ServoWorks CNC Setup and Integration Manual for the EtherCAT Interface System

Revision 1.30 © 2014 Soft Servo Systems, Inc. SERVOWORKS CNC SETUP AND INTEGRATION MANUAL FOR ETHERCAT Warnings

Warning

The product described herein has the potential – through misuse, inattention, or lack of understanding – to create conditions that could result in personal injury, damage to equipment, or damage to the product(s) described herein. Machinery in motion and high-power, high-current servo drives can be dangerous; potentially hazardous situations such as runaway motors could result in death; burning or other serious personal injury to personnel; damage to equipment or machinery; or economic loss if procedures aren’t followed properly. Soft Servo Systems, Inc. assumes no liability for any personal injury, property damage, losses or claims arising from misapplication of its products. In no event shall Soft Servo Systems, Inc. or its suppliers be liable to you or any other person for any incidental collateral, special or consequential damages to machines or products, including without limitation, property damage, damages for loss of profits, loss of customers, loss of goodwill, work stoppage, data loss, computer failure or malfunction claims by any party other than you, or any and all similar damages or loss even if Soft Servo Systems, Inc., its suppliers, or its agent has been advised of the possibility of such damages.

It is therefore necessary for any and all personnel involved in the installation, maintenance, or use of these products to thoroughly read this manual and related manuals and understand their contents. Soft Servo Systems, Inc. stands ready to answer any questions or clarify any confusion related to these products in as timely a manner as possible.

The selection and application of Soft Servo Systems, Inc.’s products remain the responsibility of the equipment designer or end user. Soft Servo Systems, Inc. accepts no responsibility for the way its controls are incorporated into a machine tool or factory automation setting. Any documentation and warnings provided by Soft Servo Systems, Inc. must be promptly provided to any end users.

This document is based on information that was available at the time of publication. All efforts have been made to ensure that this document is accurate and complete. However, due to the widely varying uses of this product, and the variety of software and hardware configurations possible in connection with these uses, the information contained in this manual does not purport to cover every possible situation, contingency or variation in hardware or software configuration that could possibly arise in connection with the installation, maintenance, and use of the products described herein. Soft Servo Systems, Inc. assumes no obligations of notice to holders of this document with respect to changes subsequently made. Under no circumstances will Soft Servo Systems, Inc. be liable for any damages or injuries resulting from any defect or omission in this manual.

Soft Servo Systems, Inc. makes no representation or warranty, expressed, implied, or statutory with respect to, and assumes no responsibility for the accuracy, completeness, sufficiency, or usefulness of the information contained herein. NO IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS OF PURPOSE SHALL APPLY.

______i SERVOWORKS CNC SETUP AND INTEGRATION MANUAL FOR ETHERCAT Warnings

Important Notice

The information contained in this manual is intended to be used only for the purposes agreed upon in the related contract with Soft Servo Systems, Inc. All material contained herein is subject to restricted rights and restrictions set forth in the contract between the parties.

These manuals contain confidential and proprietary information that is not to be shared with, nor distributed to, third parties by any means without the prior express, written permission of Soft Servo Systems, Inc. No materials contained herein are to be duplicated or reproduced in whole or in part without the express, written permission of Soft Servo Systems, Inc.

Although every effort and precaution has been taken in preparing this manual, the information contained herein is subject to change without notice. This is because Soft Servo Systems, Inc. is constantly striving to improve its products. Soft Servo Systems, Inc. assumes no responsibility for errors or omissions.

All rights reserved. Any violations of contractual agreements pertaining to the materials herein will be prosecuted to the full extent of the law.

______ii SERVOWORKS CNC SETUP AND INTEGRATION MANUAL FOR ETHERCAT Warnings

Cautions

Servo Drives Need to Be Connected and Powered Up

ServoWorks CNC applications for the EtherCAT interface system will not run unless servo drives are connected and powered up. The hardware needs to be ready to use before a ServoWorks CNC program is opened.

CAUTION !

If the servo drives are not connected and powered up, you will get a “Failed to Load ServoWorks Real-Time Engine” error upon trying to launch a ServoWorks CNC application.

Servo Manuals

The EtherCAT interface system works with a variety of EtherCAT (CoE) servo drive systems. This manual should be used in conjunction with any manuals or literature that accompanied the servo drives that you are using in your EtherCAT interface system.

IntervalZero RTX Compatibility with Windows XP Service Pack

Service Pack 3 (SP3) for Windows XP is compatible with RTX 2011, which is the version currently provided with your ServoWorks CNC product. However, RTX2011 is neither compatible with Windows XP with Service Pack 1, nor Service Pack 2.

If Windows XP Service Pack 3 has not been installed, you will need to install Windows XP Service Pack 3 in order to run your ServoWorks CNC product on a PC.

CAUTION !

Your ServoWorks CNC product will not run on a PC with RTX 7.1 or older. Please contact [email protected] for more details.

64-bit Windows Compatibility

64-bit versions of the Windows operating system are NOT COMPATIBLE with your ServoWorks CNC product.

Windows 7 Compatibility

Windows 7 (32-bit) is compatible with RTX 2011, and RTX 2011 with Service Pack 1 (SP1). However, Windows 7 (32-bit) is NOT COMPATIBLE with RTX 8.1 or with any earlier versions of RTX. Windows 7 (64-bit) is not supported at this time.

______iii SERVOWORKS CNC SETUP AND INTEGRATION MANUAL FOR ETHERCAT Warnings

HAL Compatibility Issue with RTX

There is a known compatibility issue with IntervalZero RTX, the real-time extension to Windows operating systems that is required for all of Soft Servo Systems’ products, including the Simulation versions of ServoWorks CNC products.

This compatibility issue can be avoided or easily resolved by checking and changing settings on your computer. You must review Section 3.2: Checking HAL Type for Compatibility with RTX to see if this compatibility issue applies to you. If it does, this section will also instruct you on how to resolve the issue.

! CAUTION

Review Section 3.2: Checking HAL Type for Compatibility with RTX before installing any software. CHECKING YOUR SYSTEM SETTINGS BEFORE INSTALLING SOFTWARE WILL HELP YOU TO AVOID POTENTIALLY BIG PROBLEMS.

DC-155 Servo Interface Module

The DC-155 servo interface module is not needed in the EtherCAT interface system, and does not work in the EtherCAT interface system.

CAUTION !

The DC-155 component is only for use in the VersioBus II interface system.

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Safety Notes

PC Location

CAUTION !

It is strongly recommended that you do not locate the PC inside the electric cabinet, to minimize the possibility of problems due to electrical noise being introduced into the PC motherboard (through air and/or poorly shielded wires such as keyboard, mouse or handwheel cables). Such noise could affect the PCI or ISA bus data flow within the PC, or possibly even the CPU/memory operations of the PC. In fact, it is recommended that you locate the PC as far from the servo drives (the main source of electrical noise) as practicality permits.

Mounting Location

! CAUTION

Never use EtherCAT components in an area where those components could be exposed to water (such as splashing), due to the risk of electric shock or fire.

! CAUTION

Never use EtherCAT components next to flammable items, or in a corrosive or flammable atmosphere, due to the risk of electric shock or fire.

Operational Precautions

! CAUTION

Set all system parameters before operating any components in the EtherCAT interface system. See the Reference Manual for ServoWorks CNC Parameters and Functions or the ServoWorks S-100T Parameters Manual.

______v SERVOWORKS CNC SETUP AND INTEGRATION MANUAL FOR ETHERCAT Warnings

! CAUTION

Test the Emergency Stop before operating any components in the EtherCAT interface system. Make sure the Emergency Stop can be applied at any time.

! CAUTION

Never open up any EtherCAT components, or touch the inside of any EtherCAT component. Doing so may result in damage to the component, or could result in electrical shock.

! CAUTION

Be sure no wiring is exposed before operating any components in the EtherCAT interface system.

! CAUTION

Do not change the wiring while the power is on, due to the risk of electrical shock or injury.

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Table of Contents

Warning ...... i Important Notice ...... ii Cautions ...... iii Servo Drives Need to Be Connected and Powered Up ...... iii Servo Manuals ...... iii IntervalZero RTX Compatibility with Windows XP Service Pack ...... iii 64-bit Windows Compatibility ...... iii Windows 7 Compatibility ...... iii HAL Compatibility Issue with RTX ...... iv DC-155 Servo Interface Module ...... iv Safety Notes ...... v PC Location ...... v Mounting Location ...... v Operational Precautions ...... v Table of Contents ...... i List of Tables ...... iii Chapter 1: Introduction ...... 1-1 1.1 Overview of ServoWorks CNC ...... 1-1 1.2 Overview of the EtherCAT Interface System ...... 1-1 1.3 Overview of the ServoWorks CNC Setup and Integration Manual for the EtherCAT Interface System ...... 1-1 1.4 Do You Have the Necessary Requirements for the EtherCAT Interface System?...... 1-1 1.4.1 PC Hardware Requirements ...... 1-1 1.4.2 PC Software Requirements ...... 1-3 1.4.3 PC Functions ...... 1-3 Chapter 2: Welcome to the EtherCAT Interface System ...... 2-1 2.1 What is the EtherCAT Interface System? ...... 2-1 2.2 EtherCAT Features and Specifications ...... 2-1 2.3 Interpolation Rate ...... 2-2 2.4 Encoders in the EtherCAT Interface System ...... 2-2 Installing the ServoWorks CNC Software ...... 2-1 Chapter 3: ...... 3-1 3.1 Preparing for Software Installation ...... 3-1 3.2 Checking HAL Type for Compatibility with RTX ...... 3-1 3.2.1 Overview of Incompatible HAL Type ...... 3-1 3.2.2 Potential Problems Caused by Not Addressing This Issue...... 3-1 3.2.3 Checking HAL Type ...... 3-2 3.3 Software Upgrades, Backward Compatibility and Adding Software Options ...... 3-6 3.3.1 RTX Upgrading Notification ...... 3-6 3.3.2 Upgrading From an Older Version of a ServoWorks CNC Product ...... 3-7 3.3.3 Version 3 Backward Compatibility Issues ...... 3-8 3.3.4 Adding Options to Existing ServoWorks CNC Products ...... 3-8 3.4 Installing Operating System Patches ...... 3-8 3.4.1 Overview of Service Pack Requirements for Windows Systems ...... 3-8 3.4.2 Windows XP Service Pack 3 Required ...... 3-8 3.4.3 Checking Which Service Packs Are Installed For Your Windows Operating System ...... 3-8 3.5 Enabling the Network Card Device Driver for the Ethernet Card ...... 3-12 3.6 Registering With Soft Servo Systems and IntervalZero and Obtaining Your License Code and RTX License Key ...... 3-16 3.6.1 Overview of PIK and PAC Numbers ...... 3-16 3.6.2 Registering for Your ServoWorks CNC and RTX Licenses without Internet Access ...... 3-16 3.6.3 Saving Your PAC # and RTX License Key ...... 3-18 3.6.4 Getting a Replacement RTX License Key ...... 3-18 3.6.5 Saving Your PIK # and ServoWorks CNC License Code...... 3-18

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3.7 The Installation Procedure ...... 3-19 3.7.1 Starting the Installation ...... 3-19 3.7.2 Registering Your ServoWorks CNC Product ...... 3-21 3.7.3 Installing IntervalZero RTX 2011 and ServoWorks CNC Software ...... 3-32 3.7.4 Installing LadderWorks Console and the DAO Package ...... 3-46 3.8 Finishing Your Software Installation ...... 3-49 3.9 Preventing the RtxServer Screen from Popping Up ...... 3-49 Chapter 4: Installing and Configuring the Network Card ...... 4-1 4.1 Overview ...... 4-1 4.2 Installing the Network Card for the EtherCAT Network ...... 4-1 4.3 Configuring the Device Driver for the Network Card Using the Real Time Device Installer Utility ...... 4-2 4.4.1 Overview ...... 4-2 4.3.2 Installing an RTX Device Driver Using the Real Time Device Installer Utility ...... 4-4 4.3.3 Checking the Status of Installed RTX Device Drivers Using the Real Time Device Installer Utility .... 4-7 4.3.4 Removing an RTX Device Driver Using the Real Time Device Installer Utility ...... 4-10 4.4 Configuring the Device Driver for the Network Card Manually ...... 4-14 4.4.1 Overview ...... 4-14 4.4.2 Converting the Windows Device Driver to an RTX Device Driver ...... 4-16 4.4.3 Updating the Windows Device Driver ...... 4-25 4.4.4 Verifying That the Device Has Been Correctly Installed as RTX Supported and Has Been Assigned an Exclusive IRQ or Has Been Detected as MSI Capable ...... 4-33 4.5 Starting RTX Automatically When System Boots ...... 4-38 4.5.1 Setting RTX Subsystem Startup ...... 4-38 4.6 Preventing CPU Idle State ...... 4-38 4.6.1 Settings for Preventing Intel® SpeedStep® ...... 4-38 Chapter 5: ServoWorks CNC System Integration and Initialization ...... 5-1 5.1 Overview ...... 5-1 5.2 Integrating ServoWorks CNC with the EtherCAT Interface System ...... 5-1 5.3 Configuring the EtherCAT System Information File for Your ServoWorks CNC System (PE version) ...... 5-2 5.4.1 Generating the EtherCAT Network Information File...... 5-7 5.5 Spindle Drives in the EtherCAT Interface System ...... 5-7 5.6 Setting the ServoWorks CNC Parameters for the EtherCAT Interface System ...... 5-7 5.6.1 Parameters That Must Keep Their Default Value ...... 5-7 5.6.2 Setting the ServoWorks CNC Parameters – Overview ...... 5-8 5.6.3 Setting the ServoWorks CNC Parameters Using ServoWorks MotionLite (Only for S-100M Series and MC-Quad) ...... 5-9 5.6.4 Setting the ServoWorks CNC Parameters Using ServoWorks S-100T ...... 5-11 5.7 Setting Your Servo Drive Parameters ...... 5-11 5.8 Synchronous Control with Slave Axes ...... 5-11 5.9 Absolute Encoders in the EtherCAT Interface System ...... 5-12 5.10 Including an Inverter Spindle in an EtherCAT Interface System...... 5-12 Chapter 6: I/O Connections ...... 6-1 6.1 Overview ...... 6-1 Chapter 7: Finishing Your Setup and Integration ...... 7-1 7.1 Testing and Tuning the System ...... 7-1 7.1.1 Overview ...... 7-1 7.1.2 How Position Loop Gain and Smoothing Time Relate to Trajectory Accuracy (Without 3D-DLACC) 7-1 7.1.3 How Velocity Loop Gain Relates to Trajectory Accuracy ...... 7-3 7.1.4 Using Velocity Feedforward to Increase Trajectory Accuracy ...... 7-4 7.1.5 Discussion of Tuning With 3D-DLACC ...... 7-4 7.2 Integrating LadderWorks PLC into Your System ...... 7-5 7.3 Backing Up Final Software Settings After Tuning ...... 7-5 Index...... I

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List of Tables

Table 3-1: Packing List and Product Registration Numbers ...... 3-16 Table 5-1: Parameters in the EtherCAT System Configuration File (1 of 2) ...... 5-3 Table 5-3: Parameters in the EtherCAT Network Information File (1 of 2) ...... 5-5 Table 5-4: Parameters in the EtherCAT Network Information File (2 of 2) ...... 5-6 Table 5-5: References to Procedures for Synchronous Control ...... 5-12 Table 5-6: References to Procedures for Homing Absolute Encoders...... 5-12

List of Figures

Figure 2-1: Figure 2-1: The EtherCAT Interface System ...... 2-1 Figure 3-1: Severe HAL Error Message ...... 3-1 Figure 3-2: Start Menu Selection for Control Panel (1 of 2) ...... 3-2 Figure 3-4: System and Security Window (1 of 2) ...... 3-3 Figure 3-5: Control Panel Small Icon View ...... 3-3 Figure 3-6: Windows 7 System Properties Window (1 of 2)...... 3-4 Figure 3-7: XP System Properties Window (1 of 3) ...... 3-4 Figure 3-8: Device Manager Window (1 of 5) ...... 3-5 Figure 3-9: Notification Dialog for Uninstalling RTX 7.0 or Earlier ...... 3-6 Figure 3-10: Notification Dialog for Uninstalling RTX 8.1 ...... 3-6 Figure 3-11: Installation Options Window for Uninstalling a ServoWorks CNC Product ...... 3-7 Figure 3-12: Start Menu Selection for “Run…” ...... 3-9 Figure 3-13: Start Menu Search for "Run" ...... 3-9 Figure 3-14: The Run Dialog Boxes ...... 3-9 Figure 3-15: The “About Windows” Window for Windows XP ...... 3-10 Figure 3-16: The "About Windows" Window for Windows 7 ...... 3-10 Figure 3-17: Start Menu Selection for Control Panel (2 of 2) ...... 3-12 Figure 3-18: Control Panel Window (2 of 2)...... 3-13 Figure 3-19: System and Security Window (2 of 2) ...... 3-13 Figure 3-20: Windows 7 System Properties Window (2 of 3) ...... 3-14 Figure 3-21: System Properties Window (2 of 3)...... 3-14 Figure 3-22: Device Manager Window (2 of 5) ...... 3-15 Figure 3-23: Welcome Window (1 of 2) ...... 3-20 Figure 3-24: System Properties Window (3 of 3)...... 3-21 Figure 3-25: Device Manager Window (3 of 5) ...... 3-22 Figure 3-26: Device Manager Window (4 of 5)...... 3-22 Figure 3-27: Welcome Window (2 of 2)...... 3-23 Figure 3-28: ServoWorks CNC License Code Window (1 of 2) ...... 3-24 Figure 3-29: ServoWorks CNC Registration Options Window ...... 3-24 Figure 3-30: ServoWorks CNC Product Registration Form (1 of 2)...... 3-25 Figure 3-31: ServoWorks CNC Completed Registration Form (1 of 2) ...... 3-26 Figure 3-32: Sample Web Page for Automatic Retrieval of a ServoWorks CNC License Key (1 of 2) ...... 3-27 Figure 3-33: Sample Web Page for Automatic Retrieval of a ServoWorks CNC License Key (2 of 2) ...... 3-28 Figure 3-34: ServoWorks CNC Product Registration Form (2 of 2) ...... 3-29 Figure 3-35: ServoWorks CNC Completed Registration Form (2 of 2) ...... 3-29 Figure 3-36: Registration File Saved Dialog Box ...... 3-30 Figure 3-37: Registration.txt File ...... 3-30 Figure 3-38: ServoWorks CNC License Code Window (2 of 2) ...... 3-31 Figure 3-39: Device Manager Window (2 of 5) ...... 3-32 Figure 3-40: Windows Installer Dialog Box ...... 3-32 Figure 3-41: Welcome to the Setup Wizard Window ...... 3-33 Figure 3-42: Choose Setup Type Window...... 3-33 Figure 3-43: Custom Setup Window ...... 3-34

