Explanations

How to troubleshoot Ethercat

Allura Xper FD
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 Table of Contents

1 INTRODUCTION ..............................................................................................................................4
1.1 Purpose of Document .......................................................................................................................4
1.2 Document history ..............................................................................................................................4
1.3 Abbreviation List ...............................................................................................................................4
1.4 Sources .............................................................................................................................................4

2 ETHERCAT ......................................................................................................................................5
2.1 Benefits of ethercat ...........................................................................................................................5
2.2 Protocol .............................................................................................................................................6
2.2.1 EtherCAT Frame ............................................................................................................................6
2.2.2 EtherCAT Header ...........................................................................................................................6
2.2.3 Process Data ..................................................................................................................................6
2.2.4 Working Counter ............................................................................................................................7
2.2.5 Ethercat communication train analogy ...........................................................................................7

3 ETHERCAT SLAVE FRAME PROCESSING ..................................................................................8

3.1 Port Control, loop control and loop state ..........................................................................................8
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3.1.1 Manual open ...................................................................................................................................8

3.1.2 Manual close ..................................................................................................................................8
3.1.3 Auto ................................................................................................................................................8
3.1.4 Auto close (manual open) ..............................................................................................................8
3.2 Frame processing order....................................................................................................................8
3.3 Circulating frames. ..........................................................................................................................10
3.4 Unconnected Port 0 ........................................................................................................................10

4 THE USE OF ETHERCAT WITHIN GEOMETRY PLATFORM .....................................................11

4.1 Ethercat devices within geometry platform .....................................................................................11
4.2 Software ..........................................................................................................................................13
4.3 Geometry Interface Box (GIB) ........................................................................................................13
4.4 Ethercat topology within geometry platform ...................................................................................14
4.5 Ethercat topology depending on configuration ...............................................................................14
4.6 The Ethercat HUB present at the GIB: ...........................................................................................16
4.7 Ethercat slaves with 3-axe/1-axe serve drive: ................................................................................17
4.8 Topology Physical ...........................................................................................................................17
4.9 Topology Logical .............................................................................................................................17
4.10 Ethercat execution and bus cycle within geometry ........................................................................18

5 GEOMETRY START UP ETHERCAT INITIALISATION ...............................................................18

5.1 Initialization .....................................................................................................................................18

6 ETHERCAT GEOMETRY LOGGING ............................................................................................19

6.1 IPC logging .....................................................................................................................................19
6.1.1 IPC logging via Safe Data For PR ................................................................................................19
6.1.2 Direct IPC logging ........................................................................................................................19
6.1.3 IPC logging via remote desktop ...................................................................................................19
6.2 Event number (ranges) to expect for ethercat based systems ......................................................21
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 6.3 Additonal ethercat logging in case of problems ..............................................................................21
6.3.1 IPC logging explanation in a good situation .................................................................................23

7 ETHERCAT TOPOLOGY FAULTFINDING. ..................................................................................27

7.1 Configuration ..................................................................................................................................27
7.1.1 Via system logfile file ....................................................................................................................27
7.1.2 Via GTCRT file .............................................................................................................................27
7.1.3 Via Config table ............................................................................................................................28
7.1.4 Via maximum to actual determination ..........................................................................................29
7.2 Compare .........................................................................................................................................29

8 EXAMPLES FROM THE FIELD .....................................................................................................31

8.1 Input (cn1) output (cn2) swapped at 2spc (3 Axis Servo Drive) .....................................................31
8.1.1 Symptom ......................................................................................................................................31
8.1.2 Rootcause investingation .............................................................................................................31
8.1.3 Rootcause ....................................................................................................................................35
8.1.4 Solution.........................................................................................................................................35
8.2 Geometry not starting due to Ethercat problems. ...........................................................................36
8.2.1 Symptom ......................................................................................................................................36
8.2.2 Root cause investigation ..............................................................................................................36
8.2.3 Solution.........................................................................................................................................37
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 1 INTRODUCTION

1.1 Purpose of Document

This document gives information on how to troubleshoot Ethercat in Geometry CAN issues.
It is intended for the Philips engineer who is CardioVascular modality service specialist and has extensive insights,
experience and knowledge to use and understand the content of this document
Due to their limited experience and knowledge this document is not to be used by multimodality engineers nor in-
house hospital.

1.2 Document history

Revision Reason for changes
00 First issue

1.3 Abbreviation List

BIB Bodyguard Interface Box
CAN Controller Area Network
CANopen Controller Area Network family type
CoE CANopen over Ethercat
DC Distributed Clocks
EoE Ethernet over Ethercat
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ESC Ethercat Slave Controller

ESC DL Ethercat Slave Controller Data Link
EtherCat Ethernet for Control Automation Technology
Ethernet HUB box for interconnecting RJ45 connections
FPGA Field Programmable Gate Array
FSE Field Service Engineer
GIB Geometry Interface Box
GPDU General Power Distribution Unit
PD Process Data
RJ45 Registered Jack type 45
Sercos serial real-time communication system
SoE SERCOS over Ethercat
UTP Unshielded Twisted Pair
WC Working Counter

1.4 Sources

DHF112734_UDS_MotionPlatform Harry Franken R&D Pos.

DHF159400_SSIS_Positioning_Logging Bart Rem R&D Pos.
DHF143657 BBRS GEO IO BOX SPD6159110191R06 Prodrive manufaturer GIB
EtherCAT_ET1100_Datasheet_all_v1i8 Beckhoff (www.beckhoff.com) Ethercat control
module
Ethercat in general www

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 2 ETHERCAT
In the current products CAN is used, but in a Philips proprietary way. This means that there are no off-
the-shelf components and only a limited set of suppliers.
Obsolescence of CAN hardware/suppliers will become a problem in the future.
In addition to that the bandwidth of the CAN-bus is limited and a faster protocol is needed for future
developments.
Several alternative industry standard solutions are available, such as CANopen, Sercos, and EtherCat,
each with its own protocol, cabling and connection requirements.
Studies showed that the best alternative was to go for EtherCAT.
EtherCAT uses the same UTP cabling, and RJ45 connectors as for Ethernet which makes the cable
infrastructure cheap reliable and familiar for FSE’s.
Ethercat is centralized processed, processing only takes place at the master stack this is a big benefit
compared with CAN based nodes.
Supports 100 Mbit half/full duplex modes.

2.1 Benefits of ethercat

Send and receiving packets within one ethercat message
Multiple nodes are using the same ethercat messages for data exchange.
The data exchange rate is higher than with standard Ethernet.
Maximum bus load for cyclic data is expected to be less than 10% in a full configuration.
Real time communication
The distributed clock technique takes care that status signals are simultaneously processed at the
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nodes.
The Ethernet packet is no longer received, then interpreted and process data then copied at every
device.
The EtherCAT slave devices read the data addressed to them while the frame passes through the node.
Input data is inserted while the telegram passes through the frames are only delayed by a few
nanoseconds.
Since an Ethernet frame comprises the data of many devices both in send and receive direction, the
usable data rate increases dramatically compared with standard internet.
Runs on Real Time Platform which is needed for optimum performance
Processing takes only place at the master stack which makes the hardware relative cheep

Small movie ethercat frame travel http://www.youtube.com/watch?v=N2HJq62qP9M

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 2.2 Protocol
The EtherCAT protocol is optimized for process data and is transported directly within the Ethernet frame
thanks to a special Ethertype.

2.2.1 EtherCAT Frame

Looking at the EtherCAT frame, its analogy to a train is quite apparent.
The header acts like a locomotive. The wagons , plus their content, Process Data (PD) . The last wagon
(caboose), complete with shipping information, is the working counter.

Work
EtherCat Process Data
Counter
Header (PD)
(WC)

Ethernet
CRC
Header

IP Package
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All of these parts fit simply into the EtherCAT frame, and the frame fits simply into an Ethernet frame.
The Ethernet is the transmission media that allows EtherCAT to operate.
The EtherCAT frame simply replaces the IP frame of a standard Ethernet message.
The Ethernet frame does not need modification, again contributing to flexibility for EtherCAT.

2.2.2 EtherCAT Header

The EtherCAT frame starts with a standard header. The first integer is a length identifier. This bit tells the
nodes how long the EtherCAT portion of the frame will be.
Length is especially important in an EtherCAT frame; the length varies with the number of message
bytes and nodes just like more train wagons of product makes the train longer.
The second portion of the EtherCAT header is a reserved bit, which is followed by a type integer. The
type integer defines the type of message, ensuring correct interpretation.

2.2.3 Process Data

After the header, the Ether CAT frame contains Process Data . The PDs correspond to the number of
nodes and messages within the frame.
Each PD contains data for a node, the product inside the box wagon.
The PD’s are also individually addressed, telling the nodes which PDs to take.

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 2.2.4 Working Counter
The final portion of an EtherCAT frame is the working counter.
By ensuring the working counter is correct, each node can ensure it receives the entirety of the frame.
Working Counter enables the information in each Datagram to be monitored for consistency. Every node
that is addressed by the Datagram and whose memory is accessible increments the Working Counter
automatically. The master is then able to cyclically confirm if all nodes are working with consistent data.
If the Working Counter has a different value than it should, the master does not forward this Datagram’s
data to the control application.

2.2.5 Ethercat communication train analogy

Master Start’s cars (Data Frames)
Passengers (Data) can get on or off at stations (Slaves)
Multiple stations (slaves) are working in parallel
Cars form a continuous loop “filling the track” and the train is not stopping or slowing down.
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 3 ETHERCAT SLAVE FRAME PROCESSING
Each ethercat node is having a port controlling FPGA on which is determined how the ethercat node is implemented
into the ethercat network. Via those ports the data flow can be regulated.

