Beckhoff EL3413-0000, EL3413-0001, EL3413-0120, EL3433 Documentation

Documentation

EL34x3

3-phase power measurement terminal

Version:
Date:

4.4
2019-03-28

Table of contents

Table of contents

1 Foreword ....................................................................................................................................................7

1.1 Product overview - Power measurement terminals ...........................................................................7

1.2 Notes on the documentation..............................................................................................................7

1.3 Safety instructions .............................................................................................................................9

1.4 Documentation issue status ............................................................................................................10

1.5 Version identification of EtherCAT devices .....................................................................................11

2 Product overview.....................................................................................................................................16

2.1 EL3413 ............................................................................................................................................16

2.1.1 Introduction ...................................................................................................................... 16

2.1.2 Technical data ................................................................................................................. 18

2.2 EL3433 ............................................................................................................................................19

2.2.1 Introduction ...................................................................................................................... 19

2.2.2 Technical data ................................................................................................................. 20

2.3 Basic function principles ..................................................................................................................21

2.3.1 Measuring principle.......................................................................................................... 21

2.3.2 RMS value calculation ..................................................................................................... 21

2.3.3 Effective power measurement ......................................................................................... 22

2.3.4 Apparent power measurement ........................................................................................ 22

2.3.5 Sign for power measurement........................................................................................... 24

2.3.6 Sign of the energy values ................................................................................................ 25

2.3.7 Frequency measurement................................................................................................. 25

2.4 Current transformer .........................................................................................................................25

2.5 Start .................................................................................................................................................26

3 Basics communication ...........................................................................................................................27

3.1 EtherCAT basics..............................................................................................................................27

3.2 EtherCAT cabling – wire-bound.......................................................................................................27

3.3 General notes for setting the watchdog...........................................................................................28

3.4 EtherCAT State Machine.................................................................................................................30

3.5 CoE Interface...................................................................................................................................32

3.6 Distributed Clock .............................................................................................................................37

4 Installation................................................................................................................................................38

4.1 Instructions for ESD protection........................................................................................................38

4.2 Installation on mounting rails ...........................................................................................................38

4.3 Connection ......................................................................................................................................41

4.3.1 Connection system .......................................................................................................... 41

4.3.2 Wiring............................................................................................................................... 44

4.3.3 Shielding .......................................................................................................................... 45

4.4 Installation positions ........................................................................................................................45

4.5 Positioning of passive Terminals .....................................................................................................48

4.6 UL notice .........................................................................................................................................48

4.7 EL34x3 - LEDs and connection .......................................................................................................50

4.7.1 EL3413-0000 ................................................................................................................... 50

4.7.2 EL3413-0001 ................................................................................................................... 53

EL34x3 3Version: 4.4

Table of contents

4.7.3 EL3413-0120 ................................................................................................................... 56

4.7.4 EL3433-0000 ................................................................................................................... 59

5 Commissioning........................................................................................................................................62

5.1 TwinCAT Quick Start .......................................................................................................................62

5.1.1 TwinCAT2 ....................................................................................................................... 65

5.1.2 TwinCAT 3 ....................................................................................................................... 75

5.2 TwinCAT Development Environment ..............................................................................................87

5.2.1 Installation of the TwinCAT real-time driver..................................................................... 87

5.2.2 Notes regarding ESI device description........................................................................... 93

5.2.3 TwinCAT ESI Updater ..................................................................................................... 97

5.2.4 Distinction between Online and Offline............................................................................ 97

5.2.5 OFFLINE configuration creation ...................................................................................... 98

5.2.6 ONLINE configuration creation ...................................................................................... 103

5.2.7 EtherCAT subscriber configuration................................................................................ 111

5.3 General Notes - EtherCAT Slave Application................................................................................120

5.4 Process data..................................................................................................................................128

5.4.1 Sync Manager (SM)....................................................................................................... 128

5.4.2 Operating modes and settings....................................................................................... 131

5.4.3 Predefined PDO Assignment......................................................................................... 133

5.5 Start-up and parameter configuration............................................................................................133

5.5.1 Settings.......................................................................................................................... 133

5.5.2 Measurements ............................................................................................................... 135

5.5.3 Scaling factors ............................................................................................................... 139

5.6 Notices on analog specifications ...................................................................................................140

5.6.1 Full scale value (FSV).................................................................................................... 141

5.6.2 Measuring error/ measurement deviation ...................................................................... 141

5.6.3 Temperature coefficient tK [ppm/K] ............................................................................... 142

5.6.4 Single-ended/differential typification .............................................................................. 143

5.6.5 Common-mode voltage and reference ground (based on differential inputs)................ 148

5.6.6 Dielectric strength .......................................................................................................... 148

5.6.7 Temporal aspects of analog/digital conversion.............................................................. 149

5.7 Object description and parameterization .......................................................................................152

5.7.1 Restore object................................................................................................................ 152

5.7.2 Configuration data ......................................................................................................... 153

5.7.3 Command object............................................................................................................ 153

5.7.4 Configuration data (vendor-specific).............................................................................. 155

5.7.5 Input data....................................................................................................................... 158

5.7.6 Output data .................................................................................................................... 163

5.7.7 Information and diagnostic data..................................................................................... 163

5.7.8 Standard objects............................................................................................................ 165

6 Diagnostics – basic principles of diag messages..............................................................................173

7 Appendix ................................................................................................................................................183

7.1 EtherCAT AL Status Codes...........................................................................................................183

7.2 Firmware compatibility...................................................................................................................183

7.3 Firmware Update EL/ES/EM/ELM/EPxxxx ....................................................................................184

EL34x34 Version: 4.4

Table of contents

7.3.1 Device description ESI file/XML..................................................................................... 185

7.3.2 Firmware explanation .................................................................................................... 188

7.3.3 Updating controller firmware *.efw................................................................................. 189

7.3.4 FPGA firmware *.rbf....................................................................................................... 190

7.3.5 Simultaneous updating of several EtherCAT devices.................................................... 194

7.4 Restoring the delivery state ...........................................................................................................195

7.5 Support and Service ......................................................................................................................196

EL34x3 5Version: 4.4

Table of contents

EL34x36 Version: 4.4

1 Foreword

1.1 Product overview - Power measurement terminals

EL3413 [}16]

3-phase power measurement terminal up to 690 V AC

EL3413-0001 [}16]

3-phase power measurement terminal up to 600 V AC, UL approval

EL3413-0120 [}16]

3-phase power measurement terminal up to 210 V AC

EL3433 [}19]

3-phase power measurement terminal up to 500 V AC, 10A

1.2 Notes on the documentation

Foreword

Intended audience

This description is only intended for the use of trained specialists in control and automation engineering who
are familiar with the applicable national standards.
It is essential that the documentation and the following notes and explanations are followed when installing
and commissioning these components.
It is the duty of the technical personnel to use the documentation published at the respective time of each
installation and commissioning.

The responsible staff must ensure that the application or use of the products described satisfy all the
requirements for safety, including all the relevant laws, regulations, guidelines and standards.

Disclaimer

The documentation has been prepared with care. The products described are, however, constantly under
development.

We reserve the right to revise and change the documentation at any time and without prior announcement.

No claims for the modification of products that have already been supplied may be made on the basis of the
data, diagrams and descriptions in this documentation.

Trademarks

Beckhoff®, TwinCAT®, EtherCAT®, EtherCATP®, SafetyoverEtherCAT®, TwinSAFE®, XFC® and XTS® are
registered trademarks of and licensed by Beckhoff Automation GmbH.
Other designations used in this publication may be trademarks whose use by third parties for their own
purposes could violate the rights of the owners.

Patent Pending

The EtherCAT Technology is covered, including but not limited to the following patent applications and
patents: EP1590927, EP1789857, DE102004044764, DE102007017835 with corresponding applications or
registrations in various other countries.

The TwinCAT Technology is covered, including but not limited to the following patent applications and
patents: EP0851348, US6167425 with corresponding applications or registrations in various other countries.

EL34x3 7Version: 4.4

Foreword

EtherCAT® is registered trademark and patented technology, licensed by Beckhoff Automation GmbH,
Germany.

Copyright

© Beckhoff Automation GmbH & Co. KG, Germany.
The reproduction, distribution and utilization of this document as well as the communication of its contents to
others without express authorization are prohibited.
Offenders will be held liable for the payment of damages. All rights reserved in the event of the grant of a
patent, utility model or design.

EL34x38 Version: 4.4

Foreword

1.3 Safety instructions

Safety regulations

Please note the following safety instructions and explanations!
Product-specific safety instructions can be found on following pages or in the areas mounting, wiring,
commissioning etc.

Exclusion of liability

All the components are supplied in particular hardware and software configurations appropriate for the
application. Modifications to hardware or software configurations other than those described in the
documentation are not permitted, and nullify the liability of Beckhoff Automation GmbH & Co. KG.

Personnel qualification

This description is only intended for trained specialists in control, automation and drive engineering who are
familiar with the applicable national standards.

Description of instructions

In this documentation the following instructions are used.
These instructions must be read carefully and followed without fail!

DANGER

Serious risk of injury!

Failure to follow this safety instruction directly endangers the life and health of persons.

WARNING

Risk of injury!

Failure to follow this safety instruction endangers the life and health of persons.

CAUTION

Personal injuries!

Failure to follow this safety instruction can lead to injuries to persons.

NOTE

Damage to environment/equipment or data loss

Failure to follow this instruction can lead to environmental damage, equipment damage or data loss.

Tip or pointer

This symbol indicates information that contributes to better understanding.

EL34x3 9Version: 4.4

Foreword

1.4 Documentation issue status

Version Comment

4.4 • Update chapter "LEDs and connection"

• Update structure

• Update revision status

4.3 • Update chapter "Technical data"

• Update chapter "Connection system" -> "Connection"

• Update structure

• Update revision status

4.2 • Update revision status

• Update structure

4.1 • Update chapter "Technical data"

• Update structure

4.0 • Update chapter "Technical data"

• Update chapter "Basic function principles"

• Update chapter "Process data"

• Update chapter "Start-up and parameter configuration"

• Update chapter "Object description and parameterization"

• Update revision status

• Update structure

3.9 • Update chapter "Technical data"

• Update structure

3.8 • Update chapter "Technical data"

• Update chapter “Measurements”

• Update structure

3.7 • Update chapter "Technical data"

• Update chapter “Measurements”

• Addenda chapter "Instructions for ESD protection"

• Update chapter "Notices on Analog specification"

• Update chapter "Diagnostics - basic principles of diag messages"

• Update revision status

3.6 • Update chapter "Start-up and parameter configuration"

3.5 • Update chapter "Notes on the documentation"

• Correction of Technical data

• Addenda chapter "TwinCAT Quick Start"

• Update chapter "Diagnostics – basic principles of diag messages"

3.4 • Update chapter "Object description"

• Update revision status

• Update structure

3.3 • Update chapter "Object description"

• Update structure

3.2 • Update chapter "process data, setting"

• Update structure

3.1 • Update chapter "scaling factors"

• Update structure

EL34x310 Version: 4.4

Version Comment

3.0 • Migration

• Update structure

• Update revision status

2.2 • Update chapter "Object description and parameterization"

• “Technical data” section updated

• Update revision status

• Update structure

2.1 • “Technical data” section updated

• Update revision status

• Update structure

2.0 • Update chapter "Introduction"

• Update chapter "Current transformer"

• Update structure

1.9 • Addenda chapter "LEDs and connection"

• Update chapter "Process data"

• Update chapter "Measurements"

• Update chapter "Object description and parameterization"

• Update chapter "Scaling factors"

• Update revision status

• Update structure

1.8 • Addenda chapter "LEDs and connection"

1.7 • Update chapter "Scaling factors"

1.6 • Update structure

• Addendum EL3413-0001, EL3413-0120, EL3433

1.5 • Update "Technical data"

1.4 • Update "Technical data"

1.3 • Update "Object description"

1.2 • Update "Object description"

1.1 • Update "Technical data"

1.0 • Addenda, 1st public issue

0.1 • Provisional documentation for EL3413

Foreword

1.5 Version identification of EtherCAT devices

Designation

A Beckhoff EtherCAT device has a 14-digit designation, made up of

• family key

• type

• version

• revision

Example Family Type Version Revision

EL3314-0000-0016 EL terminal

(12 mm, non­pluggable connection
level)

ES3602-0010-0017 ES terminal

(12 mm, pluggable
connection level)

CU2008-0000-0000 CU device 2008 (8-port fast ethernet switch) 0000 (basic type) 0000

3314 (4-channel thermocouple
terminal)

3602 (2-channel voltage
measurement)

0000 (basic type) 0016

0010 (high-

0017

precision version)

EL34x3 11Version: 4.4

Foreword

Notes

• The elements mentioned above result in the technical designation. EL3314-0000-0016 is used in the
example below.

