Name Type Attr. PDO Units Description ind. Mapp 4001h 0 Output active level UINT8 Output active levels Output active levels - bank 0 UINT32 RW No Maps to OUTPUTACTIVELEVEL 4003h 0 Input mode UINT8 Input mode (edge / level triggering) Input mode - bank 0 UINT32 RW No Maps to INPUTMODE...
  • Page 54 54 Reference Index Sub- Obj. Name Type Attr. PDO Units Description ind. Mapp 400Fh 0 ARR Latch UINT8 Number of latch channels Channel 0 (Main encoder) INT32 user Maps to LATCH(0) units Channel 1 (Step & Dir. inputs) user Maps to LATCH(1) units Channel 2 (Master incremental user...
  • Page 55 Reference 55 Index Sub- Obj. Name Type Attr. PDO Units Description ind. Mapp 4017h 0 ARR Latch trigger edge UINT8 Number of latch channels Latch channel 0 INT16 RW No Maps to LATCHTRIGGEREDGE(0) Latch channel 1 RW No Maps to LATCHTRIGGEREDGE(1) Latch channel 2 RW No Maps to LATCHTRIGGEREDGE(2)
  • Page 56 56 Reference Index Sub- Obj. Name Type Attr. PDO Units Description ind. Mapp 4028h 0 ARR Analog input dead band hysteresis UINT8 Number of analog inputs Channel 0 INT16 RW No Maps to ADCDEADBANDHYSTERESIS(0) Channel 1 RW No Maps to ADCDEADBANDHYSTERESIS(1) 4029h 0 ARR Analog input dead band offset...
  • Page 57 Reference 57 Index Sub- Obj. Name Type Attr. PDO Units Description ind. Mapp 403Dh 0 ARR ENC_AbsEncoderSinGain_AI16 ARRAY RO Number of encoder inputs Channel 0 (Main encoder) INT16 RW No 0.01% Maps to ABSENCODERSINGAIN(0) Channel 1 (Step & Direction inputs) RW No 0.01% Maps to ABSENCODERSINGAIN(1) Channel 2 (Extra / master...
  • Page 58 58 Reference Index Sub- Obj. Name Type Attr. PDO Units Description ind. Mapp 4045h 0 ARR ENC_EncParamEnDat2_2Cmd_AI ARRAY RO Number of encoder inputs Channel 0 (Main encoder) INT32 RW No Maps to ENCODERPARAMETER(0,5) Channel 1 (Step & Dir. inputs) RW No Maps to ENCODERPARAMETER(1,5) Channel 2 (Extra / master...
  • Page 59 RW No (Not required) encoder) 4064h 0 ARR ENC_EncParamFaultRegister_AI3 ARRAY RO Encoder parameter: fault register (for MotiFlex e180 options FB-03 & FB- Channel 0 (Main encoder) INT32 Maps to ENCODERPARAMETER(0,10) Channel 1 (Step & Direction inputs) (Not required) Channel 2 (Master incremental...
  • Page 60 60 Reference Index Sub- Obj. Name Type Attr. PDO Units Description ind. Mapp 4067h 0 ARR ENC_AbsEncoderCosOffset_AI16 ARRAY RO Encoder scale Channel 0 (Main encoder) INT16 RW No Maps to ABSENCODERCOSOFFSET(0) Channel 1 (Step & Direction inputs) RW No (Not required) Channel 2 (Master incremental RW No (Not required)
  • Page 61 Reference 61 Index Sub- Obj. Name Type Attr. PDO Units Description ind. Mapp 412Eh 0 CIP_EipEnabled_BOOL BOOL RW No Internal 412Fh 0 ARR CIP_AssemblyInstance_AU8 ARRAY RO Internal AssemblyInstance_U8 UINT8 Internal AssemblyInstance_U8 Internal 4130h 0 ARR CIP_Assembly_0h_AU32 ARRAY RW No Internal EPath_U32 UINT32 RW No Internal...
  • Page 62 62 Reference Index Sub- Obj. Name Type Attr. PDO Units Description ind. Mapp 4151h 0 ARR MTC_ServerAddress_AIPAD ARRAY RO Internal MTC_ServerAddress_AIPAD[1] UINT32 RW No Internal MTC_ServerAddress_AIPAD[2] RW No Internal MTC_ServerAddress_AIPAD[3] RW No Internal MTC_ServerAddress_AIPAD[4] RW No Internal MTC_ServerAddress_AIPAD[5] RW No Internal MTC_ServerAddress_AIPAD[6] RW No...