3.1 Port Control, loop control and loop state

Each port of an ESC can be in one of two states: open or closed. If a port is open, frames are
Transmitted to other ESCs at this port, and frames from other ESCs are received. A port which is
closed will not exchange frames with other ESCs, instead, the frames are forwarded internally to the
next logical port, until an open port is reached.
The loop state of each port can be controlled by the master. The ESCs supports four loop control
settings, two manual configurations, and two automatic modes:

3.1.1 Manual open

The port is open regardless of the link state. If there is no link, outgoing frames will be lost.

3.1.2 Manual close

The port is closed regardless of the link state. No frames will be sent out or received at this port, even
if there is a link with incoming frames.

3.1.3 Auto
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The loop state of each port is determined by the link state of the port. The loop is open if there is a
link, and it is closed without a link.
Slave

3.1.4 Auto close (manual open)

The port is closed depending on the link state, i.e., if the link is lost, the loop will be closed (auto
close). If the link is established, the loop will not be automatically opened, instead, it will remain closed
(closed wait state). Typically, the port has to be opened by the master explicitly by writing the loop
configuration again to the ESC DL Control register 0x0100.

3.2 Frame processing order

The frame processing order of EtherCAT Slave Controllers depends on the number of ports (logical
port numbers are used)

Number of Ports Frame processing order

1 0→EtherCAT Processing Unit→0

2 0→EtherCAT Processing Unit→1 / 1→0
3 0→EtherCAT Processing Unit→1 / 1→2 / 2→0 (log. ports 0,1, and 2)
or
0→EtherCAT Processing Unit→3 / 3→1 / 1→0 (log. ports 0,1, and 3)
4 0→EtherCAT Processing Unit→3 / 3→1 / 1→2 / 2→0

The direction through an ESC including the EtherCAT Processing Unit is called “processing” direction,
other directions without passing the EtherCAT Processing Unit are called “forwarding” direction.
Ports which are not implemented behave similar to closed ports, the frame is forwarded to the next.
The figure shows the frame processing in general

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Example Port Configuration with Ports 0, 1, and 2

1. If there are only ports 0, 1, and 2, a frame received at port 0 goes via the Auto-Forwarder and the Loopback
function to the EtherCAT Processing Unit which processes it.
2. Then, the frame is sent to logical port 3 which is not configured, so the Loopback function of port 3 forwards
it to port 1.
3. If port 1is closed, the frame is forwarded by the Loopback function to port 2.
4. If port 1 is open, the frame is sent out at port 1.
5. When the frame comes back into port 1, it is handled by the Auto-Forwarder and sent to port 2.
6. Again, if port 2 is closed, the frame is forwarded to port 0, otherwise, it is sent out at port 2.
7. When the frame comes back into port 2, it is handled by the Auto-Forwarder and then sent to the Loopback
function of port 0.
8. Then it is handled by the Loopback function and sent out at port 0 – backto the master.

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 3.3 Circulating frames.
The ESCs incorporate a mechanism for prevention of circulating frames. This mechanism is very
important for proper watchdog functionality. This is an example network with a link failure between slave
1 and slave 2:

Both slave 1 and slave 2 detect the link failure and close their ports (port 1 at slave 1 and port 0 at
slave 2). A frame currently traveling through the ring at the right side of slave 2 might start circulating.
If such a frame contains output data, it might trigger the built-in watchdog of the ESCs, so the
watchdog never expires, although the EtherCAT master cannot update the outputs anymore.
To prevent this, a slave with no link at port 0 and loop control for port 0 set to Auto or Auto close (ESC
DL Control register 0x0100) will do the following inside the EtherCAT Processing Unit:
• If the Circulating bit of the EtherCAT datagram is 0, set the Circulating bit to 1
• If the Circulating bit is 1, do not process the frame and destroy it
The result is that circulating frames are detected and destroyed. Since the ESCs do not store the
frames for processing, a fragment of the frame will still circulate triggering the Link/Activity LEDs.
Nevertheless, the fragment is not processed.
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3.4 Unconnected Port 0

Port 0 must not be left intentionally unconnected (slave hardware or topology) because of the
circulating frame prevention. All frames will be dropped after they have passed an automatically
closed Port 0 for the second time, and this can prohibit any EtherCAT communication.
Example: Port 0 of slave 1 and 3 are automatically closed because nothing is connected. The
Circulating bit of each frame is set at slave 3. Slave 1 detects this and destroys the frames.

All frames are dropped because of Circulating Frame Prevention

In redundancy operation, only one Port 0 is automatically closed, so the communication remains
active.

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 4 THE USE OF ETHERCAT WITHIN GEOMETRY PLATFORM

4.1 Ethercat devices within geometry platform

Two 3-axis AMC drives are located inside the L-arm.

 AMC Ecat drive (1SPC) that controls movement of the L-arm. These movements are:
o Longitudinal drive.
o Propeller rotation drive.
o L-arm Z-rotation drive.
 AMC Ecat drive (2SPC) that controls movement of the C-arc. These movements are:
o FD shift drive.
o FD rotation drive.
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o C-arc roll drive.

Ecat Leds

Source CMM

 Bodyguard Interface Box (SPB) is located in the C-arc cabeling junction box.
o Only Etercat node with dedicated I/O intefacing for the bodyguards no servo drive included.

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  Maximum of 6 Singles axis AMC drives are located inside the AD7X Table
o Height (SAF11)
o Swivel (SAW11)
o Tilt (SAT12)
o Lateral (SAT11)
o Cradle (SAR11)
o Longitudinal (SAR12)
Ecat Leds and status
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Source CMM

 Geometry Interface Box (GIB) is located at the R-cainet and consist the 6-fault ethercat Hub
o Ethercat HUB function.
o I/O interfacing
o B =GIB,A =HEB provides backwards compatibility for CAN/LUC based control topologies in Allura
Xper systems

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 2-axis AMC drive (SPM) for flexmove is located at the The Flexmove AMC:
o Y dirction flexmove system
o X dirction flexmove system
 For Leds see 3-axis box

 Geometry Industrial Personal Computer (IPC) located at R-cabinet

o Ethercat Master is running at IPC
o Ethercat connection via RC –X11

4.2 Software
The master stack is located on the Geometry IPC and the software is running as part of the Geo Host
software.
The Geo Host software is the heart of Motion Control.
On the Geo IPC, Windows and VxWorks are running in parallel.
Geo Host software is controlling all geometry parts ethercat based and non ethercat based
The real-time software runs on VxWorks and the non-real-time software on Windows.
Real-time processing is needed to support the EtherCAT motion platform.
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On the IPC desk top screen the GSC/GSCRT cmd screens must always be visible when both processes
are running

4.3 Geometry Interface Box (GIB)

The GIB has the following functionality:
Ethercat I/O for support of configurations with older hardware e.g. CAN topology in the Poly G stand.
Ethercat I/O for support of configurations with third party equipment e.g. Magnus table.
Perform emergency stop functionality.
Power switching for motion control (servo Power)
Interfacing with system and sub-system building blocks like GPDU
Ethercat Hub function is build up around two Ethercat slave controllers and has dedicated fixed input and output
ports
HEB (Hybrid Extension Box) provides backwards compatibility for CAN/LUC based control topologies in Allura Xper
systems like poly G, Clea and Larc

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Printed copies are uncontrolled

4.4 Ethercat topology within geometry platform

Ethercat slaves with and without servo control are used for the motor drives and for reading out status signals like
bodyguard, GIB etc.
At system level the host PC communicates with the GEOIPC through an Ethernet connection.
In the R-cabinet the GEO I/O Box is situated that contains the Ethercat Hub.
From the GEOIPC to the Hub the Ethercat cables are routed through the building blocks (e.g. Clea2, AD7X or
Flexmove).
Heart of the Ethercat network is the Ethercat hub which is integrated in the Geo I/O Box (GIB).
The hub connects the external Ethercat motion controllers of the various building blocks (e.g. table, stand).
The GIB internal ethercat nodes are always the first nodes in the Ethercat network.
Standard Cat5e straight network cables are used

4.5 Ethercat topology depending on configuration

The number of ethercat slaves present as well Ethercat network cable topology depends on the hardware
configuration which is fixed by delivery. The followed Etercat Slave Device order is crucial to get the system in a
working state.
Maximum number of ethercat slaves is at the moment 12 but could be extended in the future.

Check configuration within FSF or via order list.

The ethercat configuration table must be read top down GIB, Table and Stand
Add the highest number of each segment (if present) with next segment slave order.
See example on next page.

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 Ethercat Configuration Table

GIB HUB Device Sub device Usage Ethercat slaves

GIB ESC 0 (fixed) * Ethercat HUB 1

CN1 GeoIoBox

GIB ESC 1 (fixed) * Ethercat HUB 2

Spare

CN2 - - -

Clea 2 L-arm(fixed) 3-axes servo drive 1

Clea-2

CN3 Clea 2 C-ARC(fixed) 3-axes servo drive 2

Clea 2 BIB Bodyguard control 3

Height Longitudinal Lateral Tilt Cradle Swivel

drive drive drive drive drive drive

basic 1

AD7XNT long 1 2

Long + lat 1 3 2
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Longt +Tilt 1 3 2

Longt +Tilt+lat 1 4 3 2
AD7XT
Long + tilt + cradle 1 4 2 3
table

CN4
Long + tilt + lat + cradle 1 5 3 2 4

basic 1 2

AD7NT SWIVEL long 1 3 2

Long + lat 1 4 3 2

Longt +Tilt 1 5 3 4 2

Longt +Tilt+lat 1 6 4 3 5 2
AD7XT SWIVEL
Long + tilt + cradle 1 5 3 4 2

Long + tilt + lat + cradle 1 6 4 3 5 2

Flexmove

CN5 Flexmove XY Box 2-axes servo drive 1

Spare

CN6 - - -

* GIB is always present

* VA brake option is having no influence on the ethercat configuration that why it isn’t mentioned in the table.

