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EtherCAT F/T Interface for OEM

Installation and Operation Manual

Document #: 9610-05-1032

August 2014

Engineered Products for Robotic Productivity

Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 USA • Tel: 919.772.0115 • Fax: 919.772.8259 • www.ati-ia.com • Email: [email protected]

EtherCAT F/T Interface for OEM Installation and Operation Manual

Document #9610-05-1032-03

Foreword

Information contained in this document is the property of ATI Industrial Automation, Inc. and shall not be reproduced in whole or in part without prior written approval of ATI Industrial Automation, Inc. The information herein is subject to change without notice and should not be construed as a commitment of ATI Industrial Automation, Inc. This manual is periodically revised to reflect and incorporate changes made to the F/T system.

ATI Industrial Automation, Inc. assumes no responsibility for any errors or omissions in this document.

Copyright © by ATI Industrial Automation, Inc., Apex, North Carolina USA. All Rights Reserved. Published in the USA.

In consideration that ATI Industrial Automation, Inc. (ATI) products are intended for use with robotic and/or automated machines, ATI does not recommend the use of its products for applications wherein failure or malfunction of an ATI component or system threatens life or makes injury probable. Anyone who uses or incorporates ATI components within any potentially life-threatening system must obtain ATI’s prior consent based upon assurance to ATI that a malfunction of ATI’s component does not pose direct or indirect threat of injury or death, and (even if such consent is given) shall indemnify ATI from any claim, loss, liability, and related expenses arising from any injury or death resulting from use of

ATI components.

All trademarks belong to their respective owners.

Windows™ is a registered trademark of Microsoft Corporation.

Note

Please read the manual before calling customer service. Before calling, have the following information available:

1.

Serial number (e.g., FT01234)

2. Transducer model (e.g., Nano17, Gamma, Theta, etc.)

3. Calibration (e.g., US-15-50, SI-65-6, etc.)

4. Accurate and complete description of the question or problem

5. Computer and software information. Operating system, PC type, drivers, application software, and other relevant information about your configuration.

If possible, be near the F/T system when calling.

How to Reach Us

Sale, Service and Information about ATI products:

ATI Industrial Automation

1031 Goodworth Drive

Apex, NC 27539 USA

www.ati-ia.com

Tel: 919.772.0115

Fax: 919.772.8259

E-mail:

[email protected]

Technical support and questions:

Application Engineering

Tel: 919.772.0115, Option 2, Option 2

Fax: 919.772.8259

E-mail:

[email protected]

Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 USA • Tel: 919.772.0115 • Fax: 919.772.8259 • www.ati-ia.com • Email: [email protected]

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EtherCAT F/T Interface for OEM Installation and Operation Manual

Document #9610-05-1032-03

Table of Contents

1. Safety ......................................................................................................................................... 6

1.1 Explanation of Notifications ......................................................................................................... 6

1.2 General Safety Guidelines ............................................................................................................ 6

1.3 Safety Precautions ........................................................................................................................ 6

2. Product Overview ..................................................................................................................... 7

3. Compatible Transducer ........................................................................................................... 8

4. ECATOEM Interface Board ...................................................................................................... 8

4.1 Connectors .................................................................................................................................. 10

4.1.1 P900 Connector for Optional 24VDC Power & Monitor Signal Interface .......................... 10

4.1.2 P901 Connector for EtherCAT Interfaces ......................................................................... 11

4.1.3 P902 Connector for optional external LEDs ..................................................................... 11

4.1.4 P904 Connector for Transducer Strain Gage Signals ...................................................... 11

4.2 Switch ........................................................................................................................................... 12

4.2.1 SW1 .................................................................................................................................. 12

4.3 LEDs ............................................................................................................................................. 12

4.3.1 LED900 Link/Activity ........................................................................................................ 12

4.3.2 LED901 EtherCAT Status ................................................................................................. 12

4.3.3 LED902 Board status ....................................................................................................... 13

5. Operation ................................................................................................................................ 14

5.1 Sample Rate ................................................................................................................................. 14

5.2 Filtering ........................................................................................................................................ 14

5.3 Threshold Monitoring ................................................................................................................. 14

5.4 Discrete output ............................................................................................................................ 14

5.5 Tool Transformation .................................................................................................................... 14

6. EtherCAT Bus Interface ......................................................................................................... 15

6.1 PDO Interface ............................................................................................................................... 15

6.2 EtherCAT Dictionary Objects (SDO Data) ................................................................................ 15

6.2.1 Object 0x2020: Tool Transformation ................................................................................. 15

6.2.2 Object 0x2040: Calibration ............................................................................................... 16

6.2.3 Object 0x2060: Monitor Condition .................................................................................... 18

6.2.4 Object 0x2080: Diagnostic readings ................................................................................. 18

6.2.5 Object 0x2090: Version .................................................................................................... 19

6.2.6 Object 0x6000: Reading Data .......................................................................................... 19

6.2.7 Object 0x6010: Status Code ............................................................................................ 20

6.2.8 Object 0x6020: Sample Counter ...................................................................................... 21

6.2.9 Object 0x7010: Control Codes ......................................................................................... 21

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EtherCAT F/T Interface for OEM Installation and Operation Manual

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7. Hardware Installation ............................................................................................................. 22

7.1 Chassis Grounding ..................................................................................................................... 22

