Omron CK3E Series Startup Manual
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Omron CK3E Series Startup Manual

Programmable multi-axis controller, ethercat coupler unit safety cpu unit safety i/o units idev4
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Programmable Multi-Axis Controller
Startup Guide
EtherCAT Coupler Unit
Safety CPU Unit
Safety I/O Units
(IDEv4)
CK3E-□□□□
CK3M-CPU1□1
NY51□-A□□□
O042-E1-01

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  • Page 1 Programmable Multi-Axis Controller Startup Guide EtherCAT Coupler Unit Safety CPU Unit Safety I/O Units (IDEv4) CK3E-□□□□ CK3M-CPU1□1 NY51□-A□□□ O042-E1-01...
  • Page 2 EtherCAT® is a patented technology and registered trademark licensed by Beckhoff Automation GmbH, Germany. Sysmac is a trademark or registered trademark of OMRON Corporation in Japan and other countries for OMRON factory automation products. Company names and product names in this document are trademarks or registered trademarks...

  • Page 3: Table Of Contents

    Contents Related Manuals ................. 4 Terms and Definitions ................ 5 Precautions ..................6 Overview ..................... 7 Applicable Devices and Device Configuration ........ 8 5.1. Applicable Devices ................8 5.2. Device Configuration ................9 EtherCAT Connection Procedure ........... 10 6.1. Workflow .................... 10 6.2.

  • Page 4: Related Manuals

    To ensure system safety, always read and follow the information provided in all Safety Precautions and Precautions for Safe Use in the manuals for the devices that are used in the system. The following shows the manuals for OMRON Corporation (hereafter referred to as OMRON) and Delta Tau Data Systems, Inc (DT). Manufacturer Manual No.

  • Page 5: Terms And Definitions

    2. Terms and Definitions Term Explanation and Definition Slave Slaves are devices connected to EtherCAT. There are various types of slaves such as servo drivers handling position data and I/O terminals handling the bit signals. Object Represents information such as in-slave data and parameters. One type of EtherCAT communications in which process data objects communications (PDOs) are used to exchange information cyclically and in realtime.

  • Page 6: Precautions

    (4) It is prohibited to copy, reproduce, or distribute a part or the whole of this document without the permission of OMRON Corporation. (5) The information contained in this document is current as of April 2019. It is subject to change without prior notice for improvement purposes.

  • Page 7: Overview

    4. Overview This document describes the procedures used to connect the Safety CPU Unit and Safety I/O Units (hereafter referred to as the Slave) attached to OMRON High EtherCAT Coupler Unit model NX-ECC203 using OMRON Programmable Multi-Axis Controller model CK3E-□□□...

  • Page 8: Applicable Devices And Device Configuration

    This document describes the procedures to establish the network connections. It does not provide information on operations, installations, wiring methods, device functionalities, or device operations, which are not related to the connection procedures. For more information, refer to the manuals or contact your OMRON representative.

  • Page 9: Device Configuration

    Power PMAC IDE Ver.4.2.1.19 Precautions for Correct Use Prepare the ESI file described in this section in advance. Contact your OMRON representative for information on how to procure the ESI file. Precautions for Correct Use Do not share the connection line of EtherCAT communications with other Ethernet networks.

  • Page 10: Ethercat Connection Procedure

    6. EtherCAT Connection Procedure This section describes the procedure for connecting the Controller with the Slave via EtherCAT. The description assumes that the Controller is set to factory default. 6.1. Workflow Take the following steps to operate the PDO communications via EtherCAT after connecting the Controller with the Slave via EtherCAT.
  • Page 11 6.4 Installation of ESI Files Install the ESI file for the Slave into ▽ PowerPMAC IDE. 6.5 EtherCAT Communications Setup Set up EtherCAT communications. ▼ 6.5.1 Communications Setup for the EtherCAT Master ▼ 6.5.2 Distributed Clock Setup ▼ 6.5.3 Safety Controller Variable Settings ▼...