  • Page 63 Reference 63 Index Sub- Obj. Name Type Attr. PDO Units Description ind. Mapp 4155h 0 ARR MTC_ServerTimeout_AU32 ARRAY RO Internal MTC_ServerTimeout_AU32[1] UINT32 RW No Internal MTC_ServerTimeout_AU32[2] RW No Internal MTC_ServerTimeout_AU32[3] RW No Internal MTC_ServerTimeout_AU32[4] RW No Internal MTC_ServerTimeout_AU32[5] RW No Internal MTC_ServerTimeout_AU32[6] RW No...
  • Page 64 64 Reference Index Sub- Obj. Name Type Attr. PDO Units Description ind. Mapp 4D00h 0 REC NIC_NatTable_00h_REC Internal NIC_NatTable_00h_REC.GenAddr UINT32 RW No Internal ess_IPV4 NIC_NatTable_00h_REC.RteAddr UINT32 RW No Internal ess_IPV4 NIC_NatTable_00h_REC.Mask_IP UINT32 RW No Internal NIC_NatTable_00h_REC.Valid_BO BOOL RW No Internal 4D01h 0 REC NIC_NatTable_01h_REC Internal...
  • Page 65 Reference 65 Index Sub- Obj. Name Type Attr. PDO Units Description ind. Mapp 500Bh 0 REC AX0_TorqueFilter_1_REC Number of torque filter 1 parameters TorqueFilterType_I16 INT16 RW No Maps to TORQUEFILTERTYPE(0, 1) TorqueFilterFreq_U16 UINT16 RW No Maps to TORQUEFILTERFREQ(0, 1) TorqueFilterBand_U16 UINT16 RW No Maps to TORQUEFILTERBAND(0, 1) TorqueFilterDepth_U16...
  • Page 66 66 Reference Index Sub- Obj. Name Type Attr. PDO Units Description ind. Mapp 502Ch 0 REC AX0_ComparePos_AI32 ARRAY RO Number of position compare channels ComparePos_Channel0_I32 INT32 RW No Maps to COMPAREPOS(0, 0) units ComparePos_Channel1_I32 RW No Maps to COMPAREPOS(0, 1) units 502Eh 0 AX0_ControlModeStartup_U16...
  • Page 67 Reference 67 Index Sub- Obj. Name Type Attr. PDO Units Description ind. Mapp 5201h 0 REC AX1_ControlRate_REC Control loop frequencies ProfilerRate_I32 INT32 RW No Maps to CONTROLRATE(1,0) PositionLoopRate_I32 RW No Maps to CONTROLRATE(1,1) VelocityLoopRate_I32 RW No Maps to CONTROLRATE(1,2) 5203h 0 AX1_AxisPosEncoder_I16 INT16 RW No...
  • Page 68 68 Reference Index Sub- Obj. Name Type Attr. PDO Units Description ind. Mapp 60B9h 0 VAR AX0_TouchProbeStatus_U16 UINT16 RO Poss. - Internal 60BAh 0 VAR AX0_TouchProbePositionPos1_I INT32 Poss. - Internal 60BBh 0 VAR AX0_TouchProbePositionNeg1_I INT32 Poss. - Internal 60BCh 0 VAR AX0_TouchProbePositionPos2_I INT32 Poss.
  • Page 69 Reference 69 Index Sub- Obj. Name Type Attr. PDO Units Description ind. Mapp 6410h 0 REC AX0_MotorParameters_REC Number of motor parameters MotorLinearPolePitch_R32 UINT32 RW No µm Maps to MOTORLINEARPOLEPITCH MotorPoles_I16 INT16 RW No Maps to MOTORPOLES MotorFlux_U32 UINT32 RW No µWb Maps to MOTORFLUX MotorPeakCurrent_U32...
  • Page 70 70 Reference...

  • Page 71: Product And Service Inquiries

    Product and service inquiries Address any inquiries about the product to your local ABB representative, quoting the type designation and serial number of the unit in question. A listing of ABB sales, support and service contacts can be found by navigating to www.abb.com/searchchcannels.
  • Page 72 Contact us www.abb.com/motion www.abb.com/drives www.abb.com/drivespartners www.abb.com/PLC 3AXD50000048672 REV B (EN) EFFECTIVE: 2017-01-30...

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