7.2 Transducer Handling ................................................................................................................... 22

7.3 Ground and cable shield considerations .................................................................................. 22

7.4 Power Supply Considerations ................................................................................................... 22

7.5 Installation ................................................................................................................................... 23

8. Troubleshooting ..................................................................................................................... 24

8.1 Questions and Answers.............................................................................................................. 24

8.1.1 Errors with Force and Torque Readings ........................................................................... 24

9. Specifications ......................................................................................................................... 25

9.1 Storage and Operating Conditions ............................................................................................ 25

9.2 Electrical Specifications ............................................................................................................. 25

9.3 Weights and Dimensions ............................................................................................................ 25

10. Drawings ................................................................................................................................. 26

11. Terms and Conditions of Sale ............................................................................................... 27

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4

SDO

STG

TAP

Transducer

UDINT

UINT

USINT

Term

CoE

DINT

E-Exit

EtherCAT

FoE

F/T

F/T Transducer

MAP

MOLEX PicoBlade

PDO

PoE

EtherCAT F/T Interface for OEM Installation and Operation Manual

Document #9610-05-1032-03

Glossary of Terms

Definition

CANopen over EtherCAT, the preferred embedded protocol for configuring EtherCAT devices. Used within SDO to encode the configuration data.

A data type representing an unsigned integer with 32 bits.

ATI’s E-Exit transducers have a cable with an over-molded strain relief.

An industrial automation fieldbus.

File access over EtherCAT, the preferred embedded protocol for uploading new firmware to EtherCAT devices.

Force/Torque.

Converts force and torque into an electrical signal.

The Mounting Adapter Plate (MAP) is the transducer plate that attaches to the fixed surface or robot arm.

Product series from the connector manufacturer Molex.

Process Data Object, a protocol for reading and writing real-time process information cyclically.

Power-over-Ethernet, is a method of delivering electrical power to a PoE-compatible

Ethernet device through the Ethernet cable. This simplifies installation of the Ethernet device since a separate power supply is not needed. The EtherCAT OEM F/T system is

PoE compatible.

Service Data Object, a protocol for reading and writing configuration information acyclically.

Strain Gage

Tool Adapter Plate (TAP) is the transducer surface that attaches to the load to be measured.

Transducer is the component that converts the sensed load into electrical signals.

A data type representing an unsigned integer with 32 bits.

A data type representing an unsigned integer with 16 bits.

A data type representing an unsigned integer with 8 bits.

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EtherCAT F/T Interface for OEM Installation and Operation Manual

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1. Safety

The safety section describes general safety guidelines to be followed with this product, explanation of the notification found in this manual, and safety precaution that apply to the product. More specific notification are imbedded within the sections of the manual where they apply.

1.1

Explanation of Notifications

The notifications included here are specific to the product(s) covered by this manual. It is expected that the user heed all notifications from the robot manufacturer and/or the manufacturers of other components used in the installation.

DANGER:

Notification of information or instructions that if not followed will result in death or serious injury. The notification provides information about the nature of the hazardous situation, the consequences of not avoiding the hazard, and the method for avoiding the situation.

WARNING:

Notification of information or instructions that if not followed could result in death or serious injury. The notification provides information about the nature of the hazardous situation, the consequences of not avoiding the hazard, and the method for avoiding the situation.

CAUTION:

Notification of information or instructions that if not followed could result in moderate injury or will cause damage to equipment. The notification provides information about the nature of the hazardous situation, the consequences of not avoiding the hazard, and the method for avoiding the situation.

NOTICE:

Notification of specific information or instructions about maintaining, operating, installation, or setup of the product that if not followed could result in damage to equipment. The notification can emphasize but is not limited to specific grease types, good operating practices, or maintenance tips.

1.2 General Safety Guidelines

The customer should verify that the transducer selected is rated for maximum loads and moments expected during operation. Refer to F/T Transducer Manual (9620-05-Transducer Section—Installation and

Operation Manual) found in Net F/T Installation and Operation Manual (9610-05-1022) or contact ATI

Industrial Automation for assistance. Particular attention should be paid to dynamic loads caused by robot acceleration and deceleration. These forces can be many times the value of static forces in high acceleration or deceleration situations.

1.3 Safety Precautions

CAUTION: Do not remove any fasteners or disassemble transducers without a removable mounting adapter plate. These include Nano, Mini, IP-rated, and some

Omega transducers. This will cause irreparable damage to the transducer and void the warranty. Leave all fasteners in place and do not disassemble the transducer.

CAUTION: Do not probe any openings in the transducer. This will damage the instrumentation.

CAUTION: Do not exert excessive force on the transducer. The transducer is a sensitive instrument and can be damaged by applying force exceeding the single-axis overload values of the transducer and cause irreparable damage. Small Nano and Mini transducers can easily be overloaded during installation. Refer to the F/T Transducer manual (9620-05-Transducer Section) for specific transducer overload values.

Pinnacle Park • 1031 Goodworth Drive • Apex, NC 27539 USA • Tel: 919.772.0115 • Fax: 919.772.8259 • www.ati-ia.com • Email: [email protected]

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EtherCAT F/T Interface for OEM Installation and Operation Manual

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2. Product Overview

The EtherCAT F/T Interface for OEM System consists of an ATI transducer and a F/T-to-EtherCAT interface board

(ECATOEM). The transducer selected will include a Molex PicoBlade connector. The interface board is designed to be mounted within a customer’s enclosure and gets supplied by customer provided 24VDC or PoE power supply.