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Figure 3-44: Change Destination Folder Window...... 3-34 Figure 3-45: Intel® Hyper-Threading Confirmation Window ...... 3-35 Figure 3-46: RTX Installation Window...... 3-35 Figure 3-47: Question Dialog Box ...... 3-36 Figure 3-48: RTX License Key Window (1 of 2)...... 3-36 Figure 3-49: Sample Web Page for Product Licensing for RTX ...... 3-37 Figure 3-50: Sample Web Page for IntervalZero License Key Agreement ...... 3-38 Figure 3-51: Warning Message Regarding Terms & Conditions...... 3-38 Figure 3-52: Sample Web Page for IntervalZero License Key Display ...... 3-39 Figure 3-53: RTX Manual Registration Window ...... 3-40 Figure 3-54: RTX License Key Window (2 of 2) ...... 3-41 Figure 3-55: IntervalZero RTX Installation Dialog ...... 3-42 Figure 3-56: Confirm Installation Window...... 3-42 Figure 3-57: Installing Window ...... 3-43 Figure 3-58: Installation Complete Window ...... 3-43 Figure 3-59: IntervalZero RTX 2011 with Service Pack 1 Update 1 Preparing Dialog...... 3-44 Figure 3-60: Welcome to RTX 2011 with Service Pack 1 Update 5 Window ...... 3-44 Figure 3-61: Ready to Install the Program Window ...... 3-45 Figure 3-62: Installing IntervalZero RTX 2011 with Service Pack 1 Update 5 Window...... 3-45 Figure 3-63: IntervalZero RTX 2011 with Service Pack 1 Update 5 Installation Completed Window...... 3-46 Figure 3-64: LadderWorks Install Dialog Box ...... 3-46 Figure 3-65: Setup Dialog Box ...... 3-47 Figure 3-66: Welcome to the DAO Setup Window...... 3-47 Figure 3-67: Select Components Window (1 of 2) ...... 3-48 Figure 3-68: Select Components Window (2 of 2)...... 3-48 Figure 3-69: Installation Progress Dialog Box ...... 3-49 Figure 3-70: Information Dialog Box...... 3-49 Figure 3-71: Start Menu Selection for RTX Properties ...... 3-50 Figure 3-72: RTX Properties Window – About Tab...... 3-50 Figure 3-73: RTX Properties Window – Control Tab...... 3-51 Figure 3-74: Start Menu Selection for RTX Properties ...... 3-52 Figure 3-75: RtxServer Window ...... 3-52 Figure 3-76: RtxServer Window – Options Pull-Down Menu...... 3-53 Figure 3-77: Options Window (1 of 2) ...... 3-53 Figure 3-78: Options Window (2 of 2) ...... 3-54 Figure 3-79: RtxServer Window – File Pull-Down Menu...... 3-54 Figure 4-1: Windows 7 Start Menu Selection for RTX Properties ...... 4-2 Figure 4-2: RTX Properties Window – About Tab...... 4-3 Figure 4-3: RTX Properties Window – Control Tab ...... 4-3 Figure 4-4: Real Time Device Installer - Install New Real Time Device Screen (1 of 3) ...... 4-4 Figure 4-5: Time Device Installer - Install New Real Time Device Screen (2 of 3) ...... 4-5 Figure 4-6: Real Time Device Installer - Installing New Real Time Device Screen...... 4-5 Figure 4-7: Real Time Device Installer - Device Successfully Installed Screen...... 4-6 Figure 4-8: Real Time Device Installer - A Problem Was Encountered While Installing Screen ...... 4-6 Figure 4-9: Real Time Device Installer - Main Screen (1 of 2) ...... 4-7 Figure 4-10: Real Time Device Installer - Install New Real Time Device Screen (3 of 3) ...... 4-8 Figure 4-11: Real Time Device Installer - View Status Screen (1 of 2)...... 4-8 Figure 4-12: Time Device Installer - View Status Screen (2 of 2) ...... 4-10 Figure 4-13: Real Time Device Installer - Main Screen (2 of 2) ...... 4-11 Figure 4-14: Real Time Device Installer - Remove Real Time Device Screen...... 4-11 Figure 4-15: Real Time Device Installer - Removing Real Time Device Screen ...... 4-12 Figure 4-16: Real Time Device Installer - Device Successfully Removed Screen...... 4-12 Figure 4-17: Found New Hardware Popup and Wizard ...... 4-13 Figure 4-18: Real Time Device Installer - Problem Was Encountered While Removing the Device Screen...... 4-13 Figure 4-19: Windows 7 Start Menu Selection for RTX Properties...... 4-14 Figure 4-20: RTX Properties Window – About Tab...... 4-15

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Figure 4-21: RTX Properties Window – Control Tab ...... 4-15 Figure 4-22: System Properties Window 7 ...... 4-16 Figure 4-23: Win XP Device Manager Window ...... 4-17 Figure 4-24: Win 7 Device Manager Window ...... 4-18 Figure 4-25: Property -Hardware Ids...... 4-18 Figure 4-26: Driver Config Templates (1 of 2) ...... 4-19 Figure 4-27: Driver Config Templates (2 of 2)...... 4-19 Figure 4-28: RtxTcpIp.ini File...... 4-20 Figure 4-29: RTX Properties Window – Hardware Tab ...... 4-21 Figure 4-30: Pnp Device Settings Window ...... 4-22 Figure 4-31: Windows PCI Device Properties Window...... 4-22 Figure 4-32: RtxTcpIp.ini File for RTE1000 NIC Device ...... 4-23 Figure 4-33: RTX Properties Window – TCP/IP Tab...... 4-23 Figure 4-34: RTX Properties Window – Hardware Tab...... 4-24 Figure 4-35: PnP Device Settings Window ...... 4-24 Figure 4-36: RTX Properties Dialog...... 4-25 Figure 4-37: Device Manager Window ...... 4-25 Figure 4-38: Confirm Device Removal Dialog ...... 4-26 Figure 4-39: Device Manager Window...... 4-26 Figure 4-40: Update Driver Software...... 4-27 Figure 4-41: Update Driver Software Screen (1 of 4) ...... 4-27 Figure 4-42: Update Driver Software Screen (1 of 4) ...... 4-28 Figure 4-43: Windows Security Popup ...... 4-28 Figure 4-44: Update Driver Software Screen (1 of 4) ...... 4-29 Figure 4-45: Update Driver Software Screen (1 of 4) ...... 4-29 Figure 4-46: Device Manager (of) ...... 4-30 Figure 4-47: Found New Hardware Wizard (1 of 7) ...... 4-30 Figure 4-48: New Hardware Wizard (2 of 7)...... 4-31 Figure 4-49: New Hardware Wizard (3 of 7)...... 4-31 Figure 4-50: Found New Hardware Wizard (4 of 7) ...... 4-32 Figure 4-51: Found New Hardware Wizard (5 of 7)...... 4-32 Figure 4-52: Found New Hardware Wizard (6 of 7) ...... 4-33 Figure 4-53: Found New Hardware Wizard (7 of 7)...... 4-33 Figure 4-54: Device Manager (1 of 2)...... 4-34 Figure 4-55: Manager (2 of 2) ...... 4-35 Figure 4-56: RTX Properties Window – Hardware Tab ...... 4-36 Figure 4-57: Pnp Device Settings ...... 4-37 Figure 4-58: RTX PCI Device Properties...... 4-37 Figure 4-59: RTX Subsystem startup Settings...... 4-38 Figure 4-60: SpeedStep® settings ...... 4-39 Figure 5-1: EtherCAT Interface System Integration Example Diagram...... 5-1 Figure 5-2: Example ec_network.def File ...... 5-4 Figure 5-3: Example EtherCAT Network Information File ...... 5-7 Figure 5-4: ServoWorks MotionLite Main Window ...... 5-9 Figure 5-5: ServoWorks MotionLite Main Window – View Pull-Down Menu ...... 5-10 Figure 5-6: MotionLite Parameters Window – Servo Control Tab...... 5-10 Figure 5-7: Example of a General Inverter Spindle in an EtherCAT Interface System ...... 5-14 Figure 7-1: Example: When Smoothing Time Is Too Long ...... 7-2 Figure 7-2: Embedded Feedback Loops: Current Loop, Velocity Loop and Position Loop ...... 7-3

______v SERVOWORKS CNC SETUP AND INTEGRATION MANUAL FOR ETHERCAT Chapter 1: Introduction

Chapter 1: Introduction

1.1 Overview of ServoWorks CNC

ServoWorks is a soft CNC technology forming the basis of Soft Servo Systems’ truly PC-based CNC solutions, with a single host CPU performing all real-time servo and CNC tasks, including feedback loops, multi-axis interpolation, G code processing and PLC, as well as providing the graphical user interface, network communication, and more. ServoWorks CNC software technology runs on Windows XP, Windows 7 with IntervalZero’s RTX technology.

Soft Servo Systems’ CNC solutions are currently available for many servo communications platforms, based on many different communications technologies:

 EtherCAT Ethernet-based servo network

 VersioBus™ II fiber-optic digital servo network

 Yaskawa Electric’s MECHATROLINK™ II (10 Mbps) digital servo communications platform

 Yaskawa Electric’s MECHATROLINK™ III (100 Mbps) digital servo communications platform

1.2 Overview of the EtherCAT Interface System

The high-speed, real-time open architecture EtherCAT interface system provides an all-digital, minimal-hardware control architecture for next-generation motion control.

The EtherCAT interface system works with low-cost Ethernet cables and with EtherCAT (CoE) servo drive systems.

This system uses an Ethernet port to interface the servo drives with the PC. The NIC chip must be supported by RTX. See www.softservo.com/pub/users/Documentation/EtherCAT_NIC.pdf for an up to date list of compatible NIC chips. You will need to supply the user name “users” and password “softservo” (without the quotation marks).

1.3 Overview of the ServoWorks CNC Setup and Integration Manual for the EtherCAT Interface System

This ServoWorks CNC Setup and Integration Manual for the EtherCAT Interface System will take you through the software installation and the hardware setup, the connections between the PC and the EtherCAT servo drives, and system integration and initialization.

Prior to setting up the hardware, you will need to install the software. To finish your setup, you will need to use ServoWorks S-100T to set your servo control, motor and drive parameters, and test and tune the system. Refer to the ServoWorks S-100T Operator’s Manual.

1.4 Do You Have the Necessary Requirements for the EtherCAT Interface System?

1.4.1 PC Hardware Requirements

System requirements for running an EtherCAT interface system are as follows:

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 CPU:

o Minimum: Intel® Core™ 2 Series, Intel® Core™ i Series, or equivalent

o Suggested and minimum for 3D-DLACC (three-dimensional dynamic look-ahead contour control): Core i Series or faster

! CAUTION

We require Hyper-Threading to be disabled if your PC’s CPU supports this feature. Because each physical core in a Hyper-Threaded CPU is treated as a pair of logical cores, each logical core may starve its paired logical core of resources, leading to adverse effects on real time performance.

 Random Access Memory (RAM): 512 MB (1GB suggested)

 Hard disk space: 300 MB

 Ethernet connection: 10 MB/sec or 100 MB/sec

o An active, enabled, properly configured Ethernet port with a properly configured network card device driver. THE ETHERNET CONNECTION MUST NOT BE DISABLED.

o The Ethernet port CANNOT be the Ethernet port you are using in the EtherCAT network.

o You do not need an actual Ethernet cable plugged in or connected to a LAN or to the Internet, just an active Ethernet port.

o The Ethernet connection can be substituted with a Wi-Fi connection. The Ethernet or Wi-Fi card can be in any format – an USB card, a PCI card, or built in to the motherboard.

 Ethernet connection: 100 MB/sec

o A second Ethernet port to interface to the EtherCAT network.

o The NIC chip must be supported by RTX. See www.softservo.com/pub/users/Documentation/EtherCAT_NIC.pdf for an up to date list of compatible NIC chips. You will need to supply the user name “users” and password “softservo” (without the quotation marks) o PCI Bus boards require dedicated IRQ. PCI-Express is MSI-X compatible, so it does not require a dedicated IRQ.

 Display

o 256-color graphic adapter

o Color monitor capable of 1024 x 768 pixel resolution (recommended)

o Recommended video chips: AMD or Nvidia (medium grade)

o Video chips that are known to be incompatible with Soft Servo Systems' products: Any chips that are, or integrated with the following: S3, SMI Lynx, Trident, and VIA. [NOTE: This list of video

______1-2 SERVOWORKS CNC SETUP AND INTEGRATION MANUAL FOR ETHERCAT Chapter 1: Introduction

chips is not comprehensive; any video chip other than our recommended video chips should be tested with RTX.]

 One of the following HAL types must be supported:

o MPS 1.4 – APIC platform HAL

o ACPI 1.0 – APIC Platform UP

o ACPI 1.0 – APIC Platform MP

o ACPI x86 Platform

NOTE: Some hardware configurations are not supported by RTX installations and therefore are not supported by ServoWorks CNC installations: Compaq AP400, Dell 7000 portables, HP Kayak and Alpha systems.

1.4.2 PC Software Requirements

 ServoWorks CNC products require 32-bit Microsoft Windows 7, or 32-bit Microsoft Windows XP (Professional Edition) with Service Pack 3. ServoWorks CNC products do not include an operating system.

 ServoWorks CNC products require IntervalZero RTX RunTime software, the real-time extension to the Windows operating system, which is included with all ServoWorks CNC products.

 Administrator privileges (which allow access to system settings) are required for installing, uninstalling and using IntervalZero RTX.

 One of the following standard Microsoft HALs must be installed:

o Standard PC

o Advanced Configuration and Power Interface (ACPI) PC

o MPS Multiprocessor PC

o ACPI Uniprocessor PC

o ACPI Multiprocessor PC

o ACPI x86-based PC

 Internet Explorer 8.0 or higher is required

1.4.3 PC Functions

Depending upon the hardware and software configuration, there is the potential that some PC functions might have to be disabled due to IRQ conflicts. These functions include, but are not limited to: USB, Ethernet, sound, modem, and other hardware components.

Soft Servo Systems recommends consulting with our sales staff prior to purchasing a PC on which to run your Soft Servo product.

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Chapter 2: Welcome to the EtherCAT Interface System

2.1 What is the EtherCAT Interface System?

The EtherCAT interface system is a servo system for the truly PC-based CNC products offered by Soft Servo Systems, Inc. that combines ServoWorks CNC software technology with EtherCAT, a fast (with an interpolation rate as fast as 0.5 ms), vendor-independent, Ethernet-based realtime open network for servo and I/O communications that works with CANopen over EtherCAT (CoE) servo drives and I/O devices. EtherCAT (Ethernet Control Automation Technology) is an industrial Ethernet fieldbus network that is real-time down to the I/O level — no delays in gateways, no underlying sub-systems.

ServoWorks is an innovative, PC-based soft CNC technology for real-time CNC.

Soft Servo Systems, Inc. offers the following ServoWorks CNC products that run on the EtherCAT platform: ServoWorks MC-Quad for 4-axis general CNC; ServoWorks S-100M, S-120M and S-140M for mills and machining centers; ServoWorks S-100T and S-120T for lathes.

The EtherCAT interface system is summarized in the following figure:

Host CPU Windows or Linux EtherCAT (CoE) CNC Motion RJ45 Ethernet servo drives

Soft PLC and I/O devices CNC GUI EtherCAT driver

Figure 2-1: Figure 2-1: The EtherCAT Interface System

2.2 EtherCAT Features and Specifications

 Extremely fast — control of up to 32 servo axes with a cycle time as fast as 0.5 ms

 Simple wiring — single-line daisy chain without even a terminator

 Normal, off-the-shelf Ethernet cabling

 Easy to configure, diagnose and maintain

 Less expensive, due to simplified configuration, no plug in cards, no switches/hubs, and standard cabling

 Well proven technology

 Offers redundancy against cable or node failures (with second Ethernet port)

 Servo drives from different manufacturers can be connected in the same network

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2.3 Interpolation Rate

For ServoWorks CNC products using the EtherCAT interface system, the interrupt service routine (ISR) that begins each servo loop can be set to either 0.5ms or 1ms.

2.4 Encoders in the EtherCAT Interface System

Both incremental and absolute encoders are supported in the EtherCAT interface system.

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Chapter 3: Installing the ServoWorks CNC Software

3.1 Preparing for Software Installation

Before you begin installing the ServoWorks CNC software, you must check (and possibly address) some issues regarding your computer and its settings.

First, you must make sure that you meet the necessary PC hardware and operating system requirements. See Section 1.4: Do You Have the Necessary Requirements for the EtherCAT Interface System? if you haven’t already checked for these requirements.

Second, make sure that you are logged in with administrator privileges (which allows access to system settings), or you will not be able to install, uninstall or use IntervalZero RTX, the real-time extension to the Windows operating system.

The next few sections will guide you through checking a known compatibility issue with RTX, installing operating system patches (if necessary), and enabling the network card device driver for the Ethernet card.

3.2 Checking HAL Type for Compatibility with RTX

3.2.1 Overview of Incompatible HAL Type

There is a known compatibility issue between systems with certain Hardware Abstract Layer (HAL) types, and IntervalZero RTX. There are only four HAL types that are acceptable for use with RTX 2011.

You should read this section to see if this issue applies to you, and take the steps outlined to resolve the issue if necessary.

CHECKING YOUR SYSTEM SETTINGS NOW WILL HELP YOU TO AVOID POTENTIALLY BIG PROBLEMS LATER.