• EL3314-0000 is the order identifier, in the case of “-0000” usually abbreviated to EL3314. “-0016” is the
EtherCAT revision.

• The order identifier is made up of

- family key (EL, EP, CU, ES, KL, CX, etc.)

- type (3314)

- version (-0000)

• The revision -0016 shows the technical progress, such as the extension of features with regard to the
EtherCAT communication, and is managed by Beckhoff.
In principle, a device with a higher revision can replace a device with a lower revision, unless specified
otherwise, e.g. in the documentation.
Associated and synonymous with each revision there is usually a description (ESI, EtherCAT Slave
Information) in the form of an XML file, which is available for download from the Beckhoff web site.
From 2014/01 the revision is shown on the outside of the IP20 terminals, see Fig. “EL5021 EL terminal,
standard IP20 IO device with batch number and revision ID (since 2014/01)”.

• The type, version and revision are read as decimal numbers, even if they are technically saved in
hexadecimal.

Identification number

Beckhoff EtherCAT devices from the different lines have different kinds of identification numbers:

Production lot/batch number/serial number/date code/D number

The serial number for Beckhoff IO devices is usually the 8-digit number printed on the device or on a sticker.
The serial number indicates the configuration in delivery state and therefore refers to a whole production
batch, without distinguishing the individual modules of a batch.

Structure of the serial number: KKYYFFHH

KK - week of production (CW, calendar week)
YY - year of production
FF - firmware version
HH - hardware version

Example with
Ser. no.: 12063A02: 12 - production week 12 06 - production year 2006 3A - firmware version 3A 02 ­hardware version 02

Exceptions can occur in the IP67 area, where the following syntax can be used (see respective device
documentation):

Syntax: D ww yy x y z u

D - prefix designation
ww - calendar week
yy - year
x - firmware version of the bus PCB
y - hardware version of the bus PCB
z - firmware version of the I/O PCB
u - hardware version of the I/O PCB

Example: D.22081501 calendar week 22 of the year 2008 firmware version of bus PCB: 1 hardware version
of bus PCB: 5 firmware version of I/O PCB: 0 (no firmware necessary for this PCB) hardware version of I/O
PCB: 1

Unique serial number/ID, ID number

In addition, in some series each individual module has its own unique serial number.

See also the further documentation in the area

EL34x312 Version: 4.4

• IP67: EtherCAT Box

• Safety: TwinSafe

• Terminals with factory calibration certificate and other measuring terminals

Examples of markings

Fig.1: EL5021 EL terminal, standard IP20 IO device with serial/ batch number and revision ID (since
2014/01)

Foreword

Fig.2: EK1100 EtherCAT coupler, standard IP20 IO device with serial/ batch number

Fig.3: CU2016 switch with serial/ batch number

EL34x3 13Version: 4.4

Foreword

Fig.4: EL3202-0020 with serial/ batch number 26131006 and unique ID-number 204418

Fig.5: EP1258-00001 IP67 EtherCAT Box with batch number/ date code 22090101 and unique serial
number 158102

Fig.6: EP1908-0002 IP67 EtherCAT Safety Box with batch number/ date code 071201FF and unique serial
number 00346070

Fig.7: EL2904 IP20 safety terminal with batch number/ date code 50110302 and unique serial number
00331701

EL34x314 Version: 4.4

Foreword

Fig.8: ELM3604-0002 terminal with unique ID number (QR code) 100001051 and serial/ batch number
44160201

EL34x3 15Version: 4.4

Product overview

2 Product overview

2.1 EL3413

2.1.1 Introduction

Fig.9: EL3413

Fig.10: EL3413-0001

EL34x316 Version: 4.4

Fig.11: EL3413-0120

Product overview

3-Phase Power Measurement Terminal

The EL3413 EtherCAT power measurement terminal is a further development of the EL3403. With up to
690VAC the voltage inputs are optimized for direct monitoring of high-performance generators, as used in
the wind power industry, for sample.
The full scale value for the current can be set to 0.1 A, 1 A or 5 A via the CoE directory.

No upstream voltage transformer is required. The current inputs are electrically isolated so that the terminal
can be used in all common grounded current transformer configurations such as 2- or 3-transformer
configurations with star or delta connection.

Like all measured terminal data, the harmonic content can be read via the process data.

The EL3413-0001 has a maximum input voltage of 600 V AC and is additionally UL-certified.
In the case of the EL3413-0120 the voltage range is limited to 210 V AC.

Quick links

• EtherCAT basics

• Basic function principles EL34x3 [}21]

• CoE object description and parameterization [}152]

• Process data and operating modes [}128]

EL34x3 17Version: 4.4

Product overview

2.1.2 Technical data

Technical data EL3413-0000 EL3413-0001 EL3413-0120

Measured values Current, voltage, effective power, apparent power, frequency
Calculated values Reactive power, energy, power factor (cosφ), harmonic frequencies,

phase angle

Measuring voltage max. 690VAC3~

(ULX-N: max. 400VAC)

Fed-in voltages must comply with overvoltage category II
Measuring current max. 5A (AC) (configurable), via measuring transformerxA/5A
Input resistance voltage circuit

(typ.)
Input resistance current circuit

(typ.)
Fuse protection Voltage circuit: according to the connected conductor size

Resolution 0.1µA, 0.1mV, 10mW

Measuring accuracy 0.5% in relation to the full scale value (U/I),

Frequency range 45Hz to 65Hz
Signal type any (taking into account the frequency range and the limit frequency)
Measuring procedure True RMS calculation with 16,800 (2,800 per channel)samples/s
Measuring cycle time 200ms per measured value preset, freely configurable, mains-

Electrical isolation 4500V (connection terminal/E-bus)
Supply voltage for electronic via the E-bus
E-Bus current consumption typ. 160mA
Configuration via TwinCAT System Manager
Dimensions (W x H x D) approx. 27mm x 100mm x 70mm (width aligned: 24mm)
Weight approx. 75g

Mounting [}38]

Operating temperature -25°C ... +60°C (extended temperature range)
Storage temperature -40°C ... +85°C
Relative humidity 95 % no condensation
Vibration/shock resistance conforms to EN 60068-2-6 / EN 60068-2-27
EMC immunity/emission conforms to EN 61000-6-2 / EN 61000-6-4
Protect. class / installation pos. IP20/any
Approvals CE CE

1MΩ

<3mΩ

Current circuit: primary side of the current transformer, according to the

connected conductor size

(0.1A measuring

range)

1µA, 0.1mV, 10mW

(1A measuring range)

5µA, 0.1mV, 10mW

(5A measuring range)

1% calculated value (P)

Notice:

For the EL3413, an accuracy of 2% FSV (full scale value) of the largest

measuring range of the terminal is valid referring to the neutral conductor

current measurement. The neutral conductor current measurement is only

possible for this measuring range.

synchronous

on 35mm mounting rail conforms to EN 60715

max. 600VAC3~
(ULX-N: max. 346VAC)

1µA, 0.1mV, 10mW
(1A measuring range)
5µA, 0.1mV, 10mW
(5A measuring range)

cULus [}48]

max. 210 VAC3~
(ULX-N: max. 120VAC)

0.1µA, 0.1mV, 10mW
(0.1A measuring
range)
1µA, 0.1mV, 10mW
(1A measuring range)
5µA, 0.1mV, 10mW
(5A measuring range)

CE

EL34x318 Version: 4.4

2.2 EL3433

2.2.1 Introduction

Product overview

Fig.12: EL3433

3-phase power measurement terminal, 500 V AC, 10 A

The EL3433 EtherCAT power measurement terminal is a further development of the EL3403.

Currents of up to 10A can be directly measured with the internal current transformers. Hence, there are no
additional costs for external current transformers. The external bridges 5&1', 6&2' and 7&3' are already
pre-wired. As a result it is possible to directly connect the supply voltage (5', 6' and 7') and the consumer (1,
2 and 3).

The EL3433 can deal with simple network analysis up to the 21stharmonic analysis. Like all measured
terminal data, the harmonic content can be read via the process data.

Quick links

• EtherCAT basics

• Basic function principles EL34x3 [}21]

• CoE object description and parameterization [}152]

• Process data and operating modes [}128]

EL34x3 19Version: 4.4

Product overview

2.2.2 Technical data

Technical data EL3433

Measured values Current, voltage, effective power, apparent power, frequency
Calculated values Reactive power, energy, power factor (cosφ), harmonic frequencies,

phase angle
Measuring voltage max. 500VAC3~ (ULX-N: max. 288VAC)

Fed-in voltages must comply with overvoltage category II
Measuring current max. 10A (AC) (configurable)
Input resistance voltage circuit

(typ.)
Input resistance current circuit

(typ.)
Fuse protection Voltage circuit: according to the connected conductor size

Resolution 1µA, 0.1mV, 10mW
Measuring accuracy 0.5% in relation to the full scale value (U/I) (at 0°C…55°C)

Frequency range 45Hz to 65Hz
Signal type any (taking into account the frequency range and the limit frequency)
Measuring procedure True RMS calculation with 16,800 (2,800 per channel)samples/s
Measuring cycle time 200ms per measured value preset, freely configurable, mains-

Electrical isolation 4500V (connection terminal/E-bus)
Supply voltage for electronic via the E-bus
E-Bus current consumption 200mA typ.
Configuration via TwinCAT System Manager
Dimensions (W x H x D) approx. 27mm x 100mm x 70mm (width aligned: 24mm)
Weight approx. 100g

Mounting [}38]

Operating temperature -25 °C ... +60 °C (extended temperature range)
Storage temperature -40 °C ... +85 °C
Relative humidity 95 % no condensation
Vibration/shock resistance conforms to EN 60068-2-6 / EN 60068-2-27
EMC immunity/emission conforms to EN 61000-6-2 / EN 61000-6-4
Protect. class / installation pos. IP20/any
Approvals CE

1MΩ

<3mΩ

Current circuit: primary side of the current transformer, according to the

connected conductor size

1% in relation to the full scale value (U/I) (when the extended temperature

range is used)

1% calculated value (P)

Notice:

For the EL3433, an accuracy of 2% FSV (full scale value) of the largest

measuring range of the terminal is valid referring to the neutral conductor

current measurement. The neutral conductor current measurement is only

possible for this measuring range.

synchronous

on 35mm mounting rail conforms to EN 60715

cULus [}48]

EL34x320 Version: 4.4

Product overview

2.3 Basic function principles

2.3.1 Measuring principle

The EL34x3 terminals operate with 1 analog/digital converter for measuring the current and voltage variables
of all three phases.