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 Example:
8.2 system with AD7XT, swivel, Cradle, tilt , bolus chase and clea2
Add the highest number (max) of each segment (if the segment is present) with next segment slave order.
e.g. for this configuration GIB highest is 2, AD7 highest is 5

ESC Nr/segment Geo slave

Slave order order/numbering
GIB ESC 0 (fixed) 1 1
GIB
GIB ESC 1 (fixed) 2 (max) 2
Height drive 1 3
Swivel drive 2 4
Tilt drive 3 5
AD7XT
Cradle 4 6
Longitudinal 5 (max) 7
drive
Clea 2 L- 1 8
arm(fixed)
Stand Clea 2 C- 2 9
ARC(fixed)
Clea 2 BIB 3 (max) 10

4.6 The Ethercat HUB present at the GIB:

The Ethercat HUB is build up around two Ethercat slaves and has dedicated fixed output ports.
Topology will follow the blue loop (ring) and will run via the configured Ethercat slave ports which again depends on
the Geometry configuration. This HUB is a real time device thus this means a standard switch/hub cannot be used.
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HUB

Processing Processing
3 3

0 1 0 1
GIB ESC 0 GIB ESC 1

2 2

CN1 CN3 CN2 CN5 CN4 CN6

IPC Fr Stand Spare FlexMove AD7X Spare

Ethercat connector (HUB) overview on the GIB

CN1 (IPC) CN3 CN5

CN2 CN4 CN6

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 4.7 Ethercat slaves with 3-axe/1-axe serve drive:
Depending on system configuration ethercat slaves have dedicated port configuration. In our case two
ports (0/1) with two connectors CN1/CN2 are used or one port (0) with one connector CN1 is used.

Processing Processing
3 3

CN2
CN1

CN1
0 1 0 1
GIB ESC 0 GIB ESC 0

2 2

4.8 Topology Physical

Example max configuration AD7,flexmove and CLEA 2

HUB
CN6

SPM Flexmove
CN5 CN1
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SAF11 Height SAW11 Swivel SAT12 Tilt SAT11 Lateral SAR11 Cradle SAR12 Long
CN4 CN1 CN2 CN1 CN2 CN1 CN2 CN1 CN2 CN1 CN2 CN1

1SPC L-arm 2SPC C-arm BIB Bodyguard

CN3 CN1 CN2 CN1 CN2 CN1

CN2
IPC Geometry controller
Ethercat Master
Stack
CN1 X11

4.9 Topology Logical

Considering the fact that Ethercat is a ring structure (two

way road) which has been implemented in a string
Master Stack (IPC)
structure it will be clear that in case of a failure in a part of GIB ESC0
the string the rest of the network devices further down the GIB ESC1
string will become unavailable! SAF11 Height
Depending of the configuration nodes are added or SAW11 Swivel
removed. SAT12 Tilt
SAT11 Lateral
In the Future more nodes are possible. SAR11 Cradle
When one node fails the system fails it start-up. SAR12 Long.
SPM Flexmove
1SPC L-arm
2SPC C-arm
BIB Bodyguard

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 4.10 Ethercat execution and bus cycle within geometry

Ethercat cyclic frames:

Cyclic frames are mandatory acyclic frames are optional
Cyclic will be used in our application for Position Variables and Feed Forward motion control.
Repeated frame, at a fixed cycle time. The ethercat cycle time for our motion application is fixed to 2
millisecs
It contains a DC (Distributed Clocks) datagram to distribute bus time information.
The ethercat master sends this cyclic frame.

Ethercat acyclic frames:

Acyclic frames are used by Motion the Platform for event handling, control signals, downloading and
other forms of non-time critical data transport.
Transfer of parameterization information without interference of the synchronized data stream, Cyclic
and acyclic frames are interspersed, acyclic frames will be inserted after the PD frames
Mailbox communication path, which is used for CoE (CANopen over Ethercat) , (File Access over
EtherCAT) , EoE (Etehernet over Ethercat) and SoE(SERCOS over Ethercat).

5 GEOMETRY START UP ETHERCAT INITIALISATION

Etehercat initialization takes place in multiple steps and each step depending on pass or failed will lead to a new
situation on which next step is based. ECS devices are having a couple of states before going to application mode
Printed copies are uncontrolled

(Init, Pre-0perational,Safe operational and Operational, Bootstrap(optional)) Each state has its own tests and
routines and influences the Startup success of the geometry. If one of the ESC’s fails then the Master (IPC) will
indicate in the event logging that it cannot go to safeop.

Technical Event Description: Application error: EtherCat Memo: [FREE_TEXT] Time of occurrence :
ID: 063001124 POST error [item=TopologyTest] 2014-09-11, 19:24:38 [SEVERITY] Error
[EXCEPTION_DESCRIPTION] [detail=Cannot
start set master state to SAFEOP (Result =
ERROR: Time-out (0x98110010)) ]

Next chapter described the steps in a good situation with finally leads to a ethercat running state.
The steps can be found back in the IPC logging

5.1 Initialization
1. Initial startup, Create Master, make selection which ethercat topo configuration file to pick based on
geometry configuration.
2. Select file example: c:\Geo_Geometry_prod\EtherCAT_Topology_GIBCleaCeilingAd7_3axis.xml. The
ethercat cabling routing per configuration is assumed to be fixed, because the service engineer installs the
system according to the installation instructions.
3. Prepare settings for all ethercat axis/load config settings for all axes.
4. Perform bus scan which reads out Ethercat Slave Parameters and compares them with configuration and
axis settings (example: Axis SAM_TblHeight: calculated add file crc (0x2935982e) matches the configured
crc.)
5. Check if the slaves have correct sw levels and are correctly downloaded
6. Perform post powered
7. Read out calibration data to check calibration data/status
8. Run application.

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 6 ETHERCAT GEOMETRY LOGGING
The Ethercat geometry logging is part of the normal event logging and more details in IPC logging .
Both logging types are present in the Safe Data for PR file.

6.1 IPC logging

The IPC logging is present in a Safe File for PR logging or directly at the IPC at C:\Temp directory.
The logging can be accessed by connecting keyboard/mouse/monitor to the IPC or via remote desktop
at the system host.

6.1.1 IPC logging via Safe Data For PR

1. In FSF, click the System tab.

2. On the Command List frame, click
Installation and then Installation.
3. A pop-up window with the message The
system will now restart… appears.
Click Yes.
4. The system starts-up in Open Profile.
5. Trace data can be found in in
C:\ftproot\SaveDevData and can be
copied to usb key or other media.
6. Use the icon Shutdown to Start System
(to close Open Profile)
Printed copies are uncontrolled

This takes about 5 minutes do not

interrupt this procedure!

9. Open GSCRT_CONS file corresponding

with the date/time looking for e.g.
GSCRT_CONS_15_35.geolog

6.1.2 Direct IPC logging

The logging can be accessed by connecting keyboard/mouse/monitor to the IPC. Use windows explorer to acces the
C:\Temp directory. Open or store GSCRT_CONS file corresponding with the date/time looking for e.g.
SCRT_CONS_15_35.geolog
6.1.3 IPC logging via remote desktop
1. In FSF, click the System tab.
2. On the Command List frame,
click Installation and then
Installation.
3. A pop-up window with the
message The system will now
restart… appears.
Click Yes.

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 4. Wait until the message It is now
safe to turn off your system
appears.
5. Turn off the system.
6. Turn on the system.
7. The system starts-up in Open
Profile.
8. Trace data can be found in in
C:\ftproot\SaveDevData and can
be copied to usb key or other
media.
9. Use the icon Shutdown to Start
System (to close Open Profile)
This takes about 5 minutes do
not interrupt this procedure!

10. Connect by RemoteDesktop to

Geoipc
type mstc in the run field to start
remote desktop
Printed copies are uncontrolled

11. Coputer name: GeoIpc

User Name:Headless
Password: H34dl3ss
12. Open windows explorer on the IPC
13. Logfiles are located at C:\Temp
14. Open or save the GSCRT_CONS
file corresponding with the date/time
looking for e.g.
GSCRT_CONS_15_35.geolog
15.When ready use the icon
Shutdown to Start System (to
close Open Profile) at the system
host. This takes about 5 minutes
do not interrupt this procedure!

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 6.2 Event number (ranges) to expect for ethercat based systems
From To Description
6000.0000 6000.9999 Events reserved for Geohost which is running at system client
6300.0000 6300.0999 Events reserved for GEOIPC + LUC based hardware. Real-time OS/non real-
time OS
6300.1100 6300.1119 Event reserved for SERVICEABLE ethercat based hardware in R7.8/R8.1
6300.1120 6300.1499 Event reserved for SERVICEABLE ethercat based hardware
6300.1500 6300.1599 Event reserved for NON SERVICEABLE ethercat events thus always for
HD/R&D

6.3 Additonal ethercat logging in case of problems

Technical event
ID Discribtion additional info
63001501 ATEM slave device event. Supplier specific events generated by ethercat slave devices only
understandable for development.
63001500 ATEM stack event. Supplier specific events generated by the ethercat master stack
only understandable for development.
63001104 AMC drive XY firmware Downloading to XYBOX fails and a user message is generated at
download error startup.

