Huichuan AM600 Motion Controller Malfunction and Replacement Guide

Inovance AM600 Motion Controller System Integration and Troubleshooting Guide

In the field of high-end automation equipment, Inovance's AM600 series motion controller, with its powerful EtherCAT bus capability, flexible I/O scalability, and IEC 61131-3 standard programming environment, has become the core control unit for industries such as packaging, electronic manufacturing, robotics, and CNC machine tools. As equipment ages or production lines upgrade, engineers often face challenges such as controller replacement, program migration, EtherCAT network debugging, and axis control parameter optimization. This article is based on the official technical information of AM600, and provides an in-depth analysis of the hardware architecture, software tools, system integration points, typical fault diagnosis, and complete replacement process of the controller, helping on-site engineers quickly master maintenance and debugging methods.

Hardware Architecture and Model Identification of AM600 Controller

AM600 is a centralized motion controller with built-in PLC function. The main module adopts ARM Cortex A8 1 GHz processor and supports IEEE 754 double precision floating-point operation, ensuring the accuracy of complex trajectory calculation. The main hardware features are as follows:

EtherCAT Master Station: A standard EtherCAT port that can control up to 32 axes for point-to-point positioning, with a PTP refresh time of 4 ms; up to 8 axes can perform interpolation motion (straight line, arc, spiral line), and 16 axes can achieve electronic cam (CAM) control, with a synchronization period of 2 ms.

Built in communication interface:

Ethernet port (used for programming, debugging, and Modbus TCP master/slave)

Two RS485 interfaces (supporting Modbus RTU master/slave)

CANopen slave interface (also supports CANlink protocol)

Local I/O: 16 point high-speed input (up to 200 kHz, supports A/B phase pulse counting, pulse width/frequency measurement, accuracy ± 2 μ s), 8-point high-speed output.

Storage: 4 MByte user program storage, SD card slot for program backup and firmware upgrade.

Power supply: 24 VDC input.

Size: 80 x 90 x 95 mm (width x height x depth), suitable for installation in compact cabinets.

Scalability:

The main CPU module can connect up to 16 local I/O modules (DI/DO, AI/AO, etc.).

RTU-ECTA remote couplers can be mounted through the EtherCAT bus, with each coupler capable of expanding up to 125 modules (DI/DO/AI/AO) and supporting CoE services (PDO, SDO).

Replacement selection note: AM600 has different firmware versions, and when replacing, it is necessary to confirm that the firmware version of the new controller is compatible with the original application. If the original system uses a third-party EtherCAT slave device, the AM600 standard EtherCAT port supports connection, but the ESI file of the slave must be correctly configured in InoProShop.

Software tool InoProShop and project migration

The programming environment for AM600 is InoProShop (based on the Codesys kernel), which fully complies with the IEC 61131-3 standard and supports the following languages:

Structured Text (ST)

Ladder diagram (LD)

Sequential Function Diagram (SFC)

Continuous Function Diagram (CFC)

In addition, InoProShop integrates a CAM graphic editor that supports up to 65535 CAM points and can perform linear or fifth degree polynomial interpolation, simplifying electronic cam design.

2.1 Program Backup and Recovery

Backup steps:

Connect the PC to the Ethernet port of AM600 using a standard Ethernet cable (IP address needs to be in the same network segment, default may be 192.168.1. xxx).

Open InoProShop, scan devices on the network, and establish an online connection.

Execute "Online" → "Login" → "Upload" to upload the current program in the controller to the PC project.

Save the project as a. pro file and export device parameter configurations (such as EtherCAT slave list, axis parameters, PDO mapping).

Insert the SD card into the SD card slot of AM600 and backup the complete system image through InoProShop's "File" → "Store to SD Card".

Restore and replace:

After powering on the new AM600, connect it to the PC using the same Ethernet cable and scan the device through InoProShop.

If the IP address of the new controller is different from the original one, the IP address needs to be modified first (through "Device" → "Communication Settings").

After logging in, execute "Download" → "All" to write the original program and configuration into the new controller.

If an SD card image is used, the SD card can be inserted into a new controller while the power is off, and the system will automatically recover after power on.

2.2 Firmware Upgrade

The AM600 firmware can be upgraded online through SD card or InoProShop. Before upgrading, it is necessary to confirm that the new firmware version is compatible with the module being used (such as RTU-ECTA). The upgrade steps are as follows:

Download the firmware package (. bin file) corresponding to the AM600 model from the official website of Huichuan.