3.2.2 Potential Problems Caused by Not Addressing This Issue

If you try to install RTX on a PC with an incompatible HAL type, you may see a severe error similar to the following:

Figure 3-1: Severe HAL Error Message

It is possible that RTX will not prevent you from installing RTX on a system with a wrong HAL setting, in which case this incompatibility issue could cause some serious system failures, such as:

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1) Fatal application exit (i.e., “application crash”)

2) System lock-up (or “freeze”)

3) System bug check (i.e., “Blue Screen of Death” or “Green Screen of Death”)

You must check to see whether or not your PC has an incompatible HAL type before installing RTX.

3.2.3 Checking HAL Type

1) From the Windows “Start” menu, go to “Control Panel” (Start Menu) as shown:

Figure 3-2: Start Menu Selection for Control Panel (1 of 2)

2) Upon clicking, you will see the “Control Panel” window appear. Click on "System and Security":

Figure 3-3: Control Panel Window (1 of 2)

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3) Next, click on "System", or "Device Manager" [Skip to step #5 if clicking Device Manager]. [NOTE: From the small icon view, click on "System," and skip to step #5.] For Windows XP, click on the “Performance and Maintenance” icon. [NOTE: If you are in Classic View, just click on the “System” icon – the “System Properties” window will appear, and you should skip ahead to Step #5.]

Figure 3-4: System and Security Window (1 of 2)

Figure 3-5: Control Panel Small Icon View

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4) After clicking on “System”, the “System Properties” window will appear, as shown below. Click on "Device Manager" highlighted on the left side of the screen.

Figure 3-6: Windows 7 System Properties Window (1 of 2)

5) For Windows XP, click on the "Hardware" tab in the System Properties. In the “Device Manager” frame, click on the “Device Manager” button. You will see the “Device Manager” window appear.

Figure 3-7: XP System Properties Window (1 of 3)

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Figure 3-8: Device Manager Window (1 of 5)

6) Click on the symbol next to the “Computer” node to see the drop-down list under “Computer”. The leaf listed below “Computer” is your HAL model (“ACPI x86-based PC” in the previous example window).

Acceptable HAL models for “Standard Computers” and RTX 2011 are:

 MPS Multiprocessor PC HAL (MPS 1.4 – APIC Platform HAL)

 ACPI Uniprocessor PC HAL (ACPI 1.0 – APIC Platform UP)

 ACPI Multiprocessor PC HAL (ACPI 1.0 – APIC Platform MP)

 ACPI x86-based PC (ACPI x86 Platform)

If your HAL model is NOT listed above, then RTX cannot be installed on your system. Contact Soft Servo Systems, Inc. to discuss your options.

Otherwise, if you already have an acceptable HAL model to start installing IntervalZero RTX, proceed to the next section.

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3.3 Software Upgrades, Backward Compatibility and Adding Software Options

3.3.1 RTX Upgrading Notification

If you use RTX 7.0 or an earlier version, you will be prompted to upgrade to RTX 2011. You will be prompted to uninstall the older version of RTX with a similar following window, and the install buttons will be disabled after closing this notification:

Figure 3-9: Notification Dialog for Uninstalling RTX 7.0 or Earlier

Upgrading users with RTX 8.1 series (including RTX 8.1.1 and 8.1.2) will see the following window:

Figure 3-10: Notification Dialog for Uninstalling RTX 8.1

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It is highly recommended to install RTX 2011 to set up the EtherCAT platform. First, uninstall the older version of RTX from “Add or Remove Programs” in Windows (from the Windows “Start” menu, go to “Control Panel”  “Add or Remove Programs”). Contact [email protected] to receive a new PAC number for RTX 2011. Make sure to keep your old license information before uninstalling.

3.3.2 Upgrading From an Older Version of a ServoWorks CNC Product

If you are upgrading from an older version to a newer version of a ServoWorks CNC product, you will receive a new installer for the newer version of the ServoWorks CNC product. You must use that installer to uninstall the relevant ServoWorks CNC component(s) before installing the newer version of the component(s). Unless you are upgrading from a version prior to Version 3.0 to Version 3.0 or greater, you will not get a new PIK number, nor will you need to reregister your software. You can use the same license code – your ServoWorks CNC license code will be automatically maintained during this upgrading process.

For ServoWorks S-140M, for instance, if you use the installer for a new version of ServoWorks S-140M and click on the “S140M” button, you will be prompted to uninstall ServoWorks S-140M with the following window:

Figure 3-11: Installation Options Window for Uninstalling a ServoWorks CNC Product

Select the components you wish to uninstall. Only select “SWPLC” if you are upgrading your version of LadderWorks PLC.

It is not possible to update or remove IntervalZero RTX with this installer. In most cases, the RTX version should not need to be uninstalled/ reinstalled unless you have purchased a new RTX version with a new RTX PAC code. If you do need to upgrade to a newer version of RTX, use the “Add or Remove Programs” application (from the Windows “Start” menu, go to “Control Panel”  “Add or Remove Programs”).

Once you have selected the component(s) to uninstall and update, click on the “Install/Update” button. The uninstall process will proceed automatically. Then you can use the installer to reinstall the component(s) you are upgrading.

Once you have completed the installation of the new version of your ServoWorks CNC product, you must ensure that all of the parameters are correctly set.

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3.3.3 Version 3 Backward Compatibility Issues

If you are upgrading to Version 3.0 or greater from a version prior to Version 3.0, there are a few known issues:

1) Pitch error compensation values will be initialized as 0. In other words, previously set pitch error data will not be imported into the new software, and will need to be input again.

2) The “Distance Per Encoder Revolution” and “Plus Stroke” parameters of Axis 1 will swap, and will need to be corrected.

Correct values for these two items will be kept from this point on, with any future post-3.0 versions.

3.3.4 Adding Options to Existing ServoWorks CNC Products

If you purchase software options to add to your existing ServoWorks CNC product, your PIK number will be reactivated by Soft Servo Systems. You must reregister your ServoWorks CNC product (using the original PIK number for your product) to activate those options, but you won’t need to reinstall your ServoWorks CNC product.

3.4 Installing Operating System Patches

3.4.1 Overview of Service Pack Requirements for Windows Systems

As noted in Chapter 1, the Microsoft Windows XP operating system requires Service Pack 3, for the IntervalZero RTX real-time extension to function properly.

3.4.2 Windows XP Service Pack 3 Required

Service Pack 3 is required for Windows XP, and it is compatible with RTX2011 Your ServoWorks CNC product will not run on a PC with Windows XP without the Service Pack 3.

3.4.3 Checking Which Service Packs Are Installed For Your Windows Operating System

You can check to see which service packs (if any) are installed on your PC with the following procedure:

1) Click on the “Start” menu in the lower left hand corner of your PC’s desktop.

2) Click on “Run…”, as shown in the following figure for XP, or type "Run" in the search box as shown in the following:

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Figure 3-12: Start Menu Selection for “Run…”

Figure 3-13: Start Menu Search for "Run"

3) A dialog box will appear, as shown in the following figures:

Figure 3-14: The Run Dialog Boxes

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4) Type “winver.exe” or "winver" in the text box, and click “OK.” A window similar to that shown in the following window will appear telling you the latest service pack installed on your PC:

Figure 3-15: The “About Windows” Window for Windows XP

Figure 3-16: The "About Windows" Window for Windows 7

If the latest patches from these service packs haven’t been installed, you must install them now. You can install the latest service packs by going to Microsoft’s web site (www.microsoft.com), and clicking on “Downloads", "Security & utilities", then "Service Packs"), choose the appropriate OS, and then selecting “Windows Update” to start the procedure.

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! CAUTION

If you install the IntervalZero RTX software before you install the required operating system patches, there could be subtle problems with your installation. The operating system patches must be installed before you begin the ServoWorks CNC installation.

! CAUTION

On April 8, 2014, Microsoft support has ended for Windows XP, including security updates for your PC. If you continue to use Windows XP, your computer might become more vulnerable to security and virus risks.

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3.5 Enabling the Network Card Device Driver for the Ethernet Card

One of the system requirements for running a ServoWorks CNC product is an Ethernet connection of 10 MB/sec or 100 MB/sec. However, just having an Ethernet connection on your PC is not enough; the device driver for the Ethernet network card must be installed and enabled. Otherwise, you will not be able to properly register your ServoWorks CNC product.

This Ethernet connection CANNOT be the Ethernet port you are using in the EtherCAT network. You will need a second, separate Ethernet connection to fulfill this requirement. You do not need an actual Ethernet cable plugged in or connected to a LAN or to the Internet, just an active Ethernet port. A USB network or Wi-Fi card can be substituted.

NOTE: There doesn’t need to be an actual network connection (cable) to a LAN or to the Internet, just an active Ethernet port. ETHERNET CANNOT BE DISABLED. We recommend checking to make sure the Ethernet card and its device driver are correctly installed and enabled in the computer, with the following procedure.

1) From the Windows “Start” menu, go to “Control Panel” (Start Menu) as shown:

Figure 3-17: Start Menu Selection for Control Panel (2 of 2)

2) You will see the “Control Panel” window appear, as shown:

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Figure 3-18: Control Panel Window (2 of 2)

3) From the Category view, click on "System and Security" category. [From the small icon/Classic view, click on "System," and skip to step #5.] For XP, click on the “Performance and Maintenance” icon, and then click on "System".

Figure 3-19: System and Security Window (2 of 2)

4) Click on the “System” icon, and you will see the “System Properties” window appear. From the XP System Properties, click on Hardware tab:

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Figure 3-20: Windows 7 System Properties Window (2 of 3)

Figure 3-21: System Properties Window (2 of 3)

5) Click on the “Device Manager.”

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Figure 3-22: Device Manager Window (2 of 5)

6) Click on the symbol to see the drop-down list under “Network adapters.” This will display the current network devices that are detected by Windows. In our example, there are two devices, one of which is the Realtek RTL8169/811x Family PCI Gigabit Ethernet NIC (NDIS 6.20) #5 RTX Supported #5. This is the network card, which can have many different names depending on the computer, but usually contains the words “Ethernet” or “network” in its description.

In this example, the network card appears to be in working order. One of the following will appear in the Device Manager if there is a problem: (a) The Network card does not appear at all, or the “Network adapters” icon ( ) cannot be found in the Device Manager. In this case the network card may not be installed correctly, as Windows should detect almost all cards put into the computer. Recheck the card’s connection. (b) There is a listing for “Other devices” ( ) in the Device Manager. Check this listing to see if there is an item that may be the network card. If this is the case, the drivers could not be found by Windows, so the device it detected was placed in the “Other devices” category. Windows does not currently know what the device is, so updating the drivers to the correct ones will help to resolve this. (c) The card appears, but has a yellow exclamation point ( ) over the icon. In this case, the card has been detected and Windows recognizes it as a network card, but incorrect drivers may have been installed or there is another conflict with the card. (d) There are multiple network cards with the same name but there is only one network card installed in the machine. One or both of the cards may have a yellow exclamation point ( ) over its icon. In this case, right click on the network card, and select “Uninstall” from the drop-down menu. Do this for each card that appears until there are no more cards listed. Close the Device Manager and restart the computer. Windows should detect only one device when it boots up.

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Right clicking on a device and selecting “Properties” from the drop-down menu will open a new window for that device – the “Device status” frame in that window may have a message that could give some insight into a problem with a device. For troubleshooting any problems, consult the literature provided with your PC.

3.6 Registering With Soft Servo Systems and IntervalZero and Obtaining Your License Code and RTX License Key

3.6.1 Overview of PIK and PAC Numbers

If you have access to the Internet from the computer on which you are installing this software, you can skip this section, proceed to Section 3.7: The Installation Procedure, and obtain your ServoWorks CNC license code and your RTX license key during the software installation procedure for your ServoWorks CNC product.

You will need to register your ServoWorks CNC software to obtain your license code, and register your IntervalZero RTX software and obtain your RTX license key, during the software installation procedure detailed in Section 3.7: The Installation Procedure. Ideally, you need Internet access to obtain these license codes.

You must have the SSS PIK # (Soft Servo Systems Product Identification Key) and the PAC # (Purchase Authentication Code for RTX) that Soft Servo Systems provided with your ServoWorks CNC product (on stickers inside the CD case, and on the license packing list inside the CD case).

FOLLOW REGISTRATION PRODUCT FIND ON PACKING LIST: PROCEDURE TO OBTAIN:

ServoWorks CNC product (ServoWorks MC-Quad, S-100M, SSS PIK # ServoWorks CNC license code S-120M, S-140M, S-100T, S-120T) IntervalZero RTX (real-time extension to Windows operating PAC # RTX license key system, included with ServoWorks CNC product)

Table 3-1: Packing List and Product Registration Numbers

3.6.2 Registering for Your ServoWorks CNC and RTX Licenses without Internet Access

If you don’t have Internet access from the computer on which you are installing this software, you should obtain both the ServoWorks CNC license code and the RTX license key from another computer with Internet access during the installation procedure, or you won’t be able to complete the procedure. (You’ll have to start the installation procedure on the computer on which you are installing the ServoWorks CNC product in order to get the Computer ID number and the Product Part Number. With this information, you can go to a computer with Internet access, go to Soft Servo Systems’ registration web page, and get the license code to take back to the first computer. Similarly, you must continue the installation on the first computer to get the Machine ID number. With the Machine ID number, you can get the RTX license key using the computer with Internet access, then go back to the first computer to finish the RTX installation.) Make sure you have Internet access from some computer before you start the installation procedure.

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NOTE: If you don’t have any Internet access on any computer, you can still get your ServoWorks CNC license code and your RTX license key. To get your ServoWorks CNC license code, you will have to fax a text page created automatically by the installation software during the registration process to Soft Servo Systems, Inc. – instructions will be provided during the installation process if you indicate that you don’t have Internet access. [You can also phone Soft Servo Systems, Inc. at 1-781-891-9555 if you don’t have a fax machine.]

To get your RTX license key without Internet access, you can call technical support at IntervalZero at 1-800-334- 8649 from within the United States, or at 1-781-996-4481 (Ext. 226) from outside the United States. You must provide the PAC # and the Machine ID number (which you can only get by starting the installation procedure), and an IntervalZero representative will go to the web site for you, register you, and provide your license key number over the phone. Again, you must have your Machine ID number before calling, so you must have started the installation procedure to get that number before calling.

At the time of this writing, IntervalZero’s telephone technical support is available from Monday-Friday, 8:30 AM to 5:30 PM Eastern Standard Time (excluding U.S. holidays). If you plan to register by telephone, you should perform the ServoWorks CNC installation during those hours.

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3.6.3 Saving Your PAC # and RTX License Key

When you get your IntervalZero RTX license key, it is VERY important that you retain this RTX license key, as well as your PAC number, in a safe and accessible place.

If you replace the hard drive, change the partition of your hard drive, reformat your hard drive, reinstall your operating system, change to a new operating system, or move your ServoWorks CNC product to another computer (and possibly if you update the service pack for your operating system), you will need a replacement RTX license key (without which IntervalZero RTX will no longer operate). To get a replacement RTX license key, you will need your PAC number AND your previous RTX license key.

We recommend that you report your RTX license key number (and PAC#) to Soft Servo Systems at [email protected]. Soft Servo Systems maintains a database of RTX license keys for the PAC numbers we distribute, for your convenience in the event that you lose your license key number.

3.6.4 Getting a Replacement RTX License Key

To get a replacement RTX license key, you will have to contact Soft Servo Systems at [email protected] and provide the following information:

1) PAC # (Purchase Authentication Code for RTX)

2) Previous RTX license key

3) Machine ID of the computer on which you want to install RTX (to get this Machine ID number, start the RTX installation procedure and follow the steps until the installer gives you the machine ID).

CAUTION !

This is a change from how RTX replacement license keys were previously generated. Until recently, you could obtain an RTX replacement license key using the IntervalZero web site during the RTX installation procedure. Therefore, there was no delay in reinstalling RTX after reformatting your hard drive, changing to a new operating system, etc.

Now, you must contact Soft Servo Systems via e-mail for a replacement license key, and await a reply. You should plan your RTX reinstallation accordingly.

3.6.5 Saving Your PIK # and ServoWorks CNC License Code

It is VERY important that you retain your PIK number and your ServoWorks CNC license code in a safe and accessible place.

You will need to contact Soft Servo Systems (by phone, fax or e-mail) to reactivate your PIK number if you need to reinstall your ServoWorks CNC product because you do any of the following:

 Replace the hard drive

 Change the partition of your hard drive

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 Reformat your hard drive

 Reinstall your operating system

 Switch to a new operating system

 Update the service pack for your operating system (possibly, depending upon the service pack – some service packs may require re-registration of your ServoWorks CNC product; others may not)

 Move your ServoWorks CNC product to another computer

When your PIK number has been reactivated by Soft Servo Systems, you will need to reregister your ServoWorks CNC product to obtain a new ServoWorks CNC license code (by clicking the “Register” button in the ServoWorks CNC installer).

NOTE: If you upgrade your ServoWorks CNC product to a newer version, you will not need to reactive your PIK number or reregister your ServoWorks CNC product. You will uninstall the older version of the software, and then install the new version. The ServoWorks CNC license code for that product will be automatically maintained during this process.

If you purchase new options for your ServoWorks CNC product, Soft Servo Systems will automatically reactivate your PIK number, and you will need to reregister your ServoWorks CNC product to activate those new options (by clicking the “Register” button in the ServoWorks CNC installer).

3.7 The Installation Procedure

3.7.1 Starting the Installation

The ServoWorks CNC installation procedure includes registering your ServoWorks CNC product with Soft Servo Systems, Inc.; registering and installing IntervalZero RTX; installing LadderWorks PLC, the ServoWorks CNC base components and the ServoWorks CNC HMI application; installing ServoWorks MotionLite (Only for S-100M Series and MC-Quad); and installing the LadderWorks Console application and the DAO (Data Access Objects) package.

Before starting this installation procedure, you should review Section 3.2: Checking HAL Type for Compatibility with RTX to check for and resolve any known compatibility issues with IntervalZero RTX.

MAKE SURE YOU ARE LOGGED IN WITH ADMINISTRATOR PRIVILEGES (WHICH ALLOWS ACCESS TO SYSTEM SETTINGS), OR YOU WILL NOT BE ABLE TO INSTALL, UNINSTALL OR USE INTERVALZERO RTX, THE REAL-TIME EXTENSION TO THE WINDOWS OPERATING SYSTEM.