Figure 2.1

shows a sample application using the ECATOEM mounted in a segment of a light weight arm and a

Mini45 transducer mounted on the arm.

Figure 2.1—Sample Application

MINI45 Transducer

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EtherCAT F/T Interface for OEM Installation and Operation Manual

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3. Compatible Transducer

Transducers with part numbers ending in EC8 are custom designed for use with ECATOEM. It differs from a standard Nano or Mini transducers in the following features:

• MOLEX PicoBlade connector contacts crimped to the eight wires of the transducer cable

Figure 3.1—Transducer with Strain Relieved EC8 Cable

Strain Relief

Molex Picoblade

Connector

Transducer with EC8 Cable

4. ECATOEM Interface Board

The ECATOEM provides an EtherCAT bus interface for ATI’s TW transducers. Equipped with an 8-pin MOLEX

PicoBlade connector (like the 9105-TW-MINI45-AE-0.3-EC8), they can be plugged directly into the ECATOEM interface board.

Figure 4.1—ECATOEM System

Power and Monitor

Signal

Optional

LED's

Transducer

EtherCAT

Interface Board

EtherCAT with Optional PoE

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EtherCAT F/T Interface for OEM Installation and Operation Manual

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The 9105-ECATOEM interfaces with the transducer’s strain gages via connector P903 and P904. The strain gage signals get digitized with a 16bit A/D converter, multiplied with the selected calibration matrix and the resulting force/torque data are then transmitted over an EtherCAT bus interface.

Up to 16 transducer calibrations can be stored in the on-board EEPROM.

The ECATOEM can be supplied with a DC voltage between 20V and 48V or with PoE.

Figure 4.2—ECATOEM Block Diagram

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EtherCAT F/T Interface for OEM Installation and Operation Manual

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P900

Optional 24VDC Power and Monitor Signal

1

Figure 4.3—ECATOEM – Components

Top View

1

(B) Mounting Hole

SW1 Dip Switch

1

LED901

EtherCAT Status

LED902

Board Status

(A) Chassis Connection

P904

Transducer Strain Gage Signals

(C) Chassis Connection

1

Bottom View

P902

Optional External LEDs

LED900

Activity

P901

EtherCAT Interface with Optional PoE

P903

Internal Use Only

4.1 Connectors

The following connectors are available on the ECATOEM PCB Assembly:

4.1.1 P900 Connector for Optional 24VDC Power & Monitor Signal Interface

Mating connector housing: Molex 51021-0700

Mating connector contact: Molex 50058-8000

Pin No.

Signal Name Description

1 SL_GND 24V Power Supply Ground

2

3

RS485-

DRAIN

- Serial Interface to NetBox

Serial Interface Shield

6

7

4

5

RS485+

SL_VP

+ Serial Interface to NetBox

24V Power Supply Positive

MONITOR_E Monitor signal: emitter contact of opto isolator

MONITOR_C Monitor signal: collector contact of opto isolator

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EtherCAT F/T Interface for OEM Installation and Operation Manual

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4.1.2 P901 Connector for EtherCAT Interfaces

Mating connector housing: Molex 51021-0500

Mating connector contact: Molex 50058-8000

Pin No.

Signal Name Description

1 TX+ Ethernet Transmit +

2

3

TX-

RX+

Ethernet Transmit -

Ethernet Receive +

4

5

RX-

Shield

Ethernet Receive -

Ethernet cable shield

4.1.3 P902 Connector for optional external LEDs

Mating connector housing: Molex 51021-0900

Mating connector contact: Molex 50058-8000

Pin No. Signal Name

1 RUN_LED

2

3

Description

Connect to cathode of optional external EtherCAT RUN LED

+3.3V

Connect to anode of optional external LEDs

ACTIVITY_LED Connect to cathode of optional external ACTIVITY LED

4

5

+3.3V

RED_STATUS_

LED

Connect to anode of optional external LEDs

Connect to cathode of optional external Board Status LED

8

9

6

7

Reserved

Reserved

Reserved

DGND

For uC programming

For uC programming

For uC programming

Ground for +3.3V; used for uC programming

Figure 4.4—P902 LED Wiring Diagram

P902 - Optional External LEDs

4.1.4 P904 Connector for Transducer Strain Gage Signals

Mating connector housing: Molex 51021-0800

Mating connector contact: Molex 50058-8000

Pin No.

Signal Name Description

1 +VSG 5V, Positive strain gage bridge supply voltage

2

3

-VSG

G0

0V, Negative strain gage bridge supply voltage

Strain gage 0 voltage

6

7

8

4

5

G1

G2

G3

G4

G5

Strain gage 1 voltage

Strain gage 2 voltage

Strain gage 3 voltage

Strain gage 4 voltage

Strain gage 5 voltage

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EtherCAT F/T Interface for OEM Installation and Operation Manual

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4.2 Switch

The following switch is available on the ECATOEM PCB Assembly:

4.2.1 SW1

The two-position DIP switch is currently unused.

