AMKAMAC Product description Controller A-Series

Transcription

1 AMKAMAC Product description Controller A-Series Version: Part no.: 2013/ Translation of the "Original Beschreibung"

2 Notes on This Document Name: PDK_202975_A4-A5_Produktbeschreibung_en Version: Version Changes Initials 2013/04 New chapter: USB stick how to deactivate an active partition New chapter: Mating plug X41 (for Profibus) KoJ Previous version: 2012/45 Products version: Copyright notice: Reservation: Publisher: Product Firmware version (AMK part-no.) A4S-xxx A4 V /28 (204195) 1.00 A4D-xxx-07T 1.00 A5S-XXX A5 V /13 (204071) 1.04 A5D-XXX-07T 1.06 A5D-XXX-09T 1.06 A5D-XXX-12T 1.06 A5D-XXX-15T 1.01 AMK Arnold Müller GmbH & Co. KG Hardware version (AMK part-no.) Any transfer or reproduction of this document, as well as utilisation or communication of its contents, requires express consent. Offenders are liable for the payment of damages. All rights are reserved in the event of the grant of a patent or the registration of a utility model or design. We reserve the right to modify the content of the documentation as well as the delivery options for the product. AMK Arnold Müller GmbH & Co. KG Gaußstraße D Kirchheim/Teck Germany Phone: 0049/(0)7021/ Fax: 0049/(0)7021/ info@amk-antriebe.de Managing director: Dr.h.c. Arnold Müller, Eberhard A. Müller, Dr. Günther Vogt Registration court: Stuttgart HRB ; HRA Service: Phone: 0049/(0)7021/ , Fax -193 Internet address: Office hours: Mon. - Thu. Fri. Sat., Sun. and holidays 7:30 am - 12:00 pm and 1:00 pm - 4:30 pm 7:30 am - 12:00 pm and 1:00 pm - 3:30 pm Please leave your contact data on the answering phone, which is monitored regularly between 9:00 am and 5:00 pm. Our service will call you back as soon as possible. For fast and reliable troubleshooting, you can help us by informing our Customer Service about the following: Type plate data for each unit Software version Device configuration and application Type of fault/problem and suspected cause Diagnostic messages (error messages) service@amk-antriebe.de 2 / 91 PDK_202975_A4-A5_Produktbeschreibung_en / Version 2013/04

3 Appendant Documents Name PDK_ PDK_ PDK_ PDK_ PDK_ Titel AMK Diagnostic Messages AIPEX PRO software description (PC software for startup and parameter setting) Parameter description Software Qt-Visualisation Software ATF - AMK Tool Flasher (PC software for firmware update) Display Conventions Representation Meaning This text passage requires your undivided attention! 0x 'Names' 'Parameter' 'Diagnostic messages' 'xxx' 0x followed by a hexadecimal number, e.g. 0x500A E.g.: Call up the 'PLC clear program' function. ID1234 'Parameter text' 1234 'Diagnostic message' Menu items and buttons in software or a control unit, e.g.: Click the 'OK'' button in the 'Options' menu to call up the 'PLC clear program' function >xxx< Wildcard, variable e.g. IP address of the controller: > < -> Process of an input / operating sequence, e. g. 'Start' -> 'All Programmes' -> 'Accessories' -> 'Editor' See 'Chapter' on page x Link inside the PDF document PDK_202975_A4-A5_Produktbeschreibung_en / Version 2013/04 3 / 91

4 Content 1 For Your Safety Configuration of Safety Informations Classes of Hazard Used Safety Symbols Prerequisite for Safe Operation with the Drive System Intended Use CE Mark Requirements for the Personnel and Their Qualification Safety Rules Warranty 8 2 Product Overview Scope of Delivery Product Description Ordering Data Prerequisites minimum Model Identification Technical Data Climatic Conditions Climatic Conditions During Operation Climatic Conditions During Storage Climatic Conditions During Transport Side View (Interfaces) A4S- / A5S-M00 and A4D- / A5D-M A4S- / A5S-M0E and A4D- / A5D-M0E A4S- / A5S-MC0, A4S-GC0 and A4D- / A5D-MC A4S- / A5S-MCE and A4D- / A5D-MCE Dimensional Drawings A4S- / A5S-xxx A4D- / A5D-xxx-07T A5D-xxx-09T A5D-xxx-12T A5D-xxx-15T Application Examples Drive Communication Cross-Communication A4S-GC0 Gateway 26 3 Transport and Assembly Avoiding Material Damage Installation Location and Position 27 4 Electrical Connections Avoiding Material Damage EMC Information Switch Cabinet Construction Cable Shielding Earthing Cable Fixation and Strain Relief with Shielding Clamps X01 Supply X20 Ethernet X22 USB Host X41 Profibus DP Slave [Controller Variants A5S/D-xCx] X60 Ethernet [Controller Variants A4x/A5x-xCx] 33 4 / 91 PDK_202975_A4-A5_Produktbeschreibung_en / Version 2013/04

5 4.9 X85/X86 Real-Time Ethernet [Controller Variants A4x/A5x-xCx] X120 Analogue Inputs and Square-Wave Signal Input [Controller Variants A4x/A5x-xxE] X121 Binary Inputs [Controller Variants A4x/A5x-xxE] X122 Binary Outputs and Probe Inputs [Controller Variants A4x/A5x-xxE] X137 ACC Bus Master X185 Real-Time Ethernet Master 2 [Controller Variants A4x/A5x-xCx] X186 Real-Time Ethernet Master X235 USB Device 41 5 Functionality PLC Programming Information about the data exchange between A4 and A5 controllers (different memory alignment) PLC Projects (application programs) from A5 Used on A4 Controllers Programming Under PLCopen Web Visualisation Qt Visualisation A4 CoDeSys Target-Visualization A4S-GC0 Gateway Parameterisation Status LEDs H0 and H Ethernet (Connection X20) Configuration USB Host (Connection X22) External USB to Serial RS232/RS485 Converters ProfibusDP Slave Option (Connection X41) Characteristics Parameterisation Adjustment PB-Master Ethernet (Option C, Connection X60) Parameterisation EtherCAT Slave (Connection X85/X86) Configuration Cross-Communication ACC Bus Master (Connection X137) Configuring Cyclic Data Parameterisation EtherCAT Master (Connection X186) Configuring Cyclic Data Configuration USB Device (Connection X235) --> In Preparation! Parameterisation I/O Expansion [Option E] (Connections X120, X121, X122) Parameterisation Probe Inputs Timestamp Outputs Analogue Inputs Square-Wave Signal Input Indexlist I/O-Option Device Type Structure Device Data Service Data Configuration and Process Data Initial Program Loading Data Exchange via File Transfer Protocol FTP Example: FTP Connection with Microsoft Internet Explorer 72 PDK_202975_A4-A5_Produktbeschreibung_en / Version 2013/04 5 / 91

6 5.20 Time Synchronisation Dimming of Backlight UPS 74 6 Startup For Your Safety Avoiding Material Damage Prerequisites Establishing Connection Between Controller and PC Connection via USB Device X Connection via Ethernet Interface X Changing the IP Address A4D / A5D Startup with a Keyboard 78 7 Maintenance 82 8 Service Diagnosis Transferring Firmware Into the Controller AS-C conversion to A5 controller CoDeSys controller configuration PLC programme AIPEX PRO messages configuration Transmission USB stick how to deactivate an active partition AMK Service: Updating Firmware via FTP 87 9 Accessories and Options Options Software Mating Plug X Mating Plug X Counter-Connector Single-Conductor Technology for X121, X122 [Controller Variant Axx-xxE-xxxx] Counter-Connector Triple-Conductor Technology for X121, X122 [Controller Variant Axx-xxE-xxxx] Ethernet / EtherCAT Cable ACC Bus Cable USB Cable Shielding Clamp Decommissioning and Disposal Preparing the Disassembly Disposal 90 6 / 91 PDK_202975_A4-A5_Produktbeschreibung_en / Version 2013/04

7 1 For Your Safety 1.1 Configuration of Safety Informations Any safety information is configured as follows: SIGNAL WORD Type and source of risk Consequence(s) of non-observance Steps to prevent: Classes of Hazard Safety and warning messages are graduated into classes of hazard (according to ANSI Z535). The class of hazard defines the risk if the safety message is not heeded and is defined by the signal word. The signal word is followed by a safety alert symbol (ISO 3864, DIN ). In accordance with ANSI Z535, the following signal words are used to define the class of hazard. Safety alert symbol and signal word DANGER WARNING CAUTION NOTICE Class of hazard and its meaning DANGER indicates a hazardous situation which, if not avoided, will result in death or serious injury WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury CAUTION, used with the safety alert symbol, indicates a hazardous situation which, if not avoided, could result in minor or moderate injury NOTICE is used to address preventions to avoid material damage, but not related to personal injury. 1.3 Used Safety Symbols Safety symbol Meaning Warning of a danger! Warning against dangerous electrical voltage! 1.4 Prerequisite for Safe Operation with the Drive System The electricity, mechanical movements and high temperatures in electrical drive systems present hazards that can result in fatal injuries and material damage. These hazards are present while starting up and operating the unit, and also during servicing or maintenance work. Personnel must have read and understood the safety instructions before installing and operating the unit. In the documentation included with the product, the usage warnings pertain to direct hazards and must therefore be followed directly when operating or handling the unit by the operator. Compliance with all of the instructions given in the documentation included with the product will ensure safe and faultfree operation of the unit and is a prerequisite for asserting guarantee claims. AMK Arnold Müller GmbH & Co. KG shall not be held liable for any damages ensuing from using the unit in a manner contrary to the intended use, from faulty installation or from using the unit beyond the specified operating characteristics and conditions. Do not start the system in which the AMK products are installed (begin of intended use) until you can determine that all relevant standards, laws and directives have been complied with. PDK_202975_A4-A5_Produktbeschreibung_en / Version 2013/04 7 / 91

8 1.5 Intended Use All devices in the A4 and A5 controller lines have to be securely installed in a closed dry control cabinet. The controllers are used for controlling the AMK converter for regulating the AMK servo motors. Only components certified by AMK for use with the controllers may be connected to the data lines or otherwise fieldbuses. The manufacturer / operator of the system is liable for any damage resulting from improper use. 1.6 CE Mark AMK products have been constructed using state-of-the-art technology and are safe to operate. AMK issues an EC declaration of conformity in which the standards and guidelines relevant for the product are listed, for each of its products and designates the products with the CE mark. The CE mark signifies conformity to the standards. Prior to starting up a machine in which the AMK products have been installed, the machine manufacturer has to ensure that the currently valid EC machinery directive and all other regulations, laws, standards and guidelines relevant for the machine are observed. 1.7 Requirements for the Personnel and Their Qualification Only authorised and qualified personnel may work on and with the AMK drive systems. Specialised personnel must: Perform mechanical and electrical work that is described in this documentation, such as mounting and connecting Observe all information in the documentation accompanying the product in order to work with the product safely and in an error-free manner Understand and know hazards that occur when handling the product Know connections and functions of the system Be familiar with the control concept in order to operate the Be authorised to switch circuits and devices on and off, earth and label them Observe local specific safety requirements 1.8 Safety Rules In particular on drive systems, the instructions pertaining to safety and the following five safety rules have to be kept in the specified sequence: 1. Switch off electrical circuits (also electronic and auxiliary circuits). 2. Secure against being switched on again. 3. Determine that there is no voltage. 4. Earth and short circuit. 5. Cover or close off neighbouring parts that are under voltage. Reverse the measures taken in reverse order after completing the work. 1.9 Warranty All information in the documents accompanying the product must be complied with for a safe and trouble-free operation. The assertion of warranty claims is excluded if the information in the documents is not observed completely. Hardware and firmware may not be modified except by personnel authorised by AMK and after consultation with AMK. The company AMK Arnold Müller GmbH & Co.KG is not liable for damages from improper use, incorrect installation or operation, exceeding rated values and non-observance with the environmental conditions. 8 / 91 PDK_202975_A4-A5_Produktbeschreibung_en / Version 2013/04

9 2 Product Overview 2.1 Scope of Delivery Controller with loaded firmware Counter-connector for connection X01 supply Check the delivery with the specifications on the delivery note. 2.2 Product Description The controller series A4 and A5 combine high functionality, connectivity and flexibility with extreme compactness. A compact switch cabinet installation casing contains all features and interfaces necessary for highly complex applications in order to designate the controller as an "all-in-one platform". CoDeSys PLC with AMK motion control libraries Real-time Ethernet field buses as master and slave Optional PLCopen - functionality Optional integrated I/O component with functions such as: Fast I/O (real-time) Pulse encoder input Analogue inputs Display variants with different diagonals, based on the same controller component expand the flexibility of this platform. Diagonal Dimensions W x H [mm] Display Format Resolution 17,8 cm / 7" 152,4 x 91,44 16:9 WVGA 800 x ,7 cm / 9" 195 x :9 WVGA 800 x ,5 cm / 12" 246 x 184,5 4:3 SVGA 800 x ,1 cm / 15" 304,1 x 228,1 4:3 XVGA 1024 x 768 The integrated PLC of the A4 and A5 controller series can be programmed according to the IEC norm. The supplied AMK libraries according to IEC include numerous pre-programmed motion control functions. PLC programs communicate with AMKASYN converter, other controllers, HMI terminals, central computers and external I/O components via the communications interfaces. Visualisations can be created in the CoDeSys programming system or by use of the development environment AMK Qt Visualisation. Visualisation objects out of CoDeSys are downloaded into the control system in XML format (XML description). A web server converts the control data into XML format there too and makes the continually updated visualization available. This is guilty for all A5 controllers and additional for A4 controllers with enabled Web-Visualization. The A4 controller works with the CoDeSys target visualization. Visualisation based on AMK Qt Visualisation exist in binary format. Qt Visualisation supports USB webcams with 'uvcvideo' driver. Great emphasis has been placed on synchronized communication between several controllers as well as between controller and AMKASYN converter. The controller's real-time operating system in conjunction with the real-time Ethernet buses (RT Ethernet) or otherwise the ACC bus provide a synchronised data exchange with drive groups and other controllers at a maximum jitter of under 1µs. The controller communicates with the drives by EtherCAT via the Profile SoE (servo drive profile over EtherCAT) and/or the ACC bus. The ACC bus (ACC: AMK CAN COMMUNICATION) is a standard 2.0B CAN bus connection, which features an additional hardware synchronisation. It supports the CANopen protocol DS301 V4.01. A4 controllers: Minimum cycle time (ID2 'SERCOS cycle time') for all bus systems is 1 ms. A5 controllers: Minimum cycle time (ID2 'SERCOS cycle time') for the real-time task in the CoDeSys programming software "fast task" and EtherCAT bus is 0.5 ms, for other bus systems and I/O option is 1 ms. PDK_202975_A4-A5_Produktbeschreibung_en / Version 2013/04 9 / 91