IF YOU TAKE A FEW MOMENTS TO CHECK YOUR SYSTEM SETTINGS BEFORE INSTALLING RTX, YOU CAN AVOID POTENTIALLY BIG PROBLEMS.

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The following software will be installed:

1) IntervalZero RTX RunTime

2) ServoWorks CNC Engine

3) ServoWorks G-Code Parser

4) LadderWorks PLC Engine

5) ServoWorks RealTime DLL

6) ServoWorks MotionLite (Only for S100M Series and MC-Quad)

7) ServoWorks CNC application (ServoWorks MC-Quad, ServoWorks S-100M, ServoWorks S-120M, ServoWorks S-140M, ServoWorks S-100T, or ServoWorks S-120T) HMI

8) LadderWorks PLC, including the LadderWorks Console application (refer to the LadderWorks manuals for setting up your PLC environment)

Also, the screen shots for the software installation are for ServoWorks S-140M, but the procedure is the same (and the screen shots differ only in product name) for all ServoWorks CNC products.

Start the ServoWorks CNC software installation process with the following steps:

1) Close all running applications.

2) Place the ServoWorks CNC CD-ROM in the CD-ROM drive. The installation software will start automatically and the “Welcome” window will appear, as shown in the following figure. [NOTE: If the “Welcome” window doesn’t appear automatically, click on *_Install.exe file (S140M_Install.exe, for instance, or similarly named file), and a window similar to the following will appear.]

NOTE: This button’s label varies, depending upon the particular ServoWorks CNC product you are installing: ServoWorks MC-Quad, ServoWorks S-100M, ServoWorks S-120M, ServoWorks S-140M, ServoWorks S-100T, or ServoWorks S-120T

Figure 3-23: Welcome Window (1 of 2) ______3-20 SERVOWORKS CNC SETUP AND INTEGRATION MANUAL FOR ETHERCAT Chapter 3: Installing the ServoWorks CNC Software

3) In the “Welcome” window (Figure 3-18), click on the “Read Me” button. This will open up a Notepad file with installation information. We recommend that you print out this file for reference during the installation procedure and for future reference. Exit the Notepad application to continue.

3.7.2 Registering Your ServoWorks CNC Product

1) Before registering your software, you will have to temporarily disable the network card you plan to interface with the EtherCAT network. This step is necessary to ensure that the hardware setup “fingerprint” taken during registration matches the “fingerprint” after the entire installation, when the network card interfacing with the EtherCAT network will be controlled by the real-time operating system and be invisible to Windows. First, open the Windows Device Manager. The Windows Device Manager can be opened by clicking on the “Device Manager” button in the “Hardware” tab of the “System Properties” window. The “System Properties” window can be accessed by clicking on the “System” icon in the Windows Control Panel. The following figure shows the “System Properties” window.

Figure 3-24: System Properties Window (3 of 3)

2) Find the network card you plan to interface with your EtherCAT network. If installed correctly, the network card will appear under “Network adapters,” as shown below:

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Figure 3-25: Device Manager Window (3 of 5)

3) Right click on the network card and click on the “Disable” option. Click “Yes” on the pop-up that appears warning “Disabling this device will cause it to stop functioning. Do you really want to disable it?” You should see a red X appear on top of the icon of your network card, as shown in the figure below:

Figure 3-26: Device Manager Window (4 of 5)

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CAUTION ! Before continuing with the following steps, make sure that you have a second, active Ethernet connection. A second Ethernet connection is required to install and register the ServoWorks CNC software for the EtherCAT platform. This Ethernet connection can be substituted with a Wi-Fi connection. The Ethernet or Wi-Fi card can be of any format – an USB card, a PCI card, or built into the motherboard.

4) Navigate back to the “Welcome” window of the software installer (shown in the figure below).

Figure 3-27: Welcome Window (2 of 2)

5) In the “Welcome” window, click on the “Registration” button – this will start the registration procedure, and the License Code Window will appear as shown:

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Figure 3-28: ServoWorks CNC License Code Window (1 of 2)

6) If you have already obtained a license code from Soft Servo Systems, Inc. (if, for example, you are reinstalling this software), you can proceed directly to step #16, skipping all steps in between. Otherwise, click the “Get License Code” button (not the “Finish” button), and you will see the following window appear:

Figure 3-29: ServoWorks CNC Registration Options Window

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If you have access to the Internet (either on the computer on which you are installing your ServoWorks CNC product, or on another computer), select “Register over the Internet,” click the “Next” button, and proceed to step #8.

If you do not have access to the Internet, select “Manually register by e-mail, fax, or telephone,” click the “Next” button, and skip ahead to step #12.

7) You should see the registration form shown in the following figure:

Figure 3-30: ServoWorks CNC Product Registration Form (1 of 2)

8) The Computer ID number and the Product Part Number are filled in automatically. Fill in the rest of the required information for every remaining field in the above window, as shown:

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Figure 3-31: ServoWorks CNC Completed Registration Form (1 of 2)

9) When you have completed the form, click the “Next” button.

If you have Internet access, a browser will open up taking you to a secure web page on Soft Servo Systems’ on-line registration web site (similar to the following web page). [NOTE: The browser may open up below your installation software window – you may have to click on your computer’s status bar to see it.] The web page should be automatically filled in with all the information you provided in the product registration window.

If you don’t have Internet access from the computer on which you are installing your ServoWorks CNC product, but you do have Internet access on another computer, make a note of your PIK Code, your Computer ID number, and your Product Part Number, and take this information to the computer with Internet access. Open up a web browser with the following URL: https://www.servoworks.com/register. Select your ServoWorks CNC product from the “Software” pull-down menu – valid values are “MC-Quad,” “S-100M,” “S-120M”, “S-140M” , “S-100T”, and "S-120T". Select your interface platform – EtherCAT – from the “Platform” pull-down menu.

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Figure 3-32: Sample Web Page for Automatic Retrieval of a ServoWorks CNC License Key (1 of 2)

10) Click on the “GET YOUR LICENSE CODE” button, and the license code will be displayed on screen (as shown in the following figure), and will also be e-mailed to you at the e-mail address you have provided. Select and copy the license code into your computer’s Clipboard (or make a note of it and take it back to the computer on which you are installing your ServoWorks CNC product). Proceed directly to step #13.

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Figure 3-33: Sample Web Page for Automatic Retrieval of a ServoWorks CNC License Key (2 of 2)

11) If you selected “Manually register by e-mail, fax, or telephone,” you should see the registration form shown in the following figure:

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Figure 3-34: ServoWorks CNC Product Registration Form (2 of 2)

12) The Computer ID number and the Product Part Number will be filled in for you. Fill in the rest of the required information for every remaining field, as shown:

Figure 3-35: ServoWorks CNC Completed Registration Form (2 of 2)

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13) Click the “Save” button, and the following message will appear:

Figure 3-36: Registration File Saved Dialog Box

14) This dialog box tells you the location of the registration text file that was created by the installation software: in this case, the file name is Registration.txt, and it is located on the C: drive. This file may open up automatically; if it does not, open up the file in Notepad, or some other word processor, and then click the “OK” button to close the dialog box.

Print this registration text file, and either e-mail or fax it to Soft Servo Systems, Inc. (the e-mail address and fax number in the United States are provided in the Registration.txt file). The text file appears similar to the following:

Figure 3-37: Registration.txt File

15) Soft Servo Systems, Inc. will mail or e-mail your license code to you, depending upon how you submitted your registration file.

When you receive the license code (either by Internet, phone or e-mail), go back to the ServoWorks CNC

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License Code window, as shown in the following figure:

Figure 3-38: ServoWorks CNC License Code Window (2 of 2)

16) Input your license code. (If you have obtained your license key automatically, using Internet access on the computer on which you are installing a ServoWorks CNC product, you should cut and paste the license key number from the web page to the License Code Window. If you had to go to a different computer or phone Soft Servo Systems, Inc. to obtain the license key, you’ll need to type in your license number.) Click the “Finish” button to continue.

17) Once you have finished registration, you can re-enable the network card you disabled at the beginning of this section. Return to the Windows Device Manager window, right click on the network card you disabled, and click on “Enable.” You should see the red X disappear, as shown below:

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Figure 3-39: Device Manager Window (2 of 5)

3.7.3 Installing IntervalZero RTX 2011 and ServoWorks CNC Software

1) In the “Welcome” window (Figure 3-18), click on the third button (the “S100T” button in this example) again – you will see a Windows Installer dialog box briefly appear, followed by a Welcome to the Setup Wizard window, shown in the following two figures:

Figure 3-40: Windows Installer Dialog Box

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Figure 3-41: Welcome to the Setup Wizard Window

2) Click the “Next” button, and a Choose Setup Type window will appear, as shown in the following figure. Click the “Typical” button to install the ServoWorks CNC software to the default install location (“C:\Program Files\SoftServo” folder if the system drive is the C drive), or click “Custom” for custom setup. Skip to step #5 if you choose “Typical” setup.

Figure 3-42: Choose Setup Type Window

3) You will see a Custom Setup window, as shown in the following figure, if you choose “Custom” setup. You can choose software features you will install, and the location where you will install. Select the feature(s) to install from the tree. Click the “Browse…” button to select the install location.

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Figure 3-43: Custom Setup Window

4) The following figure shows the Change Destination Folder window. Choose the destination folder for your installation and click the “OK” button. The destination folder will appear next to “Location” in the Custom Setup window in Figure 3-43. Click the “Next” button to continue:

Figure 3-44: Change Destination Folder Window

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5) If IntervalZero RTX has not been installed, the dialog shown in the following figure will appear. Make sure that Intel® Hyper-Threading is disabled, and then click the “OK” button to continue. Skip to step #18 if IntervalZero RTX is already installed.

Figure 3-45: Intel® Hyper-Threading Confirmation Window

6) An RTX Installation window, as shown in the following figure, will appear. Fill in the RTX PAC Number (Purchase Authentication Code number – you can find it on a sticker on your ServoWorks CNC CD case). Then click the “Install” button.

Figure 3-46: RTX Installation Window

7) A dialog box will appear, as shown in the following figure, asking whether you have access to the Internet on this computer.

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Figure 3-47: Question Dialog Box

8) If you don’t have access to the Internet, skip ahead to step #14.

9) If you do have access to the Internet, click “Yes”, and a window will appear, as shown in the following figure:

Figure 3-48: RTX License Key Window (1 of 2)

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A web browser should have opened up taking you to IntervalZero’s web site (similar to the web page shown in the following figure). [NOTE: The browser will probably open up below the RTX License Key window shown in the previous figure – you may have to click on your computer’s status bar to see it.] The web page should be automatically filled in with your PAC #, your Machine ID number, and your e-mail address.

! CAUTION

If for some reason your web browser does not launch automatically, you should visit https://licensing.intervalzero.com/licenseform.asp. You will have to manually fill in your PAC #, Machine ID and e-mail address. To get your Machine ID, you will have to click on the “Back” button to cancel the installation. Then, start the installation again from the beginning of this section. When you reach the Question dialog box shown in Figure 3-47, click “No” this time and skip ahead to step #14.

NOTE: If you need a replacement (new) RTX license key because you are reinstalling IntervalZero RTX on a different computer from where it was previously installed, and reusing the PAC number, please see Section 3.6.4: Getting A Replacement RTX License Key. You will be unable to continue with your installation until you have contacted IntervalZero and received your replacement RTX license key from them.

Figure 3-49: Sample Web Page for Product Licensing for RTX

10) Click on the Terms & Conditions link, to view the IntervalZero RTX license agreement, as shown in the following window:

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Figure 3-50: Sample Web Page for IntervalZero License Key Agreement

NOTE: You cannot skip this step. If you click on “GET LICENSE!” without clicking the Terms & Conditions link, you will get the following message:

Figure 3-51: Warning Message Regarding Terms & Conditions

11) You should read the license agreement, and then close this web page. You will be taken back to the previous web page shown in Figure 3-49. Check the “I agree with the Terms & Conditions…” check box to accept the terms of the agreement.

12) Click on the “GET LICENSE!” button, and an RTX license key number will be displayed on the screen (as shown in the following figure), and will also be e-mailed to you at the e-mail address you have provided. Highlight (select) this license key, and copy it into your computer’s clipboard (to paste into the installer window). Save or print this number, and keep this number in a safe place. Close your web browser.

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Figure 3-52: Sample Web Page for IntervalZero License Key Display

! CAUTION

It is VERY important that you retain this RTX license key, as well as your PAC number, in a safe and accessible place.

If you change the partition of your hard drive, reformat your hard drive, reinstall your operating system, or move your CNC product to another computer, you will need a replacement RTX license key (without which IntervalZero RTX will no longer operate). To get a replacement RTX license key, you will need your PAC number AND your previous RTX license key. See Section 3.6.4 Getting A Replacement RTX License Key.

We recommend that you report your RTX license key number (and PAC#) to Soft Servo Systems at [email protected]. Soft Servo Systems maintains a database of RTX license keys for the PAC numbers we distribute, for your convenience in the event that you lose your license key number.

Skip ahead to step #17.

13) If you don’t have Internet access, click the “No” button in the Question dialog box shown in Figure 3-47, and instructions will appear (as shown in the Manual Registration window in the following figure) as to how you can obtain your RTX license number from another computer WITH Internet access. Also, see Section 3.6: Registering With Soft Servo Systems and IntervalZero and Obtaining Your License Code and RTX License Key for more information, including how to register by phone if you don’t have Internet access available to you on any computer.

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Figure 3-53: RTX Manual Registration Window

14) To get an IntervalZero RTX license key using Internet access, use another computer to get on the Internet and go to https://licensing.intervalzero.com/Licenseform.asp?. The web page will appear as shown in Figure 3-44. Input the PAC # (Purchase Authentication Code number – you can find this on a sticker on the CNC CD case) in the “PAC Number” text box in the web page. Input the Machine ID number for your computer (which has been provided by the IntervalZero RTX installation procedure and is shown in the Manual Registration window in the previous figure), in the “Machine ID” text box in the web page. Input your e-mail address in the “Email Address” text box in the web page.

NOTE: If you need a replacement (new) RTX license key because you are reinstalling IntervalZero RTX on a different computer from where it was previously installed, and reusing the PAC number, please see Section 3.6.4: Getting A Replacement RTX License Key. You will be unable to continue with your installation until you have contacted IntervalZero and received your replacement RTX license key from them.

Click on the Terms & Conditions link, to view the IntervalZero RTX license agreement, as shown in Figure 3-45. [NOTE: You cannot skip this step. If you click on “GET LICENSE!” without clicking the Terms & Conditions link, you will the message shown in Figure 3-51.]

You should read the license agreement, and close this web page. You will be taken back to the previous web page shown in Figure 3-49. Check the “I agree with the Terms & Conditions…” check box to accept the terms of the agreement.

Click on the “GET LICENSE!” button, and an RTX license key number will be displayed on the screen (as shown in Figure 3-50), and will also be e-mailed to you at the e-mail address you have provided. Write this number down, and take it back to the computer on which you are installing your CNC product.

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! CAUTION

It is VERY important that you retain this RTX license key, as well as your PAC number, in a safe and accessible place.

If you change the partition of your hard drive, reformat your hard drive, reinstall your operating system, or move your CNC product to another computer, you will need a replacement RTX license key (without which IntervalZero RTX will no longer operate). To get a replacement RTX license key, you will need your PAC number AND your previous RTX license key. Otherwise, you will have to contact IntervalZero, Inc. directly to get a replacement license key.

We recommend that you report your RTX license key number (and PAC#) to Soft Servo Systems at [email protected]. Soft Servo Systems maintains a database of RTX license keys for the PAC numbers we distribute, for your convenience in the event that you lose your license key number.

15) After you obtain your RTX license key, click the “Next” button in the Registration window to continue, and you will see the RTX License Key window appear, as shown in the following window:

Figure 3-54: RTX License Key Window (2 of 2)

16) If you have obtained your license key automatically, using Internet access on the computer on which you are installing a ServoWorks CNC product, you should paste the license key number from the web page to the RTX License Key Window. If you had to go to a different computer or phone IntervalZero to obtain the license key, you’ll need to type in your RTX license key number. Click the “Next” button to continue,

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and you will see the IntervalZero RTX Installation dialog appear, as shown in the following figure, until the IntervalZero RTX installation has been completed.

Figure 3-55: IntervalZero RTX Installation Dialog

17) The following figure shows the Confirm Installation window showing where the S-100T software will be installed. Click the “Next” button, and the ServoWorks CNC installation will start automatically.

Figure 3-56: Confirm Installation Window

18) The Installing S-100T (or similar) window will appear and display the installation progress, as shown in the following figure.

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Figure 3-57: Installing Window

19) When the installation has completed, the following Installation Complete window will appear. You will see the “Close” button if there are no further ServoWorks CNC software features to be installed. Click “Close” and continue to Section 3.7.4 Installing LadderWorks Console and the DAO Package. If you installed IntervalZero RTX2011 Service Pack 5, you will see the “Next” button in the window; click the button to install IntervalZero RTX2011 Service Pack 1 Update 5.

Figure 3-58: Installation Complete Window

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20) The Preparing IntervalZero RTX 2011 with Service Pack 1 Update 5 dialog will automatically appear while the installation package is decompressing. After the decompression has been completed, you will see the Welcome Window as shown in Figure 3-60. Click the “Next” button to continue the installation.

Figure 3-59: IntervalZero RTX 2011 with Service Pack 1 Update 1 Preparing Dialog

Figure 3-60: Welcome to RTX 2011 with Service Pack 1 Update 5 Window

21) A Ready to Install the Program Window will appear as shown in the following figure. Click the “Install” button to start the installation.

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Figure 3-61: Ready to Install the Program Window

22) The IntervalZero RTX2011 with Service Pack 1 Update 5 installation will start and the following figure will appear:

Figure 3-62: Installing IntervalZero RTX 2011 with Service Pack 1 Update 5 Window

23) When the installation has completed, the Installation Completed Window will appear, as shown in the following figure. Click the “Finish” button.

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Figure 3-63: IntervalZero RTX 2011 with Service Pack 1 Update 5 Installation Completed Window

24) You will be prompted to restart the computer for the configuration changes. You must restart the computer to complete the installation. We recommend you to choose “Yes” to restart at this point.