The measurement and processing of the three phases take place successively (45 µs offset) in exactly the
same way. The signal processing for one phase is described below. This description applies correspondingly
for all three phases.

Fig.13: Voltage u and current i curves

2.3.2 RMS value calculation

The rms value for voltage and current is calculated over a measuring interval, in this case the period T. The
following equations are used:

u

: instantaneous voltage value

(t)

i

: instantaneous current value

(t)

n: number of measured values

Measuring interval

The choice of the right measuring interval is important for the quality of the measurement. The default setting
for the measuring interval is 10periods (10 x 20ms). Experience shows that this is a good compromise
between measuring speed and stability. Deviations from this value are only advisable in the event of
particular measurement requirements (e.g. high measuring speed).

EL34x3 21Version: 4.4

Product overview

2.3.3 Effective power measurement

The EL34x3 measures the effective power P according to the following equation

P: Active power
n: Number of samples
u

: Instantaneous voltage value

(t)

i

: instantaneous current value

(t)

Fig.14: Power s

In the first step, the power s

curve

(t)

is calculated at each sampling instant:

(t)

The mean value over the measuring interval is calculated. Here too, the correct choice of the intervals is
important, as described in section RMS value measurement (the interval can only be changed
simultaneously for U, I and P).

The power frequency is twice that of the corresponding voltages and currents.

2.3.4 Apparent power measurement

In real networks, not all consumers are purely ohmic. Phase shifts occur between current and voltage. This
does not affect the methodology for determining the rms values of voltage and current as described above.

The situation for the effective power is different: Here, the product of effective voltage and effective current is
the apparent power.

The effective power is smaller than the apparent power.

EL34x322 Version: 4.4

S: Apparent power
P: Active power
Q: Reactive power
φ: Phase shift angle

Product overview

Fig.15: u

, i

, p

(t)

curves with phase shift angle φ

(t)

(t)

In this context, further parameters of the mains system and its consumers are significant:

• apparent power S

• reactive power Q

• power factor cos φ

The EL34x3 determines the following values:

EL34x3 23Version: 4.4

Product overview

• effective power P

• effective voltage U

• effective current I

• apparent power S

• reactive power Q

• power factor cos φ

• harmonic

• phase shift λ

2.3.5 Sign for power measurement

The sign of the active power P and of the power factor cos φ provide about information the direction of the
energy flow. A positive sign indicates the motor mode, a negative sign indicates generator mode.

In addition, the sign of the reactive power Q indicates the direction of the phase shift between current and
voltage. Fig. Four-quadrant representation of active/reactive power in motor and generator mode illustrates
this. In motor mode (quadrant I & IV) a positive reactive power indicates an inductive load, a negative
reactive power indicates a capacitive load. In generator mode (quadrant II & III), an inductive acting
generator is indicated by a positive reactive power, a capacitive acting generator by a negative reactive
power.

Fig.16: Four-quadrant representation of active/reactive power in motor and generator mode

EL34x324 Version: 4.4

2.3.6 Sign of the energy values

Name Index Variant Value AUX channel CoE

Energy
difference

Energy
negative

Energy
positive

Energy
difference
(automatically
saved)

Energy
negative
(automatically
saved)

Positive
energy
(automatically
saved)

Sum (Ch 0) Channel ac-

cess (Ch
11/12/13)

2 |E+| - |E-| ∑ |E+| - ∑ |E-| |E+| - |E-| N/A N/A

5 -|E-| ∑ |E-| |E-| |E-| |E-|

30 |E+| ∑ |E+| |E+| |E+| |E+|

32 |E+| - |E-| ∑ |E+| - ∑ |E-| |E+| - |E-| N/A N/A

35 -|E-| ∑ |E-| |E-| |E-| |E-|

31 |E+| |E+| |E+| |E+| |E+|

0x90n0 0xF801

Product overview

*)

*) Access only possible from PLC

2.3.7 Frequency measurement

The EL34x3 can measure the frequency of the input signals at a voltage circuit (L1, L2 or L3).

Held frequency

The last frequency is displayed via indexes 46, 47 and 48, "Held Frequency", before one or more channels
report an "Undervoltage" or "Missing Zero Crossing" error.

The values may not represent the actual mains frequency (see also last note in chapter "PM Inputs Channel
1/2/3 [}137]").

2.4 Current transformer

In principle, the choice of current transformer for the EL34x3 is not critical. The internal resistance within the
current circuit of the EL34x3 is so small that it is negligible for the calculation of the total resistances of the
current loop. The transformers must be able to supply a secondary rated current in accordance with the set
measuring range. The primary rated current Ipn can be selected arbitrarily. The common permissible overload
of 1.2 x Ipn is no problem for the EL34x3, but may lead to small measuring inaccuracies.

Accuracy

Please note that the overall accuracy of the set-up consisting of EL34x3 and current transformers to a large
degree depends on the accuracy class of the transformers.

No approval as a billing meter

A set-up with a class 0.5 current transformer cannot be approved or authenticated. The EL34x3 is
not an approved billing meter according to the electricity meter standard (DIN43856).

EL34x3 25Version: 4.4

Product overview

Current types

The EL34x3 terminals can measure AC currents with a frequency of 45 Hz to 65 Hz and up to their 21
harmonic. Since such currents are frequently created by inverters and may contain frequencies of less than
50 Hz or even a DC component, electronic transformers should be used for such applications.

Overcurrent limiting factor FS

The overcurrent limiting factor FS of a current transformer indicates at what multiple of the primary rated
current the current transformer changes to saturation mode, in order to protect the connected measuring
instruments.

st

NOTE

Attention! Risk of damage to the device!

The EL34x3 terminals may not be continuously loaded with more than 5 A [EL3413-xxxx] or 10A [EL3433­xxxx] respectively! Additional intermediate transformers must be used in systems in which the overcurrent
limiting factors of the transformer allow higher secondary currents!

Protection against dangerous touch voltages

During appropriate operation of the EL34x3 with associated current transformers, no dangerous voltages
occur. The secondary voltage is in the range of a few Volts. However, the following faults may lead to
excessive voltages:

• Open current circuit of one or several transformers

• Neutral conductor cut on the voltage measurement side of the EL34x3

• General insulation fault

WARNING

WARNING Risk of electric shock!

The complete wiring of the EL34x3 must be protected against accidental contact and equipped with associ­ated warnings! The insulation should be designed for the maximum conductor voltage of the system to be
measured!

The EL3413-xxxxx [}18] or EL3433-xxxx [}20] allows the maximum voltage for normal conditions as specified
in the technical data. The conductor voltage on the current side must not exceed this value! For higher
voltages, an intermediate transformer stage should be used!

An EL34x3 is equipped with a protective impedance of typically 1MΩ on the voltage measurement side. If
the neutral conductor is not connected and only one connection is live on the voltage measurement side, the

resulting voltage against earth in a 3-phase system with a specific line-to-line voltage [}18] is reduced by
the factor √3. This should also be measured on the side of the current measurement using a multimeter with
an internal resistance of 10 MΩ, which does not represent an insulation fault.

Additional measuring instruments in the current circuit

Please note that the addition of additional measuring instruments (e.g. ammeters) in the current circuit can
lead to a significant increase in the total apparent power.

2.5 Start

For commissioning:

• mount the EL34x3 as described in the chapter Mounting and wiring [}38]

• configure the EL34x3 in TwinCAT as described in the chapter Commissioning [}62].

EL34x326 Version: 4.4

Basics communication

3 Basics communication

3.1 EtherCAT basics

Please refer to the EtherCAT System Documentation for the EtherCAT fieldbus basics.

3.2 EtherCAT cabling – wire-bound

The cable length between two EtherCAT devices must not exceed 100 m. This results from the FastEthernet
technology, which, above all for reasons of signal attenuation over the length of the cable, allows a maximum

link length of 5 + 90 + 5 m if cables with appropriate properties are used. See also the Design
recommendations for the infrastructure for EtherCAT/Ethernet.

Cables and connectors

For connecting EtherCAT devices only Ethernet connections (cables + plugs) that meet the requirements of
at least category 5 (CAt5) according to EN 50173 or ISO/IEC 11801 should be used. EtherCAT uses 4 wires
for signal transfer.

EtherCAT uses RJ45 plug connectors, for example. The pin assignment is compatible with the Ethernet
standard (ISO/IEC 8802-3).

Pin Color of conductor Signal Description

1 yellow TD + Transmission Data +
2 orange TD - Transmission Data ­3 white RD + Receiver Data +
6 blue RD - Receiver Data -

Due to automatic cable detection (auto-crossing) symmetric (1:1) or cross-over cables can be used between
EtherCAT devices from Beckhoff.

Recommended cables

Suitable cables for the connection of EtherCAT devices can be found on the Beckhoff website!

E-Bus supply

A bus coupler can supply the EL terminals added to it with the E-bus system voltage of 5V; a coupler is
thereby loadable up to 2A as a rule (see details in respective device documentation).
Information on how much current each EL terminal requires from the E-bus supply is available online and in
the catalogue. If the added terminals require more current than the coupler can supply, then power feed

terminals (e.g. EL9410) must be inserted at appropriate places in the terminal strand.

The pre-calculated theoretical maximum E-Bus current is displayed in the TwinCAT System Manager. A
shortfall is marked by a negative total amount and an exclamation mark; a power feed terminal is to be
placed before such a position.

EL34x3 27Version: 4.4

Basics communication

Fig.17: System manager current calculation

NOTE

Malfunction possible!

The same ground potential must be used for the E-Bus supply of all EtherCAT terminals in a terminal block!

3.3 General notes for setting the watchdog

ELxxxx terminals are equipped with a safety feature (watchdog) that switches off the outputs after a
specifiable time e.g. in the event of an interruption of the process data traffic, depending on the device and
settings, e.g. in OFF state.

The EtherCAT slave controller (ESC) in the EL2xxx terminals features 2 watchdogs:

• SM watchdog (default: 100 ms)

• PDI watchdog (default: 100 ms)

SM watchdog (SyncManager Watchdog)

The SyncManager watchdog is reset after each successful EtherCAT process data communication with the
terminal. If no EtherCAT process data communication takes place with the terminal for longer than the set
and activated SM watchdog time, e.g. in the event of a line interruption, the watchdog is triggered and the
outputs are set to FALSE. The OP state of the terminal is unaffected. The watchdog is only reset after a
successful EtherCAT process data access. Set the monitoring time as described below.

The SyncManager watchdog monitors correct and timely process data communication with the ESC from the
EtherCAT side.

PDI watchdog (Process Data Watchdog)

If no PDI communication with the EtherCAT slave controller (ESC) takes place for longer than the set and
activated PDI watchdog time, this watchdog is triggered.
PDI (Process Data Interface) is the internal interface between the ESC and local processors in the EtherCAT
slave, for example. The PDI watchdog can be used to monitor this communication for failure.