10 2.3 Ordering Data A4 controllers A5 controllers Product name Order number Product name Order number A4S-M00 E901 A5S-M00 E893 A4S-MC0 E902 A5S-MC0 E894 A4S-M0E E903 A5S-M0E E895 A4S-MCE E904 A5S-MCE E896 A4S-GC0 E1070 A5D-M00-07T E897 A4D-M00-07T E905 A5D-MC0-07T E898 A4D-MC0-07T E906 A5D-M0E-07T E899 A4D-M0E-07T E907 A5D-MCE-07T E900 A4D-MCE-07T E908 A5D-M00-09T E963 A5 controllers IP69K Product name A5D-M00-15P A5D-MC0-15P A5D-M0E-15P A5D-MCE-15P Order number A5D-MC0-09T A5D-M0E-09T A5D-MCE-09T A5D-M00-12T A5D-MC0-12T A5D-M0E-12T A5D-MCE-12T A5D-M00-15T E964 E965 E966 E967 E968 E969 E970 E971 A5D-MC0-15T E972 A5D-M0E-15T E973 A5D-MCE-15T E Prerequisites minimum A4 controllers AIPEX PRO Version /43 (AMK part no.: ) with Service Pack 4 A5 controllers AIPEX PRO Version /43 (AMK part no.: ) 2.5 Model Identification A x x - x x x - xx x x Meaning Power class 4, processor: ARM MHz Power class 5, processor: ATOM 1,1GHz D Devices with display, touch panel and / or keyboard S Switch cabinet device N NC & PLC M Motion control & PLC G Gateway control unit (without PLC) only for A4 devices P Operator control unit (without PLC) only for A4 devices No slave communication C Slave communication (-> options), additional 2nd Ethernet interface 10 / 91 PDK_202975_A4-A5_Produktbeschreibung_en / Version 2013/04

11 A x x - x x x - xx x x Meaning No I/Os E I/Os (binary inputs, binary outputs, pulse encoder input and analogue inputs) No display " Display wide screen " Display wide screen " Display " Display K - Keyboard T - Touch panel S - Special features - customised x Number of the customised version 2.6 Technical Data A4 controllers CPU velocity Operating system A4S-M00 A4D-M00-07T A4S-MC0 A4D-MC0-07T A4S-M0E A4D-M0E-07T 532 MHz Linux with RT preemption patch A4S-MCE A4D-MCE-07T User flash memory 128 Mbyte (for visualization and user files and PLC program) - of that PLC program memory PLC data memory (RAM) Buffer (retain memory) Standard interfaces X60: 2nd Ethernet 10/100 Mbit/s X22: USB host (USB memory, keyboard) X235: USB device (AIPEX PRO) X20: Ethernet 10/100 Mbit/s Real-time Ethernet master: X186: EtherCAT (SoE) [option A-MEC] AS4-GC0 16 Mbyte - 16 Mbyte kbyte - X137: CAN/ACC (CANopen+hardware synchronisation) [option A-MEC] - Yes - Yes Yes Optional interfaces: X85/X86: Realtime Ethernet slave X120/X121/X122: inputs and outputs [Controller variant Axx-xxE-xxxx] - EtherCAT SoE [Option A-SEC] - EtherCAT SoE [Option A-SEC] Binary outputs, potential-free, short-circuit safe 10 Binary inputs, potential-free, thereof 2 probe inputs 2 Analogue inputs ±10 V with 10 V-reference voltage output Square pulse input EtherCAT SoE [Option A-SEC] - PDK_202975_A4-A5_Produktbeschreibung_en / Version 2013/04 11 / 91

12 Web server for visualization Supply voltage (DC power supply unit) Reference potential A4S-M00 A4D-M00-07T A4S-MC0 A4D-MC0-07T A4S-M0E A4D-M0E-07T A4S-MCE A4D-MCE-07T AS4-GC0 Option A4-VIS standard with display controllers, optional with cabinet controllers. - Cabinet controllers without display (A4S-xxx): Power consumption [W] 24 VDC ± 15%, waviness max. 5% PE (switching GND potential connected to PE) Weight [kg] Display controllers (A4D-Mxx-07T): Power consumption [W] Weight [kg] RF suppression level according to EN Cooling Protection class as per IEC 144 housing Protection class as per IEC 144 display A Convection IP 20 IP 65 Shock-resistance 15 g for 11 ms as EN Vibration conditions A5 controllers CPU velocity Operating system User flash memory of that PLC program memory PLC data memory (RAM) Buffer (retain memory) A5S-M00 A5D-M00-7/9/12-T 1 g bei Hz as EN A5S-MC0 A5D-MC0-7/9/12-T Standard interfaces X22: USB host (USB memory, keyboard) 1.1 GHz A5S-M0E A5D-M0E-7/9/12-T Linux with RT preemption patch 128 Mbyte (for visualization and user files and PLC program) 16 Mbyte 16 Mbyte 128 kbyte A5S-MCE A5D-MCE-7/9/12-T X60: 2nd Ethernet 10/100 Mbit/s X235: USB device (AIPEX PRO) X20: Ethernet 10/100 Mbit/s Real-time Ethernet master: X186: EtherCAT (SoE) [option A-MEC] X137: CAN/ACC (CANopen+hardware synchronisation) [option A-MEC] - Yes - Yes Optional interfaces: X85/X86: Real-time Ethernet slave - EtherCAT SoE [Option A-SEC] - EtherCAT SoE [Option A-SEC] 12 / 91 PDK_202975_A4-A5_Produktbeschreibung_en / Version 2013/04

13 X120/X121/X122: inputs and outputs [Controller variant AxxxxE-xxxx] Web server for visualization Supply voltage (DC power supply unit) Reference potential A5S-M00 A5D-M00-7/9/12-T Cabinet controllers without display (A5S-Mxx): Power consumption [W] A5S-MC0 A5D-MC0-7/9/12-T A5S-M0E A5D-M0E-7/9/12-T A5S-MCE A5D-MCE-7/9/12-T Binary outputs, potential-free, short-circuit safe, thereof 2 with timestamp 10 Binary inputs, potential-free, thereof 2 probe inputs 2 Analogue inputs ±10 V with 10 V-reference voltage output Square pulse input Option A5-VIS standard with display controllers, optional with cabinet controllers. 24 VDC ± 15%, waviness max. 5% PE (switching GND potential connected to PE) Weight [kg] Display controllers (A5D-Mxx-nnT): Power consumption [W] 07T = 12 09T = 19 12T = 17 15T = 20 Weight [kg] 07T = RF suppression level according to EN Cooling Protection class as per IEC 144 housing Protection class as per IEC 144 display 09T = T = T = T = 14 09T = 22 12T = 20 15T = 23 07T = T = T = T = A Convection IP 20 IP 65 07T = 12 09T = 22 12T = 20 15T = 20 07T = T = T = T = Shock-resistance 15 g for 11 ms as EN Vibration conditions 1 g bei Hz as EN T = 14 09T = 24 12T = 22 15T = 23 07T = T = T = T = Climatic Conditions Climatic Conditions During Operation EN Table 7 type B Weather-protected sites, for instance not fully air-conditioned maintenance and operational rooms up to 2000 metres above sea level. A4 controllers Temperature: +0 C to +50 C air inlet temperature at the bottom of the casing (vertical mounting) Exception : A5x-M00 (-xxx) +0 C to +45 C Relative humidity: 20 % to 85 % No condensation or icing permitted Air pressure: 860 hpa to 1060 hpa PDK_202975_A4-A5_Produktbeschreibung_en / Version 2013/04 13 / 91

14 A5 controllers Temperature: +0 C to +40 C air inlet temperature at the bottom of the casing (vertical mounting) Exception : A5x-M00 (-xxx) +0 C to +45 C Relative humidity: 5 % to 85 % No condensation or icing permitted Air pressure: 860 hpa to 1060 hpa NOTICE Electrical short-circuit due to condensation water! If electrically conductive fluids such a condensed water enters the inverter module, there may be a short circuit, thus leading to damage or even destruction of the module. Do not allow condensation to form in the cabinet. Material Damage! Steps to prevent: The cabinet cooling needs to be designed according to the dew point table so that no condensation water forms. The dew point table specifies at which surface temperature dew water forms depending on the air temperature and the relative humidity. Example: Cabinet temperature: 32 C, humidity: 60 % The temperature of the cooling circuit may not be less than 23 C, otherwise, condensation water will form Climatic Conditions During Storage EN Table 7 type D A4 controllers Temperature: - 25 C to +55 C Relative humidity: 5 % to 95 % No condensation or icing permitted Air pressure: A5 controllers 860 hpa to 1060 hpa Temperature: - 25 C to +55 C Relative humidity: 5 % to 95 % No condensation or icing permitted Air pressure: 860 hpa to 1060 hpa Climatic Conditions During Transport EN Table 7 type E A4 controllers Temperature: - 10 C to +70 C Relative humidity: Air pressure: Up to 95 % A slight bedewing is permitted for a brief time as long as the device is not in operation. Before setting the device in operation it has to be dried completely! 700 hpa to 1060 hpa 14 / 91 PDK_202975_A4-A5_Produktbeschreibung_en / Version 2013/04

15 A5 controllers Temperature: - 25 C to +70 C Relative humidity: Air pressure: Up to 95 % A slight bedewing is permitted for a brief time as long as the device is not in operation. Before setting the device in operation it has to be dried completely! 700 hpa to 1060 hpa 2.8 Side View (Interfaces) A4S- / A5S-M00 and A4D- / A5D-M00 Connection/LED X01 X20 / H3 X22 X137 / H8 X186 / H6 X235 Use Supply Ethernet USB host ACC bus master Real-time Ethernet master USB device PDK_202975_A4-A5_Produktbeschreibung_en / Version 2013/04 15 / 91

16 2.8.2 A4S- / A5S-M0E and A4D- / A5D-M0E Connection/LED X01 X20 / H3 X22 X41 X120 X121 X122 X137 / H8 X186 / H6 X235 Use Supply Ethernet USB host Reserved Analogue inputs and square-wave input Binary inputs Binary outputs and probe inputs ACC bus master Real-time Ethernet master USB device 16 / 91 PDK_202975_A4-A5_Produktbeschreibung_en / Version 2013/04

17 2.8.3 A4S- / A5S-MC0, A4S-GC0 and A4D- / A5D-MC0 Connection/LED Use X01 Supply X20 / H3 Ethernet X22 USB host X41 Profibus DP Slave (Option) X60 / H2 Ethernet (2) X85 / H5 Real-time Ethernet slave X86 / H4 X137 / H8 ACC bus master X185 / H7 Real-time Ethernet master (2) X186 / H6 Real-time Ethernet master X235 USB device PDK_202975_A4-A5_Produktbeschreibung_en / Version 2013/04 17 / 91

18 2.8.4 A4S- / A5S-MCE and A4D- / A5D-MCE Connection/LED Use X01 Supply X20 / H3 Ethernet X22 USB host X41 Profibus DP Slave (Option) X60 / H2 Ethernet (2) X85 / H5 Real-time Ethernet slave X86 / H4 X120 Analogue inputs and square-wave input X121 Binary inputs X122 Binary outputs and probe inputs X137 / H8 ACC bus master X185 / H7 Real-time Ethernet master (2) X186 / H6 Real-time Ethernet master X235 USB device 18 / 91 PDK_202975_A4-A5_Produktbeschreibung_en / Version 2013/04

19 2.9 Dimensional Drawings A4S- / A5S-xxx Front and side view Top view PDK_202975_A4-A5_Produktbeschreibung_en / Version 2013/04 19 / 91

20 2.9.2 A4D- / A5D-xxx-07T Front view View from the bottom Side view 20 / 91 PDK_202975_A4-A5_Produktbeschreibung_en / Version 2013/04

21 2.9.3 A5D-xxx-09T Front view View from the bottom Side view PDK_202975_A4-A5_Produktbeschreibung_en / Version 2013/04 21 / 91

22 2.9.4 A5D-xxx-12T Front view View from the bottom 22 / 91 PDK_202975_A4-A5_Produktbeschreibung_en / Version 2013/04

23 Side view PDK_202975_A4-A5_Produktbeschreibung_en / Version 2013/04 23 / 91

24 2.9.5 A5D-xxx-15T Front view View from the bottom 24 / 91 PDK_202975_A4-A5_Produktbeschreibung_en / Version 2013/04

25 Side view PDK_202975_A4-A5_Produktbeschreibung_en / Version 2013/04 25 / 91

26 2.10 Application Examples Drive Communication Cross-Communication See Cross-Communication on page A4S-GC0 Gateway See A4S-GC0 Gateway on page / 91 PDK_202975_A4-A5_Produktbeschreibung_en / Version 2013/04

27 3 Transport and Assembly 3.1 Avoiding Material Damage Material Damage! NOTICE Material damage from soiling! No dirt, excessive dust or foreign particles may get into the inside of the controller, otherwise the function of the system is no longer ensured. The intake air fed in for convection cooling should be dry and free of any electrically conductive dust, lint, gases or steam that could negatively affect the functionality. Steps to prevent: Storage and transport in original packaging Operation only in closed, dry switch cabinet Make sure during the assembly and wiring that no foreign particles get into the controller; cover vent opening if necessary. Clean intake air by suitable filters. 3.2 Installation Location and Position The controllers are convection-cooled. An air circulation takes place from the casing bottom side to the casing top side; therefore the controller has to be installed vertically. There should be at least 100 mm of free space both above and below the casing to ensure sufficient ventilation. Heat is also radiated off by the casing, in particular the casing side wall. At least 20 mm free space should be maintained to devices to the side. The cabinet ventilation rating depends on the thermal dissipation loss. A cooling unit needs to be installed for cooling the control cabinet if the air temperature rises above 45 C in the switch cabinet. PDK_202975_A4-A5_Produktbeschreibung_en / Version 2013/04 27 / 91

28 4 Electrical Connections 4.1 Avoiding Material Damage Material Damage! NOTICE Electronic components could be destroyed through static discharge! Therefore touching of the electrical connections (e.g. signal and power supply cable or option and controller cards) must be avoided. Steps to prevent: Avoid touching electrical connections and contacts During handling the electronic component discharge yourself by touching PE Pay attention to the ESD-notes (electrostatic discharge) 4.2 EMC Information According to the Electromagnetic Compatibility Act (EMV-Gesetz), the system manufacturer and supplier bears the responsibility for the system's compliance with the maximum permissible values for electromagnetic emissions. The EU Machine Directive requires the entire machine/system to comply with electromagnetic emissions limits. This can only be achieved if the machine manufacturer and its supplier take all the required individual measures: EM-compatible components EM-compatible system design, installation, interference suppression and wiring EM-compatible earthing and electromagnetic shielding throughout the entire system For fundamental design reasons, every microprocessor-equipped device generates interference voltage. Specific measures are taken to ensure that interference levels remain below the legally permissible limits. Optimal performance is achieved only with proper, EMC-compliant installation, wiring, earthing and shielding. Install suitable suppressors in all electro-magnetic devices in order to limit induction voltages due to switching. Each individual manufacturer of switching devices recommends the best protective measures for use with his device Switch Cabinet Construction If the system exceeds the limit values despite having been properly installed, the following measures may be useful for reducing emissions: Provide a strong HF connection between the central PE bar in the switch cabinet and the A5 controller mounting plate (using stranded copper wire). Connect the mounting plate and switch cabinet casing with stranded copper wire. Connect switch cabinet doors and casing with stranded copper wire. Use the shortest possible PE connection with a sufficient cross-section between the switch cabinet and the machine base. If the cable duct is made up of several parts, they need to be electrically joined seamlessly and connected to the switch cabinet casing at the start and to the motor casing/machine base at the end. The power supply cable must run along the shortest possible route to the A5 controller. The power supply wiring inside the cabinet should be star-shaped Cable Shielding If shielded cables have to be interrupted by a plug connector, a continuing shield connection has to be ensured by placing the shield onto the connector casing. The shield may not lead over connector contacts. Cables leading into the casing have to be secured with grounding cable screw connections with which the cable shield is directly attached to the PG casing. 28 / 91 PDK_202975_A4-A5_Produktbeschreibung_en / Version 2013/04