3.7.4 Installing LadderWorks Console and the DAO Package

1) In the “Welcome” window (Figure 3-18), click on the “LadderWorks” button – you will see the following dialog box will appear:

Figure 3-64: LadderWorks Install Dialog Box

2) You must install the DAO package for LadderWorks PLC. Click the “OK” button to start the installation, and the following dialog box will appear:

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Figure 3-65: Setup Dialog Box

3) When the InstallShield Wizard has been set up (which happens automatically), the following window will appear:

Figure 3-66: Welcome to the DAO Setup Window

4) Click the “Next” button, and the following window will appear:

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Figure 3-67: Select Components Window (1 of 2)

5) Click the “Next” button without changing any settings, and the following window will appear:

Figure 3-68: Select Components Window (2 of 2)

6) Click the “Next” button without changing any settings, and the DAO software will automatically start installing. [NOTE: In some instances, the DAO installation may seem to hang up indefinitely. Should this happen, press any key or move your mouse to continue.] The following dialog box will be displayed to show the progress of DAO installation:

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Figure 3-69: Installation Progress Dialog Box

7) When the DAO software has been successfully installed, the following dialog box will appear:

Figure 3-70: Information Dialog Box

8) Click the “OK” button to finish the LadderWorks PLC and DAO package installation.

3.8 Finishing Your Software Installation

Click the “Exit” button in the “Welcome to Installation” window (Figure 3-18) to close the window.

In order to finish your software installation, see the LadderWorks PLC User's Manual for setting up your PLC environment, including creating and compiling a sequence program for your machine tool.

3.9 Preventing the RtxServer Screen from Popping Up

IntervalZero RTX (the real-time extension of the Windows operating system) includes a service called RtxServer. This service displays or logs messages from all RTX applications and RTDLLs, and is available while RTX services are running (i.e. when ServoWorks CNC products are running). The default setting of this RtxServer is to run in GUI mode, causing an RtxServer window to pop up and display messages, including the state of the service and error messages.

ServoWorks CNC products will provide any messages or error messages that you should require, so you won’t need to rely on this RtxServer for information. It has been our experience that customers are disconcerted and annoyed when this window pops up unexpectedly, and we recommend that you change this setting on the RtxServer to prevent this window from appearing, with the following steps:

1) From the Windows “Start” menu, go to “All Programs”  “IntervalZero”  “RTX”  “RTX Properties,” as shown:

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Figure 3-71: Start Menu Selection for RTX Properties

2) You will see the “RTX Properties” window appear, as shown in the following figure:

Figure 3-72: RTX Properties Window – About Tab

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3) Click on the “Control” tab, as shown in the following window:

Figure 3-73: RTX Properties Window – Control Tab

4) Click on the “Start” button to manually start RTX. After a moment, the “Status” displayed in the above window will change from “Stopped” to “Running.” [If the “Start” button is disabled, then the RTX service must already be running. The RTX service is automatically invoked when a ServoWorks CNC program starts.]

5) Click the “OK” button to close the RTX Properties window.

6) From the Windows “Start” menu, go to “All Programs”  “IntervalZero”  “RTX”  “RTX Server Console” or “Programs”  “IntervalZero”  “RTX”  “RTX Server Console,” as shown:

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Figure 3-74: Start Menu Selection for RTX Properties

7) The RtxServer window will appear, as shown:

Figure 3-75: RtxServer Window

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8) Select “Options..” from the “View” pull-down menu, as shown:

Figure 3-76: RtxServer Window – Options Pull-Down Menu

9) An “Options” window will appear, as shown:

Figure 3-77: Options Window (1 of 2)

10) The default setting for “Display output to screen” is checked ( ). To prevent the RtxServer window from appearing unexpectedly, this setting should be unchecked (deselected). It should appear as follows:

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Figure 3-78: Options Window (2 of 2)

11) Select “Exit” from the “File” pull-down menu of the RtxServer window, as shown:

Figure 3-79: RtxServer Window – File Pull-Down Menu

The RtxServer window won’t pop up again.

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Chapter 4: Installing and Configuring the Network Card

4.1 Overview

The following steps will guide you through installing and configuring the network card for use with the EtherCAT network. Make sure the NIC (Network Interface Chip) you are planning to use with EtherCAT is supported by RTX. See http://softservo.com/data_sheets/EtherCAT_NIC.pdf for an up to date list of compatible NIC chips.

! CAUTION

If you haven’t installed IntervalZero RTX, you will not be able to complete this procedure.

4.2 Installing the Network Card for the EtherCAT Network

Refer to the documentation that came with your network card to install the appropriate device driver for the network card. You must have the driver installed and the network card working before proceeding to the following steps.

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4.3 Configuring the Device Driver for the Network Card Using the Real Time Device Installer Utility

4.4.1 Overview

Newer versions of ServoWorks CNC software come with a utility to facilitate the configuration of network card device drivers for use with the EtherCAT network. If your ServoWorks CNC software package includes this utility, you will be able to find it in the folder “Program Files\SoftServo\Tools\Real Time Device Installer.” There will also be a shortcut in the Windows “Start” menu; go to “Start”  “All Programs”  “SoftServo”  “Tools”  “Real Time Device Installer.”

If your ServoWorks CNC software includes the Real Time Device Installer utility, complete the following steps. If your ServoWorks CNC software does not include the Real Time Device Installer utility, follow the steps in Section 4.4 Configuring the Device Driver for the Network Card Manually.

Before proceeding to the next step, it is essential that you stop RTX from the RTX Properties screen.

1) From the Windows “Start” menu, go to “All Programs”  “IntervalZero”  “RTX”  “RTX Properties,” as shown:

Figure 4-1: Windows 7 Start Menu Selection for RTX Properties

2) You will see the “RTX Properties” window appear, as shown in the following figure:

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Figure 4-2: RTX Properties Window – About Tab

3) Click on the “Control” tab, as shown in the following window:

Figure 4-3: RTX Properties Window – Control Tab

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4) Click on the “Stop” button to manually stop RTX. After a moment, the “Status” displayed in the above window will change from “Running” to “Stopped.” [If the “Stop” button is disabled, then the RTX service must already be stopped.]

5) Click the “OK” button to close the RTX Properties window.

4.3.2 Installing an RTX Device Driver Using the Real Time Device Installer Utility

Complete the following steps to convert the Windows device driver for your network card to an RTX device driver. INTERVALZERO RTX MUST HAVE BEEN INSTALLED ALREADY.

1) Start the Real Time Device Installer utility. Open the Windows “Start” menu, go to  “SoftServo”  “Tools” and click on “Real Time Device Installer.”

2) When you first start the Real Time Device Installer utility, you will see the Install New Real Time Device screen, shown below:

Figure 4-4: Real Time Device Installer - Install New Real Time Device Screen (1 of 3)

3) This screen will allow you to install a new real time device from among the valid hardware devices found on your computer. You can select your network card using the pull-down menu at the center of the screen.

If your network card is not listed, your network card is either not found on your computer or not supported by this utility. In this case, your network card cannot be installed to real time space using this utility. If you are certain that your network card is supported by the ServoWorks CNC software (see Section 1.2 Overview of the EtherCAT Interface System for a discussion about supported network cards), you should manually install the network card following the steps in Section 4.4 Configuring the Device Driver for the Network Card Manually.

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If no valid real time device is found on your computer, you will see the following screen:

Figure 4-5: Time Device Installer - Install New Real Time Device Screen (2 of 3)

4) Once you select your network card from the pull-down menu, click “Install” to install the RTX device driver for your network card. You will see the following screen, with a progress bar that fills up as the network card is installed. Note that it may take several minutes to install the RTX device driver for your network card.

Figure 4-6: Real Time Device Installer - Installing New Real Time Device Screen

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5) Once the installation finishes, you will see the following screen.

Figure 4-7: Real Time Device Installer - Device Successfully Installed Screen

6) If you see the screen in the above figure, you have successfully installed the RTX device driver for your network card.

If a problem is encountered while installing your device to real time space, you may see a screen that looks like the following:

Figure 4-8: Real Time Device Installer - A Problem Was Encountered While Installing Screen

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If you see a screen like this, read the error message to understand the problem and follow any directions that may help you resolve the problem. If the problem persists, follow the steps in Section 4.4 Configuring the Device Driver for the Network Card Manually to manually install the device.

Note that in certain cases, the device may be installed to real time space but the appropriate configuration files could not be updated. In such cases, you should update these configuration files following the directions displayed in the error message. You can also uninstall the device following the steps in Section 4.3.4: Removing an RTX Device Driver Using the Real Time Device Installer Utility and then attempt to install the device again

4.3.3 Checking the Status of Installed RTX Device Drivers Using the Real Time Device Installer Utility

The following steps guide you through checking the status of installed RTX device drivers using the Real Time Device Installer utility.

1) Start the Real Time Device Installer utility. Open the Windows “Start” menu, go to  “SoftServo”  “Tools” and click on “Real Time Device Installer.”

2) If you have at least one real time device installed, the main screen, shown in the following figure, will be displayed when you start the utility.

Figure 4-9: Real Time Device Installer - Main Screen (1 of 2)

If you don’t have any real time devices installed, you will see the following screen when you start the utility. If you see this screen, you can click on the “Cancel” button to open the main screen.

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Figure 4-10: Real Time Device Installer - Install New Real Time Device Screen (3 of 3)

3) From the main screen, click on the “View Status” button to open the View Status screen, shown in the following figure:

Figure 4-11: Real Time Device Installer - View Status Screen (1 of 2)

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4) The list labeled “Installed RTX Devices” shows the real time devices that are currently installed on your computer. If your network card is in this list, you have successfully installed the RTX device driver for your network card.

5) The first lamp indicates whether there is a device that can operate an EtherCAT network in real time installed on your computer. If this lamp is red, none of the installed real time devices (if any) are valid devices for operating an EtherCAT network.

[Note: The list of network cards that are supported by ServoWorks CNC for operating an EtherCAT network is constantly growing. Network cards made available for operating an EtherCAT network after the compilation date of this utility will be erroneously reported as invalid devices by this utility.]

6) The second lamp indicates whether all your real time devices can handle interrupts in real time. To operate in real time, real time devices require either MSI-capability or an exclusive IRQ not shared by any other device on your computer (including Windows space devices).

! CAUTION

If the network card has not been assigned its own (exclusive) IRQ and is not MSI- capable, you will need to disable all the other devices that are using the same IRQ or assign another, unoccupied IRQ to the network card (this may involve installing the network card in another hardware location).

To disable other devices that are using the same IRQ, go to the Windows “Start” menu, choose “Settings”  “Control Panel”  “System”  “Hardware”  “Device Manager,” and use the “Device Manager” window that appears. You can right click on other devices using the same IRQ, and select “Disable” if you don’t need that device.

7) The third lamp indicates whether RTX TCP/IP support is enabled or disabled. For the EtherCAT platform, RTX TCP/IP support must be enabled for operation. RTX TCP/IP support is automatically turned on or off whenever a real time device is intalled or removed using this utility. It can also be manually toggled using the RTX Properties utility that is installed with RTX.

8) If all three status lamps are green, your network card is installed and ready to operate an EtherCAT network in real time. The following figure shows the View Status when none of the lamps are green.

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Figure 4-12: Time Device Installer - View Status Screen (2 of 2)

4.3.4 Removing an RTX Device Driver Using the Real Time Device Installer Utility

The following steps guide you through uninstalling the RTX device driver for your network card and returning the network card to Windows space using the Real Time Device Installer utility.

1) Start the Real Time Device Installer utility. Open the Windows “Start” menu, go to  “SoftServo”  “Tools” and click on “Real Time Device Installer.”

2) If you have at least one real time device installed, the main screen, shown in the following figure, will be displayed when you start the utility.

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Figure 4-13: Real Time Device Installer - Main Screen (2 of 2)

3) Click on the “Remove Device” screen to open the Remove device screen, shown in the following figure:

Figure 4-14: Real Time Device Installer - Remove Real Time Device Screen

4) Select the network card to remove using the pull-down menu at the center of the screen. If your network card is not listed, your network card is either not installed in real time space or is not supported by this utility. If your network card is installed in real time space but is not supported by this utility, you should manually uninstall the device using the RTX Properties utility and the Windows Device Manager.

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After you have selected the network card to remove from the pull-down menu, click on the “Remove” button. The utility will uninstall your network card and update any associated configuration files. You will see the following screen, with a progress bar that fills up as the device is installed:

Figure 4-15: Real Time Device Installer - Removing Real Time Device Screen

5) Once the network card is removed, you will see the following screen:

Figure 4-16: Real Time Device Installer - Device Successfully Removed Screen

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6) Click on “Finish” to complete the removal of the network card. You may see a “Found New Hardware” popup in your Windows taskbar, as shown below. You may also see a “Found New Hardware Wizard” window appear, also shown below.

Figure 4-17: Found New Hardware Popup and Wizard

7) If the Windows driver for your network card does not automatically install, follow the directions in the “Found New Hardware Wizard” to install the Windows driver. Your network card will now operate normally in Windows.

8) If a problem was encountered while removing your network card from real time space, you may see a screen that looks like the following:

Figure 4-18: Real Time Device Installer - Problem Was Encountered While Removing the Device Screen

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If you see a screen like this, read the error message to understand the problem and follow any directions that may help you resolve the problem. If the problem persists, you may need to manually remove the network card from real time space using the RTX Properties utility and the Windows Device Manager.

Note that in certain cases, the network card may be removed from real time space but the appropriate configuration files could not be updated. In such cases, you should update these configuration files manually following the directions displayed in the error message.

4.4 Configuring the Device Driver for the Network Card Manually

4.4.1 Overview

You will be configuring the network card device driver, which will show up under “Network adapters” in the Windows Device Manager. The procedures that follow will guide you in properly configuring this device for use with the EtherCAT network, using Intel Ethernet Server Adapter I210-T1 network card and the Intel Gigabit CT Desktop Adapter network card and as an example.

Before proceeding to the next step, it is essential that you stop RTX from the RTX Properties screen.

1) From the Windows “Start” menu, go to “All Programs”  “IntervalZero”  “RTX”  “RTX Properties,” as shown:

Figure 4-19: Windows 7 Start Menu Selection for RTX Properties

2) You will see the “RTX Properties” window appear, as shown in the following figure:

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Figure 4-20: RTX Properties Window – About Tab

3) Click on the “Control” tab, as shown in the following window:

Figure 4-21: RTX Properties Window – Control Tab

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4) Click on the “Stop” button to manually stop RTX. After a moment, the “Status” displayed in the above window will change from “Running” to “Stopped.” [If the “Stop” button is disabled, then the RTX service must already be stopped.]

5) Click the “OK” button to close the RTX Properties window.

4.4.2 Converting the Windows Device Driver to an RTX Device Driver

! CAUTION

You only need to follow the steps in this section if your ServoWorks CNC software does not include the Real Time Device Installer utility, or if the Real Time Device Installer utility was unable to properly install your network card.

You need to convert the Windows device driver for your network card to an RTX device driver by completing the following steps. INTERVALZERO RTX MUST HAVE BEEN INSTALLED ALREADY.

1) Open the Windows Device Manager. The Windows Device Manager can be opened by clicking on the “Device Manager” link in "System" window from "System and Security", or for Windows XP, in the “Hardware” tab of the “System Properties” window, which can be accessed by clicking on the “System” icon in the Windows Control Panel. The following figure shows the “System Properties” window.

Figure 4-22: System Properties Window 7

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2) On the Windows Device Manager, select “View -> Resources by connection.” If the device is not PCI Express or MSI capable, confirm that the NIC chip has an exclusive IRQ number. The IRQ number can be any number, but it must not be shared with any other device. If you do not have an exclusive IRQ number for your NIC chip, you must disable the other devices sharing the IRQ number or assign another, unoccupied IRQ number to your NIC chip (this may involve installing the NIC card in another hardware location). However, if the device is MSI capable, RTX will assign the device to MSI and you do not need to make sure it has an exclusive IRQ number.

The figure 4-23 below shows that the MSI capable Intel Gigabit CT Desktop Adapter has the nonexclusive IRQ 18. Figure 4-24 below shows MSI capable (MSI-X) Intel Ethernet Server Adapter I210-T1. Note the "-" sign before the IRQ.

PCI Express is always MSI Capable (MSI-X), which can be identified with the "-" sign before the IRQ number. Because PCI Express Bus is 100% MSI capable, you do not have to check for a dedicated IRQ. Please note that PCI has both MSI capable version and a MSI non-compatible version.

While in Windows 7 you can check whether the device is MSI capable or non-compatible, in Windows XP you must move the hardware into RTX to check whether it is MSI capable or not. You must go through with the following process and check for a dedicated IRQ.

Figure 4-23: Win XP Device Manager Window

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Figure 4-24: Win 7 Device Manager Window

3) For Windows 7, right click on the desired device and click on "Properties". Then click on the "Details" tab. Under "Property" dropdown menu, choose Hardware Ids. Note the number after "DEV_". That is your device ID.

Figure 4-25: Property -Hardware Ids

4) Open the template files folder, “RTX\drivers config templates,” inside the installer CD or the installer folder and find the appropriate template file for your NIC driver. See

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http://softservo.com/data_sheets/EtherCAT_NIC.pdf to find which template files works with your NIC driver. Look for your device ID, and then note the Driver ID. The figure below shows the contents of the template files folder. Look for the file with the same Driver ID. That will be the file to use.

Figure 4-26: Driver Config Templates (1 of 2)

5) Open the folder “C:\Program Files\IntervalZero\RTX\bin”, shown in Figure 4-27. Copy and paste the appropriate template file from the “drivers config templates” folder into this “bin” folder. Delete the “RtxTcpIp.ini” file that already exists in the “bin” folder, and then rename the template file you just copied to “RtxTcpIp.ini”.

Figure 4-27: Driver Config Templates (2 of 2)

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6) Open the “RtxTcpIp.ini” template file you just copied using a text editor. Look for the three items named “TimerPriority,” “InterruptPriority,” and “ReceivePriority.” Change the value of "TimerPriority" to 116, "InterruptPriority" to 119, and "ReceivePriority" as 118, as shown in the following figure.

Figure 4-28: RtxTcpIp.ini File

7) If your NIC device uses the “RtxTcpIp_E1000.ini” template file (this is the template file name before it was renamed to “RtxTcpIp.ini”), follow steps #6 to #10 in order to set the device location. If your NIC device uses any other template file, proceed directly to step #11.