Position

1

2

ON/OFF Description

ON

Do Not Use

OFF

ON

OFF

Default settings OFF

Do Not Use

Default settings OFF

NOTICE: Leave Dip switch in Default state. Changing Dip Switch settings may adversely affect the EtherCAT board functionality.

4.3 LEDs

The following LEDs are available on the ECATOEM PCB Assembly:

4.3.1 LED900 Link/Activity

One green LED signals activity on the EtherCAT port.

LED State

Off

Green

Flashing Green

Link

No

Yes

Yes

Activity Condition

No

No

Yes

Port closed

Port open

Port open

4.3.2 LED901 EtherCAT Status

One dual-color LED signals the status of the EtherCAT Network in the following way.

LED State RUN State ERROR State Description

OFF INIT No Device is in state INIT

PRE-OP No Device is in state PRE-OPERATIONAL GREEN

Blinking

GREEN

Single Flash

GREEN

SAFE-OP

OP

No Device is in state SAFE-OPERATIONAL

RED Double

Flash

No

Process Data

Watchdog

Timeout

Device is in state OPERATIONAL

An application watchdog timeout has occurred. E.g. Sync Manager Watchdog timeout

RED Single

Flash

RED

Blinking

Local Error Slave device application has changed the

EtherCAT state autonomously, due to local error. E.g. device changes its EtherCAT state from OP to SAFE-OP due to a

Invalid

Configuration

Error synchronization error

General configuration error.

E.g

State change commanded by master is impossible due to register or object settings, or invalid hardware configuration (pin sharing violation detected by ESC)

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EtherCAT F/T Interface for OEM Installation and Operation Manual

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4.3.3 LED902 Board status

One dual-color LED signals the status of the EtherCAT Board in the following way.

LED State

OFF

Green

Orange

(Amber)

Red

Red Blinking

(1Hz)

Red Blinking

(10Hz)

Status

No Power

All OK

Saturation

Diagnostic voltage error

No calibration loaded communication error with ECAT

ASIC

Description

The board doesn’t have sufficient power

Fully Operational, No errors

Transducer input is saturated; one of the strain gage input voltages is too high; all force and torque data are invalid; use less sensitive calibration if available;

One of the internal diagnostic voltages is outside the acceptable range;

Active calibration slot is empty or has checksum error;

No or faulty communication between uC and EtherCAT

ASIC

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EtherCAT F/T Interface for OEM Installation and Operation Manual

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5. Operation

5.1 Sample Rate

The firmware samples internally at 3000 Hz.

5.2 Filtering

The “Filter Selection” field in

Section 6.2.9—Object 0x7010: Control Codes

controls the coefficient used in the internal IIR filter. The cutoff frequency is dependent on the internal sample rate, which is defined in

Section 5.1—Sample Rate

. The relative cutoff frequencies for different values of this coefficient are:

6

7

4

5

8

2

3

Coefficient Cutoff Frequency (Percent of Internal Sample Rate) Frequency

0

No filter

N/A

1 11.97% 360 Hz

4.66%

2.17%

140 Hz

64 Hz

1.04%

0.51%

0.26%

0.12%

0.07%

32 Hz

16 Hz

8 Hz

4 Hz

2 Hz

5.3 Threshold Monitoring

The EtherCAT OEM FT system will allow the user to configure thresholds. To activate a threshold, first write the appropriate values in

Section 6.2.3—Object 0x2060: Monitor Condition

, then set the bit corresponding to that threshold in the “Monitor Condition Enable Bitmap” in

Section 6.2.9—Object 0x7010:

Control Codes

.

The software currently supports one monitor condition.

5.4 Discrete output

The discrete output will turn on whenever any active monitor condition becomes true. The user can also configure it to turn on whenever any error bit becomes true (this is not yet available in the beta software).

5.5 Tool Transformation

To activate a tool transformation, first write the appropriate transform coefficients to

Section 6.2.1—Object

0x2020: Tool Transformation

, then set the “Tool Transform Index Selection” bits in

Section 6.2.9—

Object 0x7010: Control Codes

to activate that condition. The software currently only supports one tool transformation.

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6. EtherCAT Bus Interface

The EtherCAT bus interface allows a user to:

Determine which calibration is active

• Select a calibration to be active

• Read the active calibration information matrix, serial number, etc.

Read the firmware revision of the ECATOEM

Read force/torque data

• Read strain gage data and status information.

Configure tool transformation.

• Set monitor conditions

Set low pass filter cutoff frequency.

• Bias transducer.

6.1 PDO Interface

The PDO interface is used to exchange data in real-time with the F/T sensor.

a. a. TxPDO Map / Output Data

The TxPDO combines

Object 0x6000: Reading Data

,

Object 0x6010: Status Code

, and

Object

0x6020: Sample Counter

.

b. b. RxPDO Map / Input Data

The RxPDO map consists of

Object 0x7010: Control Codes

.

6.2 EtherCAT Dictionary Objects (SDO Data)

The SDO data is used to configure the sensor and read manufacturing and calibration information. This section documents dictionary objects that are specific to the EtherCAT F/T sensor application; it does not list objects which are a required part of the EtherCAT standard.

6.2.1 Object 0x2020: Tool Transformation

This writable object contains the following 32-bit signed integer fields:

Subindex

0x01

0x02

0x03

0x04

0x05

0x06

Name

Rx

Ry

Rz

Dx

Dy

Dz

Description

The rotation about the X axis, in units of

0.1 degrees, e.g. an Rx value of 900 = 90 degrees.