29 4.2.3 Earthing PE is the reference potential for internal power supply and voltage sensing purposes. An electrically conductive, short as possible connection is made to the PE using the earthing screw on the top side of the controller. Throughout the entire system, the earth should be star-like in shape, extending from the central earthing point. All PE connections should be as short as possible. Cable cross-section at least 10 mm². 4.3 Cable Fixation and Strain Relief with Shielding Clamps The connection cables of the controller can be attached with shielding clamps to the casing. A shielding clamp can be fastened to the top side and another one to the bottom side of the controller. See 'Shielding Clamp' on page 89. PDK_202975_A4-A5_Produktbeschreibung_en / Version 2013/04 29 / 91

30 4.4 X01 Supply Description: Supply connection of the controller Technical data: Input voltage range: 20.4 VDC VDC Maximum length of connection: 30 m Features: Type Pins Class Manufacturer Connector 2 2-pin pin strip Phönix Assignment: Drawing Port Signal Direction Description Connection: Mating plug (type, model, manufacturer, designation) Cable type Cross-section min-max Cable stripping length Cable assembly Note - - GND E Reference potential VDC E Supply 24 VDC ± 15 % Connector, 2-pin, socket, Phönix 2-wired Conductor cross-section (flexible/fixed) without wire end ferrule: mm² / AWG Conductor cross-section (flexible/fixed) with wire end ferrule without plastic sheath: mm² / AWG Conductor cross-section (flexible/fixed) with wire end ferrule with plastic sheath: mm² / AWG mm with/without wire end ferrule, with wire end ferrule and plastic sheath 4.5 X20 Ethernet Description: The Ethernet interface connects the controller to an network. The interface contains a status LED (H3) that indicates the current condition of the network connection. Status LED H3 Off Green lit Green/Orange flashing Meaning No physical connection Ethernet in link mode (physical connection) Ethernet in link/activity mode (connection with data traffic) Technical data: 10/100BASE-T Data frame and assignment of the RJ45 socket acc. to IEEE802.3 Features: Type Pins Class RJ45 8 Socket 30 / 91 PDK_202975_A4-A5_Produktbeschreibung_en / Version 2013/04

31 Assignment: Drawing Port Signal Direction Description Connection: Mating plug (type, model, manufacturer, designation) Cable type 1 Tx+ A Transmit data + 2 Tx- A Transmit data - 3 Rx+ E Receive data Reserved Reserved 6 Rx- E Receive data Reserved Reserved RJ45 Cross-section min-max 0.32 mm² / AWG 22 Shield connection 4-wire, patch cable of the category CAT5e, shielded Both sides Cable assembly Prefabricated cables: see Ethernet / EtherCAT Cable on page X22 USB Host Description: USB memory media can be connected to the USB 2.0 interface (e.g., external USB hard disk or USB memory stick) or a keyboard for display units can be connected. Technical data: USB 2.0 with 480 Mbit/s Maximum current load of the USB interface: 500 ma Features: Type Pins Class Designation USB 4 Socket USB type A Assignment: Drawing Port Signal Direction Description 1 +5 VDC A 5 VDC supply for external USB device, maximum current load 500 ma 2 D I/O Data 3 D+ I/O Data + 4 GND A Reference potential supply Connection: Mating plug USB type A (type, model, manufacturer, designation) Cable type Data- and Data+ pair-stranded, shielded Cross-section min-max 0.08 mm² / AWG 28 Shield connection Both sides PDK_202975_A4-A5_Produktbeschreibung_en / Version 2013/04 31 / 91

32 4.7 X41 Profibus DP Slave [Controller Variants A5S/D-xCx] Description: The Profibus DP Slave interface connects the controller to a Profibus Master acc. to DIN19245, part 3. The interface includes a status LED (H4) which shows the actual state of the network connection. Status LED H4 Off Orange lit Orange flashing Green flashing Green flashing (once) Green lit Red flashing Red flashing (once) Red flashing (twice) Meaning No physical connection / Profibus DP not activated Profibus DP in link mode (physical connection) Profibus DP in link/activity mode (connection with data traffic) Profibus DP in pre-operational mode Profibus DP in save-operational mode Profibus DP in operational mode General configuration error (hardware error or bus configuration error) See Diagnosis on page 83. Slave leaves the operational mode. See Diagnosis on page 83. One data package could not be received/sent. See Diagnosis on page 83. Technical data: Maximum of 32 devices per line By repeater enlarged up to 4 lines max. 122 devices. Maximum baudrate = 12 Mbit/s, automatically adapted to the baudrate of the MASTER Standards: DIN 19245, EN and IEC Features: Type Pins Class D-SUB 9 Socket Assignment: Drawing Port Signal Direction Description Connection: Mating plug (type, model, manufacturer, designation) Cable type 1 N.C. Not used 2 N.C. Not used 3 RxD/TxD-P O / I Receive/Transmit data P 4 CMTR-P O Repeater control signal 5 DGND Data signal common 6 VP O Positive supply voltage (+5 V, max. 150 ma) 7 N.C. Not used 8 RxD/TxD-N O / I Receive/Transmit data N 9 N.C. Not used D-SUB plug Cross-section min-max 0.64 mm² / AWG 22 Shield connection 2-wire bus interfacing with electrical isolation. Both sides Cable assembly AMK recommends: See Mating Plug X41 on page / 91 PDK_202975_A4-A5_Produktbeschreibung_en / Version 2013/04

33 4.8 X60 Ethernet [Controller Variants A4x/A5x-xCx] Description: X60 is an optional 2nd Ethernet interface (refer to X20). The interface contains a status LED (H2) that indicates the current condition of the connection. Status LED H2 Off Green lit Green flashing Meaning No physical connection Ethernet in link mode (physical connection) Ethernet in link/activity mode (connection with data traffic) Technical data: 10/100BASE-T Data frame and assignment of the RJ45 socket acc. to IEEE802.3 Features: Type Pins Class RJ45 8 Socket Assignment: Drawing Port Signal Direction Description Connection: Mating plug (type, model, manufacturer, designation) Cable type 1 Tx+ A Transmit data + 2 Tx- A Transmit data - 3 Rx+ E Receive data Reserved Reserved 6 Rx- E Receive data Reserved Reserved RJ45 Cross-section min-max 0.32 mm² / AWG 22 Shield connection 4-wire, patch cable of the category CAT5e, shielded Both sides Cable assembly Prefabricated cables: see Ethernet / EtherCAT Cable on page X85/X86 Real-Time Ethernet [Controller Variants A4x/A5x-xCx] Description: The interface is constructed as a real-time Ethernet slave interface and supports the EtherCAT SoE protocol (Servo Drive Profile according to IEC ). The interfaces each contain a status LED (H4/H5) that indicate the current condition of the EtherCAT bus. X85: Connection master or precious node X86: Connection next node (AMK device X85) (If you use a external module, mark in and out) PDK_202975_A4-A5_Produktbeschreibung_en / Version 2013/04 33 / 91

34 Status LED H4/H5 Meaning Off No physical connection / EtherCAT not activated Orange lit EtherCAT in link mode (physical connection) Orange flashing EtherCAT in link/activity mode (connection with data traffic) Green flashing EtherCAT in pre-operational mode Green flashing (once) EtherCAT in save-operational mode Green lit EtherCAT in operational mode Red flashing General configuration error (hardware error or bus configuration error) See Diagnosis on page 83. Red flashing (once) Slave leaves the operational mode. See Diagnosis on page 83. Red flashing (twice) One data package could not be received/sent. See Diagnosis on page 83. If a further slave is connected to X86, H4 functions as H5, otherwise H4 is not active (off). Technical data: 100BASE-T 100 Mbit/s Ethernet standard Data frame and assignment of the RJ45 socket acc. to IEEE802.3 Maximum length 50 m (industrial environment) Features: Type Pins Class RJ45 8 Socket Assignment: Drawing Port Signal Direction Description Connection: Mating plug (type, model, manufacturer, designation) Cable type 1 Tx+ A Transmit data + 2 Tx- A Transmit data - 3 Rx+ E Receive data Reserved Reserved 6 Rx- E Receive data Reserved Reserved RJ45 Cross-section min-max 0.32 mm² / AWG 22 Shield connection Patch cable of the category CAT5e, shielded Both sides Cable assembly Prefabricated cables: see Ethernet / EtherCAT Cable on page 89 The Ethernet interfaces X85 and X86 are out of function when Profibus DP slave functionality with A-SPB is in operation. 34 / 91 PDK_202975_A4-A5_Produktbeschreibung_en / Version 2013/04

35 4.10 X120 Analogue Inputs and Square-Wave Signal Input [Controller Variants A4x/A5xxxE] Description: 2 analogue inputs 1 square-wave input Technical data: Square-wave input 2 square-wave signal with a 90 offset and zero pulse Maximum input frequency: 4 MHz The inputs IG0I/IG0N and IG2I/IG2N are each terminated with 120 ohm. The electrical delay is Ton = 2-12 µs, Toff = 2-12 µs and the differential switch threshold is at least ± 0.2 V. Analogue input Features: 12 bit resolution 10 V reference voltage output 2 modes can be parameterised: mode 1: -10 V V, mode 2: 0V V Electrical bandwidth: 45 khz Precision in the entire input voltage range: ± 0.5% (10V input voltage correspond to 9.95 V V) Common-mode voltage U CM = 10 V max. Type Pins Class Manufacturer Pin strip SL socket 16 2 row / 3.5 mm raster Weidmüller Assignment: Drawing Port Signal Direction Description 1A AGND E Reference potential analogue input 1B REF A 10 V Reference ± 1 %, max. 5 ma, 2A AN1I E Analogue input 1-2B AN1N E Analogue input 1+ 3A AGND E Reference potential analogue input 3B REF A 10 V Reference ± 1 %, max. 5 ma, 4A AN2I E Analogue input 2-4B AN2N E Analogue input 2+ 5A IG0I E Square-wave input zero pulse- (NIP-) 5B IG0N E Square-wave input zero pulse+ (NIP+) 6A IG1I E Square-wave input track 1-6B IG1N E Square-wave input track 1+ 7A IG2I E Square-wave input track 2-7B IG2N E Square-wave input track 2+ 8A 5 V A Supply square-wave encoder 5 VDC ± 5 %, max. 500 ma 8B GND A Reference potential square-wave encoder PDK_202975_A4-A5_Produktbeschreibung_en / Version 2013/04 35 / 91

36 Connection: Mating plug (type, model, manufacturer, designation) Socket board connector BL, 2 rows, Weidmüller Cross-section min-max Conductor cross-section (flexible/fixed) without wire end ferrule: mm² / AWG Shield connection - Conductor cross-section (flexible/fixed) with wire end ferrule without plastic sheath: mm² / AWG Conductor cross-section (flexible/fixed) with wire end ferrule with plastic sheath: mm² / AWG Cable assembly see Mating Plug X120 on page 88 Schaltungsprinzip: Analogue input with reference voltage output 4.11 X121 Binary Inputs [Controller Variants A4x/A5x-xxE] Description: 8 binary inputs Technical data: Potentially separated by optocoupler Norm IEC type 3 binary inputs Input nominal voltage 0-30 VDC, max. input current at 30 V = 15 ma Electric delay E1 to E8 of Ton = 3-8 µs, Toff = µs The connection 1 must be equipped with a coding pin. Features: In order to avoid confusion of plug-in connectors, plug and socket connector have to be coded. If the codings are fixed at different poles, the connectors fit into one another. If the codings are fixed at the same pole, the connector cannot be plugged. The sets of plug-in connectors for single- and triple-conductor technology (AMK part-no. O847 and O848) include material and assembly instruction for coding. Type Pins Class Manufacturer Pin strip SL socket 10 1 row / 3.5 mm raster Weidmüller By selecting the counter-connector, wiring can be done in single-, dual, or triple-conductor technique. 36 / 91 PDK_202975_A4-A5_Produktbeschreibung_en / Version 2013/04

37 Assignment: Drawing Port Signal Direction Description 1 n.c E1 E Binary input 1 3 E2 E Binary input 2 4 E3 E Binary input 3 5 E4 E Binary input 4 6 E5 E Binary input 5 7 E6 E Binary input 6 8 E7 E Binary input 7 9 E8 E Binary input 8 10 BGNDE I/O Reference potential for binary inputs at X121. The grounds of X121 and X122 are not connected internally. Connection: Mating plug (type, model, manufacturer, designation) Single-conductor technique: Socket board connector BL 10-pole, 1 row, Weidmüller Triple-conductor technology: Socket board connector BL 30-pole, 3 rows, Weidmüller Series BL-I/O 3.5 LED PNP 1) Cross-section min-max Conductor cross-section (flexible/fixed) without wire end ferrule: mm² / AWG Shield connection - Cable assembly Conductor cross-section (flexible/fixed) with wire end ferrule without plastic sheath: mm² / AWG Conductor cross-section (flexible/fixed) with wire end ferrule with plastic sheath: mm² / AWG see Counter-Connector Single-Conductor Technology for X121, X122 [Controller Variant Axx-xxE-xxxx] on page 88 see Counter-Connector Triple-Conductor Technology for X121, X122 [Controller Variant Axx-xxE-xxxx] on page 89 1) The mating plugs BL-I/O with integrated LED are suitable for connection of "plus" switching sensors and "plus" switched actors with common "minus" as reference potential Circuit principle: Example single-conductor technique (input terminal connection 2) Example single-conductor technique (input terminal connection 2) Example double-conductor technique (input terminal connection 5) Example triple-conductor technique (input terminal connection 8) Line b and line a are internal connected. Between b and c is no connection. The description (inside picture) is valid for line a. PDK_202975_A4-A5_Produktbeschreibung_en / Version 2013/04 37 / 91

38 4.12 X122 Binary Outputs and Probe Inputs [Controller Variants A4x/A5x-xxE] Description: 6 binary outputs, short-circuit safe 2 probe inputs Technical data: Norm IEC type 3 binary inputs Norm IEC binary outputs Output measurement voltage 24 VDC, output measurement current max. 0.5 A, short-circuit safe, potential separated, electrical delay of Ton 8-20 µs, Toff = µs at 200 ma load In order to avoid confusion of plug-in connectors, plug and socket connector have to be coded. If the codings are fixed at different poles, the connectors fit into one another. If the codings are fixed at the same pole, the connector cannot be plugged. The sets of plug-in connectors for single- and triple-conductor technology (AMK part-no. O847 and O848) include material and assembly instruction for coding. Features: Type Pins Class Manufacturer Pin strip SL socket 10 1 row / 3.5 mm raster Weidmüller By selecting the counter-connector, wiring can be done in single-, dual, or triple-conductor technique. Assignment: Drawing Port Signal Direction Description 1 (+) BVCC E Supply voltage for binary outputs 24 VDC ± 15 %, max. 3 A 2 EM1 E Probe input 1, input nominal voltage 0 V VDC, max. input current at 30 V = 15 ma, potential separated, delay Ton = ns, Toff = ns 3 EM2 E Probe input 2, input nominal voltage 0 V VDC, max. input current at 30 V = 15 ma, potential separated, delay Ton = ns, Toff = ns 4 A1 A Binary output 1 5 A2 A Binary output 2 6 A3 A Binary output 3 7 A4 A Binary output 4 8 A5 A Binary output 5 9 A6 A Binary output 6 10 (-) BGND I/O Reference potential for binary in- and outputs at X122. The grounds of X121 and X122 are not connected internally. 38 / 91 PDK_202975_A4-A5_Produktbeschreibung_en / Version 2013/04