Cause of events:
Problem occurs after downloading a XYBOX.

Faultfinding sequence:
Printed copies are uncontrolled

Check geometry configuration is matching the ethercat device

connection. (This is very important because it defines the motion
network topology).
Check on GEOIPC LED’s whether both LED’s are on or blinking.
Check whether ethercat LED’s on XYBOX are on or blinking.

Possible corrective actions:

Set configuration correctly.
Fix cabling.
Replace XYBOX.
63001105 FlexMove XY POST error, "FlexMove XY POST error", "[Item=EtherCAT Topology]
"[Item=EtherCAT hardware] [detail=IPC Post: EtherCAT Topology test failed]"
[detail=IPC Post: EtherCAT "FlexMove XY POST error", "[Item=XYBox present] [detail=IPC
hardware test failed]" Post: XYBox Present test failed]"
"FlexMove XY POST error", "[Item=XYBox version] [detail=IPC
Post: XYBox download status failed, download required]"
"FlexMove XY POST error", "[Item=XYBox memory access]
[detail=IPC Post: XYBox memory read and write failed, memory
can not be accessed]"
"FlexMove XY POST error", "[Item=XYBox memory access]
[detail=IPC Post: XYBox memory read and write failed, data read
is <invalidBoxName>]"
"FlexMove XY POST error", "[Item=XYBox memory access]
[detail=IPC Post: XYBox memory nvmrt version or repairing is
failed]"
"FlexMove XY POST error", "[Item=XYBox internal temp]
[detail=IPC Post: XYBox temperature too high]"
"FlexMove XY POST error", "[Item=XYBox io connector]
[detail=IPC Post: Analog input 1 = 0.6, Analog input 2 = 0.4]"
"FlexMove XY POST error", "[Item=XYBox-X present] [detail=IPC
Post: Axis not present]"
"FlexMove XY POST error", "[Item=XYBox-X drive amp state]
[detail=IPC Post: AMP State test failed]"
"FlexMove XY POST error", "[Item=XYBox-X encoder access]
[detail=IPC Post: Encoder access failed, memory cannot be
accessed]"
"FlexMove XY POST error", "[Item=XYBox-X encoder access]
[detail=Encoder access test failed]"
"FlexMove XY POST error", "[Item=XYBox-X motor access]
[detail=Motor access test failed]"
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 63001124 “EtherCat POST error [item= “EtherCat POST error [item= TopologyTest], [detail=Guidance:
TopologyTest], [detail=Slave probably wrong cable on the wrong GeoIoBox port, verify
detection mismatch - bus scan: configuration, try to download firmware via fieldservice”
detected %d slaves; cfg %d, “EtherCat POST error [item= TopologyTest], [detail= Slave
Guidance: verify configuration or detection mismatch - bus scan: more slaves detected %d on the
remove/add ethercat slaves]” ethercat bus then configurated %d %s,%s = %s [0x%x 0x%x],
Guidance: verify configuration or remove ethercat slaves]”
63001125 Firmware download error Symptom:
Downloading to [device] failed and a user message is generated at
startup.

Cause of events:
Problem occurs after downloading [device].

Faultfinding sequence:
Check geometry configuration is matching the ethercat device
connection. (This is very important because it defines the motion
network topology).
Check on GEOIPC LED’s whether both LED’s are on or blinking.
Check whether ethercat LED’s on [device] are on or blinking.

Possible corrective actions:

Set configuration correctly.
Fix cabling.
Replace [device].
63001129 Unable to connect with Ethercat Symptom:
Printed copies are uncontrolled

motion network User error message is shownafter system startup

Cause of events:
Problem will occur at startup of the system.

Faultfinding sequence:
Check Ethercat HW POST results
Check GSC POST results
Check download status
If no power on all Ethercat devices, check power supply status
gPDU.
Check logic power LED’s on GIB.
Check logic power LED’s on Drives

Possible corrective actions:

Download
Correct network and power cabling between R-cabinet and GIB
Replace power fuses
Replace GIB
63001129 “Unable to connect with Ethercat
motion network”

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 6.3.1 IPC logging explanation in a good situation
In this example it is a FD20(can Based) floor with AD7Xtilt
Only the interesting parts regarding ethercat are mentioned/shown

<configuration>

2014-Feb-03, 16:20:59 Starting MCI in application mode...

=== Configuration Start ===
ConfigurationSize = {115}
version[10] = {CF0130919}
otm_name = {}
ftm_name = {}
fr_stand_type = CF_e_XXX_fst_clea_ceiling_fdxd
fr_stand_ethercat = TRUE
lt_stand_type = CF_e_XXX_lst_none
tbl_type = CF_e_XXX_tt_ad7_tilt_lat
tbl_base_type = CF_e_XXX_tbl_base_pivot_cw
tbl_version = CF_e_XXX_tv_ad7_r1
tbl_ethercat = TRUE
tbl_top_type = CF_e_XXX_ttt_cardio
jnc_dflt_fxd = FALSE
arc_dflt_fxd = FALSE
lt_tube_docsi = FALSE
lt_lng_fp_ena = FALSE
logging = FALSE
wait_for_reboot_is_on = FALSE
Printed copies are uncontrolled

fr_stand_sim = TRUE
lt_stand_sim = TRUE
guarding = TRUE
guarding_time = 250
iso_height = 1065
min_floor_dist = 120
doctor_nurse_ss = 450
body_guard_override = FALSE
bodyguard_indication = FALSE
spacer_option = FALSE
tbl_height_offset = 30
extended ceiling rail = FALSE
park at footside = CF_e_XXX_park_at_foot_side_disabled
xy_ceiling_x = FALSE
xy_ceiling_y = FALSE
xy_cable_inlet_position = CF_e_XXX_xy_cable_inlet_nurse_side
xy_airflow = FALSE
tilt_angle_lim_pos = 3000
tilt_angle_lim_neg = 3000
startup_reason_type = CF_e_XXX_power_down
geoipc_version = CF_e_XXX_geoipc_version_2_dualcore
niobe_option = FALSE
fr_stand_zrot_lock_option = FALSE
ethercat_bib = TRUE
ethercat_gib = TRUE
*** free_value = {}
*** user_mode = CF_e_XXX_um_application
*** no_real_mechanics = FALSE
*** skip_ecat_download_firmware_check = FALSE
*** skip_ecat_adf_file_check = FALSE
=== Configuration End ===

<Based on configuration a ethercat config file is searched>

Searching for ETHERCAT XML file :
{c:\Geo_Geometry_prod\EtherCAT_Topology_GIBCleaCeilingAd7_4axis.xml} ...
Searching for ETHERCAT XML file :
{c:\Geo_Geometry_prod\EtherCAT_Topology_GIBCleaCeilingAd7_4axis.xml} crc=0xc6cba3c6... found
EtherCatTopology:
Filename = c:\Geo_Geometry_prod\EtherCAT_Topology_GIBCleaCeilingAd7_4axis.xml
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 Checksum = 0xc6cba3c6

2014-Feb-03, 16:20:59 MCI Pre Initialize call...

dc:1, hc:0, tcd:500, dm:0
etf:c:\Geo_Geometry_prod\EtherCAT_Topology_GIBCleaCeilingAd7_4axis.xml, Start Is Executed:no
<configuration containes 9 ethercat slaves>
cfgSlaves: 9, Ethercat Topology File Crc32: 0xc6cba3c6, IO box:1

<check if the cable between IPC Master and first Ethercat Slave is present>
MCI_ATEM > C : Ethercat cable between GeoIPC and the first Ethercat device is connected

<ethercat bus scan to check how many devices and types are connected and via which ports>
MCI_ATEM > C : Bus scan: detected 9 slaves, cfg 9
ATEM > I :
ATEM > I : Slave 0x0:
ATEM > I : **************************************************
ATEM > I : Vendor : Prodrive B.V., ID 1401
ATEM > I : Product : PD GIB ESC0 Drive, Code: 0x61591101
ATEM > I : Revision: 0x57040000 Serial Number: 0
ATEM > I : ESC Type: Beckhoff ASIC ET1100 (0x11)
ATEM > I : Bus Physical Address (0x10) : 1001 (0x3e9)
ATEM > I : Bus Second Address (0x12) : 0000 (0x0)
ATEM > I : Configured Fix Address : 1001 (0x3e9)
ATEM > I : PD IN Byte/Bit offset: 62/0 Size: 16 bits
ATEM > I : PD OUT Byte/Bit offset: 62/0 Size: 8 bits
ATEM > I : MBX Supported : No
Printed copies are uncontrolled