The rotation about the Y axis, in units of 0.1 degrees.

The rotation about the Z axis, in units of 0.1 degrees.

The displacement along the x axis, in units of 0.01 calibration length units. E.g. if the distance component of the torque is meters, a Dx value of 100 = 1 meter.

The displacement along the y axis, in units of 0.01 calibration length units.

The displacement along the z axis, in units of 0.01 calibration length units.

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6.2.2 Object 0x2040: Calibration

This read-only object contains information about the currently active calibration selected by the

“Calibration Selection” field in

Section 6.2.9—Object 0x7010: Control Codes

. It contains the following fields:

Subindex

0x01

0x02

0x18

0x19

0x1a

0x1b

0x1c

0x1d

0x1e

0x11

0x12

0x13

0x14

0x15

0x16

0x17

0x0a

0x0b

0x0c

0x0d

0x0e

0x0f

0x10

0x03

0x04

0x05

0x06

0x07

0x08

0x09

0x1f

0x20

0x21

0x22

0x23

0x24

0x25

0x26

0x27

0x28

Name

FT Serial

Matrix FzG0

Matrix FzG1

Matrix FzG2

Matrix FzG3

Matrix FzG4

Matrix FzG5

Matrix TxG0

Matrix TxG1

Matrix TxG2

Matrix TxG3

Matrix TxG4

Matrix TxG5

Matrix TyG0

Matrix TyG1

Calibration Part

Number

Calibration Family

Calibration Time

Matrix FxG0

Matrix FxG1

Matrix FxG2

Matrix FxG3

Matrix FxG4

Matrix FxG5

Matrix FyG0

Matrix FyG1

Matrix FyG2

Matrix FyG3

Matrix FyG4

Matrix FyG5

Matrix TyG2

Matrix TyG3

Matrix TyG4

Matrix TyG5

Matrix TzG0

Matrix TyG1

Matrix TyG2

Matrix TyG3

Matrix TyG4

Matrix TyG5

Type

STRING(8)

STRING(30)

STRING(8)

STRING(30)

DINT

Description

The FT Serial Number, e.g.

“FT01234.”

The calibration part number e.g.

“SI-120-95.”

Always reads “ECAT”

The date the sensor was calibrated

These 36 elements contain the scaled “working” matrix used for this calibration. This will not necessarily match the calibration matrix in the calibration file, because the calibration matrix has to be scaled to suitably large integers before it can be used by the sensor.

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Subindex

0x29

0x2a

Name

Force Units

Torque Units

Type

USINT

USINT

Value

0x2a

1

2

3

Description

Unit

3

4

1

2

4

Value

0

Lbf

N

Klbf kN

Kg

Unit

Lbf-in

Lbf-ft

N-m

N-mm

Kg-cm

5 kN-m

The maximum rated value for this axis, in counts.

1

0x2b

0x2c

0x2d

0x2e

0x2f

0x30

0x31

Max Fx Counts

Max Fy Counts

Max Fz Counts

Max Tx Counts

Max Ty Counts

Max Tz Counts

Counts Per Force

DINT

0x32 Counts Per Torque

Gain G0

Gain G1

Gain G2

Gain G3

Gain G4

Gain G5

Offset G0

Offset G1

Offset G2

Offset G3

DINT

DINT

The calibration counts per force unit.1

The calibration counts per torque unit.

1

The code used to program the gain potentiometer

0x33

0x34

0x35

0x36

0x37

0x38

0x39

0x3a

0x3b

0x3c

UINT16

UINT16 The code used to program the offset DAC.

0x3d

0x3e

Offset G4

Offset G5

Note:

1. In the beta version of the software, divide these values by 16 to get the actual counts that will be used in the EtherCAT interface.

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6.2.3 Object 0x2060: Monitor Condition

This user-writable object allows the user to configure an axis, a threshold value, and direction to continuously evaluate against the current F/T data. When an enabled condition becomes true, the monitor output becomes active and stays active until reset via setting the “Reset Monitor

Condition” bit in

Section 6.2.9—Object 0x7010: Control Codes

, which is also mapped into the

TxPDO data.

The following fields are available in the monitor condition:

Subindex Name

0x01

0x02

0x03

Threshold Value

Axis

Type

DINT The threshold value to compare against, in counts.

USINT

Value

0x03

Description

Axis

Fx

3

4

1

2

Fy

Fz

Tx

Ty

5 Tz

CompareGreaterThan BOOL If TRUE, the monitor condition is true when the selected axis is greater than the selected threshold value. If FALSE, the monitor condition is true when the selected axis is less than the selected threshold value.

6.2.4 Object 0x2080: Diagnostic readings

This read-only object provides access to diagnostic values. These values may be useful when troubleshooting the system. All diagnostic voltages are filtered with the filter coefficient set to “8”

– see

Section 5.2—Filtering

for details.

The following fields are available in the Diagnostic Readings object:

Subindex Name

0x01 6V Supply

Sense

Type Description

UINT16 The 6V supply

ADC reading.

Limits

2568 to 3970 counts

0x02 Thermistor UINT16 The thermistor

ADC reading.

None, information only.

0x03

0x04

VBridge

Volts

VBridge

Current

INT16 The excitation voltage ADC reading.