8) Open the RTX Properties utility in “Start -> All Programs -> IntervalZero -> RTX.” Click on the “Hardware” tab then click the “Settings” button in the “Devices” group, as shown in the following figure.

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Figure 4-29: RTX Properties Window – Hardware Tab

9) Find your NIC device in the list under “Devices,” right click on the NIC device, and select “Properties,” as shown in the following figure.

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Figure 4-30: Pnp Device Settings Window

10) Look for three numbers next to “Location.” These numbers are the PCI bus number, the device number, and the function number. In the following figure, the NIC device has 2 for the PCI bus number, 0 for the device number, and 0 for the function number.

Figure 4-31: Windows PCI Device Properties Window

11) Open the “RtxTcpIp.ini” file in the folder “C:\Program Files\IntervalZero\RTX\bin” (this is the file you just copied). Add a new line under the “[rtnd0]” group. Then, in that line, type in “Location=” followed by the

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PCI bus number, the device number, and the function number you have found in the previous step, using semicolons as separators, as shown in the following figure.

Figure 4-32: RtxTcpIp.ini File for RTE1000 NIC Device

12) Save and close the “RtxTcpIp.ini” file.

13) Open the RTX Properties utility in “Start -> All Programs -> IntervalZero -> RTX.” Open the “TCP/IP” tab and check the box labeled “Enable RT-TCP/IP stack.” Then, click the “Apply” button, as shown below:

Figure 4-33: RTX Properties Window – TCP/IP Tab

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14) Open the “Hardware” tab and click on the “Settings” button in the “Devices” group (NOT the “Latency Causing Devices” group). The following figure shows the “Settings” button.

Figure 4-34: RTX Properties Window – Hardware Tab

15) Find the NIC device from the list in “Devices,” right click on the NIC device, and select “Add RTX INF Support,” as shown in the following figure.

Figure 4-35: PnP Device Settings Window

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16) Press the “Apply” button, and press “OK” at the following dialog:

Figure 4-36: RTX Properties Dialog

4.4.3 Updating the Windows Device Driver

Now you need to update the Windows Device Driver with the following steps:

1) Open the Windows Device Manager as shown in the following figure, right click on the NIC device, and select “Uninstall.”

Figure 4-37: Device Manager Window

2) Press “OK” to remove the device.

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Figure 4-38: Confirm Device Removal Dialog

3) Scan the computer for the NIC device by clicking on “Scan for hardware changes” under the “Action” menu, as shown in the following figure.

Figure 4-39: Device Manager Window

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4) For Windows XP, the "Found New Hardware Wizard will popup. Proceed to Step #10. For Windows 7, right click the device again and click "Update Driver Software..."

Figure 4-40: Update Driver Software

5) The Update Driver Software Window will show. Click "Let me pick from a list of device drivers on my computer"

Figure 4-41: Update Driver Software Screen (1 of 4)

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6) Select the desired device from the list. (In our case there our device is listed twice, choose either one) Click "Next".

Figure 4-42: Update Driver Software Screen (1 of 4)

7) This, or similar Windows Security screen may show upon clicking "Next". Click on the "Install this driver software anyway".

Figure 4-43: Windows Security Popup

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Figure 4-44: Update Driver Software Screen (1 of 4)

8) The selected device has been successfully updated.

Figure 4-45: Update Driver Software Screen (1 of 4)

9) The device now reads "Intel(R) Ethernet Server Adapter I210-T1 RTX Supported"

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Figure 4-46: Device Manager (of)

10) For the Windows XP, the "Found New Hardware Wizard" will show. On the Found New Hardware Wizard, select “No, not this time” and press “Next,” as shown in the following figure.

Figure 4-47: Found New Hardware Wizard (1 of 7)

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11) On the next screen, choose “Install from a list or specific location (Advanced)” and press “Next,” as shown in the following figure.

Figure 4-48: New Hardware Wizard (2 of 7)

12) Select “Don’t search. I will choose the driver to install” and press “Next,” as shown in the following figure.

Figure 4-49: New Hardware Wizard (3 of 7)

13) If your NIC device is not automatically recognized, the “Hardware Type” list appears, as shown in the following figure. If this “Hardware Type” list appears, select “Rtx Drivers,” then click “Next.” However, most NIC devices are automatically recognized as network cards and the “Hardware Type” list will not appear. If the “Hardware Type” list does not appear, go ahead to the next step.

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Figure 4-50: Found New Hardware Wizard (4 of 7)

14) The next screen shows the available drivers for the NIC device. Select the NIC device driver with “RTX Supported” at the end and press “Next,” as shown in the following figure.

Figure 4-51: Found New Hardware Wizard (5 of 7)

15) The NIC device driver with RTX support will automatically be installed, as shown in the following figure.

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Figure 4-52: Found New Hardware Wizard (6 of 7)

16) When the software has finished installing, you will see the window shown in the following figure. Click the “Finish” button.

Figure 4-53: Found New Hardware Wizard (7 of 7)

4.4.4 Verifying That the Device Has Been Correctly Installed as RTX Supported and Has Been Assigned an Exclusive IRQ or Has Been Detected as MSI Capable

1) Open t he Windows Device Manager again. To check whether the device has been correctly installed as RTX supported, you can either 1) check that the NIC device you chose to use for the EtherCAT network is now under “Rtx Drivers” instead of “Network adapters”, or, while the device is still under "Network Adapters", the device now reads "RTX Supported". The following figures show the Intel(R) Ethernet Server Adapter I210-T1 now has the phrase "RTX Supported".

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Figure 4-54: Device Manager (1 of 2)

2) If the NIC device requires an exclusive IRQ (which it will if it is not MSI-capable), you will confirm that the NIC device has an exclusive IRQ by choosing “View -> Resources” and opening the “Interrupt Request (IRQ)” tree. You should see the NIC device with “RTX Supported” in its name with an exclusive IRQ assigned. The following figure shows the Realtek RTL 8139 card (a different NIC card from the previous examples) exclusively with IRQ 7.

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Figure 4-55: Manager (2 of 2)

! CAUTION

If the network card has not been assigned its own (exclusive) IRQ and is not MSI- capable, you will need to disable all the other devices that are using the same IRQ or assign another, unoccupied IRQ to the network card (this may involve installing the network card in another hardware location).

To disable other devices that are using the same IRQ, go to the Windows “Start” menu, choose “Settings”  “Control Panel”  “System”  “Hardware”  “Device Manager,” and use the “Device Manager” window that appears. You can right click on other devices using the same IRQ, and select “Disable” if you don’t need that device.

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! CAUTION

YOU HAVE JUST VERIFIED AN EXCLUSIVE IRQ FOR YOUR NETWORK CARD. THIS EXCLUSIVE IRQ NEEDS TO BE MAINTAINED.

IF IN THE FUTURE YOU INSTALL ANY ADDITIONAL DEVICES IN YOUR PC, YOU WILL NEED TO RE-CHECK TO MAKE SURE YOUR NETWORK CARD IS STILL ASSIGNED TO AN EXCLUSIVE IRQ.

3) Open the RTX Properties utility in “Start -> All Programs -> IntervalZero -> RTX” and click on the “Settings” button in the “Hardware” tab and “Devices” group, as shown in the following figure.

Figure 4-56: RTX Properties Window – Hardware Tab

4) In the window that appears, confirm that the NIC device is under RTX (NOT Windows) as shown below:

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Figure 4-57: Pnp Device Settings

5) Double click on the NIC device to open its Properties window. Confirm that there are no error messages in the “Status” field. If the device is detected MSI and MSI-X capable, you will be able to confirm that the device is assigned to MSI. The following figure shows the device without any errors and properly detected as MSI.

Figure 4-58: RTX PCI Device Properties

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4.5 Starting RTX Automatically When System Boots

4.5.1 Setting RTX Subsystem Startup

It is recommended that RTX is started and shared memory is opened before the ServoWorks CNC application starts. Setting the RTX Subsystem Startup to “Automatic” allows RTX to open shared memory when the system boots, preventing errors from failure to open shared memory.

Follow the steps below to set RTX Subsystem Startup:

1) Open “RTX Properties” and click on the “System” tab, as shown in the following figure.

2) In “Startup Type” group, select “Automatic (System Startup)” from the list.

3) Click “Apply” to apply the change of settings.

Figure 4-59: RTX Subsystem startup Settings

4.6 Preventing CPU Idle State

4.6.1 Settings for Preventing Intel® SpeedStep®

The idle state of a CPU with Intel® SpeedStep® can affect the real time performance of the system. Following the procedure below to avoid the idle state of the CPU is strongly recommended for optimal system performance:

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1) Open “RTX Properties” and click on the “Hardware” tab, as shown in the following figure.

2) Confirm that the two checkboxes under SpeedStep® are checked, as shown below.

3) Click “Apply” to apply the change in settings.

Figure 4-60: SpeedStep® settings

! CAUTION

Prevent Windows idle state prevents the Windows idle thread from running by running an RTSS idle thread instead. Intel® SpeedStep® modifications occur after the Windows idle thread has run for some period of time, so by disabling the Windows idle thread, Intel SpeedStep technology is disabled as well.

Preventing Windows idle state may have the side effect of the Windows task manager constantly showing 100% CPU usage while RTX is running. This should not be a concern - as the RTSS idle thread runs with the lowest possible priority, the responsiveness of Windows and any running Windows applications is unaffected.

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Chapter 5: ServoWorks CNC System Integration and Initialization

5.1 Overview

After the ServoWorks CNC software and the network card are installed, you still need to finish the following steps before running the ServoWorks CNC system:

1) Physically integrate the ServoWorks CNC system with the EtherCAT (CoE) servo drives and with any optional I/O modules in the EtherCAT servo network.

2) Configure the ServoWorks CNC software.

3) Set the ServoWorks CNC parameters.

NOTE: Refer also to the documentation for the EtherCAT (CoE) servo drives as well as this manual.

5.2 Integrating ServoWorks CNC with the EtherCAT Interface System

The ServoWorks CNC system needs to be integrated with the EtherCAT (CoE) servo drives. An example integration diagram is shown in Figure 5-1.

When connecting the EtherCAT (CoE) servo drives to the Ethernet port to create an EtherCAT network, please note:

1) Use commercially available Ethernet LAN cables (shielded twisted pair cable) that are TIA/EIA-568B CAT5e compliant or more.

2) The EtherCAT (CoE) servo network should be connected in a single, daisy-chained line (as shown in Figure 5-1):

3) We recommend that any I/O devices are connected to the end of the network, farthest away from the host PC.

4) Refer also to the documentation provided with your EtherCAT (CoE) servo drives.

Ethernet port RJ45 Ethernet cable

EtherCAT (CoE) servo drives and Industrial panel PC I/O devices or regular PC – no adapter board required

Servo motors

Figure 5-1: EtherCAT Interface System Integration Example Diagram

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5.3 Configuring the EtherCAT System Information File for Your ServoWorks CNC System (PE version)

This applies to CNC software that utilizes ServoWorks_PE.ini instead of ServoWorks_ETHERCAT.ini. As part of your software installation procedure, a system information file (“ServoWorks_PE.ini”) was automatically copied to your PC’s “C:\” folder (unless a C:\ServoWorks_PE.ini file already existed, in which case that file would NOT be overwritten).

Also, please note that PlatformEngine_EtherCAT.rtss and EtherCATFilter.rtdll are downloaded in the engine folder.

Before you start your ServoWorks CNC software, this EtherCAT system information file needs to be properly configured as follows:

1) Run Windows Explorer (or “My Computer”), and open the “C:\” folder.

2) Find the “ServoWorks_PE.ini” file, and right-click on it.

3) From the drop-down menu, choose “Open.” The “ServoWorks_PE.ini” file will be opened in “Notepad.” Example content follows:

[Station 0] // X AxisMap=1 //ControlMode=1

[Station 1] // Z AxisMap=3 //ControlMode=1

[Station 2] // C AxisMap=4 //ControlMode=1

// Station No: 0 ~ 31 [the ADDRESS setting on the EtherCAT servo drive] // AxisMap: 1 ~ 32 [the maximum number of axes depends on the // CNC software package]

4) You must modify this file so that basic system information and every single node on the EtherCAT network is defined in this system configuration file. Characters following the “//” symbols in the same line are deemed as comments, and will not be processed as node definitions.

Any re-networking should be done with the power off, and the system must be rebooted and reinitialized in order to recognize the changes.

! CAUTION

If the actual number of servo drives doesn’t match the number of stations listed in the ServoWorks_PE.ini file, IT WILL CAUSE AN ERROR.

The configuration parameters are described in the following table:

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Default Parameter Include: Valid Values Notes Value [Station 0] through  Station numbers are assigned automatically and For each [Station 31] – the consecutively, starting from the device closest to the PC module in maximum number in the EtherCAT network. For example, if you have Station Number the of stations none three devices in the EtherCAT network, the device EtherCAT depends on the connected directly to the PC will be Station 0, the network CNC software device in the middle will be Station 1, and the device package that is farthest away from the PC will be Station 2. 1 – 32  Specifies the axis number of each EtherCAT station. For each [the maximum These numbers correspond to the axis numbers in the module in number of axes CNC software. AxisMap the depends on the  AxisMap includes the spindle axis. Therefore, axis 4 in EtherCAT CNC software ServoWorks S-120M and S-140M must be set to network package] AxisMap=4. For each module  Specifies that the axis is controlled by velocity control, which ControlMode 1 as is the case, for example, in inverter spindles. The uses only valid value for this parameter is 1. velocity control

Table 5-1: Parameters in the EtherCAT System Configuration File (1 of 2)

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5.4 Configuring the EtherCAT Network Information File for Your CNC System As part of your software installation procedure, a Network Information file (“ec_network.def”) was automatically copied to your PC’s “C:\” folder (unless a C:\ec_network.def file already existed, in which case that file would NOT be overwritten).

Before you start your CNC software, this EtherCAT Network Information file needs to be properly configured as follows:

1) Run Windows Explorer (or “My Computer”), and open the “C:\” folder.

2) Find the “ec_network.def” file, and right-click on it.

3) From the drop-down menu, choose “Edit.” The “ec_network.def” file will be opened in “Notepad.” Example content follows:

NetworkDefinitionFileVersion,2 DCMode=1

Figure 5-2: Example ec_network.def File

4) The default “ec_network.def” file is suitable for many systems but you may modify this file to change the Network Information from the default settings.

The Network Information file contains parameters that apply to the entire network and definitions that apply to specific devices in the network.

The first line of the Network Information file must be “NetworkDefinitionFileVersion,2” without the quotation marks.

Parameters that apply to the entire network may be defined following the first line of the Network Information file (“NetworkDefinitionFileVersion,2”). The following table summarizes the available parameters. These parameters are not case sensitive.

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Default Parameter Valid Values Notes Value  If DCMode (distributed clock) is set to 1, the first DC compatible device in the EtherCAT network will generate the master clock in place of the PC network card. Other DC compatible devices will generate their own clocks using the master clock as a reference. This reduces the clock jitter and may improve the motion profile. DCMode 0, 1 0 Note that this also applies a slight load on the PC and network card, which must adhere to an external master clock. This should typically be set to 1 unless no device in your EtherCAT network is capable of DC functionality (and hence no device is capable of generating the master clock).  If UseSlaveDef is set to 1, the slave device definitions in the Network Information file will be compared against the slave UseSlaveDef 0, 1 0 devices that are detected in the network. If the EtherCAT network does not match the network described by the Network Information file, communication is stopped.  If AliasCheck is set to 1, devices in the EtherCAT network will be checked against the VendorID, ProductCode, and Alias values in the Network Information file. If AliasCheck is set to 0, devices in AliasCheck 0, 1 0 the EtherCAT network will be checked against the VendorID and ProductCode values only. This parameter is applicable only when UseSlaveDef is set to 1.

Table 5-2: Parameters in the EtherCAT Network Information File (1 of 2)

After defining parameters that apply to the entire network, the specific devices in the network may be defined. The devices should be defined in the order they are connected to the PC running the EtherCAT master, starting with the device closest to the PC in the network.

The definition of each device starts with the parameter “VendorID”. Any number of additional parameters may be specified for that device in the subsequent lines. The definition for the next device begins when another “VendorID” parameter is stated.

If the UseSlaveDef parameter is set to 1, the device definitions in the Network Information file are read when communication with the EtherCAT network is initiated. If the devices in the EtherCAT network do not match the devices listed in the Network Information file, communication is stopped. This ensures that CNC software runs on only the intended EtherCAT network.

There is one exception to the requirement that the devices in the EtherCAT network match the devices listed in the Network Information file. If a device is listed in the Network Information file, but does not exist in the actual EtherCAT network, communication is not stopped. This means that devices can be removed from the EtherCAT network without modifying the Network Information file.

In addition, if devices are removed from the EtherCAT network without modifying the Network Information file, any I/O addresses from the removed device are not reallocated. For example, consider an EtherCAT network with three devices, each with 2 bytes of inputs and 2 bytes of outputs. The I/O addresses allocated to each device are as follows:

Device A – Input addresses: 0.0-1.7; Output addresses: 0.0-1.7 Device B – Input addresses: 2.0-3.7; Output addresses: 2.0-3.7 Device C – Input addresses: 4.0-5.7; Output addresses: 4.0-5.7

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Assume that a Network Information file that describes this network has been created. If Device B is then removed from the EtherCAT network (so that Device A connects directly to Device C), then I/O addresses will be allocated as follows:

Device A – Input addresses: 0.0-1.7; Output addresses: 0.0-1.7 Device C – Input addresses: 4.0-5.7; Output addresses: 4.0-5.7

Note that if the UseSlaveDef parameter is set to 0, I/O addresses would have been reallocated, and Device C would occupy input addresses 2.0-3.7 and output addresses 2.0-3.7.

The following table summarizes the available parameters that define each device in the network. These parameters are not case sensitive.

Default Parameter Valid Values Notes Value  This value is the Vendor ID number to check against the EtherCAT device’s Vendor ID. 4-byte VendorID none  This parameter designates the beginning of a new device hexadecimal value definition. The first parameter specified for each device must be this parameter. 4-byte  This value is the Product Code to check against the EtherCAT ProductCode none hexadecimal value device’s Product Code.  This value is the Alias to check against the EtherCAT device’s 2-byte Alias, if the AliasCheck parameter is set to 1. Alias none hexadecimal value  The EtherCAT device’s Alias will not be checked if this parameter is not specified, even if the AliasCheck parameter is set to 1. in_size Decimal value none  The number of input I/O bytes this device possesses. out_size Decimal value none  The number of output I/O bytes this device possesses.