39 Connection: Mating plug (type, model, manufacturer, designation) Single-conductor technique: Socket board connector BL 10-pole, 1 row, Weidmüller Triple-conductor technology: Socket board connector BL 30-pole, 3 rows, Weidmüller Series BL-I/O 3.5 LED PNP 1) Cross-section min-max Conductor cross-section (flexible/fixed) without wire end ferrule: mm² / AWG Shield connection - Cable assembly Conductor cross-section (flexible/fixed) with wire end ferrule without plastic sheath: mm² / AWG Conductor cross-section (flexible/fixed) with wire end ferrule with plastic sheath: mm² / AWG see Counter-Connector Single-Conductor Technology for X121, X122 [Controller Variant Axx-xxE-xxxx] on page 88 see Counter-Connector Triple-Conductor Technology for X121, X122 [Controller Variant Axx-xxE-xxxx] on page 89 1) The mating plugs BL-I/O with integrated LED are suitable for connection of "plus" switching sensors and "plus" switched actors with common "minus" as reference potential Circuit principle: Example single-conductor technique (input terminal connection 2 on rather 3) (output terminal connection 4 on rather 9) Example double-conductor technique (output terminal connection 3 on rather 8) Example triple-conductor technique (output terminal connection 2 on rather 6) Line b and line a are internal connected. Between b and c is no connection. The description (inside picture) is valid for line a X137 ACC Bus Master Description: The ACC bus master interface is a CANopen interface with additional hardware synchronisation cycle. The interface contains a status LED (H8) that indicates the current condition of the ACC bus. Status LED H8 Off Green flashing Green lit Meaning No physical connection ACC bus in pre-operational mode ACC bus in operational mode Technical data: The bus terminal resistors are internally equipped with 2x120 ohm. PDK_202975_A4-A5_Produktbeschreibung_en / Version 2013/04 39 / 91

40 Features: Type Pins Class Manufacturer Designation IEEE 1394 connector 6 Socket Assignment: Drawing Port Signal X137 (X237) Description Connection: Mating plug (type, model, manufacturer, designation) Cable type 1 GND Reference potential 2 GND Reference potential 3 CAN_H CAN high 4 CAN_L CAN low 5 SYNC_H Hardware cycle SYNC high 6 SYNC_L Hardware cycle SYNC low IEEE1394 firewire Pair-stranded, shielded Cross-section min-max 0.8 mm² / AWG 18 Shield connection Both sides Cable assembly Prefabricated cables: see ACC Bus Cable on page 89 Note The ACC bus connector X137 needs to be connected to the next participant with the connection X136 or X236. From there, the next participant can be connected by connecting the connection X137 to X136 or X236 of the next participant and so forth. At the last participant, a bus terminating plug (120 ohm) needs to be attached to connection X137 or X X185 Real-Time Ethernet Master 2 [Controller Variants A4x/A5x-xCx] Reserved for future applications X186 Real-Time Ethernet Master Description: The real-time Ethernet master interface supports the protocol EtherCAT SoE. The interface contains a status LED (H6) that indicates the current condition of the EtherCAT bus. Status LED H6 Off Orange lit Orange flashing Green flashing Green flashing (once) Green lit Red flashing Red flashing (once) Red flashing (twice) Meaning No physical connection EtherCAT in link mode (physical connection) EtherCAT in link/activity mode (connection with data traffic) EtherCAT in pre-operational mode EtherCAT in save-operational mode EtherCAT in operational mode General configuration error (hardware error or bus configuration error) see Diagnosis on page 83 Slave leaves the operational mode. see Diagnosis on page 83 One data package could not be received/sent. see Diagnosis on page / 91 PDK_202975_A4-A5_Produktbeschreibung_en / Version 2013/04

41 Technical data: 100BASE-T 100 Mbit/s Ethernet standard Data frame and assignment of the RJ45 socket acc. to IEEE802.3 Maximum length 50 m (industrial environment) Features: Type Pins Class RJ45 8 Socket Assignment: Drawing Port Signal Direction Description Connection: Mating plug (type, model, manufacturer, designation) Cable type 1 TX+ A Transmit data + 2 TX- A Transmit data - 3 RX+ E Receive data Reserved Reserved 6 RX- E Receive data Reserved Reserved RJ45 Cross-section min-max 0.32 mm² / AWG 22 Shield connection Patch cable of the category CAT5e, shielded Both sides Cable assembly Prefabricated cables: see Ethernet / EtherCAT Cable on page X235 USB Device Description: The X235 is a USB-client interface by which the controller can be connected directly to the USB interface of a PC in order to make use of the AIPEX PRO software. Technical data: USB 2.0 Features: Type Pins Class Designation USB 5 Socket Mini-USB type B Assignment: Drawing Port Signal Direction Description 1 +5 VDC E External 5 VDC supply, max. 50 ma current consumption 2 D I/O Data 3 D+ I/O Data + 4 n.c GND Reference potential supply PDK_202975_A4-A5_Produktbeschreibung_en / Version 2013/04 41 / 91

42 Connection: Mating plug (type, model, manufacturer, designation) Cable type Mini-USB type B Cross-section min-max 0.08 mm² / AWG 28 Shield connection Data+ and Data pair-stranded, shielded Both sides Cable assembly Prefabricated cables: see USB Cable on page 89 Note Maximum 3 metres length permitted for USB cable. With active USB repeater, longer cable lengths are possible. 42 / 91 PDK_202975_A4-A5_Produktbeschreibung_en / Version 2013/04

43 5 Functionality 5.1 PLC Programming All controllers are equipped with high-performance PLCs. CoDeSys target: A4 (C16384D16384R128) V3.01/1128. A5 (C16384D16384R128) V3.01/1018. The CoDeSys programming and visualization interface is used for programming the PLC in the IEC programming languages: Command lists (AWL) Structured text (ST) Function component language (FUP) Contact plan (KOP) Procedure language (AS) Graphic function plan editor (CFC) The integrated AMK libraries support the programming with prepared Motion Control modules: Positioning Electronic transmission Conductance interpolators (virtual main axes) Function interpolators (electronic cams) Register controller (printing mark control) Electronic cam controller Measuring functions Reading/Writing drive parameters Communication via fieldbuses and Ethernet using TCP/IP and UDP Access to all system parameters and functions The PLC application has access to the fieldbus interfaces for initialisation and control. The PLC also has read-and-write access to the interfaces for transmitting user data to drives and drive assemblies, as well as other control information such as setpoints and control signals, actual values and status signals, or process data for visualisation and control components. In order to protect the controller from overload the PLC program is monitored for detection of infinite loops. In case of failure the PLC program is stopped and diagnostic message 3862, 'System diagnostics: System exception CPU error', Info 1 = 39 is caused. The controllers A4 and A5 have different processors. The compilers from the company 3S translate the user program, which was programmed with CoDeSys, for the respective processor. Due to the different compiler behaviour, there are cases in which the programmers know the differences between A4 and A5 projects and must note: When exchanging data between the A4 and A5 controllers, it must be noted that the internal memory alignment in the A4 and A5 controllers are different. See Information about the data exchange between A4 and A5 controllers (different memory alignment) on page 43. If A5 user programmes should be used on an A4 controller, adjustments must be made. See PLC Projects (application programs) from A5 Used on A4 Controllers on page Information about the data exchange between A4 and A5 controllers (different memory alignment) Occupy the variables of a PLC programme after compiling and transferring to the controller; areas in the internal memory of a controller: Type of variable BOOL BYTE Minimum memory requirement in the internal memory 1 bytes 1 bytes PDK_202975_A4-A5_Produktbeschreibung_en / Version 2013/04 43 / 91

44 Type of variable WORD DWORD REAL LREAL 1) Minimum memory requirement in the internal memory 2 bytes 4 bytes 4 bytes 8 bytes 1) LREAL variables may not be exchanged between A4 and A5. The variable type LREAL is not supported in A4. See 'PLC Projects (application programs) from A5 Used on A4 Controllers' on page 45. For structural variables, several variables are combined into data structures. These structures occupy different areas (compiler-dependent) in the internal memory of a controller. The programming software CoDeSys uses different compilers for the controllers A4 and A5, which results in the structure variables being stored differently in the internal memory. The A5 controller compiler stores data in succession in the internal memory, regardless of the data type. The A4 controller compiler works according to the following rules: A variable from the WORD type is in an internal memory area whose byte index is divisible by 2 without a remainder. A variable from the DWORD type is in an internal memory area whose byte index is divisible by 4 without a remainder. A variable from the REAL type is in an internal memory area whose byte index is divisible by 4 without a remainder. A variable from the BYTE type is stored in any internal memory. A type BOOL variable occupies one byte and behaves like the BYTE type. Example: An assumed structure from an A5 controller should be transferred to an A4. Exemplary assumed structure variable: Structure content Internal memory Variable name Type of variable Memory requirement in the internal memory bovar1 BOOL 1 bytes dwvar2 DWORD 4 bytes byvar3 BYTE 1 bytes wvar4 WORD 2 bytes Alignment in the internal memory [bytes] A5 controller bovar1 dwvar2 byvar3 wvar4 A4 controller bovar1 dwvar2 byvar3 wvar4 As long as structure variables are not exchanged between different controllers, the internal memory allocation is not relevant for the user. If data is exchanged between the controllers A4 and A5, the transmitted data in the receiver's internal memory is stored as it was sent. However, the receiver's compiler expects the data in the above-illustrated arrangement, which causes the transmitted data in the receiver to be incorrectly assigned to the structure variables. In the previous example, only the variable 'bovar1' in the receiver unit would be assigned the correct content. Proposals for solutions, shown by example The data in the transmitter must be arranged so that it can also be correctly assigned in the memory alignment of the receiver. The structure content in the example must be changed as follows in order to adapt the data alignment to the receiver. Alignment in the internal memory [bytes] A5 controller (transmitter) bovar1 bydummy1 bydummy2 bydummy3 dwvar2 byvar3 bydummy4 wvar4 A4 controller (receiver) bovar1 dwvar2 byvar3 wvar4 The exemplary accepted structure variable must be expanded as follows. 44 / 91 PDK_202975_A4-A5_Produktbeschreibung_en / Version 2013/04

45 Structure content Internal memory Variable name Type of variable Memory requirement in the internal memory bovar1 BOOL 1 bytes bydummy1 Byte 1 byte bydummy2 Byte 1 byte bydummy3 Byte 1 byte dwvar2 DOUBLEWORD 4 bytes byvar3 BYTE 1 bytes bydummy4 BYTE 1 bytes wvar4 WORD 2 bytes The structure expanded with the dummy variables can be correctly transmitted from an A5 controller to an A4 controller and be correctly assigned to the structure variables by the A4 compiler. The transmission of data from an A4 to an A5 controller also works with the expanded structure variable PLC Projects (application programs) from A5 Used on A4 Controllers Please notice the following items, if you will use A5 plc projects on an A4 controller: Select A4 target Select in 'target setting' the target A4 C16384D16384R128) V3.01/ Save project 2. Close project 3. Open project again Sub-elements in 'IO-Modules' at the 'PLC Configuration' page WORD elements must have an even byte offset. DWORD elements must a byte offset which is divisible by 4. If the 'PLC Configuration' page is displayed, the offset addresses can be calculated new by choosing menu 'Extras' -> 'calculate addresses'. Treat data type LREAL as REAL The A4 controller supports no data type LREAL, so please enable the checkbox 'Treat LREAL as REAL' in menu 'Project' -> 'Options' -> 'Build'. Organization of data structures Data structures at A4 controllers can be generated larger than as A5 controllers. A sizeof -Operator feedback in this case a lager value. 5.2 Programming Under PLCopen The CoDeSys programming and visualization interface is used for programming the PLC in the IEC programming languages. Controller with the PLCopen option A4/A5-PCO support the PLCopen library 'SM_PLCopen.lib' from CoDeSys. The module description can be found in the standard CoDeSys description. AMK-specific information is available in the document: PDK_SPS_AmkDrive_en.pdf. Minimum requirements: A4 Controller with the PLCopen option A4-PCO (AMK part no. O868) CoDeSys target system: A4PlcOpen (C16384D16384R128) V03.01/1142 AIPEX PRO 1.08 SP1 A5 Controller with the PLCopen option A5-PCO (AMK part no. O844) CoDeSys target system: A5PlcOpen (C16384D16384R128) V03.01/1026 AIPEX PRO 1.07 PDK_202975_A4-A5_Produktbeschreibung_en / Version 2013/04 45 / 91

46 5.3 Web Visualisation Any visualisation created by CoDeSys can be called up as a WEB visualisation. You need the options A4-VIS (O832) resp. A5-VIS (O831). A4- / A5-VIS is a standard term at the display controller PLCs. Procedure: 1. Create the visualisation for the controller in CoDeSys as usual. 2. Activate 'WEB Visualisation' in the tab 'Target system settings' 'Visualisation'. 3. Name your visualisation PLC_VISU. The visualisation with the name 'PLC_VISU' is started automatically as soon as the initialisation of the controller is completed. 4. For visualisation objects that should not be part of the Web visualisation, go to the 'Visualisation' tab in the 'Object' 'Properties' menu and deactivate the 'Web visualisation' option. Starting the web visualisation by an external visualisation device: Specify the IP address, Port 8080 and the page name webvisu.htm in your WEB browser with active Java Virtual Machine. WEB-Browser: address of the controller>:8080/webvisu.htm Example: Webvisu.htm is the standard HTML page. It includes an <applet> tag that starts the WebVisu applet. 5.4 Qt Visualisation Instead of a visualisation based on CoDeSys, it can be implemented based on Qt software. Therefore the software AMK Qt Visualisation (O865) is required (see 'Software' on page 88). By the use of AMK Qt Visualisation, the visualisations for A4D- / A5D-XXX controllers can be programmed with C++. Qt visualisation supports USB webcams with 'uvcvideo' driver. You can get further information from the product documentation PDK_203744_Software_QtVisualisierung 5.5 A4 CoDeSys Target-Visualization Hints for creating a visualization with the CoDeSys Target-Visualization (used the software version A4 V4.06) Task Default priority A4 VISU_TASK and VISU_INPUT_TASK Password-Input Floatingpoint-Format Tooltips Colour gradient Graphical limitation Fonts Description You have to do the following adjustments manually: VISU_TASK priority = 18 VISU_INPUT_TASK priority = 17 From AIPEX PRO V1.09 this adjustment will be done automatically. If you want to use the function password input (hidden text input, ******), you have to use the target A4 (C16384D16384R128) V3.01/1128 (target version=2). requirement: AIPEXPRO V /43 with SP2 Displaying floatingpoint-format %x.yf is not possible. work around: own formatting You can find an example with AIPEXPRO V /43 with SP2..\Programme\3S Software\CoDeSys_V2.3\ AmkAddition\Examples. Tooltips are not possible. The function colour gradient is not possible. If you turn an asymmetric body, graphical errors are possible. Following fonds are supported: Times New Roman Courier New Arial Arial Unicode MS ( bold/ cursive is not possible) 46 / 91 PDK_202975_A4-A5_Produktbeschreibung_en / Version 2013/04