The PDI watchdog monitors correct and timely process data communication with the ESC from the
application side.

The settings of the SM- and PDI-watchdog must be done for each slave separately in the TwinCAT System
Manager.

EL34x328 Version: 4.4

Basics communication

Fig.18: EtherCAT tab -> Advanced Settings -> Behavior -> Watchdog

Notes:

• the multiplier is valid for both watchdogs.

• each watchdog has its own timer setting, the outcome of this in summary with the multiplier is a
resulting time.

• Important: the multiplier/timer setting is only loaded into the slave at the start up, if the checkbox is
activated.
If the checkbox is not activated, nothing is downloaded and the ESC settings remain unchanged.

Multiplier

Multiplier

Both watchdogs receive their pulses from the local terminal cycle, divided by the watchdog multiplier:

1/25 MHz * (watchdog multiplier + 2) = 100 µs (for default setting of 2498 for the multiplier)

The standard setting of 1000 for the SM watchdog corresponds to a release time of 100 ms.

The value in multiplier + 2 corresponds to the number of basic 40 ns ticks representing a watchdog tick.
The multiplier can be modified in order to adjust the watchdog time over a larger range.

EL34x3 29Version: 4.4

Basics communication

Example "Set SM watchdog"

This checkbox enables manual setting of the watchdog times. If the outputs are set and the EtherCAT
communication is interrupted, the SM watchdog is triggered after the set time and the outputs are erased.
This setting can be used for adapting a terminal to a slower EtherCAT master or long cycle times. The
default SM watchdog setting is 100 ms. The setting range is 0..65535. Together with a multiplier with a range
of 1..65535 this covers a watchdog period between 0..~170 seconds.

Calculation

Multiplier = 2498 → watchdog base time = 1 / 25MHz * (2498 + 2) = 0.0001seconds = 100µs
SM watchdog = 10000 → 10000 * 100µs = 1second watchdog monitoring time

CAUTION

Undefined state possible!

The function for switching off of the SM watchdog via SM watchdog = 0 is only implemented in terminals
from version -0016. In previous versions this operating mode should not be used.

CAUTION

Damage of devices and undefined state possible!

If the SM watchdog is activated and a value of 0 is entered the watchdog switches off completely. This is
the deactivation of the watchdog! Set outputs are NOT set in a safe state, if the communication is inter­rupted.

3.4 EtherCAT State Machine

The state of the EtherCAT slave is controlled via the EtherCAT State Machine (ESM). Depending upon the
state, different functions are accessible or executable in the EtherCAT slave. Specific commands must be
sent by the EtherCAT master to the device in each state, particularly during the bootup of the slave.

A distinction is made between the following states:

• Init

• Pre-Operational

• Safe-Operational and

• Operational

• Boot

The regular state of each EtherCAT slave after bootup is the OP state.

EL34x330 Version: 4.4

Fig.19: States of the EtherCAT State Machine

Basics communication

Init

After switch-on the EtherCAT slave in the Init state. No mailbox or process data communication is possible.
The EtherCAT master initializes sync manager channels 0 and 1 for mailbox communication.

Pre-Operational (Pre-Op)

During the transition between Init and Pre-Op the EtherCAT slave checks whether the mailbox was initialized
correctly.

In Pre-Op state mailbox communication is possible, but not process data communication. The EtherCAT
master initializes the sync manager channels for process data (from sync manager channel 2), the FMMU
channels and, if the slave supports configurable mapping, PDO mapping or the sync manager PDO
assignment. In this state the settings for the process data transfer and perhaps terminal-specific parameters
that may differ from the default settings are also transferred.

Safe-Operational (Safe-Op)

During transition between Pre-Op and Safe-Op the EtherCAT slave checks whether the sync manager
channels for process data communication and, if required, the distributed clocks settings are correct. Before
it acknowledges the change of state, the EtherCAT slave copies current input data into the associated DP­RAM areas of the EtherCAT slave controller (ECSC).

In Safe-Op state mailbox and process data communication is possible, although the slave keeps its outputs
in a safe state, while the input data are updated cyclically.

Outputs in SAFEOP state

The default set watchdog [}28] monitoring sets the outputs of the module in a safe state - depend­ing on the settings in SAFEOP and OP - e.g. in OFF state. If this is prevented by deactivation of the
watchdog monitoring in the module, the outputs can be switched or set also in the SAFEOP state.

Operational (Op)

Before the EtherCAT master switches the EtherCAT slave from Safe-Op to Op it must transfer valid output
data.

In the Op state the slave copies the output data of the masters to its outputs. Process data and mailbox
communication is possible.

EL34x3 31Version: 4.4

Basics communication

Boot

In the Boot state the slave firmware can be updated. The Boot state can only be reached via the Init state.

In the Boot state mailbox communication via the file access over EtherCAT (FoE) protocol is possible, but no
other mailbox communication and no process data communication.

3.5 CoE Interface

General description

The CoE interface (CANopen over EtherCAT) is used for parameter management of EtherCAT devices.
EtherCAT slaves or the EtherCAT master manage fixed (read only) or variable parameters which they
require for operation, diagnostics or commissioning.

CoE parameters are arranged in a table hierarchy. In principle, the user has read access via the fieldbus.
The EtherCAT master (TwinCAT System Manager) can access the local CoE lists of the slaves via
EtherCAT in read or write mode, depending on the attributes.

Different CoE parameter types are possible, including string (text), integer numbers, Boolean values or larger
byte fields. They can be used to describe a wide range of features. Examples of such parameters include
manufacturer ID, serial number, process data settings, device name, calibration values for analog
measurement or passwords.

The order is specified in 2 levels via hexadecimal numbering: (main)index, followed by subindex. The value
ranges are

• Index: 0x0000 …0xFFFF (0...65535

• SubIndex: 0x00…0xFF (0...255

dez

)

dez

)

A parameter localized in this way is normally written as 0x8010:07, with preceding "x" to identify the
hexadecimal numerical range and a colon between index and subindex.

The relevant ranges for EtherCAT fieldbus users are:

• 0x1000: This is where fixed identity information for the device is stored, including name, manufacturer,
serial number etc., plus information about the current and available process data configurations.

• 0x8000: This is where the operational and functional parameters for all channels are stored, such as
filter settings or output frequency.

Other important ranges are:

• 0x4000: In some EtherCAT devices the channel parameters are stored here (as an alternative to the
0x8000 range).

• 0x6000: Input PDOs ("input" from the perspective of the EtherCAT master)

• 0x7000: Output PDOs ("output" from the perspective of the EtherCAT master)

Availability

Not every EtherCAT device must have a CoE list. Simple I/O modules without dedicated processor
usually have no variable parameters and therefore no CoE list.

If a device has a CoE list, it is shown in the TwinCAT System Manager as a separate tab with a listing of the
elements:

EL34x332 Version: 4.4

Basics communication

Fig.20: "CoE Online " tab

The figure above shows the CoE objects available in device "EL2502", ranging from 0x1000 to 0x1600. The
subindices for 0x1018 are expanded.

Data management and function "NoCoeStorage"

Some parameters, particularly the setting parameters of the slave, are configurable and writeable. This can
be done in write or read mode

• via the System Manager (Fig. "CoE Online " tab) by clicking
This is useful for commissioning of the system/slaves. Click on the row of the index to be
parameterised and enter a value in the "SetValue" dialog.

• from the control system/PLC via ADS, e.g. through blocks from the TcEtherCAT.lib library
This is recommended for modifications while the system is running or if no System Manager or
operating staff are available.

Data management

If slave CoE parameters are modified online, Beckhoff devices store any changes in a fail-safe
manner in the EEPROM, i.e. the modified CoE parameters are still available after a restart.
The situation may be different with other manufacturers.

An EEPROM is subject to a limited lifetime with respect to write operations. From typically 100,000
write operations onwards it can no longer be guaranteed that new (changed) data are reliably saved
or are still readable. This is irrelevant for normal commissioning. However, if CoE parameters are
continuously changed via ADS at machine runtime, it is quite possible for the lifetime limit to be
reached. Support for the NoCoeStorage function, which suppresses the saving of changed CoE val­ues, depends on the firmware version.
Please refer to the technical data in this documentation as to whether this applies to the respective
device.

• If the function is supported: the function is activated by entering the code word 0x12345678 once
in CoE 0xF008 and remains active as long as the code word is not changed. After switching the
device on it is then inactive. Changed CoE values are not saved in the EEPROM and can thus
be changed any number of times.

• Function is not supported: continuous changing of CoE values is not permissible in view of the
lifetime limit.

EL34x3 33Version: 4.4

Basics communication

Startup list

Changes in the local CoE list of the terminal are lost if the terminal is replaced. If a terminal is re­placed with a new Beckhoff terminal, it will have the default settings. It is therefore advisable to link
all changes in the CoE list of an EtherCAT slave with the Startup list of the slave, which is pro­cessed whenever the EtherCAT fieldbus is started. In this way a replacement EtherCAT slave can
automatically be parameterized with the specifications of the user.

If EtherCAT slaves are used which are unable to store local CoE values permanently, the Startup
list must be used.

Recommended approach for manual modification of CoE parameters

• Make the required change in the System Manager
The values are stored locally in the EtherCAT slave

• If the value is to be stored permanently, enter it in the Startup list.
The order of the Startup entries is usually irrelevant.

Fig.21: Startup list in the TwinCAT System Manager

The Startup list may already contain values that were configured by the System Manager based on the ESI
specifications. Additional application-specific entries can be created.

Online/offline list

While working with the TwinCAT System Manager, a distinction has to be made whether the EtherCAT
device is "available", i.e. switched on and linked via EtherCAT and therefore online, or whether a
configuration is created offline without connected slaves.

In both cases a CoE list as shown in Fig. “’CoE online’ tab” is displayed. The connectivity is shown as offline/
online.

• If the slave is offline

◦ The offline list from the ESI file is displayed. In this case modifications are not meaningful or

possible.
◦ The configured status is shown under Identity.
◦ No firmware or hardware version is displayed, since these are features of the physical device.
◦ Offline is shown in red.

EL34x334 Version: 4.4

Basics communication

Fig.22: Offline list

• If the slave is online
◦ The actual current slave list is read. This may take several seconds, depending on the size and

cycle time.
◦ The actual identity is displayed
◦ The firmware and hardware version of the equipment according to the electronic information is

displayed
◦ Online is shown in green.

Fig.23: Online list

EL34x3 35Version: 4.4

Basics communication

Channel-based order

The CoE list is available in EtherCAT devices that usually feature several functionally equivalent channels.
For example, a 4-channel analog 0..10 V input terminal also has 4 logical channels and therefore 4 identical
sets of parameter data for the channels. In order to avoid having to list each channel in the documentation,
the placeholder "n" tends to be used for the individual channel numbers.

In the CoE system 16 indices, each with 255 subindices, are generally sufficient for representing all channel
parameters. The channel-based order is therefore arranged in 16

dec

/10

steps. The parameter range

hex

0x8000 exemplifies this:

• Channel 0: parameter range 0x8000:00 ... 0x800F:255

• Channel 1: parameter range 0x8010:00 ... 0x801F:255

• Channel 2: parameter range 0x8020:00 ... 0x802F:255

• ...

This is generally written as 0x80n0.

Detailed information on the CoE interface can be found in the EtherCAT system documentation on the
Beckhoff website.