Table 5-3: Parameters in the EtherCAT Network Information File (2 of 2)

A sample EtherCAT Network Information file is shown below:

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NetworkDefinitionFileVersion,2 DCMode=1 AliasCheck = 0

VendorID = 0xffffffff ProductCode = 0x00001234 in_size = 2 out_size = 4 Alias = 0x0003

VendorID = 0xffffffff ProductCode = 0x00001234 in_size = 4

Figure 5-3: Example EtherCAT Network Information File

This Network Information file contains information for two devices, both with VendorID 0xffffffff and ProductCode 0x00001234. in_size and out_size are the number of I/O bytes allocated to each device. The Alias parameter specifies an alias value that differentiates multiple devices with the same VendorID and ProductCode.

5.4.1 Generating the EtherCAT Network Information File

The EtherCAT Network Information file can be generated using the EtherCAT Network Configurator utility. This utility will generate a Network Information file from the currently running EtherCAT network. For more information, see Chapter 7: EtherCAT Network Configurator.

It is also possible to manually create the Network Information file using a text editor.

5.5 Spindle Drives in the EtherCAT Interface System

For ServoWorks S-100M, S-120M and S-140M, if a servo spindle is included in the EtherCAT system, the spindle must be the fourth axis. Therefore, the AxisMap for the spindle axis should be 4. If the spindle is used as an inverter spindle, you must set “ControlMode=1” to specify that the drive and the motor is used so.

5.6 Setting the ServoWorks CNC Parameters for the EtherCAT Interface System

5.6.1 Parameters That Must Keep Their Default Value

You must keep the default value in the ServoWorks CNC application for the following parameters:

 Encoder polarity

 Servo drive velocity sensitivity

 Motor polarity

 Position loop gain

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 Position loop integral control enable

 Position loop integral time constant

 Position loop integral saturation

 Velocity feedforward enable

 Velocity feedforward percentage

Depending upon which ServoWorks CNC application you are using, the software may or may not prevent you from changing these parameters. You must keep the default value of these parameters, because the actual value is taken from the servo drive parameter settings, not the ServoWorks CNC application settings. If you change the default values in the ServoWorks CNC application, there will be a problem.

To set these and other servo drive parameter settings, refer to the documentation for your servo drives. Each servo drive manufacturer has their own selection of servo drive parameter settings and their own method for setting these parameters.

5.6.2 Setting the ServoWorks CNC Parameters – Overview

You can configure your ServoWorks CNC software parameter settings with ServoWorks MotionLite (Only S-100M Series and MC-Quad) or ServoWorks S-100T to customize your EtherCAT interface system. If you are using ServoWorks S-100T, go straight to Section 5.6.4: Setting the ServoWorks CNC Parameters Using ServoWorks S- 100T.

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5.6.3 Setting the ServoWorks CNC Parameters Using ServoWorks MotionLite (Only for S- 100M Series and MC-Quad)

The following steps will guide you in completing the ServoWorks CNC parameter initialization:

1) Start ServoWorks MotionLite by double-clicking on the ServoWorks MotionLite icon on your PC’s

desktop ( or similar). Alternatively, double-click the “MotionLite.exe” file from the following path:

“[System Drive]:\Program Files\SoftServo\MotionLite”

If the EtherCAT interface system has been properly integrated and configured, the ServoWorks MotionLite application should successfully load the real-time “ServoWorks CNC Engine” and the main window of ServoWorks MotionLite should appear as follows:

Figure 5-4: ServoWorks MotionLite Main Window

2) Set your module configuration settings (or accept the default “Module Configuration” settings), and then click the “OK” button.

3) In the main menu, click on “View,” and select “Parameters” from the pull-down menu, as shown in the following figure:

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Figure 5-5: ServoWorks MotionLite Main Window – View Pull-Down Menu

4) You will see the following “Parameters” window appear:

Figure 5-6: MotionLite Parameters Window – Servo Control Tab

5) In the first tab titled “Servo Control”, set the “Axis Type” parameter of the axes you are going to use from “Unused” to “Normal” (or other axis type). [NOTE: If you are using 5 axes, you will need to use the “Module Configuration” window to select the second 4-axis group to set the “Axis Type” for the fifth axis.]

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6) Please refer to the Reference Manual for ServoWorks CNC Parameters and Functions to complete the rest of the parameter configurations. All ServoWorks CNC manuals are available to be downloaded from our website:

http://www.softservo.com/pub/users/ User name: users Password: softservo

After the ServoWorks CNC parameter configuration is done, please refer to the ServoWorks MotionLite Operator’s Manual for tuning and testing your ServoWorks CNC system.

5.6.4 Setting the ServoWorks CNC Parameters Using ServoWorks S-100T

Refer to the ServoWorks S-100T Operator’s Manual for instructions on setting system parameters, and tuning and testing your ServoWorks S-100T system. Also, refer to the ServoWorks S-100T Parameters Manual for additional information on parameter configurations.

All ServoWorks CNC manuals are available to be downloaded from our website:

http://www.softservo.com/pub/users/ User name: users Password: softservo

5.7 Setting Your Servo Drive Parameters

You must set your EtherCAT servo drive parameters according to the instructions in the literature that accompanied your servo drives.

5.8 Synchronous Control with Slave Axes

For ServoWorks MC-Quad, ServoWorks S-120M and ServoWorks S-140M, you can include synchronous slave axes in your EtherCAT interface system.

The procedure for setting up synchronous control varies depending upon whether or not you are using absolute encoders. If you are not using absolute encoders, you simply need to set up your slave and master axes, and enable synchronous control – this procedure varies depending upon whether you are using ServoWorks MC-Quad, or ServoWorks S-120M or S-140M.

If you are using absolute encoders, in addition to setting up your slave and master axes, and enabling synchronous control, you must also perform a homing procedure for your synchronous axes – this procedure also varies depending upon whether you are using ServoWorks MC-Quad, ServoWorks S-120M or S-140M.

Use the following table to determine where to find the proper procedure for setting up your synchronous control:

ServoWorks Synchronous Control Synchronous Control Application with No Absolute Encoders with Absolute Encoders

Section 2.4.1: Synchronous Control Without Section 2.4.2: Synchronous Control and Homing ServoWorks Absolute Encoders in the ServoWorks MC-Quad With Absolute Encoders in the ServoWorks MC-Quad Operator’s Manual MC-Quad Operator’s Manual

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ServoWorks Section 2.4.1: Synchronous Control Without Section 2.4.2: Synchronous Control and Homing S-100M, Absolute Encoders in the Operator’s Manual for With Absolute Encoders in the Operator’s Manual S-120M and ServoWorks S-100M, S-120M and S-140M for ServoWorks S-100M, S-120M and S-140M S-140M

Table 5-4: References to Procedures for Synchronous Control

5.9 Absolute Encoders in the EtherCAT Interface System

Currently, ServoWorks S-100T does not accommodate absolute encoders, but ServoWorks MC-Quad, ServoWorks S-100M, ServoWorks S-120M and ServoWorks S-140M DO accommodate absolute encoders.

If you are using absolute encoders, you must refer to the documentation for the EtherCAT servo drives to properly wire your absolute encoders and initialize the amplifiers. Refer to the documentation included with your EtherCAT servo drives.

You must perform a one-time setup procedure to set the reference position for absolute encoders. This homing operation establishes the coordinate system for the machine tool, and establishes the machine home positions within that coordinate system. This homing process is required only once. The reference point is kept even when the system is powered off.

If you are not using synchronous slave axes, the procedure for homing absolute encoders varies depending upon whether you are using a home switch or not, and it varies depending upon whether you are using ServoWorks MC-Quad, or ServoWorks S-100M, S-120M or S-140M. Use the following table to determine where to find the proper procedure for homing your absolute encoders:

ServoWorks No Home Switch In System Using A Home Switch Application

Section 2.5.3: The Homing Procedure for a System Section 2.5.4: The Homing Procedure for a System ServoWorks with Absolute Encoders with No Home Switch in the with Absolute Encoders Using A Home Switch in the MC-Quad ServoWorks MC-Quad Operator’s Manual ServoWorks MC-Quad Operator’s Manual

ServoWorks Section 2.5.3: The Homing Procedure for a System Section 2.5.4: The Homing Procedure for a System S-100M, with Absolute Encoders with No Home Switch in the with Absolute Encoders Using A Home Switch in the S-120M and Operator’s Manual for ServoWorks S-100M, Operator’s Manual for ServoWorks S-100M, S-140M S-120M and S-140M S-120M and S-140M

Table 5-5: References to Procedures for Homing Absolute Encoders

5.10 Including an Inverter Spindle in an EtherCAT Interface System

Servo drives that control servo motors are able to be used in “Inverter” mode with velocity control and “Servo” mode with position control. To use a servo motor as an “Inverter” type spindle, it must be controlled by velocity control (See section 5.3 Configuring the EtherCAT System Information File for Your ServoWorks CNC System). It can also be used as a “Servo” type spindle with position control.

There are also two other options for inverter type spindles:

1) Use an inverter that supports a digital interface (such as an 8-bit or 16-bit parallel input interface); or

2) Use an analog inverter with an external DAC module, and use S codes to control that spindle with your PLC sequence program instead of with your ServoWorks CNC application, with some additional

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programming.

In this second case, the S code generates 32-bit F data to the LadderWorks PLC Engine, and the PLC sequence program must be programmed to generate output signals (8-bit, 16-bit or even 32-bit Y data) to the inverter to control the spindle. [NOTE: This programming is already included in the default PLC sequence programs that come with ServoWorks CNC products.]

You connect the spindle axis to the system as Axis #4, and you must set Axis #4 to axis type “Unused” (axis type “Inverter” won’t be available in a digital platform). S codes are mapped to PLC F addresses (F022 to F025, 32 bits of data), so you must map F codes to your digital output device, and wire that output device accordingly.

The following is an example of how this can be achieved:

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Chapter 5: ServoWorks CNC System Integration and Initialization

S code in part Example PLC sequence program

program code

RD F022.0 WRT Y0.0 F022 value

(representing RD F022.1

“100”) WRT Y0.1 Y data is becomes: output by RD F022.2 LadderWorks I/O MODULE

0 1 1 0 0 1 0 0 WRT Y0.2 PLC Engine

AutomaticPLC F data I/O mapping (transferredEngine) by CNC Read by LadderWorks Engine PLC Engine PLC Data sentfrom through the PC the PC adapterboard over the I/O network or servo Outputby LadderWorks as follows: (64 + 32 + 4) RD F022.3 WRT Y0.3 Y0.0 = 0 S100M F022.0 = 0 Y0.1 = 0 F022.1 = 0 RD F022.4 Y0.2 = 1 F022.2 = 1 WRT Y0.4 Y0.3 = 0 F022.3 = 0 Y0.4 = 0 F022.4 = 0 RD F022.5 Y0.5 = 1 F022.5 = 1 WRT Y0.5 Y0.6 = 1 F022.6 = 1 Y0.7 = 0 DIGITAL TO F022.7 = 0 RD F022.6 ANALOG WRT Y0.6 CONVERTER

RD F022.7 WRT Y0.7 Voltage

SPINDLE

Windows subspace RTSS (real-time subspace)

PC Hardware

Figure 5-7: Example of a General Inverter Spindle in an EtherCAT Interface System

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Chapter 6: I/O Connections

6.1 Overview

Each I/O device in an EtherCAT network requires a device initialization file (Init file) specific to that device. The ServoWorks CNC application installer automatically installs Init files for commonly used I/O devices. If the I/O device you are using is not supported by any of these Init files, you will see a message in the RTX Server Console that tells you that there is no init file for the I/O device. If this happens, please contact [email protected] to see if support is available for your I/O device.

There is no limitation as to where in the EtherCAT network you connect the I/O devices. However, we recommend that the I/O devices are connected to the end of the EtherCAT network.

PLC addresses for the I/O will start from X2.0 for inputs and Y2.0 for outputs, with I/O devices earlier in the EtherCAT network occupying earlier PLC addresses. Servo drives with I/O will also occupy PLC addresses.

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Chapter 7: Finishing Your Setup and Integration

7.1 Testing and Tuning the System

7.1.1 Overview

If you have been following this manual from start to finish, you have now set up all of your EtherCAT servo drives, and made all of the connections from the machine and servo drives to the EtherCAT interface system.

To finish your machine integration, you will need to use ServoWorks MotionLite or the ServoWorks S-100T to set your servo control, motor and drive parameters, and to test and tune the system. Refer to the ServoWorks MotionLite Operator’s Manual or the ServoWorks S-100T Operator’s Manual.

Certain parameters that configure the servo drives may be set directly on the servo amplifiers. Refer to the documentation provided by your servo drive vendor for details on what these parameters are and how to set them.

In order to achieve excellent control performance with your ServoWorks CNC product, you must understand the nature of how inaccuracy is caused in CNC in general (both in Soft Servo Systems’ CNC products and in other CNC products).

! CAUTION

Without a good understanding of the CNC parameters smoothing time and position loop gain, you will be unlikely to achieve the performance you desire.

You must properly tune your ServoWorks CNC system with respect to these two parameters to maximize the performance of your ServoWorks CNC product.

A finely tuned ServoWorks CNC system with finely tuned servo drives can achieve amazing performance for demanding applications, even without look-ahead contour control.

7.1.2 How Position Loop Gain and Smoothing Time Relate to Trajectory Accuracy (Without 3D-DLACC)

The following discussion applies to ordinary CNC without the 3D-DLACC function (three-dimensional dynamic look-ahead contour control). A discussion of tuning with 3D-DLACC follows in Section 7.1.5: Discussion of Tuning with 3D-DLACC.

In general, when you cut or mill something with CNC by executing G code, you'll see some inaccuracy. Some inaccuracy is inevitable. Your objective is to reduce the inaccuracy as much as possible by tuning the CNC parameters.

The two most important and dominant parameters affecting CNC trajectory accuracy are position loop gain (Kp) and smoothing time (Ts). [NOTE: This is true for CNC without 3D-DLACC.] Position loop gain is measured in terms of Hz, and the smoothing time is measured in milliseconds. [NOTE: You can set different smoothing time parameters for different modes: rapid mode, manual modes and cutting mode.]

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In fact, the trajectory error (inaccuracy) can be broken down into the trajectory error related to position loop gain and the trajectory error related to smoothing time. Thus, the trajectory error (E) is described with the following equation:

E = E1(Kp) + E2(Ts) where E1 is the “servo lag” or “servo error,” and E2 is the “smoothing error.”

E1 is inversely proportional to Kp, and E2 is proportional to Ts. [NOTE: E1 and E2 are also functions of the axis feedrate and the radius of the curves, but for the purpose of this discussion we will not address those aspects because those are not parameters, and are not related to this discussion of tuning.]

The effect of position loop gain (Kp) is obvious. Kp is like a spring. If you have a big servo error, Kp generates the force to move it back, just like a spring. The higher the value of position loop gain, the stiffer (or firmer) the position control, the faster the response and the smaller the servo lag, but the greater the likelihood of vibration or oscillation. In other words, if the Kp is large, the spring is stiff, and you can achieve good control. If Kp is too small, it is like a too soft, compliant spring, and good control cannot be achieved. [NOTE: The Kp value is the same for all the axes; if each axis had a different Kp, perfect interpolation could not be achieved.]

The effect of the smoothing time is also obvious. A long smoothing time results in the smoothing out of sharp trajectories, resulting in a round, smoothed-out trajectory, which is not good especially for milling:

Desired trajectory

Actual, rounded-out trajectory due to a smoothing time that is too long

Figure 7-1: Example: When Smoothing Time Is Too Long

In summary, the equation for trajectory inaccuracy tells us that trajectory accuracy will improve greatly if you increase the position loop gain and reduce the smoothing time. This is very simple and common sense, and generally understood in the control industries.

When you install a ServoWorks CNC product on a PC, there are default parameter values for all CNC parameters. The default value for position loop gain (Kp) is 20.0 Hz, and the default value for all smoothing times (for rapid, manual and cutting modes) is 20 ms. These default values are, of necessity, quite conservative, because these values need to apply to many different kinds of machines. [Setting aggressive values for Kp and Ts could create a safety issue for some machines.] But for most machine tools, these default parameters will not allow you to achieve satisfactory CNC performance: Kp is too small and Ts is too large, meaning that you would get huge trajectory errors with these default parameters.

All CNC and servo drive parameters are meant to be changed by the machine tool integrator, to meet the requirements of the particular machine tool to be controlled. Obviously, the meaning of every parameter should be understood before that parameter is changed – please refer to the Reference Manual for CNC Parameters and Functions and the ServoWorks S-100T Parameters Manual. It is possible to use the equations for trajectory error to calculate the optimal parameter values for Kp and Ts, based on the dynamics of the machine tool, the servo drives and the required accuracy. Or, you can tune these parameters based on trial and error. In many cases, all that is needed for tuning is to increase Kp significantly and decrease Ts significantly, although in the interests of safety this should be done in gradual, successive increases.

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To reiterate: you must properly tune your ServoWorks CNC system and optimize the CNC and servo drive parameters (especially position loop gain and smoothing time) to maximize the performance of your ServoWorks CNC product.

7.1.3 How Velocity Loop Gain Relates to Trajectory Accuracy

As explained in the previous section, position loop gain and smoothing time are the two most important parameters that must be correctly tuned to optimize trajectory accuracy. But, in addition to these parameters that must be set correctly in the software, there are servo drive parameters that must be set for each servo drive. The most important of these, as pertains to trajectory accuracy, is the velocity loop gain parameter (Kv).

General industrial control is based on the nesting of control loops. The most internal loop is the current loop, followed by the velocity loop and then the outer position loop (as shown in the following figure). The performance of the position feedback control loop depends on the performance of the velocity feedback control loop.