47 Task Graphical-Format XML-files for a dynamic text Alarm handling actions Sort order of alarm table Trend accuracy of display `ZOOM_TO_VIS Transparent elements Description Following formats are supported: Bitmap JPEG Tabulators (special character) will be displayed as rectangle. Tabulators (space,..) between XML-Tags will be displayed as rectangle. The actions print and message will be not supported with the target visualization. You get a warning if you compile the project. The sort order is always an alarm date descending order. The adjusted sort order inside the visualization element of the alarm table will not take into account. You can adjust the horizontal accuracy. In this case it is possible that you can read in the display duration different values of display points. Calcualtion display points: Display points = duration / display accuracy. If you have a high number of display points it is possible that the cycle time VISU_ TASK (200 ms) will be over shoot. In this case the CPU load can reach 100%. (Depend on the priority of VISU_TASK and cycle time, see point 1) `ZOOM_TO_VIS is not working if you use placeholders If you draw a transparent rectangle, polygon or circle element in front of a other element, in this case it is possible to click with the mouse button through the transparent element inside the element behind. This is different to all other visualization types. 5.6 A4S-GC0 Gateway The controller A4S-GC0 is used as a gateway. Each gateway works on the input side as an EtherCAT slave and is operated in a cross communication (CC bus) to an A4 or A5 controller. In the EtherCAT master controller, which is connected with the gateways, the EtherCAT interface X186 must be set up as a CC bus in order to be able to establish a cross-communication to the gateways. See 'Cross-Communication' on page 58. The gateways do not have any PLC functionality. They only transmit synchronous and asynchronous data as well as the service channel. The delay time between the data incoming at the interfaces on the EtherCAT slave and the data outgoing at the drive bus is 2 x ID2 (instance 0). There is no delay time between the participants at the CC bus. Each gateway can be operated in parallel to the EtherCAT CC bus as an ACC bus or EtherCAT master. The gateways are configured via AIPEX PRO (min. AIPEX PRO V /43 with SP04) using the automatic configuration. Example configuration: see documentation PDK_202234_Software_AIPEX_PRO chapter / Cross Communication - Offline project and Cross Communication - Online import and configuration. Example: The figure shows the interconnection of an A4 or A5 controller and 3 A4S-GC0 gateways, which each work as an ACC bus master.s PDK_202975_A4-A5_Produktbeschreibung_en / Version 2013/04 47 / 91

48 5.7 Parameterisation Using the AIPEX PRO PC software, the controller is parameterised and diagnostic messages are read. The PC can access any connected AMK device via the controller's field bus interfaces, for instance, additional controllers or AMK inverters. The parameter structure corresponds to the AMKASYN drive systems and it is based on the SERCOS interface standard. The controller is preprogrammed, hence parameterisation is reduced to applicationoriented parameters, such as participant addresses of the bus interfaces. The default values of the parameters can be restored at any time using the "Initial program loading" function. 48 / 91 PDK_202975_A4-A5_Produktbeschreibung_en / Version 2013/04

49 Automatic detections of the interface options The controller recognises existing interfaces and assigns standard values to the communication parameters in case no data have been parameterised by the user. A user parameterisation is not overwritten by the automatic parameterisation. The parameters are checked for the automatic recognition for user values at every system booting. Should a parameter value deviate from the default value, the user value is maintained. All parameters are reset to their default values by the initial program loading function. 5.8 Status LEDs H0 and H1 Status of the controller (device condition) Status LED H0 Meaning Off Supply voltage of the controller at X01 off. Orange lit Voltage supply is switched on, controller initialised. Green lit Controller ready Red lit Error condition, reading out errors see Diagnosis on page 83 Status of the PLC in the controller Status LED H1 Green lit Green flashing Orange lit Orange flashing Red lit Red flashing Meaning PLC is running PLC stopped Warning message was generated, but PLC continues running. Warning message was generated and was PLC stopped. Error message was generated, but PLC continues running. see Diagnosis on page 83 Error message was generated and the PLC was stopped. see Diagnosis on page Ethernet (Connection X20) Link to the AMK software AIPEX PRO and the programming system CoDeSys Load PLC program Diagnostics Remote maintenance Process data provisioning Link to visualisation devices FTP server, copying of files via the File Transfer Protocol (FTP) using an FTP client (e.g., Microsoft Internet Explorer) OPC server functionality (access via external programs) Communication between different controllers at application level with CoDeSys network variables or IEC module libraries to apply the UDP & TCP protocols PDK_202975_A4-A5_Produktbeschreibung_en / Version 2013/04 49 / 91

50 5.9.1 Configuration The EtherCAT interface X20 is parameterised in the instance 4 as follows: Parameter Name Value Description ID34216 'DNS server address' 0x100007F* ID34216 = 0xddccbbaa corresponds to the DNS server address 0xaa.0xbb.0xcc.0xdd. ID34140 'AS BUS protocol' 2* Ethernet Default setting: (local host) ID34143 'Usage port' 4* Software AIPEX PRO (CoDeSys) ID34023 ID34025 'BUS address participant' 'BUS mode' 0x0001* The Ethernet IP address is set in the IDs ID34023 and ID An Ethernet address of 0xaa.0xbb.0xcc.0xdd. results in the following ID assignment: ID34023: 0xccdd and ID34026: 0xaabb Bit 2: 1 DHCP active Default setting: Bit 3: 0* Ethernet class C network (subnet mask: ) Bit 3: 1 Ethernet class B network (subnet mask: ) Bit 4: 1 Reserved Bit 5: 1* SBUS server active (required for Ethernet communication with AMK PC software AIPEX PRO and ATF) ID34026 'BUS mode attribute' 0xC0A8* see ID34023 ID34056 'Gateway address' 0xFFFFFFFF* ID34056 = 0x ddccbbaa corresponds to the gateway address 0xaa.0xbb.0xcc.0xdd. Default setting: ID34057 'Network mask' 0x00FFFFFF* ID34057 is used to set the network mask. Conditions similar to those for the ID34056 gateway address apply here. Default setting: 0x00FFFFFFh = class C network. * Default setting When using ID 34057, bit 3 must be equal to 0 in ID The two Ethernet interface X20 and X60 may not be assigned to the same network segment. Different network segments are on hand when the interfaces have been assigned different network classes or different segment addresses. Example 1: The interface X20 is set as a class B network and X60 as a class C network. Example 2: X20 is a class C network with an address of and X60 is a class C network with an address of / 91 PDK_202975_A4-A5_Produktbeschreibung_en / Version 2013/04

51 5.10 USB Host (Connection X22) USB memory media can be connected to the USB 2.0 interface (e.g., external USB hard disk or USB memory stick). USB stick requirements No active partition (not able to boot) (only A5 controller): See USB stick how to deactivate an active partition on page 87. Format FAT or FAT32 The USB interface makes the following functions possible: Reading and writing files in the USB memory medium Using the AMK library AmkFile.lib in the software CoDeSys, the following functions can be programmed: Read file Write file Create directory Delete directory Additional information in the documentation: PDK_xxxxxxx_PLC_AmkFile Update parameters in an entire system Using the AMK library SERVICE_UPD.lib in the CoDeSys software, the parameter set of an entire system or of individual axes could be saved in the USB memory medium and reloaded again. Updating PLC program Using the AMK library SERVICE_UPD.lib in CoDeSys software, a PLC program can be read from the USB memory medium that updates the PLC program in controller. Update parameter set With the function update parameter set it is possible to read and saved to a not bootable USB stick single parameters or complete parameter sets of an application (controller and / or drives) or it can be downloaded from the stick to the device. It is not possible to edit the read data file. Create a command-file named 'config.xml' with any editor. (See commands in config.xml and example config.xml) Save the command-file config.xml on a USB stick. Plug the USB stick inside X22. The read and write function starts automatically. With a <READ> tag the parameters will be saved in an update file, i.e. update_0_0_0_0_0.xml, a <WRITE> tag sends this data to the device. The command file can contain read and write tasks at the same time. If there is no update file, the <READ> tag will be executed and the update file is written. Otherwise the <WRITE> tag is processed. Commands in config.xml Tag name Attribute Description CONTENT Includes all tags of config.xml WRITE Optional READ Optional Only tags or comments are allowed Includes only the tag DEV Includes only the tag DEV PDK_202975_A4-A5_Produktbeschreibung_en / Version 2013/04 51 / 91

52 Tag name Attribute Description DEV Includes all information about one device A new DEV must be defined for each device addr AMK routing address to select a device or an update file Indicator for the name of the update file Addresses in decimal notation Character string "aa.bb.cc.dd" aa: Address of cross communication bb: Type of drive bus (0=ACC; 1=EC) cc: Drive bus address of device dd: Device sub-address newaddr AMK routing address to select the target device for write task (The parameters of an existing update file will be written to a device with the address 'newaddr'.) Optional Can be used only in WRITE tags Character string "aa.bb.cc.dd" (see above) id Indicator for the name of the update file This attribute has to be equal for reading and writing Single parameter: id="<sercos ID>" All parameters: id="0" LOG Path and name of the log file (In case of update a log file with the executed commands is saved) No tags allowed Optional (default: /tmp/update.log) Character string ASCII, no space, no " " 52 / 91 PDK_202975_A4-A5_Produktbeschreibung_en / Version 2013/04

53 Example config.xml <?xml version="1.0" encoding="windows-1250"?> <CONTENT> <READ> <DEV addr=" " id="0"> </DEV> <DEV addr=" " id="1"> </DEV> <DEV addr=" " id="34023"> </DEV> <DEV addr=" " id="0"> </DEV> <DEV addr=" " id="34024"> </DEV> </READ> <WRITE> <DEV addr=" " id="0"> </DEV> <DEV addr=" " id="1"> </DEV> <DEV addr=" " newaddr=" " id="34023"> </DEV> <DEV addr=" " id="0"> </DEV> <DEV addr=" " id="34024"> <!-- read all IDs from the controller --> <!-- read ID1 of address 4 on ACC bus--> <!-- read ID34023 of address 4 on ACC bus --> <!-- read all IDs of address 17 on EtherCAT bus --> <!-- read ID34024 of sub-address 35 (ACC)--> <!-- on address 16 of EtherCAT bus --> <!-- write all IDs to the controller--> <!-- write ID1 to address 4 an ACC bus --> <!-- write ID34023 of address 4 --> <!-- to the device with address 2 --> <!-- write all IDs to address 17 --> <!-- on EtherCAT bus --> <!-- write ID34024 to sub-address 35(ACC) --> <!-- on address 16 of EtherCAT bus --> </DEV> </WRITE> <LOG> /tmp/mnt/sdb1/updatelog.txt <!-- path and file name of log file --> </LOG> </CONTENT> External USB to Serial RS232/RS485 Converters External USB to serial RS232/RS485 converters of Lindy-Elektronik GmbH and Advantech Europe GmbH (ADAM-4561 and ADAM-4562) are supported (Virtual COM Port VCP). Devices with CDC-ACM protocol (Communications Device Class, Abstract Control Model) are also supported. During the initialisation of the serial interface the port has to be selected by the function block OPEN_COM ProfibusDP Slave Option (Connection X41) With the Profibus-DP slave option A-SPB the controller can communicate with a PROFIBUS (MASTER) acc. to DIN 19245, part 3. A-SPB can only be implemented in controller variants A4x-/A5-xCx. The Profibus Slave characteristics are saved inside the device-master-data-file ASPB0D4C.gsd. The file is part of the AIPEX PRO programing editor Characteristics The option A-SPB offers the following PROFIBUS-specific characteristics: Topology: Line, based on two-wire line acc. to RS485. Line has to be terminated by two characteristic impedances which are not integrated. The termination is realised by customer plug. Maximum of 32 devices per line By repeater enlarged up to 4 lines max. 122 devices. Maximum baudrate = 12 Mbit/s, automatically adapted to the baudrate of the MASTER Length of line depending on cable type and baudrate (see DIN 19245, part 3; e.g. 200 m with cable type A and 1,5 Mbit/s) If the baudrate is higher than 3 Mbit/s filter plug connectors must be used. AMK recommends the PROFIBUS terminating plug of ERNI Electronics GmbH, ID-No PDK_202975_A4-A5_Produktbeschreibung_en / Version 2013/04 53 / 91

54 SLAVE connection with max bytes cyclic input data bytes cyclic output data Standards: DIN 19245, EN and IEC The PLC program can also diagnose the Profibus function. Equivalent to other communication interfaces the function FuiGetNetStatus (uichannel: =2, uiaxisno:=0) can read the status of the Profibus communication. Profibus status: Bit 0 = 1: Profibus slave initialisation finished without error (ready for operation) Bit 1 = 1, Bit 4 = 1: Data exchange mode is active Parameterisation The Profibus-DP slave interface X41 is parameterised in instance 2 as follows: Parameter- ID Parameter-Name Value (Default) Description ID34140 'AS BUS protocol' 0x43 Profibus DP option A-SPB ID34143 'Usage port' 2 Cross communication ID34023 'BUS address participant' 0 Bus device adress ID34024 'BUS transmit rate' not used, automatic recognition of baudrate ID34025 'BUS mode' 0 Slave ID34026 'BUS mode attribute' 0 not used The data to exchange are configured in AIPEX PRO and also in the profibus master. (Further information please see AIPEX PRO chapter: Quick start / Profibus configuration) In the CoDeSys project the data is exchanged by function blocks for PLC/PLC communication (AmkDevAccess.lib\PlcVarAccess): Asynchronous data: GET_PLCVAR_ASYNC_XXXX resp. SET_PLCVAR_ASYNC_XXXX Synchronous data: GET_PLCVAR_SYNC_XXXX resp. SET_PLCVAR_SYNC_XXXX Thereby form the point of view of the profibus consistent modules are set up out of the synchronous function blocks respective not consistent modules out of asynchronous function blocks. Synchronous function blocks only are consistent, if they are called in the synchronous task FPLC_PRG. The run up of the Profibus communication must be completed faster than the drive fieldbus. If needed you can use at the drive fieldbus master a run up delay time via ID34026 'BUS mode attribute'. You will find further information for parameterization and data transfer inside the documentation PDK_ _Software_AIPEXpro_en.pdf chapter 'Quick start' 'Profibus configuration' Adjustment PB-Master Activate the Äquidistanten Buszyklus 54 / 91 PDK_202975_A4-A5_Produktbeschreibung_en / Version 2013/04