Copy the firmware file to the root directory of an SD card in FAT32 format.

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

The electronic cam has a large follower error between the main and slave shafts, with mismatched cycles and too few CAM points to ensure DC synchronization between the main and slave shafts; Add interpolation points to the CAM table or use a fifth degree polynomial

Zero return cannot find the origin signal. The origin switch signal is not connected to the high-speed input port, and the zero return speed is too fast. Check the wiring of the origin switch; Reduce the speed of approaching zero; Choose the correct zeroing mode

4.3 Programming and Download Issues

Possible causes and solutions for the phenomenon

Unable to connect to AM600 IP address not in the same network segment, firewall blocking IP recovery through serial port or USB (if any); Turn off the PC firewall; Using InoProShop's' Scan 'feature

When downloading, it prompts that the CPU model selected in the "Device Type Mismatch" item does not match the actual one. Modify it to the correct AM600 sub model in the device tree

After the program runs, the PLC stops the watchdog timeout and checks the program loop time in a dead loop; Add Watchdog reset command; Assign different priorities using task configuration

SD card cannot recognize format incompatibility (requires FAT32) or has a large capacity. Use an SD card with ≤ 32 GB and format it as FAT32

4.4 High speed input/output faults

The AM600 provides 16 high-speed inputs (up to 200 kHz), some of which support A/B phase pulse counting. If the pulse counting is inaccurate:

Check if the input wiring is differential or single ended (NPN/PNP).

Confirm the input filtering time setting (in hardware configuration), usually set to 1 μ s or less.

Use an oscilloscope to measure the quality of pulse signals and eliminate interference.

Example of complete process for system replacement

Assuming an old AM600 controller on site is damaged and needs to be replaced with a new controller of the same model, with the original program backed up on the PC. Perform the following steps:

Preparation:

Record the IP address of the original controller, EtherCAT slave list (station number, model), and shaft parameters (such as electronic gear ratio, limit value).

Open the backed up project file (. pro) from the PC.

Prepare a standard Ethernet cable (either crossover or direct connection, as AM600 supports Auto MDI-X).

Hardware installation:

Cut off the main power supply of the system and mark the connection positions of all I/O and EtherCAT cables.

Dismantle the old controller and install the new controller onto the DIN rail.

Reconnect the cables (24V power supply, EtherCAT Ethernet cable, I/O wiring, Ethernet programming cable) according to the original markings.

Power on and basic settings:

Only supply power to the controller (24V DC), do not connect the driver main power.

Connect the controller to the PC and modify the IP address to its original value through InoProShop.

Check firmware version: If it is lower than the original version, upgrade according to the above method.

Download program and configuration:

Open the InoProShop project, execute 'Generate Code' and 'Download'.

After downloading, switch to "Run" mode and check the system status (no red error light).

Drive parameter recovery:

If the servo drive is not replaced, its internal parameters should remain unchanged. But to avoid parameter loss, when starting through EtherCAT, AM600 will send PDO configuration parameters to the driver to ensure they match the PDO in the program.

If the driver has also been replaced, it is necessary to use Huichuan driver debugging software (such as InoDriveShop) to import the original driver parameter backup file.

System integration debugging:

Enable servo and perform low-speed jog testing on each axis.

Check the zeroing accuracy of each axis.

Perform a complete automatic loop and observe the EtherCAT communication load and CPU load.

Backup new system:

Use SD card or InoProShop's' Archive 'function to save the final project.

Performance optimization suggestions

Reduce EtherCAT bus cycle: If an application requires faster response (such as flying, high-speed patching), the synchronization cycle can be set to 1 ms, but at the same time, the number of slave stations and PDO data volume need to be reduced. The typical value for 32 axis PTP positioning is 4 ms, and forced compression is not recommended.

Use multitasking: AM600 supports multitasking (such as loop tasks, event tasks, and free running tasks). Assign motion control, logic control, and communication processing to different priority tasks to avoid blocking.

CAM point optimization: When there are more than a few thousand CAM points, it will occupy a large amount of memory and prolong the startup time. Three or five degree polynomials can be used to automatically fit and reduce the number of points, or spline interpolation can be used.

Application of high-speed input: Using a 200 kHz counting channel instead of an external high-speed counter to save costs. Note that the encoder type (NPN/PNP or differential) needs to match the input port.