  • Page 12: Ethercat Coupler Unit Settings

    6.2. EtherCAT Coupler Unit Settings Configure the slave terminal settings for the EtherCAT Coupler Unit. Prepare a computer with Sysmac Studio installed. Windows computer Model NX-ECC203 Sysmac Studio USB Cable Model NX-SL3500 Model NX-ID3417 Model NX-SID800 Model NX-OD3256 Model NX-SOD400 6.2.1.
  • Page 13 6.2.2. Network Configuration Settings Double-click EtherCAT under Configurations and Setup in the Multiview Explorer. Select EtherCAT Coupler Unit NX-ECC203 in the toolbox, and drag and drop it directly below the master in the EtherCAT Configuration Edit tab page. Right-click NX-ECC203 in the Multiview Explorer, and select Coupler Connection (USB) then Online.
  • Page 14 Click Apply Actual Unit Configuration to apply the actual unit configuration. Precautions for Correct Use You can read only the Unit configuration in the Slave Terminal by comparing and merging with the actual Unit configuration. You cannot read the I/O allocation information, Unit operation settings, and Unit application data.
  • Page 15 In the Multiview Explorer, select Configurations and Setup, then I/O map tab page to open the I/O map pane. Right-click on NX-ECC203, and select Create Device Variable from the menu. From the controller selection box in the Multiview Explorer, select the target Safety CPU Unit.
  • Page 16 6.2.4. Safety I/O Function Settings From the controller selection box in the Multiview Explorer, select the target Safety CPU Unit. Double-click Safety Slave Unit Parameter Settings under NX-SID800 of Configurations and Setup. Select Output Single-channel Semi-conductor from the toolbox Input device: Semi-conductor output type, and drag and drop it on to the input terminal.
  • Page 17 Select Single Channel (without test pulse) from the toolbox Output device, and drag and drop it on to the output terminal. 6.2.5. Creation of Safety Programs Registering programs Right-click Programs under Programming – POUs in the Multiview Explorer, and select Add –...
  • Page 18 Select parameters on on the FBD network and directly enter the variable names. CU : N2_Si00_Logical_Value Reset : reset PV : pv Q : N3_So00_Output_Value 6.2.6. Transfer via Connection to the Communications Coupler Unit From the controller selection box in the Multiview Explorer, select a Safety CPU Unit.
  • Page 19 From the controller selection box in the Multiview Explorer, select a Controller Unit. In the edit page for slave terminals, right-click the Communications Coupler Unit, then select Coupler Connection (USB) – Transfer to Computer. Click Configuration information + Unit operation setting + Unit application data.
  • Page 20 6.2.7. Output of Couple I/O Allocations Select Controller, then Offline from the menu. Double-click EtherCAT under Configurations and Setup in the Multiview Explorer. Right-click on Master, then select Export All Coupler’s I/O Allocations. 6.2.8. Changing to DEBUG Mode Select the Safety CPU Unit from the Controller Selection Box in the Multiview Explorer.
  • Page 21 The following mode confirmation Dialog Box is displayed. Click the Yes Button. The following Connect to Safety Device Dialog Box is displayed. Click the Yes Button. The following transfer confirmation Dialog Box is displayed. Click the safety of the system and then click the Yes Button.
  • Page 22 Click the Yes Button. Click the OK Button 6.2.10. Changing to RUN Mode Select Mode – RUN Mode from the Controller Menu. Click the Yes Button. Click the Yes Button. Click the OK Button.
  • Page 23 Click the OK Button.

  • Page 24: Preparation For The Controller Setup

    6.3. Preparation for the Controller Setup Prepare the Controller settings. Install Power PMAC IDE and Acontis EC-Engineer on the computer in advance. 6.3.1. Creation of a New Project Turn on the power to the Controller. Start Power PMAC IDE. * If the dialog for confirming access rights appears upon start-up, select starting of Power PMAC IDE.
  • Page 25 Power PMAC IDE starts, and is online to the Controller. From the File menu, select New then Project. Enter a project name and location, and select OK.
  • Page 26 6.3.2. Initial Settings of the Controller Configure the initial settings for the Controller. Precautions for Correct Use Configuring the initial settings clears all data in the Controller memory. Back up necessary data in advance. In the Terminal tab page, type the $$$*** command to reset the Controller to factory default.
  • Page 27 Specify Servo Frequency. Select the Servo Frequency setting from 4 kHz, 2 kHz, or 1 kHz. * Servo Frequency is set to 1 kHz for the example in this document. Click the Accept button. If you have changed the servo frequency setting, type the SAVE command in the Terminal tab page of Power PMAC IDE.
  • Page 28 In the Device Properties dialog box, select No Device for IP Address, then click the Apply button. This operation sets the Controller to the offline state. Restart the Controller. The servo frequency that has been set is reflected. Wait until the startup process of the Controller is complete.