ATEM > I : DC Supported 64-Bit : Yes

ATEM > I : Slave is Optional : No
ATEM > I : Slave is Present : Yes
ATEM > I : Slave Connection: 0xd Link: 0xd Loop: 0x2 Signal: 0xd
ATEM > I : Port 0 : Slave <Connected>
ATEM > I : Port 1 : Slave <No>
ATEM > I : Port 2 : Slave <Connected>
ATEM > I : Port 3 : Slave <Connected>
ATEM > I :
ATEM > I : Slave 0x1:
ATEM > I : **************************************************
ATEM > I : Vendor : Prodrive B.V., ID 1401
ATEM > I : Product : PD GIB ESC1 Drive, Code: 0x61591102
ATEM > I : Revision: 0x57040000 Serial Number: 0
ATEM > I : ESC Type: Beckhoff ASIC ET1100 (0x11)
ATEM > I : Bus Physical Address (0x10) : 1002 (0x3ea)
ATEM > I : Bus Second Address (0x12) : 0000 (0x0)
ATEM > I : Configured Fix Address : 1002 (0x3ea)
ATEM > I : PD IN Byte/Bit offset: 64/0 Size: 144 bits
ATEM > I : PD OUT Byte/Bit offset: 64/0 Size: 88 bits
ATEM > I : MBX Supported : No
ATEM > I : DC Supported 64-Bit : Yes
ATEM > I : Slave is Optional : No
ATEM > I : Slave is Present : Yes
ATEM > I : Slave Connection: 0x3 Link: 0x3 Loop: 0xc Signal: 0x3
ATEM > I : Port 0 : Slave <Connected>
ATEM > I : Port 1 : Slave <Connected>
ATEM > I : Port 2 : Slave <No>
ATEM > I : Port 3 : Slave <No>
ATEM > I :
ATEM > I : Slave 0x2:
ATEM > I : **************************************************
ATEM > I : Vendor : Advanced Motion Control, ID 189
ATEM > I : Product : AMC 1 Axis Servo Drive, Code: 0x12c
ATEM > I : Revision: 0x10005 Serial Number: 0
ATEM > I : ESC Type: IPCORE (0x4)
ATEM > I : Bus Physical Address (0x10) : 1003 (0x3eb)
ATEM > I : Bus Second Address (0x12) : 0000 (0x0)
ATEM > I : Configured Fix Address : 1003 (0x3eb)
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 ATEM > I : PD IN Byte/Bit offset: 82/0 Size: 256 bits
ATEM > I : PD OUT Byte/Bit offset: 82/0 Size: 160 bits
ATEM > I : MBX Supported : Yes
ATEM > I : Mailbox size Out : 0x22e In: 0x22e
ATEM > I : DC Supported 32-Bit : Yes
ATEM > I : Slave is Optional : No
ATEM > I : Slave is Present : Yes
ATEM > I : Slave Connection: 0x3 Link: 0x3 Loop: 0x0 Signal: 0x3
ATEM > I : Port 0 : Slave <Connected>
ATEM > I : Port 1 : Slave <Connected>
ATEM > I : Port 2 : Slave <No>
ATEM > I : Port 3 : Slave <No>
ATEM > I :
ATEM > I : Slave 0x3:
ATEM > I : **************************************************
ATEM > I : Vendor : Advanced Motion Control, ID 189
ATEM > I : Product : AMC 1 Axis Servo Drive, Code: 0x12c
ATEM > I : Revision: 0x10005 Serial Number: 0
ATEM > I : ESC Type: IPCORE (0x4)
ATEM > I : Bus Physical Address (0x10) : 1004 (0x3ec)
ATEM > I : Bus Second Address (0x12) : 0000 (0x0)
ATEM > I : Configured Fix Address : 1004 (0x3ec)
ATEM > I : PD IN Byte/Bit offset: 114/0 Size: 256 bits
ATEM > I : PD OUT Byte/Bit offset: 114/0 Size: 160 bits
ATEM > I : MBX Supported : Yes
ATEM > I : Mailbox size Out : 0x22e In: 0x22e
ATEM > I : DC Supported 32-Bit : Yes
Printed copies are uncontrolled

ATEM > I : Slave is Optional : No

ATEM > I : Slave is Present : Yes
ATEM > I : Slave Connection: 0x3 Link: 0x3 Loop: 0x0 Signal: 0x3
ATEM > I : Port 0 : Slave <Connected>
ATEM > I : Port 1 : Slave <Connected>
ATEM > I : Port 2 : Slave <No>
ATEM > I : Port 3 : Slave <No>
ATEM > I :
ATEM > I : Slave 0x4:
ATEM > I : **************************************************
ATEM > I : Vendor : Advanced Motion Control, ID 189
ATEM > I : Product : AMC 1 Axis Servo Drive, Code: 0x12c
ATEM > I : Revision: 0x10005 Serial Number: 0
ATEM > I : ESC Type: IPCORE (0x4)
ATEM > I : Bus Physical Address (0x10) : 1005 (0x3ed)
ATEM > I : Bus Second Address (0x12) : 0000 (0x0)
ATEM > I : Configured Fix Address : 1005 (0x3ed)
ATEM > I : PD IN Byte/Bit offset: 146/0 Size: 256 bits
ATEM > I : PD OUT Byte/Bit offset: 146/0 Size: 160 bits
ATEM > I : MBX Supported : Yes
ATEM > I : Mailbox size Out : 0x22e In: 0x22e
ATEM > I : DC Supported 32-Bit : Yes
ATEM > I : Slave is Optional : No
ATEM > I : Slave is Present : Yes
ATEM > I : Slave Connection: 0x3 Link: 0x3 Loop: 0x0 Signal: 0x3
ATEM > I : Port 0 : Slave <Connected>
ATEM > I : Port 1 : Slave <Connected>
ATEM > I : Port 2 : Slave <No>
ATEM > I : Port 3 : Slave <No>
ATEM > I :
ATEM > I : Slave 0x5:
ATEM > I : **************************************************
ATEM > I : Vendor : Advanced Motion Control, ID 189
ATEM > I : Product : AMC 1 Axis Servo Drive, Code: 0x12c
ATEM > I : Revision: 0x10005 Serial Number: 0
ATEM > I : ESC Type: IPCORE (0x4)
ATEM > I : Bus Physical Address (0x10) : 1006 (0x3ee)
ATEM > I : Bus Second Address (0x12) : 0000 (0x0)
ATEM > I : Configured Fix Address : 1006 (0x3ee)
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 ATEM > I : PD IN Byte/Bit offset: 178/0 Size: 256 bits
ATEM > I : PD OUT Byte/Bit offset: 178/0 Size: 160 bits
ATEM > I : MBX Supported : Yes
ATEM > I : Mailbox size Out : 0x22e In: 0x22e
ATEM > I : DC Supported 32-Bit : Yes
ATEM > I : Slave is Optional : No
ATEM > I : Slave is Present : Yes
ATEM > I : Slave Connection: 0x1 Link: 0x1 Loop: 0x2 Signal: 0x1
ATEM > I : Port 0 : Slave <Connected>
ATEM > I : Port 1 : Slave <No>
ATEM > I : Port 2 : Slave <No>
ATEM > I : Port 3 : Slave <No>
ATEM > I :
ATEM > I : Slave 0x6:
ATEM > I : **************************************************
ATEM > I : Vendor : Advanced Motion Control, ID 189
ATEM > I : Product : AMC 3 Axis Servo Drive, Code: 0x12f
ATEM > I : Revision: 0x10007 Serial Number: 0
ATEM > I : ESC Type: IPCORE (0x4)
ATEM > I : Bus Physical Address (0x10) : 1007 (0x3ef)
ATEM > I : Bus Second Address (0x12) : 0000 (0x0)
ATEM > I : Configured Fix Address : 1007 (0x3ef)
ATEM > I : PD IN Byte/Bit offset: 210/0 Size: 624 bits
ATEM > I : PD OUT Byte/Bit offset: 210/0 Size: 480 bits
ATEM > I : MBX Supported : Yes
ATEM > I : Mailbox size Out : 0x22e In: 0x22e
ATEM > I : DC Supported 32-Bit : Yes
Printed copies are uncontrolled

ATEM > I : Slave is Optional : No

ATEM > I : Slave is Present : Yes
ATEM > I : Slave Connection: 0x3 Link: 0x3 Loop: 0x0 Signal: 0x3
ATEM > I : Port 0 : Slave <Connected>
ATEM > I : Port 1 : Slave <Connected>
ATEM > I : Port 2 : Slave <No>
ATEM > I : Port 3 : Slave <No>
ATEM > I :
ATEM > I : Slave 0x7:
ATEM > I : **************************************************
ATEM > I : Vendor : Advanced Motion Control, ID 189
ATEM > I : Product : AMC 3 Axis Servo Drive, Code: 0x12f
ATEM > I : Revision: 0x10007 Serial Number: 0
ATEM > I : ESC Type: IPCORE (0x4)
ATEM > I : Bus Physical Address (0x10) : 1008 (0x3f0)
ATEM > I : Bus Second Address (0x12) : 0000 (0x0)
ATEM > I : Configured Fix Address : 1008 (0x3f0)
ATEM > I : PD IN Byte/Bit offset: 288/0 Size: 624 bits
ATEM > I : PD OUT Byte/Bit offset: 288/0 Size: 480 bits
ATEM > I : MBX Supported : Yes
ATEM > I : Mailbox size Out : 0x22e In: 0x22e
ATEM > I : DC Supported 32-Bit : Yes
ATEM > I : Slave is Optional : No
ATEM > I : Slave is Present : Yes
ATEM > I : Slave Connection: 0x3 Link: 0x3 Loop: 0x0 Signal: 0x3
ATEM > I : Port 0 : Slave <Connected>
ATEM > I : Port 1 : Slave <Connected>
ATEM > I : Port 2 : Slave <No>
ATEM > I : Port 3 : Slave <No>
ATEM > I :
ATEM > I : Slave 0x8:
ATEM > I : **************************************************
ATEM > I : Vendor : Prodrive B.V., ID 1401
ATEM > I : Product : PD BIB Drive, Code: 0x61591000
ATEM > I : Revision: 0x57040000 Serial Number: 0
ATEM > I : ESC Type: IPCORE (0x4)
ATEM > I : Bus Physical Address (0x10) : 1009 (0x3f1)
ATEM > I : Bus Second Address (0x12) : 0000 (0x0)
ATEM > I : Configured Fix Address : 1009 (0x3f1)
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 ATEM > I : PD IN Byte/Bit offset: 366/0 Size: 512 bits
ATEM > I : PD OUT Byte/Bit offset: 366/0 Size: 256 bits
ATEM > I : MBX Supported : Yes
ATEM > I : Mailbox size Out : 0x5ce In: 0x5ce
ATEM > I : DC Supported 32-Bit : No
ATEM > I : Slave is Optional : No
ATEM > I : Slave is Present : Yes
ATEM > I : Slave Connection: 0x1 Link: 0x1 Loop: 0x2 Signal: 0x1
ATEM > I : Port 0 : Slave <Connected>
ATEM > I : Port 1 : Slave <No>
ATEM > I : Port 2 : Slave <No>
ATEM > I : Port 3 : Slave <No>
CreateSlaveList 9 (Result = 0x0)