INT16 The excitation current ADC reading.

17050 to 17750 counts.

500 to 6554 counts.

Note:

1. See

Section 5.1—Sample Rate

for strain gage sampling rate.

Sampling Rate

½ strain gage sampling rate.

1

½ strain gage sample rate.

1

Strain gage sampling rate.

1

Strain gage sampling rate.

1

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6.2.5 Object 0x2090: Version

This read-only object provides firmware version information.

The following fields are available in the version object:

Subindex

0x01

0x02

0x03

Name

Major

Minor

Revision

Type

UINT16

UINT16

UINT16

Description

Major Version

Minor Version

Revision

6.2.6 Object 0x6000: Reading Data

This read-only object represents the current force/torque or gage data. It is mapped into the

TxPDO input data.

The following fields are present in the reading data:

Type

DINT

Subindex

0x01

0x02

0x03

0x04

0x05

0x06

Name

Fx/Gage0

Fy/Gage1

Fz/Gage2

Tx/Gage3

Ty/Gage4

Tz/Gage5

Description

If the “Gage Data” bit in

Section 6.2.9—Object 0x7010:

Control Codes

is set, these fields contain the 16-bit gage data. If the

“Gage Data” bit is cleared, these fields contain the 32-bit F/T result data, in counts.

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6.2.7 Object 0x6010: Status Code

This object contains a single DINT value (at subindex 0), with the following bitmap:

1

2

3

Bit

Number

0

4

5

6

7

6-27

28

29

30

31

Description Indicates

Error?

No Monitor Condition Tripped: This bit becomes active when an active monitor condition becomes true, and remains set until cleared with the “Reset Monitor Conditions” bit in

Section 6.2.9—

Object 0x7010: Control Codes

.

Supply Out of Range: This bit becomes active if the supply sense reading in

Section 6.2.4—Object 0x2080: Diagnostic readings

is out of the expected range. This bit remains set until power cycle.

It may indicate a system fault.

Reserved

Yes

VBridge Volts Out of Range: This bit is set if the excitation voltage in

Section 6.2.4—Object 0x2080: Diagnostic readings

is out of the expected range. This bit remains set until power cycle. It may indicate a system fault.

Yes

VBridge Current Out of Range: This bit is set if the excitation current in

Section 6.2.4—Object 0x2080: Diagnostic readings

is out of the expected range. This bit remains set until power cycle.

It may indicate a system fault.

Yes.

DPOT Fault. This bit is set if there is an error reading back the value written to a DPOT. It remains set until power cycle.

EEPROM Fault. This bit is set if there is an error reading back the value written to EEPROM. It remains set until power cycle.

Yes.

Yes.

DAC Fault. This bit is set if there is an error detected communicating with the DAC. The DAC used (LTC2600) does not support a read-back operation, but it does support daisychaining, so the firmware detects a failure by prepending a known value to any commands, and looking for an echo of that known value on the SPI input after sending the command. It remains set until power cycle.

Yes.

Reserved

Simulated Error. This bit mirrors the “Simulated Error Control” bit in

Section 6.2.9—Object 0x7010: Control Codes

.

No, but can be used to test user error handling if treated as such.

Yes.

Calibration checksum error. This bit is set if the active calibration did not have a valid checksum when read from EEPROM.

Saturation. This bit is set whenever a strain gage sample is saturated, and stays high for 32 samples after the last saturated sample, to allow time for the saturated sample’s effect on the filtered data to abate.

Error: This bit is set whenever any status code bit that indicates an error is set.

Yes.

Yes

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6.2.8 Object 0x6020: Sample Counter

This object contains a single 32-bit unsigned integer at subindex 0 that increments each time an F/T sample (one complete set of gage data) is read.

6.2.9 Object 0x7010: Control Codes

This object is mapped into the RxPDO for real-time control of the F/T system. It contains the following fields:

Subindex Name Type

0x01

0x02

Control 1 DINT

Control 2 DINT

Bit

0

1

Description

Function

1 = Set bias against current load.

0 = Use last set bias.

1 = Select gage output

0 = Select F/T output.

2

3

4-7

8-11

1 = Set test error

0 = clear test error

1 = Clear monitor condition status.

0 = Leave monitor condition status as-is.

Filter selection

Calibration Selection

12-31 Reserved

Bit Function

0-15 Monitor condition enable bitmap

16-19 Tool transform index selection.

20-30 Reserved

31 Simulated Error Control

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7. Hardware Installation

The following section provides information for installing the ECATOEM PCB into an application.

7.1 Chassis Grounding

The ECATOEM interface board provides three mounting holes. One of these (marked “C” in

Figure 7.1

) provides a path to the shield connection of the EtherCAT bus cable. The mounting hole (marked “A” in the picture below) provides a path to the shield connection of the 24VDC power and monitor signal cable. For best EMI performance both, “A” and “C” should get connected to chassis ground.

Figure 7.1—ECATOEM Interface Board Mounting

(B) Chassis Connection

P900

Optional 24VDC Power and Monitor signal

(A) Chassis Connection

P904

Transducer Strain Gage Signals

P902

Optional External LEDs

(C) Chassis Connection

P901

EtherCAT Interface with Optional PoE

NOTICE: To minimize PCB vibration, all three mounting holes should be used.