  • Page 29: Installation Of Esi Files

    Install the ESI file for the Slave into Power PMAC IDE. Precautions for Correct Use Prepare the ESI file described in this section in advance. Contact your OMRON representative for information on how to procure the ESI file. Start EC-Engineer.
  • Page 30 Before taking the following steps, make sure that the devices are connected via an Ethernet cable. If they are not connected, turn OFF the power to the devices, and connect the Ethernet cable. 6.5.1. Communications Setup for the EtherCAT Master Connect the Controller with slave devices using an Ethernet cable.
  • Page 31 In the Master tab page, specify a communication period for Cycle Time [us]. * You must specify the communication period in accordance with the servo frequency of the Controller. 1000 us is set in this document. Correspondence between the servo frequencies of the Controller and communication periods is as follows: 4 kHz : 250 us 2 kHz : 500 us...
  • Page 32 Make sure that the slave is displayed in the Solution Explorer. 6.5.2. Distributed Clock Setup...
  • Page 33 Setting Distributed Clocks (DC) for Master In the Master0 (Deactivated) tab page, select Distributed Clocks tab. Select Master Shift (EtherCAT Master Time controlled by Reference Clock).
  • Page 34  When using in DC mode Setting Distributed Clock (DC) for the Slave In the Solution Explorer, select the target slave and display the Distributed Clock tab page. Select the Overwrite Mode check box and specify Shift Time. Correspondence between the servo frequencies of the Controller and Shift Time values is as follows: 4 kHz : 125 us...
  • Page 35  When using in Free-Run mode Setting Distributed Clock (DC) for the Slave In the Solution Explorer, select the target slave and display the Distributed Clock tab page. Select FreeRun from the drop down list for Operation Mode. In the Advanced Options tab page, clear the Potential Reference Clock check box.
  • Page 36 6.5.3. Safety Controller Variable Settings (1) Checking the coupler I/O allocations Decompress the ZIP file you saved in 6.2.7 Output of Couple I/O Allocations, open the expanded “CouplerMemoryMap.xml” using Internet Explorer, and check the contents. (2) Setting Input Data Register the following input data. - Slot1(NX-SL3500)Input Data Set1 - Slot1(NX-SL3500)Input Data Set2 Select a safety controller in the...
  • Page 37 [Slot1(NX-SL3500)Input Data Set1] Registering Node1/Unit2 (NX-SID800) Click New in the Variables tab page, and register 4 variables shown on the right. FSoE Slave CMD #x6020:01 USINT Group: Module 1(NX-SL3500).Input Data Set 1 Datatype: USINT Count: 1 Safety Input 1st Word #x6021:01 UINT FSoE Slave CRC_0...
  • Page 38 [Slot1(NX-SL3500)Input Data Set2] Safety CPU Status #x6004:01 UINT Registering Safety CPU Status Group: Module 1(NX-SL3500).Input Data Set 2 Datatype: UINT Click New in the Variables tab Count: 1 page, and register the variable shown on the right. Checking Input Data Make sure that the settings (Input) in the Variables tab page are correct.
  • Page 39 (3) Setting Output Data Register the following output data. - Slot1(NX-SL3500)Output Data Set1 - Slot1(NX-SL3500)Output Data Set2 Select a safety controller in the Project Explorer pane of EC-Engineer. Display the Variables tab page. [Slot1(NX-SL3500)Output Data Set1] FSoE Master CMD #x7020:01 USINT Registering Node1/Unit2 Group: Module 1(NX-SL3500).Output Data Set 1...
  • Page 40 [Slot1(NX-SL3500)Output Data Set1] FSoE Master CMD #x7040:01 USINT Registering Node1/Unit3 Safety Output 1st Byte #x7041:01 USINT (NX-SOD400) Group: Module 1(NX-SL3500).Output Data Set 1 Datatype: USINT Click New in the Variables tab Count: 2 page, and register 4 variables shown on the right. FSoE Master CRC_0 #x7040:03 UINT...
  • Page 41 6.5.4. PDO Map Settings In the Project Explorer, select the target slave to display the PDO Mapping tab page. Setting PDO mapping (Inputs) Confirm the check boxes in the Inputs field. * If you do not want to use data in the Inputs field, clear the currently displayed check boxes.
  • Page 42 6.5.5. Coupler I/O and Variable Allocations (1) Checking the coupler I/O allocations Decompress the ZIP file you saved in 6.2.7 Output of Couple I/O Allocations, open the expanded “CouplerCopyInfo.xml” using Internet Explorer, and check the contents. (2) Setting Input Data Associate the following items: - Module 1 (NX-SL3500).Input Data Set 1, and Module 2 (NX-SID800).Output Data Set 1 - Module 1 (NX-SL3500).Input Data Set 1, and Module 3 (NX-SOD400).Output Data Set 1...
  • Page 43 Associate the variables of Inputs Module 1 (NX-SL3500).Input Data Set 1 with Outputs Module 2 (NX-SID800).Output Data Set Associate the following items: Inputs Outputs Variable 0 FSoE Master CMD Select an (NX-SL3500).Input Variable 1 Safety Output 1st Word Data Set 1 item, then select Variable 2 FSoE Master CRC_0 the corresponding...
  • Page 44 (3) Setting Output Data Associate the following items: - Module 2 (NX-SID800).Input Data Set 1, and Module 1 (NX-SL3500).Output Data Set 1 - Module 3 (NX-SOD800).Input Data Set 1, and Module 1 (NX-SL3500).Output Data Set 1 Associate the variables of Inputs Module 2 (NX-SID800).Input Data Set 1 with Outputs Module 1 (NX-SL3500).Output Data...
  • Page 45 6.5.6. Creation of an EtherCAT Network Information File Select System – EtherCAT in the Solution Explorer and right-click on Master0 (Deactivated), then select Load Mapping to PowerPMAC. An eni.xml file is added under the Configuration directory in the Solution Explorer. An ECATMap.pmh file is added under the PMAC Script Language/Global Includes...