EL34x336 Version: 4.4

3.6 Distributed Clock

Distributed Clock. The EL34x3 terminals do not support Distributed Clocks.

Basics communication

EL34x3 37Version: 4.4

Installation

4 Installation

4.1 Instructions for ESD protection

NOTE

Destruction of the devices by electrostatic discharge possible!

The devices contain components at risk from electrostatic discharge caused by improper handling.

• Please ensure you are electrostatically discharged and avoid touching the contacts of the device directly.

• Avoid contact with highly insulating materials (synthetic fibers, plastic film etc.).

• Surroundings (working place, packaging and personnel) should by grounded probably, when handling
with the devices.

• Each assembly must be terminated at the right hand end with an EL9011 or EL9012 bus end cap, to en­sure the protection class and ESD protection.

Fig.24: Spring contacts of the Beckhoff I/O components

4.2 Installation on mounting rails

WARNING

Risk of electric shock and damage of device!

Bring the bus terminal system into a safe, powered down state before starting installation, disassembly or
wiring of the bus terminals!

EL34x338 Version: 4.4

Assembly

Installation

Fig.25: Attaching on mounting rail

The bus coupler and bus terminals are attached to commercially available 35mm mounting rails (DIN rails
according to EN60715) by applying slight pressure:

1. First attach the fieldbus coupler to the mounting rail.

2. The bus terminals are now attached on the right-hand side of the fieldbus coupler. Join the compo­nents with tongue and groove and push the terminals against the mounting rail, until the lock clicks
onto the mounting rail.
If the terminals are clipped onto the mounting rail first and then pushed together without tongue and
groove, the connection will not be operational! When correctly assembled, no significant gap should
be visible between the housings.

Fixing of mounting rails

The locking mechanism of the terminals and couplers extends to the profile of the mounting rail. At
the installation, the locking mechanism of the components must not come into conflict with the fixing
bolts of the mounting rail. To mount the mounting rails with a height of 7.5mm under the terminals
and couplers, you should use flat mounting connections (e.g. countersunk screws or blind rivets).

EL34x3 39Version: 4.4

Installation

Disassembly

Fig.26: Disassembling of terminal

Each terminal is secured by a lock on the mounting rail, which must be released for disassembly:

1. Pull the terminal by its orange-colored lugs approximately 1cm away from the mounting rail. In doing
so for this terminal the mounting rail lock is released automatically and you can pull the terminal out of
the bus terminal block easily without excessive force.

2. Grasp the released terminal with thumb and index finger simultaneous at the upper and lower grooved
housing surfaces and pull the terminal out of the bus terminal block.

Connections within a bus terminal block

The electric connections between the Bus Coupler and the Bus Terminals are automatically realized by
joining the components:

• The six spring contacts of the K-Bus/E-Bus deal with the transfer of the data and the supply of the Bus
Terminal electronics.

• The power contacts deal with the supply for the field electronics and thus represent a supply rail within
the bus terminal block. The power contacts are supplied via terminals on the Bus Coupler (up to 24V)
or for higher voltages via power feed terminals.

Power Contacts

During the design of a bus terminal block, the pin assignment of the individual Bus Terminals must
be taken account of, since some types (e.g. analog Bus Terminals or digital 4-channel Bus Termi­nals) do not or not fully loop through the power contacts. Power Feed Terminals (KL91xx, KL92xx
or EL91xx, EL92xx) interrupt the power contacts and thus represent the start of a new supply rail.

PE power contact

The power contact labeled PE can be used as a protective earth. For safety reasons this contact mates first
when plugging together, and can ground short-circuit currents of up to 125A.

EL34x340 Version: 4.4

Fig.27: Power contact on left side

Installation

NOTE

Possible damage of the device

Note that, for reasons of electromagnetic compatibility, the PE contacts are capacitatively coupled to the
mounting rail. This may lead to incorrect results during insulation testing or to damage on the terminal (e.g.
disruptive discharge to the PE line during insulation testing of a consumer with a nominal voltage of 230V).
For insulation testing, disconnect the PE supply line at the Bus Coupler or the Power Feed Terminal! In or­der to decouple further feed points for testing, these Power Feed Terminals can be released and pulled at
least 10mm from the group of terminals.

WARNING

Risk of electric shock!

The PE power contact must not be used for other potentials!

4.3 Connection

4.3.1 Connection system

WARNING

Risk of electric shock and damage of device!

Bring the bus terminal system into a safe, powered down state before starting installation, disassembly or
wiring of the bus terminals!

Overview

The Bus Terminal system offers different connection options for optimum adaptation to the respective
application:

• The terminals of ELxxxx and KLxxxx series with standard wiring include electronics and connection
level in a single enclosure.

• The terminals of ESxxxx and KSxxxx series feature a pluggable connection level and enable steady
wiring while replacing.

• The High Density Terminals (HD Terminals) include electronics and connection level in a single
enclosure and have advanced packaging density.

EL34x3 41Version: 4.4

Installation

Standard wiring (ELxxxx / KLxxxx)

Fig.28: Standard wiring

The terminals of ELxxxx and KLxxxx series have been tried and tested for years.
They feature integrated screwless spring force technology for fast and simple assembly.

Pluggable wiring (ESxxxx / KSxxxx)

Fig.29: Pluggable wiring

The terminals of ESxxxx and KSxxxx series feature a pluggable connection level.
The assembly and wiring procedure is the same as for the ELxxxx and KLxxxx series.
The pluggable connection level enables the complete wiring to be removed as a plug connector from the top
of the housing for servicing.
The lower section can be removed from the terminal block by pulling the unlocking tab.
Insert the new component and plug in the connector with the wiring. This reduces the installation time and
eliminates the risk of wires being mixed up.

The familiar dimensions of the terminal only had to be changed slightly. The new connector adds about 3
mm. The maximum height of the terminal remains unchanged.

A tab for strain relief of the cable simplifies assembly in many applications and prevents tangling of individual
connection wires when the connector is removed.

Conductor cross sections between 0.08mm2 and 2.5mm2 can continue to be used with the proven spring
force technology.

The overview and nomenclature of the product names for ESxxxx and KSxxxx series has been retained as
known from ELxxxx and KLxxxx series.

High Density Terminals (HD Terminals)

Fig.30: High Density Terminals

The Bus Terminals from these series with 16 terminal points are distinguished by a particularly compact
design, as the packaging density is twice as large as that of the standard 12mm Bus Terminals. Massive
conductors and conductors with a wire end sleeve can be inserted directly into the spring loaded terminal
point without tools.

EL34x342 Version: 4.4

Wiring HD Terminals

The High Density (HD) Terminals of the ELx8xx and KLx8xx series doesn't support pluggable
wiring.

Ultrasonically "bonded" (ultrasonically welded) conductors

Ultrasonically “bonded" conductors

It is also possible to connect the Standard and High Density Terminals with ultrasonically
"bonded" (ultrasonically welded) conductors. In this case, please note the tables concerning the
wire-size width below!

Installation

EL34x3 43Version: 4.4

Installation

4.3.2 Wiring

WARNING

Risk of electric shock and damage of device!

Bring the bus terminal system into a safe, powered down state before starting installation, disassembly or
wiring of the Bus Terminals!

Terminals for standard wiring ELxxxx/KLxxxx and for pluggable wiring ESxxxx/KSxxxx

Fig.31: Connecting a cable on a terminal point

Up to eight terminal points enable the connection of solid or finely stranded cables to the Bus Terminal. The
terminal points are implemented in spring force technology. Connect the cables as follows:

1. Open a terminal point by pushing a screwdriver straight against the stop into the square opening
above the terminal point. Do not turn the screwdriver or move it alternately (don't toggle).

2. The wire can now be inserted into the round terminal opening without any force.

3. The terminal point closes automatically when the pressure is released, holding the wire securely and
permanently.

See the following table for the suitable wire size width.

Terminal housing ELxxxx, KLxxxx ESxxxx, KSxxxx
Wire size width (single core wires) 0.08 ... 2.5mm
Wire size width (fine-wire conductors) 0.08 ... 2.5mm
Wire size width (conductors with a wire end sleeve) 0.14 ... 1.5mm

2

2

2

0.08 ... 2.5mm
0,08 ... 2.5mm

0.14 ... 1.5mm

2

2

2

Wire stripping length 8 ... 9mm 9 ... 10mm

High Density Terminals (HD Terminals [}42]) with 16 terminal points

The conductors of the HD Terminals are connected without tools for single-wire conductors using the direct
plug-in technique, i.e. after stripping the wire is simply plugged into the terminal point. The cables are
released, as usual, using the contact release with the aid of a screwdriver. See the following table for the
suitable wire size width.

EL34x344 Version: 4.4

Installation

Terminal housing High Density Housing
Wire size width (single core wires) 0.08 ... 1.5mm
Wire size width (fine-wire conductors) 0.25 ... 1.5mm
Wire size width (conductors with a wire end sleeve) 0.14 ... 0.75mm
Wire size width (ultrasonically “bonded" conductors) only 1.5mm

2

2

2

2

Wire stripping length 8 ... 9mm

4.3.3 Shielding

Shielding

Encoder, analog sensors and actors should always be connected with shielded, twisted paired
wires.

4.4 Installation positions

NOTE

Constraints regarding installation position and operating temperature range

Please refer to the technical data for a terminal to ascertain whether any restrictions regarding the installa­tion position and/or the operating temperature range have been specified. When installing high power dissi­pation terminals ensure that an adequate spacing is maintained between other components above and be­low the terminal in order to guarantee adequate ventilation!

Optimum installation position (standard)

The optimum installation position requires the mounting rail to be installed horizontally and the connection
surfaces of the EL/KL terminals to face forward (see Fig. “Recommended distances for standard installation
position”). The terminals are ventilated from below, which enables optimum cooling of the electronics through
convection. "From below" is relative to the acceleration of gravity.

EL34x3 45Version: 4.4

Installation

Fig.32: Recommended distances for standard installation position

Compliance with the distances shown in Fig. “Recommended distances for standard installation position” is
recommended.

Other installation positions

All other installation positions are characterized by different spatial arrangement of the mounting rail - see
Fig “Other installation positions”.

The minimum distances to ambient specified above also apply to these installation positions.

EL34x346 Version: 4.4

Fig.33: Other installation positions

Installation

EL34x3 47Version: 4.4

Installation

4.5 Positioning of passive Terminals

Hint for positioning of passive terminals in the bus terminal block

EtherCAT Terminals (ELxxxx / ESxxxx), which do not take an active part in data transfer within the
bus terminal block are so called passive terminals. The passive terminals have no current consump­tion out of the E-Bus.
To ensure an optimal data transfer, you must not directly string together more than 2 passive termi­nals!

Examples for positioning of passive terminals (highlighted)

Fig.34: Correct positioning

Fig.35: Incorrect positioning

4.6 UL notice

Application

Beckhoff EtherCAT modules are intended for use with Beckhoff’s UL Listed EtherCAT Sys­tem only.

Examination

For cULus examination, the Beckhoff I/O System has only been investigated for risk of fire
and electrical shock (in accordance with UL508 and CSAC22.2 No.142).

EL34x348 Version: 4.4

Installation

For devices with Ethernet connectors

Not for connection to telecommunication circuits.