55 In the hardware configuration window of the SIMATIC Manager please open the window Eigenschaften DP Mastersystem and following the window Eigenschaften - Profibus. Choose the tab Netzeinstellungen and push the button Optionen. Activate the Äquidistanten Buszyklus. Push following the button Neu berechnen to calculate automatically the new "Äquidistanten DP-Zyklus. PDK_202975_A4-A5_Produktbeschreibung_en / Version 2013/04 55 / 91

56 5.12 Ethernet (Option C, Connection X60) Communication between different controllers at application level using IEC module libraries to apply UDP & TCP protocols Parameterisation The EtherCAT interface X60 is parameterised in the instance 7 as follows: Parameter Name Value Description ID34140 'AS BUS protocol' 2B* Ethernet 2 ID34143 'Usage port' 4* Software AIPEX PRO (CoDeSys) ID34023 ID34025 'BUS address participant' 'BUS mode' 0x0101* The Ethernet IP address is set in the IDs ID34023 and ID An Ethernet address of 0xaa.0xbb.0xcc.0xdd. results in the following ID assignment: ID34023: 0xccdd and ID34026: 0xaabb Default setting: Bit 3: 0* Ethernet class C network (subnet mask: ) Bit 3: 1 Ethernet class B network (subnet mask: ) ID34026 'BUS mode attribute' 0xC0A8* see ID34023 ID34057 'Network mask' 0x00FFFFFF ID34057 is used to set the network mask. Conditions similar to those for the ID34056 gateway address apply here. Example: 0x00FFFFFFh = class C network. * Default setting When using ID 34057, bit 3 must be equal to 0 in ID The two Ethernet interface X20 and X60 may not be assigned to the same network segment. Different network segments are on hand when the interfaces have been assigned different network classes or different segment addresses. Example 1: The interface X20 is set as a class B network and X60 as a class C network. Example 2: X20 is a class C network with an address of and X60 is a class C network with an address of EtherCAT Slave (Connection X85/X86) The interface is constructed as a real-time Ethernet slave interface and supports the EtherCAT SoE protocol (Servo Drive Profile according to IEC ). In connection with an EtherCAT master controller, a cross communication can be established between controllers. 56 / 91 PDK_202975_A4-A5_Produktbeschreibung_en / Version 2013/04

57 Further functions of the EtherCAT slave interface: Integration in a network according to IEC/PAS Topology: Bus, tree and star on Ethernet transmission physics Addresses possible between 1 and 255 Cyclic master-slave real-time communication Maximum baud rate according to the EtherCAT standard (currently 100 Mbaud) Unicast and multicast connections Synchronisation based on the principle of distributed clocks The controller internal system cycle (PGT) is synchronised to the bus cycle. The drive communication (EtherCAT or ACC-Bus) and the cross communication CC (EtherCAT) can be run in difference cycle times. Drive profile according to EtherCAT (SoE Servo Drive Profile IEC ) Norms IEC , IEC Further details and technical data on EtherCAT can be found at Configuration The EtherCAT slave interface X85/X86 is parameterised in the instance 2 as follows: Parameter Name Value Description ID34140 'AS BUS protocol' 0x41* EtherCAT slave option A-SEC ID34143 'Usage port' 2* CC Bus (cross communication) ID34023 'BUS address participant' 0* Bus device address ID34024 'BUS transmit rate' * 100 Mbaud ID34025 'BUS mode' 0* Slave ID34026 'BUS mode attribute' 0* - ID1204 'XML file' Bus configuration file ID1205 'XML file' Bus configuration file ID1206 'XML file' Bus configuration file ID1207 'XML file' Bus configuration file * Default setting PDK_202975_A4-A5_Produktbeschreibung_en / Version 2013/04 57 / 91

58 Cross-Communication Several controllers can be connected through the EtherCAT cross communication (CC cross communication). All controllers and the connected AMKASYN converters are synchronised by means of this cross-communication. Parameterization of CC Master controller: EtherCAT interface X186, Instance 5, ID34143 'Usage port' = 2 (CC-Bus cross communication) Parameterization of CC Slave controller: EtherCAT (CC) interface X85/X86, Instance 2, ID34143 'Usage port' = 2 (CC-Bus cross communication) 58 / 91 PDK_202975_A4-A5_Produktbeschreibung_en / Version 2013/04

59 The run up of the cross communication must be completed faster than the drive fieldbus. If needed you can use at the drive fieldbus master a run up delay time via ID34026 'BUS mode attribute'. For programming with CoDeSys all controllers must be connected via Ethernet with AIPEX PRO. Parameterization of all controllers and all drives via CC Master is possible (programming in preparation) Example configuration: see documentation PDK_202234_Software_AIPEX_PRO chapter / Cross Communication - Offline project and Cross Communication - Online import and configuration. Example: Data transfer between two controllers Enter inside the CC Master 'PLC configuration' folder 'PlcComVars' a symbolic Variable (e.g. g_plcvariablea) You will find inside the AMK library 'AmkDevAccess.lib' Ordner 'PlcVar Access' the functions blocks for asynchronous and synchronous data transfer between PLC controllers. The SET_PLCVAR blocks will send data. Activate further the automatically message configurator. Allocate your symbolic variable to the CC Slave controller (display 'Access'). Create the CC Slave CoDeSys program. The symbolic variable will be imported automatically. Use a GET_PLCVAR function block to receive your PLC Master data. Activate further the automatically message configurator. Restart the complete system ACC Bus Master (Connection X137) The ACC bus is a standard 2.0B CAN bus connection, which features an additional hardware synchronisation. It supports the CANopen protocol DS301 V4.01. The hardware synchronisation system synchronises the bus messages (PDO) on the AMK system cycle (defined in ID2) with a precision of <1µs. Position setpoints, the fine interpolation or the tracking error compensation are carried out for example synchronously on this cycle by the setpoint sources in the drive. To be able to use hardware synchronisation, a participant is configured as transmitter (recommended ACC bus master ) and all other participants as receivers of the hardware synchronisation cycle in ID34026 'BUS mode attribute'. The ACC bus master can reach all participants in the network, thereby permitting central evaluation of diagnostic messages and the master can read and write parameters in the slaves. If a connection is established with AIPEX PRO from the PC to the ACC bus master, then all connected participants can be reached by the AIPEX PRO software Configuring Cyclic Data The data, which is exchanged cyclically, is configured automatically by AIPEX PRO matching the PLC program, consisting of AMK V03 libraries, automatically configured Parameterisation The ACC bus master interface X137 is parameterised in the instance 1 as follows: Parameter Name Value Description ID34140 'AS BUS protocol' 0x40* ACC bus master [option A- MEC] ID34143 'Usage port' 1* Drive communication ID34023 'BUS address participant' 1* Bus device address ID34024 'BUS transmit rate' 1000* 100 Mbaud ID34025 'BUS mode' 2* Master ID34026 'BUS mode attribute' 88* - ID34036 'CCB-File' Bus configuration file * Default setting PDK_202975_A4-A5_Produktbeschreibung_en / Version 2013/04 59 / 91

60 5.15 EtherCAT Master (Connection X186) The EtherCAT master interface exchanges drive data such as position and speed setpoints or actual position values directly with the AMKASYN converter or establishes a cross communication to other EtherCAT slave controllers. Further functions of the EtherCAT master interface: Integration in a network according to IEC/PAS Automatic configuration with the AIPEX PRO software Topology: Bus, tree and star on Ethernet transmission physics Maximum of 255 devices Cyclic master-slave real-time communication (min. 250µs bus cycle time) Maximum baud rate according to the EtherCAT standard (currently 100 Mbaud) Unicast and multicast connections Synchronisation based on the principle of distributed clocks The controller internal system cycle (PGT) is synchronised to the bus cycle. Drive profile according to EtherCAT (SoE Servo Drive Profile IEC ) Norms IEC , IEC Further details and technical data on EtherCAT can be found at Configuring Cyclic Data The data, which is exchanged cyclically, is configured automatically by AIPEX PRO matching the PLC program, consisting of AMK V03 libraries, automatically configured Configuration The EtherCAT master interface X186 is parameterised in the instance 5 as follows: Parameter Name Value Description ID34140 'AS BUS protocol' 0x41* EtherCAT master option A- MEC ID34143 'Usage port' 1* Drive communication ID34023 'BUS address participant' 255* Bus device address ID34024 'BUS transmit rate' * 100 Mbaud ID34025 'BUS mode' 2* Master ID34026 'BUS mode attribute' 0* - ID1204 'XML file' Bus configuration file ID1205 'XML file' Bus configuration file ID1206 'XML file' Bus configuration file ID1207 'XML file' Bus configuration file * Default setting 5.16 USB Device (Connection X235) --> In Preparation! The X235 is a USB-client interface by which the controller can be connected directly to the USB interface of a PC in order to make use of the AIPEX PRO software. The connection functions without further settings with the default settings of the controller. 60 / 91 PDK_202975_A4-A5_Produktbeschreibung_en / Version 2013/04

61 Parameterisation The USB device interface X235 is parameterised in the instance 0 as follows: Parameter Name Value Description ID34140 'AS BUS protocol' tbd. tbd. ID34143 'Usage port' tbd. Drive communication ID34023 'BUS address participant' tbd. Bus device address ID34024 'BUS transmit rate' tbd. 1 Mbit/s ID34025 'BUS mode' tbd. Master ID34026 * Default setting 'BUS mode attribute' tbd. Attribute 5.17 I/O Expansion [Option E] (Connections X120, X121, X122) The I/O option expands the controller by the following interfaces: 10 digital inputs or 8 digital and 2 probe inputs 6 digital outputs or 4 digital and 2 time stamp outputs 2 analogue inputs with/without output reference voltage 10 V Parameterable modes: Mode 1: -10 V V Mode 2: V 1 hand wheel input / pulse encoder input 2 square-wave signals, offset by 90, and zero pulse Cycle time of the I/O expansion: 1 ms Parameterisation The option IO with the interfaces X120, X121, X122 are parameterised in the instance 3 as follows: Parameter Name Value Description ID34140 'AS BUS protocol' 0x50 I/O expansion, option E ID34143 'Usage port' 0 - ID34023 'BUS address participant' 0 - ID34024 'BUS transmit rate' 0 - ID34025 'BUS mode' 2 Master ID34026 'BUS mode attribute' 0 - The set up of I/O functions has to done via SDO access. See Indexlist I/O-Option on page Probe Inputs With the probe inputs (X122 pin 2 and pin 3) you can e.g. measure high-precision the time difference between physical and PLC received binary signal change. This difference time will be lend for the user as timestamp. The binary input signals are identified by the controller on the basis of the dead and cycle times at the earliest during the next cycle of the peripheral ground tact (PGT). The PGT corresponds to the value specified under ID2 'SERCOS cycle time'. The probe inputs and the CoDeSys function blocks can be used to measure and subsequently calculate the delays in ns up to signal change (see index 0x3810 and 0x3811). Furthermore, a custom dead-time can be entered for each input and each edge in the µs grid. Each input has two 64 bit timestamps: one for rising edges and one for falling edges. PDK_202975_A4-A5_Produktbeschreibung_en / Version 2013/04 61 / 91

62 With the CoDeSys you can import the application layer 'TimeStamp'. Click on the CoDeSys menu 'Edit' 'Macros' 'ImportIoSupport' 'TimeStamp'. Following you can use the function block 'GET_TS_INPUTS'. CoDeSys visualization element GET_TS_INPUTS SelInput: 1 = probe input 1 active SelInput: 2 = probe input 2 active SelInput: 3 = probe input 1+ 2 active PosTransT1: Timestamp positive edge probe input 1 NegTransT1: Timestamp negative edge probe input 1 PosTransT2: Timestamp positive edge probe input 2 NegTransT2: Timestamp negative edge probe input Timestamp Outputs Both timestamp outputs (X122 pin 4 and pin 5) will be high-precise refreshed. The user can enter the certain time. Before using, you have to activate the timestamp outputs (see index 0x6300). The timestamp outputs are applied with a timestamp by the PLC program and transferred within the periphery ground tact (PGT) to the I/O. The PGT corresponds to the value specified under ID2 'SERCOS cycle time'. The output is set when the preset time has expired and must be at least 3 PGT cycles + dead time. The timestamp is valid for both timestamp outputs. 62 / 91 PDK_202975_A4-A5_Produktbeschreibung_en / Version 2013/04

63 Furthermore, a custom dead-time can be entered for each timestamp output and each edge in the µs grid (see index 0x3810, 0x3811, 0x3900 und 0x3901). In addition, the dead times are compared for all edges during the manufacturing process. Example: StartTime ns, Output = 1 With the CoDeSys you can import the application layer 'TimeStamp'. Click on the CoDeSys menu 'Edit' 'Macros' 'ImportIoSupport' 'TimeStamp'. Following you can use the function block 'SET_TS_OUTPUTS'. CoDeSys visualization element SET_TS_OUTPUTS StartTime: Time-setting up to changing signal PDK_202975_A4-A5_Produktbeschreibung_en / Version 2013/04 63 / 91

64 With the variable 'Output' the outputs A1 and A2 will be set and reset. A a value changing of the variable output starts the function. Output A1 A Activating timestamp outputs The timestamp outputs are activated and deactivated using the parameter 'Output Mode'. The parameter 'Output Mode' occupies: index 0x6300, subindex 2, data type UINT16. The parameter 'Output Mode' must be written with an SDO command. They can use the function block WRITE_SDO in AmkSystem.lib in CoDeSys for this purpose. Controller word Index Subindex Value - Mode output Meaning 0x h (default) 6 standard binary outputs 0x h 2 timestamp outputs (X122 pins 4/5) 4 standard binary outputs Changes in parameter setting will become active after execute a system booting! Access to the binary output word (default) Binary output Index Subindex CoDeSys Parameter Standard 0x I/O map for controller configuration Output word when output mode = 0x3 ID34120 Bit A6 A5 A4 A3 A2 A1 X Pin 9 Pin 8 Pin 7 Pin 6 Pin 5 Pin 4 Output word when output mode = 0x0 Bit A6 A5 A4 A3 - - X Pin 9 Pin 8 Pin 7 Pin 6 Pin 5 Pin 4 Access to the binary output word (timestamp) Binary output Index Subindex CoDeSys Timestamp 0x I/O map for controller configuration Output word when output mode = 0x0 Bit A2 A1 X Pin 5 Pin Analogue Inputs The analogue inputs are converted cyclically in the periphery basic clock rate (PGT). The PGT is equal to the value of ID2 'SERCOS cycle time'. Analogue input 1 = X120, pin 1A, 1B, 2A, 2B 64 / 91 PDK_202975_A4-A5_Produktbeschreibung_en / Version 2013/04