7.2 Transducer Handling

In addition to the standard transducer handling instructions (see Manual 9620-05-Transducer Section for details), the following should be observed:

The transducer calibration label FTxxxx must not be removed or painted over. If a transducer gets returned to ATI for calibration or repair, it is important that this number is present.

• The transducer connector has no strain relief. To protect the fragile crimp contacts it is important to provide a suitable strain relief in the final product.

7.3 Ground and cable shield considerations

There are several options for connecting the transducer cable shield:

1. If the transducer is connected to chassis ground, then don’t connect the cable shield (since the shield is connected to the transducer body and such to chassis ground).

2. If the transducer is isolated, then: a. Connect the cable shield to chassis ground or b.

Connect the cable shield to system Ground P900 Pin 9

You may have to experiment to find the best solution for EMC compliance and best noise performance.

7.4 Power Supply Considerations

The ECATOEM interface board can be supplied with a DC voltage between 20V and 48 V on P902 or with

Power-over-Ethernet through the EtherCAT interfcae (P901)

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7.5 Installation

The transducer can be used in a variety of applications that will affect how best to route the cable and determine the proper bending radius to use. Some applications will allow the transducer and the cable to remain in a static condition, other applications require the transducer to be in a dynamic condition that requires the cable to be subjected to repetitive motion. It is important not to expose the transducer cable connectors to this repetitive motion, and properly restrain the cable close to the transducer connection. Refer to the Transducer Section Manual (

http://www.ati-ia.com/app_content/documents/9620-05-Transducer%20

Section.pdf

) for proper cable bending radius and cable restraint methods.

1.

Attach the ECATOEM interface board to the mounting using customer supplied M3 fasteners, use all three mounting holes to secure the board. Refer to

Figure 7.2.

NOTICE: Make sure mounting holes “A

” and “C” are connected to chassis ground. Not connecting the “A

” and “C” mounting holes to chassis ground may cause unpredictable behavior. Refer to

Figure 7.1

2. Route and connect the EtherCAT cable to the P901 connector on the ECATOEM interface board.

3. Route and connect the Transducer cable to the P904 connector on the ECATOEM interface board.

NOTICE: Make sure to route the Transducer cable away from the Power Transformer on the

ECATOEM interface board. Routing the Transducer cable close to the power transformer can cause noise problems.

Figure 7.2—ECATOEM Interface Board Installation

Customer Supplied Mounting

EC8 Type Transducer

(Mini45 transducer shown)

Power Transformer

ECATOEM

Interface Board

P900 Connector

Optional RS485 Cable If Used

P904 Connector

Transducer Cable

(3) Customer Supplied

(M3) Fasteners

P902 Connector

Optional External LED Cable If Used

P902 Connector

EtherCAT Cable

4. If using an external DC power supply instead of PoE then connect the 24VDC power (Pin 1(-) and Pin 5

(+)) to P900 connector on the ECATOEM interface board. Refer to

Section 4.1.1—P900 Connector for

Optional 24VDC Power & Monitor Signal Interface

for P900 connector signals.

5.

If using the Optional External LED cable route the cable and connect to the P902 connector on the

ECATOEM interface board. Refer to

Section 4.1.3—P902 Connector for optional external LEDs

for

P902 connector signals.

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8. Troubleshooting

This section includes answers to some issues that might arise when setting up and using the ECATOEM system.

The question or problem is listed followed by its probable answer or solution. They are categorized for easy reference.

The information in this section should answer many questions that might arise in the field. Customer service is available to users who have problems or questions addressed in the manuals.

ATI Industrial Automation

Attn: F/T Customer Service

Pinnacle Park

1031 Goodworth Drive

Apex, NC 27539 USA

Phone: +1.919.772.0115

Fax:+1.919.772.8259

Email:

[email protected]

NOTICE: Please read the F/T manuals before calling customer service. When calling, have the following information available:

1. Serial number(s)

2. Transducer type (e.g., Nano17, Gamma, Theta)

3. Calibration (e.g., US-15-50, SI-130-10)

4. An accurate and complete description of the question or problem.

5. If possible all information that is displayed on Net F/T page System Info (manuf.htm). The

ECATOEM has to be connected to a NetBox to access the System Info.

If possible, the F/T system should be accessible when talking with an ATI Industrial Automation customer service representative.

8.1 Questions and Answers

8.1.1 Errors with Force and Torque Readings

Bad data from the transducer’s strain gages can cause errors in force/torque readings. These errors can result in problems with transducer biasing and accuracy. Listed below are the basic conditions of bad data. Use this to troubleshoot your problem.

Question/Problem

Noise

Drift

Hysteresis

Answer/Solution

Jumps in raw strain gage readings (with transducer unloaded) greater than 80 counts is considered abnormal. Noise can be caused by mechanical vibrations and electrical disturbances, possibly from a poor ground. It can also indicate component failure within the system. Make sure that the DC supply voltage for the ECATOEM has little to no noise superimposed.

After a load is removed or applied, the raw gage reading does not stabilize, but continues to increase or decrease. This may be observed more easily in resolved data mode using the bias command. Drift is caused by temperature change, mechanical coupling, or internal failure. Mechanical coupling is caused when a physical connection is made between the tool plate and the transducer body (i.e., filings between the tool adapter plate and the transducer body). Some mechanical coupling is common, such as hoses and wires attached to a tool.