Basic principles

Two UL certificates are met in the Beckhoff EtherCAT product range, depending upon the components:

1. UL certification according to UL508. Devices with this kind of certification are marked by this sign:

2. UL certification according to UL508 with limited power consumption. The current consumed by the de­vice is limited to a max. possible current consumption of 4A. Devices with this kind of certification are
marked by this sign:

Almost all current EtherCAT products (as at 2010/05) are UL certified without restrictions.

Application

If terminals certified with restrictions are used, then the current consumption at 24VDC must be limited
accordingly by means of supply

• from an isolated source protected by a fuse of max. 4A (according to UL248) or

• from a voltage supply complying with NECclass2.
A voltage source complying with NECclass2 may not be connected in series or parallel with another
NECclass2compliant voltage supply!

These requirements apply to the supply of all EtherCAT bus couplers, power adaptor terminals, Bus
Terminals and their power contacts.

EL34x3 49Version: 4.4

Installation

4.7 EL34x3 - LEDs and connection

4.7.1 EL3413-0000

Fig.36: EL3413-0000 LEDs

LEDs

LED Color Meaning

RUN green This LED indicates the terminal's operating state:

off

fast flashing

flashing

single flash

on

IN Error red on Overcurrent on neutral (Current > 11 A)
IL1 OK green on Current IL1 ok
IL1 Error red on Overcurrent on L1.

IL2 OK green on Current IL2 ok
IL2 Error red on Overcurrent on L2.

IL3 OK green on Current IL3 ok
IL3 Error red on Overcurrent on L3.

ccw green on Counter-clockwise rotating field correctly detected
cw green on Clockwise rotating field correctly detected
L1 OK green on Voltage on L1 and zero crossing detected. Voltage > 5 V (L1-N)
L1 Error red on Over- or undervoltage on L1. Voltage < 5 V or voltage > 415 V (L1-N)

L2 OK green on Voltage on L2 and zero crossing detected. Voltage > 5 V (L2-N)
L2 Error red on Over- or undervoltage on L2. Voltage < 5 V or voltage > 415 V (L2-N)

L3 OK green on Voltage on L3 and zero crossing detected. Voltage > 5 V (L3-N)
L3 Error red on Over- or undervoltage on L3. Voltage < 5 V or voltage > 415 V (L3-N)

State of the EtherCAT State Machine [}30]:
INIT = initialization of the terminal or

State of the EtherCAT State Machine [}30]:
BOOTSTRAP = function for firmware updates [}184] of the terminal

State of the EtherCAT State Machine [}30]:
PREOP = function for mailbox communication and different standard-settings set

State of the EtherCAT State Machine [}30]:
SAFEOP = verification of the Sync Manager [}112] channels and the distributed clocks.

Outputs remain in safe state.
State of the EtherCAT State Machine [}30]:

OP = normal operating state; mailbox and process data communication is possible

Current > 110 mA (with 0.1 A measuring range)
Current > 1.1 A (with 1 A measuring range)
Current > 5.5 A (with 5 A measuring range)

Current > 110 mA (with 0.1 A measuring range)
Current > 1.1 A (with 1 A measuring range)
Current > 5.5 A (with 5 A measuring range)

Current > 110 mA (with 0.1 A measuring range)
Current > 1.1 A (with 1 A measuring range)
Current > 5.5 A (with 5 A measuring range))

No zero crossings detected correctly by L1

No zero crossings detected correctly by L2

No zero crossings detected correctly by L3

EL34x350 Version: 4.4

Connection

Installation

Fig.37: EL3413-0000 Connection

WARNING

Do not operate current transformers in no-load mode!

Please note that many manufacturers do not permit their current transformers to be operated in no-load
mode! Connect the EL3413 to the secondary windings of the current transformers before using the current
transformer!

Terminal point Description

Name No.

IL1 1 Phase L1 current measurement input
IL2 2 Phase L2 current measurement input
IL3 3 Phase L3 current measurement input
IN 4 Neutral conductor current measurement input (star point)
IL1' 5 Phase L1 current measurement output
IL2' 6 Phase L2 current measurement output
IL3' 7 Phase L3 current measurement output
N 8 Neutral conductor

WARNING

Earthing of the terminal point N when measuring current!

If you do not connect the terminal point N with the neutral conductor of your mains supply (e.g. if the termi­nal is used purely for current measurements) and use the IN current measurement channel, terminal point N
should be earthed, in order to avoid dangerous overvoltages in the event of a current transformer fault.

Earthing of the N point is not absolutely necessary if only the galvanically isolated current channels are
used.

EL34x3 51Version: 4.4

Installation

Terminal point Description

Name No.

L1 1' Phase L1 voltage measurement input
L2 2' Phase L2 voltage measurement input
L3 3' Phase L3 voltage measurement input
N 4' Neutral conductor

5' n.c.
6' n.c.
7' n.c.

N 8' Neutral conductor

EL34x352 Version: 4.4

4.7.2 EL3413-0001

Fig.38: EL3413-0001 LEDs

LEDs

LED Color Meaning

RUN green This LED indicates the terminal's operating state:

off

fast flashing

flashing

single flash

on

IN Error red on Overcurrent on neutral (Current > 11 A)
IL1 OK green on Current IL1 ok
IL1 Error red on Overcurrent on L1.

IL2 OK green on Current IL2 ok
IL2 Error red on Overcurrent on L2.

IL3 OK green on Current IL3 ok
IL3 Error red on Overcurrent on L3.

ccw green on Counter-clockwise rotating field correctly detected
cw green on Clockwise rotating field correctly detected
L1 OK green on Voltage on L1 and zero crossing detected. Voltage > 5 V (L1-N)
L1 Error red on Over- or undervoltage on L1. Voltage < 5 V or voltage > 360 V (L1-N)

L2 OK green on Voltage on L2 and zero crossing detected. Voltage > 5 V (L2-N)
L2 Error red on Over- or undervoltage on L2. Voltage < 5 V or voltage > 360 V (L2-N)

L3 OK green on Voltage on L3 and zero crossing detected. Voltage > 5 V (L3-N)
L3 Error red on Over- or undervoltage on L3. Voltage < 5 V or voltage > 360 V (L3-N)

State of the EtherCAT State Machine [}30]:
INIT = initialization of the terminal or

State of the EtherCAT State Machine [}30]:
BOOTSTRAP = function for firmware updates [}184] of the terminal

State of the EtherCAT State Machine [}30]:
PREOP = function for mailbox communication and different standard-settings set

State of the EtherCAT State Machine [}30]:
SAFEOP = verification of the Sync Manager [}112] channels and the distributed clocks.

Outputs remain in safe state.
State of the EtherCAT State Machine [}30]:

OP = normal operating state; mailbox and process data communication is possible

Current > 1.1 A (with 1 A measuring range)
Current > 5.5 A (with 5 A measuring range)

Current > 1.1 A (with 1 A measuring range)
Current > 5.5 A (with 5 A measuring range)

Current > 1.1 A (with 1 A measuring range)
Current > 5.5 A (with 5 A measuring range))

No zero crossings detected correctly by L1

No zero crossings detected correctly by L2

No zero crossings detected correctly by L3

Installation

EL34x3 53Version: 4.4

Installation

Connection

Fig.39: EL3413-0001 Connection

WARNING

Do not operate current transformers in no-load mode!

Please note that many manufacturers do not permit their current transformers to be operated in no-load
mode! Connect the EL3413 to the secondary windings of the current transformers before using the current
transformer!

Terminal point Description

Name No.

IL1 1 Phase L1 current measurement input
IL2 2 Phase L2 current measurement input
IL3 3 Phase L3 current measurement input
IN 4 Neutral conductor current measurement input (star point)
IL1' 5 Phase L1 current measurement output
IL2' 6 Phase L2 current measurement output
IL3' 7 Phase L3 current measurement output
N 8 Neutral conductor

WARNING

Earthing of the terminal point N when measuring current!

If you do not connect the terminal point N with the neutral conductor of your mains supply (e.g. if the termi­nal is used purely for current measurements) and use the IN current measurement channel, terminal point N
should be earthed, in order to avoid dangerous overvoltages in the event of a current transformer fault.

Earthing of the N point is not absolutely necessary if only the galvanically isolated current channels are
used.

EL34x354 Version: 4.4

Terminal point Description

Name No.

L1 1' Phase L1 voltage measurement input

2' n.c.
L3 3' Phase L3 voltage measurement input
N 4' Neutral conductor

5' n.c.
L2 6' Phase L2 voltage measurement input

7' n.c.
N 8' Neutral conductor

Installation

EL34x3 55Version: 4.4

Installation

4.7.3 EL3413-0120

Fig.40: EL3413-0120 LEDs

LEDs

LED Color Meaning

RUN green This LED indicates the terminal's operating state:

off

fast flashing

flashing

single flash

on

IN Error red on Overcurrent on neutral (Current > 11 A)
IL1 OK green on Current IL1 ok
IL1 Error red on Overcurrent on L1.

IL2 OK green on Current IL2 ok
IL2 Error red on Overcurrent on L2.

IL3 OK green on Current IL3 ok
IL3 Error red on Overcurrent on L3.

ccw green on Counter-clockwise rotating field correctly detected
cw green on Clockwise rotating field correctly detected
L1 OK green on Voltage on L1 and zero crossing detected. Voltage > 5 V (L1-N)
L1 Error red on Over- or undervoltage on L1. Voltage < 5 V or voltage > 130 V (L1-N)

L2 OK green on Voltage on L2 and zero crossing detected. Voltage > 5 V (L2-N)
L2 Error red on Over- or undervoltage on L2. Voltage < 5 V or voltage > 130 V (L2-N)

L3 OK green on Voltage on L3 and zero crossing detected. Voltage > 5 V (L3-N)
L3 Error red on Over- or undervoltage on L3. Voltage < 5 V or voltage > 130 V (L3-N)

State of the EtherCAT State Machine [}30]:
INIT = initialization of the terminal or

State of the EtherCAT State Machine [}30]:
BOOTSTRAP = function for firmware updates [}184] of the terminal

State of the EtherCAT State Machine [}30]:
PREOP = function for mailbox communication and different standard-settings set

State of the EtherCAT State Machine [}30]:
SAFEOP = verification of the Sync Manager [}112] channels and the distributed clocks.

Outputs remain in safe state.
State of the EtherCAT State Machine [}30]:

OP = normal operating state; mailbox and process data communication is possible

Current > 110 mA (with 0.1 A measuring range)
Current > 1.1 A (with 1 A measuring range)
Current > 5.5 A (with 5 A measuring range)

Current > 110 mA (with 0.1 A measuring range)
Current > 1.1 A (with 1 A measuring range)
Current > 5.5 A (with 5 A measuring range)

Current > 110 mA (with 0.1 A measuring range)
Current > 1.1 A (with 1 A measuring range)
Current > 5.5 A (with 5 A measuring range))

No zero crossings detected correctly by L1

No zero crossings detected correctly by L2

No zero crossings detected correctly by L3

EL34x356 Version: 4.4

Connection

Installation

Fig.41: EL3413-0120 Connection

WARNING

Do not operate current transformers in no-load mode!

Please note that many manufacturers do not permit their current transformers to be operated in no-load
mode! Connect the EL3413 to the secondary windings of the current transformers before using the current
transformer!

Terminal point Description

Name No.