65 Analogue input 2 = X120, pin 3A, 3B, 4A, 4B The voltage of the analogue input can be corrected by an offset or a scaling factor. Scaling factor = default 1 V = (Range ) ADC value = (scaling factor * input voltage [V]) + offset [mv] Parametrisation via SDO Control word Meaning Index Subindex Dimension Analogue input 1 Offset mv Analogue input 1 Scaling factor Analogue input 2 Offset 40A2 01 mv Analogue input 2 Scaling factor 40A Access to analogue input voltages Analogue input Index Subindex CoDeSys Parameter Analogue input FB GET_INPUT_ANALOG1 oder Steuerungskonfiguration ID32897 Analogue input FB GET_INPUT_ANALOG2 oder Steuerungskonfiguration ID32898 Status word Status word Index Subindex FB CoDeSys Analogue input GET_INPUT_ANALOG1_STATUS Analogue input GET_INPUT_ANALOG2_STATUS Aufbau des Statusworts Bit Name Meaning 0 Underflow Measured value < -10V 1 Overflow Measured value> +10V 2 Reserved Reserved = 0 3 Error General failure during convertion 4-15 Reserved Reserved = Square-Wave Signal Input The square-wave signal input supports the quadrature encoder mode (incremental encoder input). The square-wave signal input is mapped to a 16-bit counter with latch. The latch function can be triggered in two different manners which are addressed by the control word. Zero pulse on NIP input (X120B, pin 5A-5B) Positive or negative edge of 24 V latch signal input (X122, pin 2; matches EM1 input) There are two modes of measurement which are addressed by bit 8 of the control word: Continuous measuring: the value of the counter is saved with every latch signal, release is not necessary. Singular measuring: each measurement must be deactivated by latch signal release in the control word and then activated again. The count will be saved until a new measurement is started. Parametrisation via SDO Square-wave signal input Index Sub index CoDeSys Control word SET_ENCODER_CONTROL Structure of control word Bit Name Meaning 0 Enable NIP Latch This bit activates the latch with NIP signal. In operation mode 'continuous measuring', this bit must be set only once. In operation mode 'singular measuring', the bit must be reset and set again when the corresponding bit of the status word was reset. The maximum measuring frequency of this module is 4 khz. PDK_202975_A4-A5_Produktbeschreibung_en / Version 2013/04 65 / 91

66 Bit Name Meaning 1 Enable EM1 Latch rising edge The bit activates the latch with a rising edge on EM1 input. In operation mode 'continuous measuring', this bit must be set only once. In operation mode 'singular measuring', the bit must be reset and set again when the corresponding bit of the status word was reset. The maximum measuring frequency of this module is 4 khz. 2 Init Counter By reset and new set of this bit, an initialisation of the count with the value of index 7010, sub index 2, is made. 3 Enable EM1 Latch falling edge 8 Single Trigger Mode Access to square-wave signal input The bit activates the latch with a falling edge on EM1 input. In operation mode 'continuous measuring', this bit must be set only once. In operation mode 'singular measuring', the bit must be reset and set again when the corresponding bit of the status word was reset. The maximum measuring frequency of this module is 4 khz. This bit addresses the mode of measuring. 0: 'continuous measuring' is active 1: 'singular measuring' is active Square-wave signal input Index Sub index CoDeSys Parameter Actual count GET_ENCODER_VALUE ID34075 Saved count (Reference count) GET_ENCODER_LATCH ID34074 Status word Square-wave signal input Index Sub index CoDeSys Status word GET_ENCODER_STATUS Structure of status word Bit Name Meaning 0 Latch NIP A NIP occurs and a count is saved. The latch of a count with NIP must be activated by the control word, index 7010:1. Depending on the mode of measuring, this bit is set for one PGT cycle ('continuous measuring') or until the corresponding release bit of the control word is reset ('singular measuring'). 1 Latch EM1 A latch signal on EM1 occurs and a count is saved. The latch of a count with EM1 input must be activated by the control word, index 7010:1. Depending on the mode of measuring, this bit is set for one PGT cycle ('continuous measuring') or until the corresponding release bit of the control word is reset ('singular measuring'). 2 Initialized The initial value of index 7010:2 is loaded to the counter register. The initialisation is started by reset and set of index 7010:1, bit 2 3 Underflow In case of an underflow (0 to 65535) of the 16 bit count, this bit is set. It will be reset when the counter falls below 2/3 of the counter range (43690 to 43689) or when an overflow occurs. 4 Overflow In case of an overflow (65535 to 0) of the 16 bit count, this bit is set. It will be reset when the counter falls below 1/3 of the counter range (21845 to 21846) or when an underflow occurs. 5 EM1 Level Level of the EM1 input Indexlist I/O-Option The I/O-Option parameters are defined as CANopen parameters. The indices are in the most time compatible to the CANopen I/O-profile DS401. The access onto the index lists can be done with the CoDeSys functions blocks WRITE_SDO (FB) und READ_SDO (FB). You will find the function blocks inside the library AmkSystem.lib. 66 / 91 PDK_202975_A4-A5_Produktbeschreibung_en / Version 2013/04

67 Device Type Structure Information on the device functionality Index Subindex Bit Meaning 0x1000 0x Device communication profile device supports digital inputs device supports digital outputs device supports analog inputs device does not support analog inputs reserved auxiliary function Device Data Index Subindex Access Data type Default value Meaning 00x1000 0x0 No RO UINT32 0x Device type 0x1008 0x0 No RO String "A-IO1" Device name The low word contains the CoE profile in use. 0x1009 0x0 No RO String "AS-EA1-1.01" Hardware version description 0x100A 0x0 No RO String "AS-EA1 1049" Software version description 0x1018 0x0 No RO UINT8 0x4 Device information Length of this object 0x1 No RO UINT32 0x000001EB Manufacturer's ID 0x2 No RO UINT32 0x00FF0060 Product code 0x3 No RO UINT32 0x Hardware version 0x4 No RO UINT32 0x Device serial number Service Data Index RT RT mapping Subindex mapping Access Data type Default value Meaning 0x1011 0x0 No RO UINT8 0x1 Restore default settings 0x1 No RW String (not zeroterminated) load Length of this object If you write to this object "0x64616F6C", all configuration parameters will be returned to their default statuses. 0x2FFF 0x0 No RW UINT32 0xCC33C33 Firmware update A firmware update will be started by writing the default value to this index. The command is acknowledged and the boot loader starts. If an other value is written, the command will be acknowledged negatively. PDK_202975_A4-A5_Produktbeschreibung_en / Version 2013/04 67 / 91

68 Index RT Subindex mapping Access Data type Default value Meaning 0x5146 0x0 No RW UINT32 0x Memory access address The memory of the device can be reached by indices 0x5146 and 0x5147. This index configures the memory address of the acces. Following address ranges exist: 0x3F Flash memory RO 0x3F800 0x SEEP and data base 0x x3F7F7E CRC32 checksum of the software RO 0x5147 0x0 No RO UINT8 0x3 Memory access data 0x1 No RW UINT8 0x00 Byte data 0x2 No RW UINT16 0x0000 Word data Length of this object Byte access to the address which is written in index 0x5146 Word access to the address which is written in index 0x5146 0x3 No RW UINT32 0x Double word data Double word access to the address which is written in index 0x Configuration and Process Data Access RO = Read only Access RW = Read and write Access WO = Write only RT mapping = cyclic data exchange Index Subindex RT mapping Access Data type Default value Meaning 0x3200 0x0 No RO UINT8 0x3 Square-wave input current 0x1 Yes RO UINT16 0x0000 Status Length of this object PLC: GET_ENCODER1_STATUS 0x2 Yes RO UINT16 0x0000 Current counter value PLC: GET_ENCODER1_VALUE 0x3 Yes RO UINT16 0x0000 Reference counter PLC: GET_ENCODER1_LATCH Index Subindex RT mapping Access Data type Default value Meaning 0x3210 0x0 No RO UINT8 0x2 Square-wave input default Length of this object 0x1 Yes RW UINT16 0x0000 Controller word 0x2 No RW UINT16 0x0000 Initial value PLC: SET_ENCODER1_CONTROL 68 / 91 PDK_202975_A4-A5_Produktbeschreibung_en / Version 2013/04

69 Index Subindex RT mapping Access Data type Default value Meaning 0x3800 0x0 No RO UINT8 0x4 Manufacturer's dead-time of touch probe Length of this object 0x1 No RO UINT16 0x0000 Manufacturer's dead-time of touch probe input 1 Rising edge 0x2 No RO UINT16 0x0000 Manufacturer's dead-time of touch probe input 1 Falling edge 0x3 No RO UINT16 0x0000 Manufacturer's dead-time of touch probe input 2 Rising edge 0x4 No RO UINT16 0x0000 Manufacturer's dead-time of touch probe input 2 Falling edge Index Subindex RT mapping Access Data type Default value Meaning 0x3801 0x0 No RO UINT8 0x4 User dead-time of touch probe Length of this object 0x1 No RW UINT16 0 µs User dead-time of touch probe input 1 Rising edge [µs] 0x2 No RW UINT16 0 µs User dead-time of touch probe input 1 Falling edge [µs] 0x3 No RW UINT16 0 µs User dead-time of touch probe input 2 Rising edge [µs] 0x4 No RW UINT16 0 µs User dead-time of touch probe input 2 Falling edge [µs] Index Subindex RT mapping Access Data type Default value Meaning 0x3810 0x0 No RO UINT16 0x3 Probe input 1 Length of this object 0x1 Yes RO UINT16 0x0000 Status word PLC: GET_TS_INPUT1_STATUS 0x2 Yes RO UINT64 0 ns Timestamp, falling edge [ns] PLC: GET_TS_INPUT1_LATCH_NEG 0x3 Yes RO UINT64 0 ns Timestamp rising edge [ns] PLC: GET_TS_INPUT1_LATCH_POS 0x3811 0x0 No RO UINT8 0x3 Probe input 2 Length of this object 0x1 Yes RO UINT16 0x0000 Status word PLC: GET_TS_INPUT2_STATUS 0x2 Yes RO UINT64 0 ns Timestamp, falling edge [ns] PLC: GET_TS_INPUT2_LATCH_NEG 0x3 Yes RO UINT64 0 ns Timestamp rising edge [ns] PLC: GET_TS_INPUT2_LATCH_POS PDK_202975_A4-A5_Produktbeschreibung_en / Version 2013/04 69 / 91

70 Index Subindex RT mapping Access Data type Default value Meaning 0x3900 0x0 No RO UINT8 0x4 Manufacturer's dead-time, timestamp output Length of this object 0x1 No RO UINT16 0x0000 Manufacturer's dead-time, timestamp output 1 Rising edge 0x2 No RO UINT16 0x0000 Manufacturer's dead-time, timestamp output 1 Falling edge 0x3 No RO UINT16 0x0000 Manufacturer's dead-time, timestamp output 2 Rising edge 0x4 No RO UINT16 0x0000 Manufacturer's dead-time, timestamp output 2 Falling edge Index Subindex RT mapping Access Data type Default value Meaning 0x3901 0x0 No RO UINT8 0x4 User dead-time, timestamp output Length of this object 0x1 No RW UINT16 0 µs User dead-time, timestamp output 1 Rising edge [µs] 0x2 No RW UINT16 0 µs User dead-time, timestamp output 1 Falling edge [µs] 0x3 No RW UINT16 0 µs User dead-time, timestamp output 2 Rising edge [µs] 0x4 No RW UINT16 0 µs User dead-time, timestamp output 2 Falling edge [µs] Index Subindex RT mapping Access Data type Default value Meaning 0x3910 0x0 No RO UINT8 0x3 Timestamp outputs Length of this object 0x1 Yes RW UINT16 0x0000 Output value PLC: SET_TS_OUTPUT 0x2 Yes WO UINT16 0 ns Enable output value 0x3 Yes RW UINT64 0 ns Time default [ns] PLC: SET_TS_OUTPUT_ACTIVATE PLC: SET_TS_OUTPUT_TIME Index Subindex RT mapping Access Data type Default value Meaning 0x4042 0x0 No RO UINT8 0x2 Manufacturer parameter, analogue channel 1 Length of this object 0x1 No RO SINT16 0x0000 Manufacturer offset, analogue channel 1 0x2 No RO UINT16 0x0000 Manufacturer gain analogue channel 1 70 / 91 PDK_202975_A4-A5_Produktbeschreibung_en / Version 2013/04

71 Index Subindex RT mapping Access Data type Default value Meaning 0x4061 0x0 No RO UINT8 0x12 Analogue input channel 1 Length of this object 0x1 No RO BOOL 0x0 Underflow Flag 0x2 No RO BOOL 0x0 Overflow Flag 0x7 No RO BOOL 0x0 Error Flag 0x12 Yes RO UINT16 0x0 Status word PLC: GET_INPUT_ANALOG1_STATUS Index Subindex RT mapping Access Data type Default value Meaning 0x4062 0x0 No RO UINT8 0x2 User parameter, analogue channel 1 Length of this object 0x1 No RW SINT16 0 mv User offset analogue channel 1 [mv] 0x2 No RW UINT User gain analogue channel 1 Index Subindex RT mapping Access Data type Default value Meaning 0x4082 0x0 No RO UINT8 0x2 Manufacturer parameter, analogue channel 2 Length of this object 0x1 No RO SINT16 0x0000 Manufacturer offset analogue channel 2 0x2 No RO UINT16 0x0000 Manufacturer gain analogue channel 2 Index Subindex RT mapping Access Data type Default value Meaning 0x40A1 0x0 No RO UINT8 0x12 Analogue input channel 2 Length of this object 0x1 No RO BOOL 0x0000 Underflow flag 0x2 No RO BOOL 0x0000 Overflow flag 0x7 No RO BOOL 0x0000 Error flag 0x12 Yes RO UINT16 0x0000 Status word PLC: GET_INPUT_ANALOG2_STATUS Index Subindex RT mapping Access Data type Default value Meaning 0x40A2 0x0 No RO UINT8 0x2 User parameter, analogue channel 2 Length of this object 0x1 No RW SINT16 0 mv User offset analogue channel 2 [mv] 0x2 No RW UINT User gain analogue channel 2 Index Subindex RT mapping Access Data type Default value Meaning 0x6100 0x0 No RO UINT8 0x1 Binary inputs 0x1 Yes RO UINT16 0x0000 Input value Number of 16 bit inputs PLC: I/O map (bits 0-7),GET_TS_INPUT (bits 8-15) PDK_202975_A4-A5_Produktbeschreibung_en / Version 2013/04 71 / 91

72 Index Subindex RT mapping Access Data type Default value Meaning 0x6300 0x0 No RO UINT8 0x2 Binary outputs Length of this object 0x1 Yes RW UINT16 0x0000 Output value PLC: I/O map 0x2 No RW UINT16 0x0003 Mode output Index Subindex RT Mapping Zugriff Datentyp Default Wert Bedeutung 0x6401 0x0 No RO UINT8 0x2 Analogue inputs Number of channels 0x1 Yes RO UINT16 0 mv Analogue input voltage channel 1 [mv] PLC: GET_INPUT_ANALOG1 0x2 Yes RO UINT16 0 mv Analogue input voltage channel 2 [mv] PLC: GET_INPUT_ANALOG Initial Program Loading During the initial program loading function, all parameters (IDs) are reset to their default values and the PLC program files are deleted. This includes: PLC program PLC status files WEB visualisation files The initial program loading function is started with the AIPEX PRO PC software: Menu item 'Startup' - 'Initial program loading' or Select the button 'Initial program loading' in the 'Direct mode' Data Exchange via File Transfer Protocol FTP The File Transfer Protocol "FTP" may be used to transfer files from computer A to computer B. The computers do not even need to run the same operating systems. An FTP connection consists of one FTP server and at least one FTP client. A username and password needs to be set up at the FTP server for each client. The FTP client can log on to the FTP server and exchange files according to its user rights. FTP client programs are integrated in a standard browser, such as Microsoft Internet Explorer. The FTP server is provided by the AMK controller Example: FTP Connection with Microsoft Internet Explorer The following example shows the connection establishment and data exchange between an AMK controller (FTP server) and a computer (FTP client) on which Microsoft Internet Explorer is installed. It is asumed that FTP server function and AMK controller are active. 1. Step 2. Step Connect PC and AMK controller. For a point-to-point connection between PC and controller, you need an Ethernet crossover network cable. For a connection via network, you need a standard Ethernet network cable. Switch on the AMK controller. FTP server is started when the AMK controller is started up. Start Microsoft Internet Explorer. Enter 'ftp' and the IP address of the AMK controller into the address bar: ftp://<ip address of AMK controller> Confirm with Return 72 / 91 PDK_202975_A4-A5_Produktbeschreibung_en / Version 2013/04