7 ETHERCAT TOPOLOGY FAULTFINDING.

• The ideal situation would be that the BIST or Event logging would indicate for 100% what is wrong but
unfortunately this is not the case.
• Most detailed information is mentioned in the GSCRT file/trace files.
• A new item is added in the GSCRT file since system SW release 8.2.16 which gives an overview based on
HUB port scan.
• The idea was that this scan would be added to the standard event logging but unfortunately this was not
functioning correctly.
• Knowing the Ecat configuration is essential!!
• If the configuration or hardware is wrong setup/defect will lead to topology errors!
• There are several ways to find out what the Ecat configuration should be: FSF, Event logging , GSCRT file,
Printed copies are uncontrolled

physical checking etc

In next sub chapters an example is explained.

7.1 Configuration

7.1.1 Via system logfile file

Technical Event Description: Memo: [FREE_TEXT] FrontalStandType = Clea FLOOR;
ID: 060000021 Informational : FrontalStandEthercat = Not Installed; LateralStandType = Larc CN
Geometry FD 15; TableType = AD7 LAT; TableEthercat = Installed;
configuration TableVersion = AD7 NT; TableBaseOption = SWIVEL CCW;
TableTopType = NEURO; MinimumFloorDistance = 1200;
ISOHeight = 11350; SpacerOption = Not Installed;
TableHeightOffset = 0; TiltAngleLimitNegative = 3000;
TiltAngleLimitPositive = 3000; CeilingRail = Normal;
ParkAtFootSideOption = DISABLED; CeilingRailType =
LONGITUDINAL; CeilingInletType = NURSE SIDE;
AirflowBoxOption = Not Installed; FrontalStandZRotLockOption =
Not Installed; NiobeOption = Not Installed;

7.1.2 Via GTCRT file

fr_stand_type = CF_e_XXX_fst_clea_floor_fdxd
fr_stand_ethercat = FALSE
lt_stand_type = CF_e_XXX_lst_larc_cn_fd15
tbl_type = CF_e_XXX_tt_ad7_lat
tbl_base_type = CF_e_XXX_tbl_base_swivel_ccw
tbl_version = CF_e_XXX_tv_ad7_nt
tbl_ethercat = TRUE
ethercat_gib = TRUE

Geo_Geometry_prod\EtherCAT_Topology_GIBAd7_4axis.xml

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 7.1.3 Via Config table
Example

GIB HUB Device Sub device Usage Ethercat slaves

GeoIoBox

GIB ESC 0 (fixed) * Ethercat HUB 1

CN1
GIB ESC 1 (fixed) * Ethercat HUB 2
Spare

CN2 - - -

Clea 2 L-arm(fixed) 3-axes servo drive 1

Clea-2

CN3 Clea 2 C-ARC(fixed) 3-axes servo drive 2

Clea 2 BIB Bodyguard control 3

Height Longitudinal Lateral Tilt Cradle Swivel

drive drive drive drive drive drive

basic 1

AD7XNT long 1 2

Long + lat 1 3 2

Longt +Tilt 1 3 2
Printed copies are uncontrolled

Longt +Tilt+lat 1 4 3 2
AD7XT
Long + tilt + cradle 1 4 2 3
table

CN4
Long + tilt + lat + cradle 1 5 3 2 4

basic 1 2

AD7NT SWIVEL long 1 3 2

Long + lat 1 4 3 2

Longt +Tilt 1 5 3 4 2

Longt +Tilt+lat 1 6 4 3 5 2
AD7XT SWIVEL
Long + tilt + cradle 1 5 3 4 2

Long + tilt + lat + cradle 1 6 4 3 5 2

Flexm
ove

CN5 Flexmove XY Box 2-axes servo drive 1

Spare

CN6 - - -

Topo connected to the GIB HUB

CN1 => GIB ESC 0, GIB ESC 1
CN2 => Spare
CN3 => not used
CN4 =>Table Height, Table lateral, Table longitudinal
CN5 => not used
CN6 => Spare

Note;
The ethercat logical toplogy is build around ESC1 and ESC2 (ethercat switch) this means it will always follow the
next connector sequence .
CN1,CN6,CN4,CN5,CN2 and CN3 (GeoIoBox - R-Cabinet, Spare,Table,Flexmove,Spare,Clea-2).

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 7.1.4 Via maximum to actual determination
Printed copies are uncontrolled

Configured
CN1 IPC (Master) GIB ESC 0 GIB ESC 1
CN2 nc
CN3 nc
CN4 Table Height Swivel Table lateral Table longitudinal
CN5 nc
CN6 nc

7.2 Compare
• Event log file (POSTt) is indicating that there are two slaves missing.
• Event log file is not indicating the function thus location of the present slaves
• The GSCRT does mention which drives are present and their function
Event logging:
Description: Application error: Memo: [FREE_TEXT] Time of occurrence : 2016-02-25, 7:37:17
EtherCat POST error [SEVERITY] Error [EXCEPTION_DESCRIPTION] [detail=AMC Servo Drive
[item=TopologyTest] (3) 1-Axis - Table = not detected [0xbd 0x12c],AMC Servo Drive 1-Axis -
Table = not detected [0xbd 0x12c]]
Description: Application error: Memo: [FREE_TEXT] Time of occurrence : 2016-02-25, 7:37:17
EtherCat POST error [SEVERITY] Error [EXCEPTION_DESCRIPTION] [detail=GeoIoBox - R-
[item=TopologyTest] (2) Cabinet = available [0x579 0x61591101],GeoIoBox - R-Cabinet = available
[0x579 0x61591102],AMC Servo Drive 1-Axis - Table = available [0xbd
0x12c],AMC Servo Drive 1-Axis - Table = available [0xbd 0x12c]]
Description: Application error: Memo: [FREE_TEXT] Time of occurrence : 2016-02-25, 7:37:17
EtherCat POST error [SEVERITY] Error [EXCEPTION_DESCRIPTION] [detail=Slave detection
[item=TopologyTest] (1) mismatch - bus scan: detected 4 slaves; cfg 6,Guidance: verify configuration or
add ethercat slaves (or check outer left led on connector CN2 on missing drive.
If red then drive is in 'bootloader mode'. Replace)]

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 GSCRT file

MCI_ATEM > R : Slave detection mismatch - bus scan: detected 4 connected slaves while configuration has 6
CN1, Error=0, text={CN1([GIB0 ?0xffef 9699 E=GIBESC0][GIB1 ?0xffef 3C33 E=GIBESC1])} =>OK
CN2, Error=0, text={} =>OK
CN3, Error=0, text={} =>OK
CN4, Error=0, text={CN4([AMC1AX ?0xffef 3033 E=AD7HEI][AMC1AX ?0xffef 1211 E=AD7SWV:END])} =>NOK
CN5, Error=0, text={} =>OK
CN6, Error=0, text={} =>OK
Num Connected Slaves(4)

Configured
CN1 IPC (Master) GIB ESC 0 GIB ESC 1
CN2 nc
CN3 nc
CN4 Table Height Swivel Table lateral Table longitudinal
CN5 nc
CN6 nc

Scanned
CN1 IPC (Master) GIB ESC 0 GIB ESC 1
CN2 nc
CN3 nc
CN4 Table Height Swivel
Printed copies are uncontrolled

CN5 nc
CN6 nc

Table Lateral and Long is missing!!

Conclusion:
 The Table Lateral , longitudinal drive is not connected or defect
 The network cable from table Swivel drive towards Table longitudinal drive is defect or not connected
 The output of the table Swivel drive (CN2) is defect thus table Swivel drive is defect.
 No logical power on Table lateral, longitudinal drive

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 8 EXAMPLES FROM THE FIELD

8.1 Input (cn1) output (cn2) swapped at 2spc (3 Axis Servo Drive)

8.1.1 Symptom

After an installation, upgrade or corrective maintenance action the geometry start up no movements are possible.
Logging shows there is something wrong with ethercat topology.

8.1.2 Rootcause investingation

This problem is very common and cannot be analyzed by means of the standard event log.
The Event logging is only indicating that the ethercat bus scan failed but no details. You could check all ethercat
slave connections but that is not always so easy.