IL1 1 Phase L1 current measurement input
IL2 2 Phase L2 current measurement input
IL3 3 Phase L3 current measurement input
IN 4 Neutral conductor current measurement input (star point)
IL1' 5 Phase L1 current measurement output
IL2' 6 Phase L2 current measurement output
IL3' 7 Phase L3 current measurement output
N 8 Neutral conductor

WARNING

Earthing of the terminal point N when measuring current!

If you do not connect the terminal point N with the neutral conductor of your mains supply (e.g. if the termi­nal is used purely for current measurements) and use the IN current measurement channel, terminal point N
should be earthed, in order to avoid dangerous overvoltages in the event of a current transformer fault.

Earthing of the N point is not absolutely necessary if only the galvanically isolated current channels are
used.

EL34x3 57Version: 4.4

Installation

Terminal point Description

Name No.

L1 1' Phase L1 voltage measurement input
L2 2' Phase L2 voltage measurement input
L3 3' Phase L3 voltage measurement input
N 4' Neutral conductor

5' n.c.
6' n.c.
7' n.c.

N 8' Neutral conductor

EL34x358 Version: 4.4

4.7.4 EL3433-0000

Fig.42: EL3433-0000 LEDs

LEDs

LED Color Meaning

RUN green This LED indicates the terminal's operating state:

off

fast flashing

flashing

single flash

on

IN Error red on Overcurrent on neutral (current > 11 A)
IL1 OK green on Current IL1 ok
IL1 Error red on Overcurrent on L1.

IL2 OK green on Current IL2 ok
IL2 Error red on Overcurrent on L2.

IL3 OK green on Current IL3 ok
IL3 Error red on Overcurrent on L3.

ccw green on Counter-clockwise rotating field correctly detected
cw green on Clockwise rotating field correctly detected
L1 OK green on Voltage on L1 and zero crossing detected. Voltage > 5 V (L1-N)
L1 Error red on Over- or undervoltage on L1. Voltage < 5 V or voltage > 288 V (L1-N)

L2 OK green on Voltage on L2 and zero crossing detected. Voltage > 5 V (L2-N)
L2 Error red on Over- or undervoltage on L2. Voltage < 5 V or voltage > 288 V (L2-N)

L3 OK green on Voltage on L3 and zero crossing detected. Voltage > 5 V (L3-N)
L3 Error red on Over- or undervoltage on L3. Voltage < 5 V or voltage > 288 V (L3-N)

State of the EtherCAT State Machine [}30]:
INIT = initialization of the terminal or

State of the EtherCAT State Machine [}30]:
BOOTSTRAP = function for firmware updates [}184] of the terminal

State of the EtherCAT State Machine [}30]:
PREOP = function for mailbox communication and different standard-settings set

State of the EtherCAT State Machine [}30]:
SAFEOP = verification of the Sync Manager [}112] channels and the distributed clocks.

Outputs remain in safe state.
State of the EtherCAT State Machine [}30]:

OP = normal operating state; mailbox and process data communication is possible

Current > 220 mA (with 200 mA measuring range)
Current > 2.2 A (with 2 A measuring range)
Current > 11 A (with 10 A measuring range)

Current > 220 mA (with 200 mA measuring range)
Current > 2.2 A (with 2 A measuring range)
Current > 11 A (with 10 A measuring range)

Current > 220 mA (with 200 mA measuring range)
Current > 2.2 A (with 2 A measuring range)
Current > 11 A (with 10 A measuring range)

No zero crossings detected correctly by L1

No zero crossings detected correctly by L2

No zero crossings detected correctly by L3

Installation

EL34x3 59Version: 4.4

Installation

Connection

Fig.43: EL3433-0000 Connection

WARNING

Do not operate current transformers in no-load mode!

Please note that many manufacturers do not permit their current transformers to be operated in no-load
mode! Connect the EL3413 to the secondary windings of the current transformers before using the current
transformer!

Terminal point Description

Name No.

IL1' (U) 1 Phase L1 output
IL2' (V) 2 Phase L2 output
IL3' (W) 3 Phase L3 output
IN 4 Neutral conductor current measurement input (star point)
IL1 5 Phase L1 current measurement input
IL2 6 Phase L2 current measurement input
IL3 7 Phase L3 current measurement input
N 8 Neutral conductor

WARNING

Earthing of the terminal point N when measuring current!

If you do not connect the terminal point N with the neutral conductor of your mains supply (e.g. if the termi­nal is used purely for current measurements) and use the IN current measurement channel, terminal point N
should be earthed, in order to avoid dangerous overvoltages in the event of a current transformer fault.

Earthing of the N point is not absolutely necessary if only the galvanically isolated current channels are
used.

EL34x360 Version: 4.4

Terminal point Description

Name No.

L1' 1' Phase L1 voltage measurement output
L2' 2' Phase L2 voltage measurement output
L3' 3' Phase L3 voltage measurement output
N 4' Neutral conductor
L1 5' Phase L1 voltage measurement input
L2 6' Phase L2 voltage measurement input
L3 7' Phase L3 voltage measurement input
N 8' Neutral conductor

Installation

EL34x3 61Version: 4.4

Commissioning

5 Commissioning

5.1 TwinCAT Quick Start

TwinCAT is a development environment for real-time control including multi-PLC system, NC axis control,
programming and operation. The whole system is mapped through this environment and enables access to a
programming environment (including compilation) for the controller. Individual digital or analog inputs or
outputs can also be read or written directly, in order to verify their functionality, for example.

For further information please refer to http://infosys.beckhoff.com:

• EtherCAT Systemmanual:
Fieldbus Components → EtherCAT Terminals → EtherCAT System Documentation → Setup in the
TwinCAT System Manager

• TwinCAT2 → TwinCAT System Manager → I/O - Configuration

• In particular, TwinCAT driver installation:
Fieldbus components → Fieldbus Cards and Switches → FC900x – PCI Cards for Ethernet →
Installation

Devices contain the terminals for the actual configuration. All configuration data can be entered directly via
editor functions (offline) or via the "Scan" function (online):

• "offline": The configuration can be customized by adding and positioning individual components.
These can be selected from a directory and configured.

◦ The procedure for offline mode can be found under http://infosys.beckhoff.com:

TwinCAT2 → TwinCAT System Manager → IO - Configuration → Adding an I/O Device

• "online": The existing hardware configuration is read

◦ See also http://infosys.beckhoff.com:

Fieldbus components → Fieldbus cards and switches → FC900x – PCI Cards for Ethernet →
Installation → Searching for devices

The following relationship is envisaged from user PC to the individual control elements:

EL34x362 Version: 4.4

Commissioning

Fig.44: Relationship between user side (commissioning) and installation

The user inserting of certain components (I/O device, terminal, box...) is the same in TwinCAT2 and
TwinCAT3. The descriptions below relate to the online procedure.

Sample configuration (actual configuration)

Based on the following sample configuration, the subsequent subsections describe the procedure for
TwinCAT2 and TwinCAT3:

• Control system (PLC) CX2040 including CX2100-0004 power supply unit

• Connected to the CX2040 on the right (E-bus):
EL1004 (4-channel analog input terminal -10…+10V)

• Linked via the X001 port (RJ-45): EK1100 EtherCAT Coupler

• Connected to the EK1100 EtherCAT coupler on the right (E-bus):
EL2008 (8-channel digital output terminal 24VDC;0.5A)

• (Optional via X000: a link to an external PC for the user interface)

EL34x3 63Version: 4.4

Commissioning

Fig.45: Control configuration with Embedded PC, input (EL1004) and output (EL2008)

Note that all combinations of a configuration are possible; for example, the EL1004 terminal could also be
connected after the coupler, or the EL2008 terminal could additionally be connected to the CX2040 on the
right, in which case the EK1100 coupler wouldn’t be necessary.

EL34x364 Version: 4.4

Commissioning

5.1.1 TwinCAT2

Startup

TwinCAT basically uses two user interfaces: the TwinCAT System Manager for communication with the
electromechanical components and TwinCAT PLC Control for the development and compilation of a
controller. The starting point is the TwinCAT System Manager.

After successful installation of the TwinCAT system on the PC to be used for development, the TwinCAT2
System Manager displays the following user interface after startup:

Fig.46: Initial TwinCAT2 user interface

Generally, TwinCAT can be used in local or remote mode. Once the TwinCAT system including the user
interface (standard) is installed on the respective PLC, TwinCAT can be used in local mode and thereby the

next step is "Insert Device [}67]".

If the intention is to address the TwinCAT runtime environment installed on a PLC as development
environment remotely from another system, the target system must be made known first. In the menu under

"Actions" → "Choose Target System...", via the symbol " " or the "F8" key, open the following window:

EL34x3 65Version: 4.4

Commissioning

Fig.47: Selection of the target system

Use "Search (Ethernet)..." to enter the target system. Thus a next dialog opens to either:

• enter the known computer name after "Enter Host Name / IP:" (as shown in red)

• perform a "Broadcast Search" (if the exact computer name is not known)

• enter the known computer IP or AmsNetID.

Fig.48: Specify the PLC for access by the TwinCAT System Manager: selection of the target system

Once the target system has been entered, it is available for selection as follows (a password may have to be
entered):

After confirmation with "OK" the target system can be accessed via the System Manager.

EL34x366 Version: 4.4

Commissioning

Adding devices

In the configuration tree of the TwinCAT2 System Manager user interface on the left, select "I/ODevices”
and then right-click to open a context menu and select "ScanDevices…", or start the action in the menu bar

via . The TwinCAT System Manager may first have to be set to "Configmode" via or via menu
“Actions" → "Set/Reset TwinCAT to Config Mode…" (Shift + F4).

Fig.49: Select "Scan Devices..."

Confirm the warning message, which follows, and select "EtherCAT" in the dialog:

Fig.50: Automatic detection of I/O devices: selection the devices to be integrated

Confirm the message "Find new boxes", in order to determine the terminals connected to the devices. "Free
Run" enables manipulation of input and output values in "Config mode" and should also be acknowledged.

Based on the sample configuration [}63] described at the beginning of this section, the result is as follows:

EL34x3 67Version: 4.4

Commissioning

Fig.51: Mapping of the configuration in the TwinCAT2 System Manager

The whole process consists of two stages, which may be performed separately (first determine the devices,
then determine the connected elements such as boxes, terminals, etc.). A scan can also be initiated by
selecting "Device ..." from the context menu, which then reads the elements present in the configuration
below:

Fig.52: Reading of individual terminals connected to a device

This functionality is useful if the actual configuration is modified at short notice.

Programming and integrating the PLC

TwinCAT PLC Control is the development environment for the creation of the controller in different program
environments: TwinCAT PLC Control supports all languages described in IEC 61131-3. There are two text­based languages and three graphical languages.

• Text-based languages

◦ Instruction List (IL)

EL34x368 Version: 4.4

◦ Structured Text (ST)

• Graphical languages

◦ Function Block Diagram (FBD)
◦ Ladder Diagram (LD)
◦ The Continuous Function Chart Editor (CFC)
◦ Sequential Function Chart (SFC)

The following section refers to Structured Text (ST).

After starting TwinCAT PLC Control, the following user interface is shown for an initial project:

Commissioning

Fig.53: TwinCAT PLC Control after startup

Sample variables and a sample program have been created and stored under the name "PLC_example.pro":

EL34x3 69Version: 4.4

Commissioning

Fig.54: Sample program with variables after a compile process (without variable integration)

Warning 1990 (missing "VAR_CONFIG") after a compile process indicates that the variables defined as
external (with the ID "AT%I*" or "AT%Q*") have not been assigned. After successful compilation, TwinCAT
PLC Control creates a "*.tpy" file in the directory in which the project was stored. This file (*.tpy) contains
variable assignments and is not known to the System Manager, hence the warning. Once the System
Manager has been notified, the warning no longer appears.