When the transducer is loaded and then unloaded, gage readings do not return quickly and completely to their original readings. Hysteresis is caused by mechanical coupling

(explained in Drift section) or internal failure.

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9.

Specifications

9.1 Storage and Operating Conditions

Component

ECATOEM

Table 9.1—Temperature

Storage Temperature, °C

-40 to +100

9105-MINI45TH12-AE-0.40-EC8 See Transducer Section Manual

http://www.ati-ia.com/app_ content/documents/9620-05-

Transducer%20Section.pdf

Operating Temperature, °C

-20 to +70

See Transducer Section Manual

http://www.ati-ia.com/app_ content/documents/9620-05-

Transducer%20Section.pdf

9.2

Electrical Specifications

Power Source†

Table 9.2—Power Supply

Voltage

DCIN through P900 (20V min. to 48V max.)

Notes:

1. With Mini45 transducer connected to the ECATOEM interface board Assembly.

Maximum Power Consumption

1

3.0W

The ECATOEM power supply input is protected against wrong polarity.

9.3 Weights and Dimensions

Component

ECATOEM PCB Assembly

9105-TW-MINI45-AE-0.3-EC8

Table 9.3—Weights and Dimensions

Weight (approx.)

17g (0.6oz)

See Transducer Section Manual

http://www.ati-ia.com/app_ content/documents/9620-05-

Transducer%20Section.pdf

Dimensions

See drawing in Section 11.1

See Transducer Section Manual

http://www.ati-ia.com/app_ content/documents/9620-05-

Transducer%20Section.pdf

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10. Drawings

1031 Goodworth Drive, Apex, NC 27539, USA Tel: +1.919.772.0115 Email: [email protected] Fax: +1.919.772.8259 www.ati-ia.com ISO 9001 Registered Company

3 Max. Component Height Bottom Side

NOTES: UNLESS OTHERWISE SPECIFIED.

DO NOT SCALE DRAWING. ALL DIMENSIONS ARE IN MILLIMETERS.

6 Plated Area Both sides

Wire-To-Board connectors. Mounting holes A and C to be used for ground connection. Refer

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11. Terms and Conditions of Sale

The following Terms and Conditions are a supplement to and include a portion of ATI’s Standard Terms and

Conditions, which are on file at ATI and available upon request.

ATI warrants to Purchaser that force torque sensor products purchased hereunder will be free from defects in material and workmanship under normal use for a period of one year from the date of shipment. This warranty does not cover components subject to wear and tear under normal usage or those requiring periodic replacement.

ATI will have no liability under this warranty unless: (a) ATI is given written notice of the claimed defect and a description thereof with thirty (30) days after Purchaser discovers the defect and in any event, not later than the last day of the warranty period and (b) the defective item is received by ATI not later than (10) days after the last day of the warranty period. ATI’s entire liability and Purchaser’s sole remedy under this warranty is limited to repair or replacement, at ATI’s election, of the defective part or item or, at ATI’s election, refund of the price paid for the item. The foregoing warranty does not apply to any defect or failure resulting from improper installation, operation, maintenance, or repair by anyone other than ATI.

ATI will in no event be liable for incidental, consequential, or special damages of any kind, even if TI has been advised of the possibility of such damages. ATI’s aggregate liability will in no event exceed the amount paid by the purchaser for the item which is the subject of claim or dispute. ATI will have no liability of any kind for failure of any equipment or other items not supplied by ATI.

No action against ATI, regardless of form, arising out of or in any way connected with products or services supplied hereunder, may be brought more than one year after the cause of action accrued.

No representation or agreement varying or extending the warranty and limitation of remedy provisions contained herein is authorized by ATI, and may not be relied upon as having been authorized by ATI, unless in writing and signed by an executive officer of ATI.

Unless otherwise agreed in writing by ATI, all designs, drawings, data, inventions, software, and other technology made or developed by ATI in the course of providing products and services hereunder, and all rights therein under any patent, copyright, or other law protecting intellectual property, shall be and remain ATI’s property. The sale of products or services hereunder does not convey any expressed or implied license under any patent, copyright, or other intellectual property right owned or controlled by ATI, whether relating to the products sold or any other matter, except for the license expressly granted below.

In the course of supplying products and services hereunder, ATI may provide or disclose to Purchaser confidential and proprietary information of ATI relating to the design, operation, or other aspects of ATI’s products. As between

ATI and Purchaser, ownership of such information, including without limitation any computer software provided to Purchaser by ATI, shall remain in ATI and such information is licensed to Purchaser only for Purchaser’s use in operating the products supplied by ATI hereunder in Purchaser’s internal business operations.

Without ATI’s prior written permission, Purchaser will not use such information for any other purpose of provide or otherwise make such information available to any third party. Purchaser agrees to take all reasonable precautions to prevent any unauthorized use or disclosure of such information.

Purchaser will not be liable hereunder with respect to disclosure or use of information which: (a) is in the public domain when received from ATI, (b) is thereafter published or otherwise enters the public domain through no fault of Purchaser, (c) is in Purchaser’s possession prior to receipt from ATI, (d) is lawfully obtained by Purchaser from a third party entitled to disclose it, or (f) is required to be disclosed by judicial order or other governmental authority, provided that, with respect to such to maintain the confidentiality of such information.

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