Event logging

Geometry Error Technical Description: Application Memo: [FREE_TEXT] Time of occurrence :

Event ID: error: EtherCat POST error 2014-04-24, 12:38:34 [SEVERITY] Error
063001124 [item=TopologyTest] [EXCEPTION_DESCRIPTION] [detail=Bus
scan failed, error code: 0x9811001e,
Guidance: probably wrong cable on the wrong
GeoIoBox port, verify configuration, try to
Printed copies are uncontrolled

download firmware via fieldservice]

More details can be found in the GSCRT_CONS<last_date_time> file at the IPC computer or in in the safe data for
PR file.

Remarks GSCRT_CONS logging

Configuartation: AD7NT with 3- fr_stand_type = CF_e_XXX_fst_clea_ceiling_fdxd
axis fr_stand_ethercat = TRUE
Height lt_stand_type = CF_e_XXX_lst_none
Lateral tbl_type = CF_e_XXX_tt_ad7_lat
Long tbl_base_type = CF_e_XXX_tbl_base_pivot_cw
Configuartation:Clea-2 tbl_version = CF_e_XXX_tv_ad7_nt
L-arm tbl_ethercat = TRUE
C-arm
BIB
Configuartation: GIB
ESC-0
ESC-1
The logging is indicating the etf:c:\Geo_Geometry_prod\EtherCAT_Topology_GIBCleaCeilingAd7_3axis.xml,
ethercat bus scan error . This Start Is Executed:no
system should have 8 ethercat cfgSlaves: 8, Ethercat Topology File Crc32: 0x6c9aed18, IO box:1
slaves
The ethercat topology is MCI_ATEM > C : Bus scan 1 retry
scanned and if it is failing 5 MCI_ATEM > C : Bus scan 2 retry
retries are done. In this case it MCI_ATEM > C : Bus scan 3 retry
is kept failing. MCI_ATEM > C : Bus scan 4 retry
MCI_ATEM > C : Bus scan 5 retry
MCI_ATEM > R : Bus scan failed, error code: 0x9811001e
Fault is indicating that the Slave mismatch after 1006 (0xfffb) port 1: CFG/BUS
expected slave is not correct it VendorId: Unknown Vendor (0x0) / Prodrive B.V. (0x579)
sees the BIB slave but it ProductCode: Unknown Product Code (0x0) / PD BIB Drive (0x61591000)
should be something else.
Now its getting more clear. It can Bus responded an error : Bus configuration mismatch (0x9811001e)
scans that slave nr 6 is the BUS: Bus configuration mismatch Index: 6 Auto-inc Address: 0xfffa Vendor: 0x579
BIB slave but should be (Prodrive B.V.) Product: 0x61591000 (PD BIB Drive) Revision: 0x0
AMC 3 Axis Servo Drive CFG: Bus configuration mismatch Index: 6 EtherCAT Address: 0x0000 Vendor:
0x10007 from the CLEA 0xbd (Advanced Motion Control) Product: 0x12f (AMC 3 Axis Servo Drive)
stand. Revision: 0x10007

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 Slave order as seen by ATEM > I : Slave 0x0:
software. ATEM > I : **************************************************
ATEM > I : Vendor : Prodrive B.V., ID 1401
ATEM > I : Product : PD GIB ESC0 Drive, Code: 0x61591101
ATEM > I : Revision: 0x57040000 Serial Number: 0
ATEM > I : ESC Type: Beckhoff ASIC ET1100 (0x11)
ATEM > I : Bus Physical Address (0x10) : 1009 (0x3f1)
ATEM > I : Bus Second Address (0x12) : 0000 (0x0)
ATEM > I : Configured Fix Address : 1001 (0x3e9)
ATEM > I : PD IN Byte/Bit offset: 62/0 Size: 16 bits
ATEM > I : PD OUT Byte/Bit offset: 62/0 Size: 8 bits
ATEM > I : MBX Supported : No
ATEM > I : DC Supported 64-Bit : Yes
ATEM > I : Slave is Optional : No
ATEM > I : Slave is Present : Yes
ATEM > I : Slave Connection: 0xd Link: 0xd Loop: 0x2 Signal: 0xd
ATEM > I : Port 0 : Slave <Connected>
ATEM > I : Port 1 : Slave <No>
ATEM > I : Port 2 : Slave <Connected>
ATEM > I : Port 3 : Slave <Connected>
ATEM > I :
ATEM > I : Slave 0x1:
ATEM > I : **************************************************
ATEM > I : Vendor : Prodrive B.V., ID 1401
ATEM > I : Product : PD GIB ESC1 Drive, Code: 0x61591102
ATEM > I : Revision: 0x57040000 Serial Number: 0
ATEM > I : ESC Type: Beckhoff ASIC ET1100 (0x11)
Printed copies are uncontrolled

ATEM > I : Bus Physical Address (0x10) : 1010 (0x3f2)

ATEM > I : Bus Second Address (0x12) : 0000 (0x0)
ATEM > I : Configured Fix Address : 1002 (0x3ea)
ATEM > I : PD IN Byte/Bit offset: 64/0 Size: 144 bits
ATEM > I : PD OUT Byte/Bit offset: 64/0 Size: 88 bits
ATEM > I : MBX Supported : No
ATEM > I : DC Supported 64-Bit : Yes
ATEM > I : Slave is Optional : No
ATEM > I : Slave is Present : Yes
ATEM > I : Slave Connection: 0x3 Link: 0x3 Loop: 0xc Signal: 0x3
ATEM > I : Port 0 : Slave <Connected>
ATEM > I : Port 1 : Slave <Connected>
ATEM > I : Port 2 : Slave <No>
ATEM > I : Port 3 : Slave <No>
ATEM > I :
ATEM > I : Slave 0x2:
ATEM > I : **************************************************
ATEM > I : Vendor : Advanced Motion Control, ID 189
ATEM > I : Product : AMC 1 Axis Servo Drive, Code: 0x12c
ATEM > I : Revision: 0x10005 Serial Number: 0
ATEM > I : ESC Type: IPCORE (0x4)
ATEM > I : Bus Physical Address (0x10) : 1011 (0x3f3)
ATEM > I : Bus Second Address (0x12) : 0000 (0x0)
ATEM > I : Configured Fix Address : 1003 (0x3eb)
ATEM > I : PD IN Byte/Bit offset: 82/0 Size: 256 bits
ATEM > I : PD OUT Byte/Bit offset: 82/0 Size: 160 bits
ATEM > I : MBX Supported : Yes
ATEM > I : Mailbox size Out : 0x22e In: 0x22e
ATEM > I : DC Supported 32-Bit : Yes
ATEM > I : Slave is Optional : No
ATEM > I : Slave is Present : Yes
ATEM > I : Slave Connection: 0x3 Link: 0x3 Loop: 0x0 Signal: 0x3
ATEM > I : Port 0 : Slave <Connected>
ATEM > I : Port 1 : Slave <Connected>
ATEM > I : Port 2 : Slave <No>
ATEM > I : Port 3 : Slave <No>
ATEM > I :
ATEM > I : Slave 0x3:
ATEM > I : **************************************************
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 ATEM > I : Vendor : Advanced Motion Control, ID 189
ATEM > I : Product : AMC 1 Axis Servo Drive, Code: 0x12c
ATEM > I : Revision: 0x10005 Serial Number: 0
ATEM > I : ESC Type: IPCORE (0x4)
ATEM > I : Bus Physical Address (0x10) : 1012 (0x3f4)
ATEM > I : Bus Second Address (0x12) : 0000 (0x0)
ATEM > I : Configured Fix Address : 1004 (0x3ec)
ATEM > I : PD IN Byte/Bit offset: 114/0 Size: 256 bits
ATEM > I : PD OUT Byte/Bit offset: 114/0 Size: 160 bits
ATEM > I : MBX Supported : Yes
ATEM > I : Mailbox size Out : 0x22e In: 0x22e
ATEM > I : DC Supported 32-Bit : Yes
ATEM > I : Slave is Optional : No
ATEM > I : Slave is Present : Yes
ATEM > I : Slave Connection: 0x3 Link: 0x3 Loop: 0x0 Signal: 0x3
ATEM > I : Port 0 : Slave <Connected>
ATEM > I : Port 1 : Slave <Connected>
ATEM > I : Port 2 : Slave <No>
ATEM > I : Port 3 : Slave <No>
ATEM > I :
ATEM > I : Slave 0x4:
ATEM > I : **************************************************
ATEM > I : Vendor : Advanced Motion Control, ID 189
ATEM > I : Product : AMC 1 Axis Servo Drive, Code: 0x12c
ATEM > I : Revision: 0x10005 Serial Number: 0
ATEM > I : ESC Type: IPCORE (0x4)
ATEM > I : Bus Physical Address (0x10) : 1013 (0x3f5)
Printed copies are uncontrolled

ATEM > I : Bus Second Address (0x12) : 0000 (0x0)

