Huichuan AM600 Motion Controller Malfunction and Replacement Guide

Controller power off, insert SD card, power on. The controller automatically detects and upgrades the firmware. During the upgrade process, the indicator light flashes and automatically restarts after completion.

After upgrading, use InoProShop to download the application again (as firmware updates may affect the driver library version).

Attention: Firmware upgrade will clear user programs, so it is necessary to backup in advance.

System integration and EtherCAT network configuration

3.1 EtherCAT Topology Structure

As an EtherCAT master station, AM600 connects servo drives (such as the Huichuan IS620 series), remote I/O couplers, and other slave stations through standard RJ45 ports. The maximum number of slave stations depends on the communication cycle and PDO data volume. In a typical topology, AM600 can connect 32 servo drives (PTP positioning) with a refresh time of 4 ms; if a shorter cycle is required, the number of axes can be reduced or PDO mapping can be optimized.

Wiring points:

Use shielded Ethernet cables (CAT5e or above) with a maximum distance of 100 meters (from the main station to the first station).

The slave stations are connected in a daisy chain, and the end slave stations do not require terminal resistors (EtherCAT physical layer is LVDS, automatic termination).

Loops must be avoided as EtherCAT does not support ring network redundancy (unless specialized equipment is used).

3.2 EtherCAT Configuration in InoProShop

New Project → Select AM600 Equipment.

Right click in the "Communication" tree to add "EtherCAT Master".

Scan Slave Stations: After going online, click on "Scan Devices" and InoProShop will automatically discover all connected slave stations and generate a topology.

Assign a station number to each slave (consistent with the node address in the drive DIP or object dictionary).

Configure PDO mapping: Select process data objects (such as control words, status words, actual position, speed, etc.) according to actual needs. Excessive PDO length will increase the bus cycle and needs to be balanced.

Set up distributed clock (DC): AM600 supports DC synchronization mode, and it is recommended that the master station clock reference the first DC supported device in the slave station. The synchronization period can be set in "EtherCAT Master" → "DC", with typical values of 1 ms, 2 ms, or 4 ms.

3.3 Axis Parameters and Motion Control

AM600 provides a PLCopen motion control function library (single axis, interpolation, electronic cam). The steps for configuring the axis are as follows:

Create an "axis" object for each servo drive in the EtherCAT slave list.

Set the axis type (such as "virtual axis" or "real axis"), unit (mm, deg), scaling factor, and encoder resolution.

Set soft limit, hard limit, and return to zero mode (supports multiple return to zero modes, such as limit switch+Z pulse).

Writing PLC programs: using functional blocks such as MC-Power (enable), MC-MoveAbsolute (absolute positioning), MC-MoveVelocity (speed mode), MC_CamIn (electronic cam), etc.

Electronic cam: Import or draw the master-slave axis relationship curve in the CAM editor, with a maximum of 65535 points. Support fifth degree polynomial interpolation to ensure continuity of velocity and acceleration.

Performance reminder: When up to 8 axes perform interpolation motion simultaneously, the CPU load will increase. It is recommended to use InoProShop's "Scope Oscilloscope" function to monitor task cycles and ensure that there are no timeouts.

Common fault diagnosis and troubleshooting

4.1 EtherCAT communication failure

Possible causes and solutions for the phenomenon

The main station is unable to scan for damaged network cables, wiring errors, or failure to power on the slave station to check the network cables; Confirm the power supply of the substation; Use the link indicator light to determine the physical connection

Scan to slave station but status as OP failed. Station number conflict, PDO mapping inconsistency, DC configuration error check. Each slave station node address is unique; Generate PDO mapping again; Unified DC synchronization mode

Periodic interruption of communication, electromagnetic interference, and poor shielding of network cables using CAT5e wires with metal shielding; Ensure good grounding; Reduce EtherCAT speed (but AM600 is fixed at 100M and cannot be lowered)

The slave enters the SafeOp state, and the slave watchdog timeout increases the slave watchdog time; Check if the main station cycle is stable

4.2 Axis enablement and motion faults

Possible causes and solutions for the phenomenon

The status of the MC-Power enabled rear axle is still Disabled. The driver is not powered on, the hardware enable signal is not connected, and the driver alarm checks the power supply of the driver; Confirm the enable input of CN1 or related interfaces; Read drive fault codes

During axis movement, if the position deviation is too large and the gain is insufficient, or if the load inertia ratio is set incorrectly, perform automatic gain adjustment on the driver; Adjust position ring KP in AM600 axis parameters