Position feedback loop

Velocity feedback loop

Current feedback loop

Position Command Output Input + + + Current MOTOR - - -

Current Feedback

Velocity Feedback

Actual Position Feedback

Figure 7-2: Embedded Feedback Loops: Current Loop, Velocity Loop and Position Loop

The underlying theory of this type of control architecture is that the tuning of an outer loop is based on the assumption that the inner loop is perfectly tuned. In other words, if you want to tune the position loop, you need to have tuned the velocity loop already. If you want to tune the velocity loop, you need to have tuned the current loop already.

In general, the current loop and the velocity loop are closed inside the servo drives. The current loop is based on the power electric dynamics inside the servo drive and the servo motor, and the performance of the current loop has nothing to do with the load and other mechanical things to be controlled. So, in general, the current loop of the servo drive is already optimized in the factory before being shipped. [NOTE: Do not change any of the current loop parameters for the servo drives.]

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The velocity loop is quite different from the current loop. The performance of the velocity loop depends upon the load on the motor. So, the factory-default velocity loop gain setting (Kv) needs to be adjusted for the actual load on the motor. You can determine the optimal value of this parameter by trial and error (connecting the servo drives to real machines, and running the machines to see if Kv is good or not). Or, you can calculate the optimal Kv based on simple equations, which are generally provided in the servo manuals which accompany the servo drives. The tuning of Kv can be a little difficult, so we highly recommend paying close attention to your servo manuals.

Here are a few suggestions related to tuning the velocity loop gain parameter. We suggest increasing the velocity loop gain (Kv, also known as velocity bandwidth) setting to as high as possible. Your velocity loop gain should be three to four times higher than the position loop gain (Kp). If the velocity loop gain is 200 Hz, then you can safely set Kp to 50 Hz. If the values for Kv and Kp are too close (i.e. if you set Kp to 50 Hz, and Kv to 40 or 50 Hz), your control system becomes very unstable and cannot do any meaningful performance.

In general, the process we recommend is as follows:

1) Determine the position loop gain based on the required trajectory accuracy.

2) Determine the required velocity loop gain, which should be three or four times higher than the position gain.

3) Tune the velocity bandwidth of the servos to achieve the velocity loop gain you require.

In summary, the tuning of Kv is very important. If Kv is not tuned correctly, then no matter how you tune the ServoWorks CNC parameters Kp and Ts, it is impossible to achieve good control performance.

7.1.4 Using Velocity Feedforward to Increase Trajectory Accuracy

There is another aspect to reducing the servo error (E1) that was discussed in Section 7.1.2: How Position Loop Gain and Smoothing Time Relate to Trajectory Accuracy (Without 3D-DLACC). As discussed in that section, E1 can be reduced easily by increasing Kp. But, obviously there is a limit on Kp – you cannot increase Kp to infinity, due to the limitation of the servo capacity. But, you can make E1 even smaller with the same Kp by making use of velocity feedforward control. The velocity feedforward control predicts the future velocity and adds some portion of that predicted future velocity to the velocity command from the position loop. By using this function, you can significantly reduce E1.

7.1.5 Discussion of Tuning With 3D-DLACC

DLACC (three-dimensional dynamic look-ahead contour control) is basically a combination of a look-ahead control and smoothing before interpolation. There are many complicated algorithms involved, but the bottom line is that the DLACC is designed to reduce the smoothing error, E2, that was discussed in Section 7.1.2: How Position Loop Gain and Smoothing Time Relate to Trajectory Accuracy (Without 3D-DLACC). So, by combining velocity feedforward and 3D-DLACC, you can reduce E1 and E2 to zero, achieving perfect trajectory (E=0).

When DLACC is turned on, it disables the regular smoothing filter, meaning that smoothing time (Ts) becomes ineffective. Ts is a dominant parameter when DLACC is not in use, but Ts has no effect when DLACC is turned on. Instead, DLACC has its own smoothing filter, called look ahead smoothing time, and you need to tune this parameter well. Basically, the look ahead smoothing time is very similar to the regular smoothing time: a long look ahead smoothing time makes the surface smooth reduces the sharp accuracy of the original trajectory. It's a trade off that you must balance by determining the needs of your machine tool.

Kp, however, is still a dominant parameter with or without DLACC in effect. But, just like Kp requires a very big Kv, DLACC requires that Kp is very high. DLACC is a very demanding function that is predicated on the regular position loop being well tuned. So, if DLACC is used without the position loop being well tuned, the performance

______7-4 SERVOWORKS CNC SETUP AND INTEGRATION MANUAL FOR ETHERCAT Index will be disappointing. And, a well-tuned position loop requires a well-tuned velocity loop. So, in order to make use of the benefits of DLACC, you should tune the velocity loop first, and position loop second.

7.2 Integrating LadderWorks PLC into Your System

If you are integrating LadderWorks in your system, you must refer to the LadderWorks PLC User’s Manual for instructions on setting up the PLC environment and writing PLC sequence programs.

7.3 Backing Up Final Software Settings After Tuning

All current software settings are contained in the Windows registry. Therefore, when you have completed your installation, setup and integration (especially the important process of tuning your system), we highly recommend that you back up the GMC and Windows application folders in the HKEY_CLASSES_ROOT\ServoWorks key of the Windows registry. This will save you time and money if you need to recreate your optimized software environment for any reason. This is also useful for creating an identical control system on a new PC.

To back up your current parameter settings, you must export two folders to two Windows files (as explained in Section 4.2: Exporting Current Parameter Settings to Windows Files in the Windows Registry Reference Manual for ServoWorks CNC Products and SMP Series General Motion Control Products). [We recommend saving these files somewhere other than your PC.]

______7-5 SERVOWORKS CNC SETUP AND INTEGRATION MANUAL FOR ETHERCAT Index

Index

// 5-2 DC-155 servo interface module ...... iv 3D-DLACC ...... 1-2, 7-4 default parameter values ...... 7-2 5-axis machining...... 2-1 default parameters...... 5-7 absolute encoders ...... 2-2, 5-12 Dell 7000 portables ...... 1-3 homing...... 5-12 device driver installation...... 4-1 ACPI 1.0 – APIC Platform MP ...... 3-5 disabled PC functions ...... 1-4 ACPI 1.0 – APIC Platform UP ...... 3-5 display requirements ...... 1-2 ACPI Multiprocessor PC ...... 3-5 distance per encoder revolution ...... 3-8 ACPI Uniprocessor PC ...... 3-5 DLACC...... 7-4 ACPI x86-based PC (ACPI x86 Platform ...... 3-5 duplicating a control system ...... 7-5 active Ethernet ...... 3-12 dynamic look-ahead contour control ...... 7-4 adding options to existing ServoWorks CNC ec_network.def ...... 5-4 products ...... 3-8 electrical noise ...... v administrator privileges ...... 1-3, 3-1, 3-19 embedded feedback loops ...... 7-3 Alpha systems ...... 1-3 enabling the network card device driver for the analog inverter ...... 5-12 Ethernet card ...... 3-12 ATI ...... 1-3 encoder polarity ...... 5-7 Axis #4 ...... 5-13 encoders Axis Type ...... 5-10 absolute ...... 2-2 AxisMap ...... 5-3 incremental ...... 2-2 backing up final software settings after tuning ...... 7-5 encoders, absolute ...... 5-12 backward compatibility ...... 3-6, 3-8 EtherCAT ...... 1-1 blue screen ...... 3-1 EtherCAT CoE servo drives ...... 5-1 cables ...... 2-1 EtherCAT interface system cautions ...... iii advantages...... 2-1 change partition of hard drive ...... 3-18 description...... 1-1, 2-1 CNC Engine ...... 3-20 schematic overview ...... 2-1 color monitor ...... 1-3 EtherCAT network ...... 5-1 comments ...... 5-2 EtherCAT Network Information file ...... 5-4 Compaq AP400 ...... 1-3 EtherCAT servo drive systems ...... 1-1 compatibility issues of IntervalZero RTX iv, 3-1, 3-19 Ethernet - disabled ...... 1-4 compatibility, backward ...... 3-6 Ethernet connection ...... 1-2 computer freezes ...... 3-1 Ethernet LAN servo cables ...... 2-1 computer requirements ...... 1-2 Ethernet requirements ...... 3-12 configuration parameters ...... 5-2 exporting current parameter settings ...... 7-5 configuring PCI device driver F data ...... 5-13 Windows XP ...... 4-1 Failed to Load ServoWorks Real-Time Engine ...... iii conflicting slots ...... 1-4 fatal system errors ...... 3-1 connecting EtherCAT CoE servo drives ...... 5-1 finishing your setup and integration ...... 7-1 connecting servo drives ...... iii, 5-1 freezing, computer ...... 3-1 contour control ...... 1-2, 7-4 G-Code Parser ...... 3-20 control loops ...... 7-3 general CNC ...... 2-1 converting the Windows PCI driver to an RTX green screen of death ...... 3-1 device driver ...... 4-16 HAL settings ...... 3-1 coordinate system ...... 5-12 HAL type selection ...... 3-1 CPU ...... 1-2 HAL types ...... 1-3 creating an identical control system...... 7-5 hard disk space ...... 1-2 current control loop ...... 7-3 hard drive, change partition ...... 3-18 cycle time...... 2-1, 2-2 hard drive, reformat ...... 3-19 DAC module ...... 5-12 hard drive, replace ...... 3-18 DAO package ...... 3-46 hardware components - disabled ...... 1-4

______I SERVOWORKS CNC SETUP AND INTEGRATION MANUAL FOR ETHERCAT Index hardware configurations ...... 1-3 Mitsubishi ...... 1-1 HKEY_CLASSES_ROOT\ServoWorks ...... 7-5 modem - disabled...... 1-4 home position ...... 5-12 monitor ...... 1-3 homing absolute encoders...... 5-12 MotionLite ...... 3-20, See ServoWorks MotionLite homing operation ...... 5-12 MotionLite Operator’s Manual ...... 7-1 HP Kayak...... 1-3 motor polarity ...... 5-7 I/O Connections ...... 6-1 mounting location ...... v identical control system ...... 7-5 MPS 1.4 – APIC Platform HAL ...... 3-5 inaccuracy in CNC...... 7-1 MPS Multiprocessor PC ...... 3-5 incompatible HAL type ...... 3-1 network card ...... 3-15 incremental encoders ...... 2-2 network card device driver ...... 3-12 initialization of the system ...... 5-1 Network Information file ...... 5-4 installation network, EtherCAT ...... 5-1 PCI device driver for Windows XP ...... 4-1 networking ...... 5-2 installing software...... 2-1, 3-19 new operating system ...... 3-19 LadderWorks Console and DAO ...... 3-46 new options ...... 3-19 LadderWorks PLC ...... 3-32 new version of ServoWorks CNC product ...... 3-19 order of installation ...... 3-10 node definitions ...... 5-2 ServoWorks CNC ...... 3-32 Normal (Axis Type) ...... 5-10 installing the EtherCAT network card operating system Windows XP ...... 4-1 requirements ...... 1-3 integration ...... 5-1 operating system, new ...... 3-19 Internet access ...... 3-16 operating system, new service pack ...... 3-19 Internet Explorer ...... 1-3 operating system, reinstall ...... 3-19 Internet registration...... 3-37 operating systems ...... 1-1 interpolation rate ...... 2-2 patches ...... 3-8 interrupt service routine ...... 2-2 options ...... 3-8, 3-19 IntervalZero RTX ...... 1-3, 3-20 PAC # ...... 3-16 compatibility issues ...... iv, 3-1, 3-19 Panasonic ...... 1-1 registration ...... 3-16 technical support...... 3-17 parameter settings ...... 5-8 inverter spindle ...... 5-12 backing up ...... 7-5 IRQ conflicts ...... 1-4 parameters CNC ...... 7-1 ISR ...... 2-2 default ...... 5-7, 7-2 kp 7-1 servo drive ...... 7-3 Kv ...... 7-3 parameters, configuration ...... 5-2 LadderWorks ...... 3-49, 7-5 partition hard drive ...... 3-18 LadderWorks Console ...... 3-46 PC LadderWorks PLC ...... 3-20 hardware requirements ...... 1-2 LadderWorks PLC Engine ...... 3-20 requirements ...... 1-2, 3-1 lathes ...... 2-1 PC functions ...... 1-4 license code ...... 3-23 PC location ...... v license code ...... 3-16 PC problems ...... 3-1 license key ...... 3-16, 3-37 PC requirements license number ...... See also license code Internet access ...... 3-16 location operating system patches ...... 3-8 mounting ...... v PC-based ...... 1-1 PC ...... v PCI device driver locking up ...... 3-1 Windows XP ...... 4-1 look ahead smoothing time ...... 7-4 performing a homing operation ...... 5-12 look-ahead contour control ...... 7-4 personal computer...... See PC machine position ...... 5-12 phone registration ...... 3-17 machining centers ...... 2-1 PIK # ...... 3-16 manuals for servo drives ...... iii PIK number ...... 3-19 MC-Quad ...... 2-1 pitch error compensation values ...... 3-8 MECHATROLINK ...... 1-1 PLC mills ...... 2-1 integration of ...... 7-5

______II SERVOWORKS CNC SETUP AND INTEGRATION MANUAL FOR ETHERCAT Index

PLC Engine ...... 3-20 saving final software settings after tuning ...... 7-5 PLC sequence program ...... 5-12 Service Pack 3, Windows XP ...... iii, 3-8 plus stroke ...... 3-8 service pack for operating system ...... 3-19 pop ups ...... 3-49 service packs ...... 3-8 position control loop ...... 7-3 servo communications platforms ...... 1-1 position feedback rate ...... 2-2 servo drive manuals ...... iii position loop gain ...... 5-7, 7-1 servo drive parameters ...... 5-7, 7-3 position loop integral control enable ...... 5-8 servo drive velocity sensitivity ...... 5-7 position loop integral saturation ...... 5-8 servo drives position loop integral time constant ...... 5-8 connecting ...... iii, 5-1 powering servo drives ...... iii servo error ...... 7-2 preparing for software installation ...... 3-1 servo interface module ...... iv preventing the RtxServer screen from popping up .. 3- servo lag...... 7-2 49 servo manuals ...... iii privileges ...... 1-3, 3-1, 3-19 ServoWorks CNC problems with RTX ...... iv, 3-1, 3-19 description...... 1-1 Product Identification Key ...... 3-16 ServoWorks CNC description ...... 2-1 product registration ...... 3-23 ServoWorks CNC Engine ...... 3-20 Purchase Authentication Code ...... 3-16 ServoWorks CNC products RAM ...... 1-2 registration ...... 3-16 Random Access Memory ...... 1-2 ServoWorks G-Code Parser ...... 3-20 reactivating PIK number ...... 3-19 ServoWorks key ...... 7-5 Real Time Device Installer ...... 4-4, 4-7, 4-10 ServoWorks MC-Quad ...... 2-1 RealTime DLL ...... 3-20 ServoWorks MotionLite ...... 3-20, 5-9 Realtime Express ...... 1-1 ServoWorks MotionLite Operator’s Manual .. 1-1, 7-1 reformat hard drive ...... 3-19 ServoWorks RealTime DLL ...... 3-20 registration ServoWorks S-100M, S-120M and S-140M ...... 2-1 IntervalZero RTX ...... 3-16 ServoWorks S-100T ...... 2-1 ServoWorks CNC products ...... 3-16 ServoWorks S-100T Operator’s Manual ...... 1-1, 7-1 ServoWorks software ...... 3-23 ServoWorks software Registration button ...... 3-23 registration ...... 3-23 registration by phone ...... 3-17 setting the home position ...... 5-12 registration code ...... See also license code setup and integration registration code ...... 3-31 finishing ...... 7-1 registration text file ...... 3-30 severe error, HAL not supported by RTX ...... 3-1 Registration.txt ...... 3-30 Slave Axes ...... 5-11 registry ...... 7-5 SMI Lynx...... 1-3 reinstall operating system ...... 3-19 smoothing error ...... 7-2 re-networking ...... 5-2 smoothing time ...... 7-1 replace hard drive ...... 3-18 soft CNC ...... 1-1 required updates ...... 3-8 Soft Servo Systems Product Identification Key ... 3-16 requirements software installation ...... 2-1, 3-19 Internet access ...... 3-16 software options ...... 3-6, 3-8 operating system ...... 1-3 software upgrades ...... 3-6 PC ...... 1-2 software versions ...... 3-6 RTEX ...... 1-1 sound - disabled ...... 1-4 RTX ...... See IntervalZero RTX SP3, Windows XP ...... iii, 3-8 RTX Device Driver ...... 4-16 spindle ...... 5-12 RTX INF support SSCNET ...... 1-1 Windows XP ...... 4-25 SSS PIK # ...... 3-16 RTX version ...... 1-3 station number ...... 5-3 RtxServer ...... 3-49 Synchronous Control ...... 5-11 RX connector ...... 5-1 system errors ...... 3-1 S codes ...... 5-12 system information file ...... 5-2 S-100M, S-120M and S-140M ...... 2-1 system integration ...... 5-1 S-100T ...... 2-1 system integration and initialization ...... 5-1 S3 ...... 1-3

______III SERVOWORKS CNC SETUP AND INTEGRATION MANUAL FOR ETHERCAT Index system settings ...... 1-3, 3-1, 3-19 velocity feedforward percentage ...... 5-8 technical support, IntervalZero RTX ...... 3-17 velocity loop gain ...... 7-3 testing the system...... 7-1 VersioBus II™ fiber-optic digital servo network .. 1-1 trajectory error ...... 7-1 version ...... 3-19 Trident ...... 1-3 Version 3 backward compatibility issues ...... 3-8 Ts 7-1 version of RTX ...... 1-3 tuning the system ...... 7-1 VIA ...... 1-3 TX connector ...... 5-1 video chips ...... 1-3 unsupported hardware configurations ...... 1-3 Windows 2000 ...... 1-3 Unused (Axis Type) ...... 5-10 Windows driver updates for operating systems ...... 3-8 updating (Windows XP) ...... 4-25 updating the Windows device driver ...... 4-25 Windows registry ...... 7-5 upgrade ServoWorks CNC product ...... 3-19 Windows XP ...... 1-3 upgrading software ...... 3-6 Service Pack 3 ...... iii, 3-8 USB - disabled ...... 1-4 Windows XPe ...... 1-3 velocity control loop ...... 7-3 winver.exe ...... 3-10 velocity feedforward ...... 7-4 wiring ...... 2-1 velocity feedforward enable ...... 5-8 Y data ...... 5-13

______IV