ATEM > I : Configured Fix Address : 1005 (0x3ed)
ATEM > I : PD IN Byte/Bit offset: 146/0 Size: 256 bits
ATEM > I : PD OUT Byte/Bit offset: 146/0 Size: 160 bits
ATEM > I : MBX Supported : Yes
ATEM > I : Mailbox size Out : 0x22e In: 0x22e
ATEM > I : DC Supported 32-Bit : Yes
ATEM > I : Slave is Optional : No
ATEM > I : Slave is Present : Yes
ATEM > I : Slave Connection: 0x1 Link: 0x1 Loop: 0x2 Signal: 0x1
ATEM > I : Port 0 : Slave <Connected>
ATEM > I : Port 1 : Slave <No>
ATEM > I : Port 2 : Slave <No>
ATEM > I : Port 3 : Slave <No>
ATEM > I :
ATEM > I : Slave 0x5:
ATEM > I : **************************************************
ATEM > I : Vendor : Advanced Motion Control, ID 189
ATEM > I : Product : AMC 3 Axis Servo Drive, Code: 0x12f
ATEM > I : Revision: 0x10007 Serial Number: 0
ATEM > I : ESC Type: IPCORE (0x4)
ATEM > I : Bus Physical Address (0x10) : 1014 (0x3f6)
ATEM > I : Bus Second Address (0x12) : 0000 (0x0)
ATEM > I : Configured Fix Address : 1006 (0x3ee)
ATEM > I : PD IN Byte/Bit offset: 178/0 Size: 624 bits
ATEM > I : PD OUT Byte/Bit offset: 178/0 Size: 480 bits
ATEM > I : MBX Supported : Yes
ATEM > I : Mailbox size Out : 0x22e In: 0x22e
ATEM > I : DC Supported 32-Bit : Yes
ATEM > I : Slave is Optional : No
ATEM > I : Slave is Present : Yes
ATEM > I : Slave Connection: 0x3 Link: 0x3 Loop: 0x0 Signal: 0x3
ATEM > I : Port 0 : Slave <Connected>
ATEM > I : Port 1 : Slave <Connected>
ATEM > I : Port 2 : Slave <No>
ATEM > I : Port 3 : Slave <No>
ATEM > I :
ATEM > I : Slave 0x6:
ATEM > I : **************************************************
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 ATEM > I : Vendor : Prodrive B.V., ID 1401
ATEM > I : Product : PD BIB Drive, Code: 0x61591000
ATEM > I : Revision: 0x0 Serial Number: 0
ATEM > I : ESC Type: IPCORE (0x4)
ATEM > I : Bus Physical Address (0x10) : 1015 (0x3f7)
ATEM > I : Bus Second Address (0x12) : 0000 (0x0)
ATEM > I : Configured Fix Address : 0000 (0x0)
ATEM > I : MBX Supported : No
ATEM > I : DC Supported 32-Bit : No
ATEM > I : Slave is Optional : No
ATEM > I : Slave is Present : No
ATEM > I : Slave Connection: 0x1 Link: 0x1 Loop: 0x2 Signal: 0x1
ATEM > I : Port 0 : Slave <Connected>
ATEM > I : Port 1 : Slave <No>
ATEM > I : Port 2 : Slave <No>
ATEM > I : Port 3 : Slave <No>
ATEM > I :
ATEM > I : Slave 0x7:
ATEM > I : **************************************************
ATEM > I : Vendor : Advanced Motion Control, ID 189
ATEM > I : Product : AMC 3 Axis Servo Drive, Code: 0x12f
ATEM > I : Revision: 0x0 Serial Number: 0
ATEM > I : ESC Type: IPCORE (0x4)
ATEM > I : Bus Physical Address (0x10) : 1016 (0x3f8)
ATEM > I : Bus Second Address (0x12) : 0000 (0x0)
ATEM > I : Configured Fix Address : 0000 (0x0)
ATEM > I : MBX Supported : No
Printed copies are uncontrolled

ATEM > I : DC Supported 32-Bit : Yes

ATEM > I : Slave is Optional : No
ATEM > I : Slave is Present : No
ATEM > I : Slave Connection: 0x3 Link: 0x3 Loop: 0x0 Signal: 0x3
ATEM > I : Port 0 : Slave <Connected>
ATEM > I : Port 1 : Slave <Connected>
ATEM > I : Port 2 : Slave <No>
ATEM > I : Port 3 : Slave <No>

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 8.1.3 Rootcause
Until slave 5 it is OK but the topology directly after slave 5 is wrong.
The ethercat topology is scanned and if it is failing 5 retries are done. .
When looking to the slave order 2SPC is in de dataflow forward direction skipped and in the return direction seen.
This can only mean that the ethercat cables at 2SPC are swapped.

What you see is when cn1 and cn2 are swapped at 2SPC then the port direction is also swapped thus first port 1 is
accessed and afterwards port 2 . The dataflow will follow the forward direction and will never pass the processing
block within the ESC as if it is not there. At The BIB the data flow is returned so then all nodes are not seen except
2SPC which port direction is swapped.

Good situation as it should be based on the Bad situation

configuration

slave Master Stack (IPC) slave Master Stack (IPC)

0 GIB ESC0 0 GIB ESC0
1 GIB ESC1 1 GIB ESC1
2 SAF11 Height 2 SAF11 Height
3 SAT11 Lateral 3 SAT11 Lateral
4 SAR12 Long 4 SAR12 Long
5 1SPC L-arm 5 1SPC L-arm
6 2SPC C-arm 6 BIB bodyguard
7 BIB bodyguard 7 2SPC C-arm
Printed copies are uncontrolled

8.1.4 Solution
Swap CN1 and CN2 cable at 2SPC ethercat slave

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 8.2 Geometry not starting due to Ethercat problems.
Geo configuration
Clea2 with AD7XT Tilt BC APC

8.2.1 Symptom
Geometry is not starting because ethercat network is not initializing. No information in event logging and/or IPC
logging which could lead directly to the root cause.

8.2.2 Root cause investigation

Ethercat was not initializing although the supplies, network topology and configuration were OK.
It was necessary to go for a minimum ethercat configuration. This can be done by configuring not table present etc..
Only check the ethercat start up behavior al other errors can be ignored. see \taken steps

ECat configuration as delivered ADXT Tilt, BC, APC

HUB
CN6

CN5

SAF11 Height SAT12 Tilt SAT11 Lateral SAR12 Long

CN4 CN1 CN2 CN1 CN2 CN1 CN2 CN1

1SPC L-arm 2SPC C-arm BIB Bodyguard

CN3 CN1 CN2 CN1 CN2 CN1
Printed copies are uncontrolled

CN2
IPC Geometry controller
Ethercat Master
Stack
CN1 X11

Ecat config no AD7 table Ecat initialization OK

HUB
CN6

CN5

SAF11 Height SAT12 Tilt SAT11 Lateral SAR12 Long

CN4 CN1 CN2 CN1 CN2 CN1 CN2 CN1

1SPC L-arm 2SPC C-arm BIB Bodyguard

CN3 CN1 CN2 CN1 CN2 CN1

CN2
IPC Geometry controller
Ethercat Master
Stack
CN1 X11

Ecat config AD7NT table no options only height drive present Ecat initialization OK

HUB
CN6

CN5

SAF11 Height SAT12 Tilt SAT11 Lateral SAR12 Long

CN4 CN1 CN2 CN1 CN2 CN1 CN2 CN1

1SPC L-arm 2SPC C-arm BIB Bodyguard

CN3 CN1 CN2 CN1 CN2 CN1

CN2
IPC Geometry controller
Ethercat Master
Stack
CN1 X11

DEP127602, Rev: 00 CSIP Level 2 36 of 37

ATTENTION: THIS PAGE CONTAINS COPYRIGHTED MATERIALS THAT ARE CONFIDENTIAL AND/OR PROPRIETARY.
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Copyright © 2016 Koninklijke Philips N.V. All rights reserved
 Ecat config AD7NT table no options skip height drive then next drive becomes height drive Ecat initialization OK
Use short network patch cable to make the connection.

HUB
CN6

CN5

SAF11 Height SAT12 Tilt SAT11 Lateral SAR12 Long

CN4 CN1 CN2 CN1 CN2 CN1 CN2 CN1

1SPC L-arm 2SPC C-arm BIB Bodyguard

CN3 CN1 CN2 CN1 CN2 CN1

CN2
IPC Geometry controller
Ethercat Master
Stack
CN1 X11

Ecat config AD7NT table no options skip height and Tilt drive then next drive becomes height drive Ecat initialization
OK. Use short network patch cable to make the connection.

HUB
CN6

CN5

SAF11 Height SAT12 Tilt SAT11 Lateral SAR12 Long

CN4 CN1 CN2 CN1 CN2 CN1 CN2 CN1
Printed copies are uncontrolled

1SPC L-arm 2SPC C-arm BIB Bodyguard

CN3 CN1 CN2 CN1 CN2 CN1

CN2
IPC Geometry controller
Ethercat Master
Stack
CN1 X11

Ecat config AD7NT table no options skip height, Tilt and lateral drive then next drive becomes height drive Ecat
initialization NOK. Use short network patch cable to make the connection.

HUB
CN6

CN5

SAF11 Height SAT12 Tilt SAT11 Lateral SAR12 Long

CN4 CN1 CN2 CN1 CN2 CN1 CN2 CN1

1SPC L-arm 2SPC C-arm BIB Bodyguard

CN3 CN1 CN2 CN1 CN2 CN1

CN2
IPC Geometry controller
Ethercat Master
Stack
CN1 X11

8.2.3 Solution
Replace Longitudinal E-cat drive and configure back to as delivered situation.

DEP127602, Rev: 00 CSIP Level 2 37 of 37

ATTENTION: THIS PAGE CONTAINS COPYRIGHTED MATERIALS THAT ARE CONFIDENTIAL AND/OR PROPRIETARY.
ANY RELEASE OR DISTRIBUTION OF THIS MATERIAL, WITHOUT PERMISSION, IS A VIOLATION OF LAW.
Copyright © 2016 Koninklijke Philips N.V. All rights reserved