73 3. Step The AMK controller is protected by password. So you cannot login directly. Confirm the 'FTP Folder Error' with OK. 4. Step Login as user onto the AMK controller Therefore select 'Login As...' in menu 'File' 5. Step In the AMK controller two users are defined: User password 'user' Service password '*******' With 'user', you get access onto the (customer) cst directory. In this directory all files (i.e. tables of the cam editor) are saved on which the PLC program needs to access. With 'service' you get complete access to the whole directory structure of the AMK controller. To log on, enter a user name and password. 6. Step The following picture shows how the CST directory can look like All standard Windows functions (i.e. copy, paste, delete) can be used in the CST directory PDK_202975_A4-A5_Produktbeschreibung_en / Version 2013/04 73 / 91

74 5.20 Time Synchronisation The controlller time can be synchronised via ethernet with an external time server (NTP server) so that all synchronised controllers get the same time. It can be used for example as a time stamp when writing files. The synchronisation occurs by 'network time protocol (NTP)'. The IP address of the NTP server (ID 34173, 'NTP server address') must be declared in the controller. On each 'power on' of the controller the internal time and the real time clock are one-time set to the time of the NTP server. During operation the internal time is constantly updated to the server time. If the NTP server can not be reached at power-on the time synchronisatin will not be started Dimming of Backlight The backlight of controllers with display A4D / A5D can be dimmed after a adjustable time. The function is configured by the following parameters: Parameter Name Description ID34267 'Backlight dim delay' Delay time: Time after the last touch of the screen until the backlight will be reduced ID34268 'Backlight brightness' Brightness of the backlight if it is not dimmed [% of maximum brightness] ID34269 'Backlight dim value' Brightness of the backlight when it is dimmed [% of maximum brightness] 5.22 UPS In preparation 74 / 91 PDK_202975_A4-A5_Produktbeschreibung_en / Version 2013/04

75 6 Startup 6.1 For Your Safety WARNING Hazard because of changing parameters! The faulty entering of parameters to the controller card significantly influences the drive system characteristics and creates an increased risk of accidents and damages! Steps to prevent: Parameters may not be modified by the machine operator unless upon consultation with the machine manufacturer. Change parameters only if you are sure of the meanings and the consequences. If you are unsure, read the parameter documentation or ask the manufacturer or supplier. 6.2 Avoiding Material Damage Material Damage! NOTICE Electronic components could be destroyed through static discharge! Therefore touching of the electrical connections (e.g. signal and power supply cable or option and controller cards) must be avoided. Steps to prevent: Avoid touching electrical connections and contacts During handling the electronic component discharge yourself by touching PE Pay attention to the ESD-notes (electrostatic discharge) NOTICE Electrical short-circuit due to condensation water! If electrically conductive fluids such a condensed water enters the inverter module, there may be a short circuit, thus leading to damage or even destruction of the module. Do not allow condensation to form in the cabinet. Material Damage! Steps to prevent: The cabinet cooling needs to be designed according to the dew point table so that no condensation water forms. The dew point table specifies at which surface temperature dew water forms depending on the air temperature and the relative humidity. Example: Cabinet temperature: 32 C, humidity: 60 % The temperature of the cooling circuit may not be less than 23 C, otherwise, condensation water will form. 6.3 Prerequisites Check if the controller has been properly installed and connected. Make sure that the vent openings of the controller are free. Consult your IT administrator before you connect the controller to an existing network. 6.4 Establishing Connection Between Controller and PC For starting up, a connection needs to be established between the controller and a PC with the AMK software AIPEX PRO. The connection can be established either by the USB device port X235 or the Ethernet interface X20. PDK_202975_A4-A5_Produktbeschreibung_en / Version 2013/04 75 / 91

76 Name Default value Parameter instance 4 IP address ID34023 and ID34026 Network mask ID34057 Gateway address ID34056 DNS server address ID32416 Using AIPEX PRO, you can adapt the parameters for your network Connection via USB Device X235 The PC software AIPEX PRO can directly access the USB controller's interface via the USB interface on the PC if both devices are connected by a USB cable Connection via Ethernet Interface X20 If you want the put the controller into operation with the Ethernet interface X20, carry out the following steps: 1. Connect the controller (Ethernet connection X20) to a PC by one of the following methods: Point-to-point connection: The PC and the controller are connected directly with each other by a crossover cable. Network connection: The controller is connected to an existing network. Information on the parameterisation: see Ethernet (Connection X20) on page Setting IP address In order for a controller to be operated in a network, a unique IP address has to be assigned to it. The participants in the network are recognised by their IP address and can communicate with each other. The IP address can be permanently set or assigned dynamically by the server (DHCP) Information on the parameterisation: see Ethernet (Connection X20) on page Setting the network mask A network mask has to be specified for each IP address. The network mask specifies at which partial network the controller is connected (class C network) (class B network) (class A network) Information on the parameterisation: see Ethernet (Connection X20) on page Setting the gateway address The gateway connects two different networks. Different networks can meet each other, for example during remote maintenance tasks. The gateway address is the IP address of the device in the own network that is used as a gateway to the other network (e.g., PC or router). The participants that do not function as a gateway need to be informed about this factory-set gateway address ( ). Information on the parameterisation: see Ethernet (Connection X20) on page Setting the DNS server address If the DNS server receives a host name e.g., it responds with the corresponding IP address e.g., The DNS server address may only be changed if there is a DNS server in the network. (This function is only important if you use the library AmkFile.Lib in the CoDeSys. Information on the parameterisation: see Ethernet (Connection X20) on page / 91 PDK_202975_A4-A5_Produktbeschreibung_en / Version 2013/04

77 6.5 Changing the IP Address With the AMK Ethernet monitor, the IP address can be modified directly in the controllers. The AMK default address is identified independently of the subnet mask (network class). Prerequisite: AIPEX PRO 1.07 Device is not connected to a PC. (status white) Button present (starting from firmware version AS_402_1036_203229) Press the button. In the Set IP dialog you can enter the new IP address and the associated subnet mask. After confirming with OK, the new address is accepted. To do so, the controller is restarted. The communication between PC and controller is interrupted for this period. PDK_202975_A4-A5_Produktbeschreibung_en / Version 2013/04 77 / 91

78 6.6 A4D / A5D Startup with a Keyboard This chapter describes how to configure and calibrate a display controller using an external keyboard. Connect a keyboard to USB interface X22. Switch on the controller by connecting it to the main power supply. After initialisation, the following window section appears. Press any key of the USB keyboard within the next 2 seconds. The subsequent password query prevents unauthorised modification of the settings. Divulge the password " " only to authorised persons (end customers). Menu selection 1 Configuration: Configuration of IP settings and PLC address (Web-Visu) 2 tools: Selection menu 'Touch Screen Calibration' or time/date settings Confirm by pressing < Select [RETURN button] > 78 / 91 PDK_202975_A4-A5_Produktbeschreibung_en / Version 2013/04

79 Configuration of IP settings and the PLC address (Web-Visu) X20 IP Address IP address of default Ethernet interface X20 Subnetmask Network mask for X20 IP address X60 IP Address IP address of optional Ethernet interface [controller version A5S/D-xCx] X20 Subnetmask Network mask for X20 IP address Gateway address No gateway found. For more information on the IP address, network mask and gateway address: See Establishing Connection Between Controller and PC on page 75. DNS Serveraddr. Default setting (local host) When using a domain name system service in the network, the IP address of the DNS server must be entered. PDK_202975_A4-A5_Produktbeschreibung_en / Version 2013/04 79 / 91

80 PLC Address With the A5D display controller, the PLC address is IP address of the device-internal PLC controller. This is not to be confused with the device address X20 and X60. The factory preset PLC address is: (Local Host) This means the WEB visualization stored in the controller is automatically loaded. If you are using the controller only as a visualization device, the IP address of the controller that serves as the WEB-VISU server must be entered as the PLC address. Mouse visible Use 'Mouse visible' to show or hide the cursor on the controller. Connect the mouse instead of the keyboard to USB interface X22. Upright mode: Off = Default setting (controller installed upright) On = If the controller is installed upright, the display can be rotated by 90. Qt Visualization: Off = Qt visualization disabled On = Controller supports Qt visualization Press < Apply [RETURN button] > to save the changes and close the configuration menu. Selection menu 'Touch Screen Calibration' or time/date settings Select the required menu. Confirm by pressing < Start [RETURN button] > Touch Screen calibration Follow the instructions shown on the display. 80 / 91 PDK_202975_A4-A5_Produktbeschreibung_en / Version 2013/04

81 Set Real-Time clock Configuration menu for time/date The time zone is set in parameter ID32917 'Time zone' Press < Apply [RETURN button] > to save the changes and close the configuration menu. PDK_202975_A4-A5_Produktbeschreibung_en / Version 2013/04 81 / 91

82 7 Maintenance The BIOS settings as well as date and time are stored in a battery-buffered CMOS module. Every time you switch on the condition of the controller's battery is checked. In case of an error, the controller generates the warning 3863 'System diagnostics: Router memory overflow',info1 = 11 'Battery error'. The system time is set to 00:00:00 hours and the system date to Battery life is 3 years if the device is not switched on. If the device is switched on, service life extends to 5-10 years. To exchange the battery, send the device to AMK for maintenance. 82 / 91 PDK_202975_A4-A5_Produktbeschreibung_en / Version 2013/04

83 8 Service 8.1 Diagnosis Diagnostic messages (error and warning messages) are saved in an internal diagnosis buffer. The diagnostic messages can be accessed by reading out the diagnosis parameters ID390 'Diagnostic number', ID32840 'Diagnostic list', ID32962 'List of error codes' or the event memory ID34088 'Event trace'. The diagnosis parameters can be evaluated with AIPEX PRO or the PLC application program. Error and warning messages are deleted by writing the value 1 into the parameter ID32913 'Clear error'. Additional information: PDK_xxxxxx_Parameter_AMKAMAC_A4-5 (in preparation) 8.2 Transferring Firmware Into the Controller The firmware is the firmware of the controller. The current firmware is pre-installed by the factory on the controller. In case you want to replace the firmware existing in the controller by a different one, proceed as follows: Prerequisites: Software AMK Tool Flasher (ATF) at least version /18, installation with the AIPEX PRO software AIPEX PRO at least version 1.07 Complete firmware files as AS_xxx_xxxx_xxxxxx.zip file A4: at least A4 V /51 (AMK part no.: ) A5: at least AS V /20 (AMK part no.: ) or Update-file AS_xxx_xxxx_xxxxxx_Update.zip (The most actual update-file contains also all other updates.) Updating complete firmware in the controller 1. Establish a connection between the PC and the Ethernet connection X20 of the controller. A crossover Ethernet cable is required for a direct connection between the PC and the X20. A network connection requires a regular Ethernet cable. 2. Attach a empty non-booting USB memory with at least 512 Mbyte capacity as temporary memory into the USB host port X Power up the controller and what until it has completed booting. 4. Enter inside the AMK Toolflasher the communication parameters. 5. Open the Firmware files AS_xxx_xxxx_xxxxxx.zip. 6. Start the programming process in the software ATF. 7. Switch off the controller once the programming has been completed. 8. Power up the controller. The controller carries out a further reboot automatically when the internal programming processes are completed. Wait until the booting is completed. 9. The USB memory medium can be unplugged; the controller's firmware has been updated. Updating Update-file in the controller 1. Establish a connection between the PC and the Ethernet connection X20 of the controller. A crossover Ethernet cable is required for a direct connection between the PC and the X20. A network connection requires a regular Ethernet cable. 2. Power up the controller and wait until it has completed booting. 3. Enter inside the AMK Toolflasher the communication parameters. 4. Open the Firmware files AS_xxx_xxxx_xxxxxx_Update.zip. 5. Start the programming process in the software ATF. 6. Switch off the controller once the programming has been completed. 7. Power up the controller. The controller carries out a further reboot automatically when the internal programming processes are completed. Wait until the booting is completed, the controller's firmware has been updated. 8.3 AS-C conversion to A5 controller This chapter deals with the controller and message configuration In the case of a replacement, if you insert an A5 controller for an AS-C controller, you must re-create the controller configuration in CoDeSys and the message configuration in AIPEX PRO. The following example shows the replacement of an AS-C controller with only one used ACC bus channel. If the second ACC bus channel of the AS-C controller is also occupied, an A4 gateway must also be used. PDK_202975_A4-A5_Produktbeschreibung_en / Version 2013/04 83 / 91

84 Create the following printouts for later input assistance. For this purpose, call up the configurations. You can find the print function in CoDeSys in the menu "File" "Print" and for AIPEX PRO in the menu "Project" "Print." PLC programme was created with the AS-C library version V02.01/0604 Create a printout of the "controller configuration" in CoDeSys and the message configuration in AIPEX PRO. PLC program was created with the AS-C library version V03.01/0827 Create a printout of the "controller configuration" in CoDeSys. The message configuration is automatically created by AIPEX PRO CoDeSys controller configuration Open the existing PLC program. Click on the 'Resources' tab and then on the 'Controller configuration' menu. Click on "AS-FCT" with the right mouse button. Replace this element with the "AMK field bus." Click on "AMK field bus" with the right mouse button. Supplement all originally existing sub-elements. To do so, use the printout of the controller configuration. 84 / 91 PDK_202975_A4-A5_Produktbeschreibung_en / Version 2013/04

85 Enter all originally existing addresses. To do so, use the printout of the controller configuration PLC programme The Bit7 of the FuiGetNetStatus function is not set by the A5 controller and therefore may no longer be used in the PLC programme. If necessary, adjust the PLC programme. PDK_202975_A4-A5_Produktbeschreibung_en / Version 2013/04 85 / 91

86 8.3.3 AIPEX PRO messages configuration First, create a new AIPEX PRO project with the existing components. The PLC programme was programmed with the AS-C library version V02.01/0604 Select the "Messages configuration" tab. Add all originally existing network variables. To do so, use the printout of the messages configuration. You will find the description of this in the documentation PDK_202234_Software_AIPEXpro. Chapter 'AIPEX PRO menu' 'Messages' 'Manual messages configuration.' PLC program was created with the AS-C library version V03.01/0827 The automatic messages configuration is available to you. Start the function in the AIPEX PRO menu 'Configuration' 'Create configuration.' 86 / 91 PDK_202975_A4-A5_Produktbeschreibung_en / Version 2013/04