  • Page 46: Controller Settings

    6.6. Controller Settings 6.6.1. EtherCAT Communications Check Take the following steps to ensure that EtherCAT communications are available. From the Terminal pane, run the ECAT[0].Enable=1 command to start EtherCAT communications. In the Terminal or Watch pane, make sure that the ECAT[0].Enable value turns to 1.
  • Page 47 6.6.2. Writing the User Program Create programs to be used to check operations. A specific language is used for the operation check programs. Refer to Power PMAC User’s Manual and Power PMAC Software Reference Manual for details. In the Solution Explorer pane, open Project name –...
  • Page 48 In the programming area of the pp_disable.txt tab page, add enable plc 1; the program shown on the right to the last line. The pp_disable.txt program is automatically executed when the Controller starts. This example program runs the PLC1 script. 6.6.3.
  • Page 49 Downloading a project Right-click the project name in the Solution Explorer pane on the upper right of the IDE screen, and select Build and Download All Programs to run the build and download. * The transferred project is not yet saved to the Controller at this stage.
  • Page 50 The program starts running when it has been downloaded successfully. EtherCAT communications are in the OP state. Make sure that the NX-OD3256 output indicator blinks. * If the indicator does not blink, check that the ECAT[0].Enable value is 1 in the Terminal tab page or Watch Window.

  • Page 51: Appendix Saving And Loading A Project

    7. Appendix Saving and Loading a Project The following describes the procedures to save a Power PMAC IDE project on the computer, and to reuse it. 7.1. Saving a Project Creating a Configuration File Create a Configuration File to save parameters you have changed.
  • Page 52 Saving a Project In the File menu, run Save All to save the project on the computer.

  • Page 53: Loading And Downloading A Project

    7.2. Loading and Downloading a Project Start Power PMAC IDE, and connect to the Controller. In the Terminal tab page, type the $$$*** command to reset the Controller settings to factory default. In the File menu, Click Open – Project/Solution to load the project that you saved.
  • Page 54 Right-click the project name in the Solution Explorer pane, and select Build and Download All Programs to run the build and download. When the download process is complete, make sure that there are no errors in the Output Window. Stopping a program If a program is running, execute the following command from the Terminal tab page to stop the...
  • Page 55 Saving the downloaded settings and programs After the download process is complete and you make sure that there are no errors in the Output Window, run the save command from the Terminal tab page. * The save command stores the downloaded project in the Controller.

  • Page 56: Appendix Troubleshooting

    8. Appendix Troubleshooting 8.1. Factors Causing EtherCAT Communications To Be Unavailable, and Corrective Actions Description Factor Corrective Action The link is not established. The Ethernet cable is broken or If the Ethernet cable is broken the specified cable is not being or if the specified cable was not used.

  • Page 57: How To Check For Errors

    8.2. How to Check for Errors 8.2.1. Checking the EtherCAT Status You can check the EtherCAT status from Diagnosis Mode of Power PMAC IDE. Right-click on Master0 (Deactivated) under EtherCAT in the Solution Explorer, then select Diagnosis Mode to open the Diagnosis Mode page You can check the status of the slaves in the Diagnosis Mode page.
  • Page 58 8.2.2. Checking the Controller Status In the Status page of Power PMAC IDE, you can check the status of the motor, coordinate system, and system. To display the Status page, click Status on the toolbar.  Global Status You can check system errors such as the WDT error.
  • Page 59  Motor Status You can check deviation errors, limit errors, and other states of the motor.  Coordinate Status You can check deviation errors, limit errors and other states of the coordinate system.

  • Page 60: Appendix Ecat[I] Structure Elements

    9. Appendix ECAT[i] Structure Elements The Controller uses motion controller technology developed by Delta Tau Data Systems, Inc., (hereafter referred to as DT) in the U.S., however, the ECAT[i] structure elements differ from those of DT controllers. The following table shows the major changes that have been made from DT controllers.

  • Page 61: Revision History

    10. Revision History Revision Revised date Revised content code 5-Apr, 2019 First edition...
  • Page 62 Note: Do not use this document to operate the Unit. 2019 O042-E1-01 0419 (0419)

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