First, integrate the TwinCAT PLC Control project in the System Manager via the context menu of the PLC
configuration; right-click and select "Append PLC Project…":

Fig.55: Appending the TwinCAT PLC Control project

EL34x370 Version: 4.4

Commissioning

Select the PLC configuration "PLC_example.tpy" in the browser window that opens. The project including the
two variables identified with "AT" are then integrated in the configuration tree of the System Manager:

Fig.56: PLC project integrated in the PLC configuration of the System Manager

The two variables "bEL1004_Ch4" and "nEL2008_value" can now be assigned to certain process objects of
the I/O configuration.

Assigning variables

Open a window for selecting a suitable process object (PDO) via the context menu of a variable of the
integrated project "PLC_example" and via "Modify Link..." "Standard":

Fig.57: Creating the links between PLC variables and process objects

In the window that opens, the process object for the variable “bEL1004_Ch4” of type BOOL can be selected
from the PLC configuration tree:

EL34x3 71Version: 4.4

Commissioning

Fig.58: Selecting PDO of type BOOL

According to the default setting, certain PDO objects are now available for selection. In this sample the input
of channel 4 of the EL1004 terminal is selected for linking. In contrast, the checkbox "All types" must be
ticked for creating the link for the output variables, in order to allocate a set of eight separate output bits to a
byte variable. The following diagram shows the whole process:

Fig.59: Selecting several PDOs simultaneously: activate "Continuous" and "All types"

Note that the "Continuous" checkbox was also activated. This is designed to allocate the bits contained in the
byte of the variable "nEL2008_value" sequentially to all eight selected output bits of the EL2008 terminal. In
this way it is possible to subsequently address all eight outputs of the terminal in the program with a byte

corresponding to bit 0 for channel 1 to bit 7 for channel 8 of the PLC. A special symbol ( ) at the yellow or
red object of the variable indicates that a link exists. The links can also be checked by selecting a "Goto Link
Variable” from the context menu of a variable. The object opposite, in this case the PDO, is automatically
selected:

EL34x372 Version: 4.4

Commissioning

Fig.60: Application of a "Goto Link" variable, using "MAIN.bEL1004_Ch4" as a sample

The process of assigning variables to the PDO is completed via the menu selection "Actions" → "Generate

Mappings”, key Ctrl+M or by clicking on the symbol in the menu.

This can be visualized in the configuration:

The process of creating links can also take place in the opposite direction, i.e. starting with individual PDOs
to variable. However, in this example it would then not be possible to select all output bits for the EL2008,
since the terminal only makes individual digital outputs available. If a terminal has a byte, word, integer or
similar PDO, it is possible to allocate this a set of bit-standardised variables (type "BOOL"). Here, too, a
"Goto Link Variable” from the context menu of a PDO can be executed in the other direction, so that the
respective PLC instance can then be selected.

Activation of the configuration

The allocation of PDO to PLC variables has now established the connection from the controller to the inputs
and outputs of the terminals. The configuration can now be activated. First, the configuration can be verified

via (or via "Actions" → "Check Configuration”). If no error is present, the configuration can be

activated via (or via "Actions" → "Activate Configuration…") to transfer the System Manager settings
to the runtime system. Confirm the messages "Old configurations are overwritten!" and "Restart TwinCAT
system in Run mode" with "OK".

A few seconds later the real-time status is displayed at the bottom right in the System Manager.
The PLC system can then be started as described below.

Starting the controller

Starting from a remote system, the PLC control has to be linked with the Embedded PC over Ethernet via
"Online" → “Choose Run-Time System…":

EL34x3 73Version: 4.4

Commissioning

Fig.61: Choose target system (remote)

In this sample "Runtime system 1 (port 801)" is selected and confirmed. Link the PLC with the real-time

system via menu option "Online" → "Login", the F11 key or by clicking on the symbol .The control
program can then be loaded for execution. This results in the message "No program on the controller!
Should the new program be loaded?", which should be acknowledged with "Yes". The runtime environment
is ready for the program start:

EL34x374 Version: 4.4

Commissioning

Fig.62: PLC Control logged in, ready for program startup

The PLC can now be started via "Online" → "Run", F5 key or .

5.1.2 TwinCAT 3

Startup

TwinCAT makes the development environment areas available together with Microsoft Visual Studio: after
startup, the project folder explorer appears on the left in the general window area (cf. "TwinCAT System
Manager" of TwinCAT2) for communication with the electromechanical components.

After successful installation of the TwinCAT system on the PC to be used for development, TwinCAT3
(shell) displays the following user interface after startup:

EL34x3 75Version: 4.4

Commissioning

Fig.63: Initial TwinCAT3 user interface

First create a new project via (or under "File"→“New"→ "Project…"). In the
following dialog make the corresponding entries as required (as shown in the diagram):

Fig.64: Create new TwinCAT project

The new project is then available in the project folder explorer:

EL34x376 Version: 4.4

Commissioning

Fig.65: New TwinCAT3 project in the project folder explorer

Generally, TwinCAT can be used in local or remote mode. Once the TwinCAT system including the user
interface (standard) is installed on the respective PLC, TwinCAT can be used in local mode and thereby the

next step is "Insert Device [}78]".

If the intention is to address the TwinCAT runtime environment installed on a PLC as development
environment remotely from another system, the target system must be made known first. Via the symbol in
the menu bar:

expand the pull-down menu:

and open the following window:

Fig.66: Selection dialog: Choose the target system

EL34x3 77Version: 4.4

Commissioning

Use "Search (Ethernet)..." to enter the target system. Thus a next dialog opens to either:

• enter the known computer name after "Enter Host Name / IP:" (as shown in red)

• perform a "Broadcast Search" (if the exact computer name is not known)

• enter the known computer IP or AmsNetID.

Fig.67: Specify the PLC for access by the TwinCAT System Manager: selection of the target system

Once the target system has been entered, it is available for selection as follows (a password may have to be
entered):

After confirmation with "OK" the target system can be accessed via the Visual Studio shell.

Adding devices

In the project folder explorer of the Visual Studio shell user interface on the left, select "Devices" within

element “I/O”, then right-click to open a context menu and select "Scan" or start the action via in the

menu bar. The TwinCAT System Manager may first have to be set to "Config mode" via or via the
menu "TwinCAT" → "Restart TwinCAT (Config mode)".

Fig.68: Select "Scan"

Confirm the warning message, which follows, and select "EtherCAT" in the dialog:

EL34x378 Version: 4.4

Commissioning

Fig.69: Automatic detection of I/O devices: selection the devices to be integrated

Confirm the message "Find new boxes", in order to determine the terminals connected to the devices. "Free
Run" enables manipulation of input and output values in "Config mode" and should also be acknowledged.

Based on the sample configuration [}63] described at the beginning of this section, the result is as follows:

Fig.70: Mapping of the configuration in VS shell of the TwinCAT3 environment

The whole process consists of two stages, which may be performed separately (first determine the devices,
then determine the connected elements such as boxes, terminals, etc.). A scan can also be initiated by
selecting "Device ..." from the context menu, which then reads the elements present in the configuration
below:

EL34x3 79Version: 4.4

Commissioning

Fig.71: Reading of individual terminals connected to a device

This functionality is useful if the actual configuration is modified at short notice.

Programming the PLC

TwinCAT PLC Control is the development environment for the creation of the controller in different program
environments: TwinCAT PLC Control supports all languages described in IEC 61131-3. There are two text­based languages and three graphical languages.

• Text-based languages

◦ Instruction List (IL)
◦ Structured Text (ST)

• Graphical languages

◦ Function Block Diagram (FBD)
◦ Ladder Diagram (LD)
◦ The Continuous Function Chart Editor (CFC)
◦ Sequential Function Chart (SFC)

The following section refers to Structured Text (ST).

In order to create a programming environment, a PLC subproject is added to the project sample via the
context menu of "PLC" in the project folder explorer by selecting "Add New Item….":

EL34x380 Version: 4.4

Fig.72: Adding the programming environment in "PLC"

Commissioning

In the dialog that opens select "Standard PLC project" and enter "PLC_example" as project name, for
example, and select a corresponding directory:

Fig.73: Specifying the name and directory for the PLC programming environment

The "Main" program, which already exists by selecting "Standard PLC project", can be opened by double­clicking on "PLC_example_project" in "POUs”. The following user interface is shown for an initial project:

EL34x3 81Version: 4.4

Commissioning

Fig.74: Initial "Main" program of the standard PLC project

To continue, sample variables and a sample program have now been created:

EL34x382 Version: 4.4

Commissioning

Fig.75: Sample program with variables after a compile process (without variable integration)

The control program is now created as a project folder, followed by the compile process:

Fig.76: Start program compilation

The following variables, identified in the ST/ PLC program with "AT%", are then available in under
"Assignments" in the project folder explorer:

Assigning variables

Via the menu of an instance - variables in the "PLC” context, use the "Modify Link…" option to open a
window for selecting a suitable process object (PDO) for linking:

EL34x3 83Version: 4.4

Commissioning

Fig.77: Creating the links between PLC variables and process objects

In the window that opens, the process object for the variable "bEL1004_Ch4" of type BOOL can be selected
from the PLC configuration tree:

Fig.78: Selecting PDO of type BOOL

According to the default setting, certain PDO objects are now available for selection. In this sample the input
of channel 4 of the EL1004 terminal is selected for linking. In contrast, the checkbox "All types" must be
ticked for creating the link for the output variables, in order to allocate a set of eight separate output bits to a
byte variable. The following diagram shows the whole process:

EL34x384 Version: 4.4

Commissioning

Fig.79: Selecting several PDOs simultaneously: activate "Continuous" and "All types"

Note that the "Continuous" checkbox was also activated. This is designed to allocate the bits contained in the
byte of the variable "nEL2008_value" sequentially to all eight selected output bits of the EL2008 terminal. In
this way it is possible to subsequently address all eight outputs of the terminal in the program with a byte

corresponding to bit 0 for channel 1 to bit 7 for channel 8 of the PLC. A special symbol ( ) at the yellow or
red object of the variable indicates that a link exists. The links can also be checked by selecting a "Goto Link
Variable” from the context menu of a variable. The object opposite, in this case the PDO, is automatically
selected:

Fig.80: Application of a "Goto Link" variable, using "MAIN.bEL1004_Ch4" as a sample

The process of creating links can also take place in the opposite direction, i.e. starting with individual PDOs
to variable. However, in this example it would then not be possible to select all output bits for the EL2008,
since the terminal only makes individual digital outputs available. If a terminal has a byte, word, integer or
similar PDO, it is possible to allocate this a set of bit-standardised variables (type "BOOL"). Here, too, a
"Goto Link Variable” from the context menu of a PDO can be executed in the other direction, so that the
respective PLC instance can then be selected.

EL34x3 85Version: 4.4

Commissioning

Activation of the configuration

The allocation of PDO to PLC variables has now established the connection from the controller to the inputs

and outputs of the terminals. The configuration can now be activated with or via the menu under
"TwinCAT" in order to transfer settings of the development environment to the runtime system. Confirm the
messages "Old configurations are overwritten!" and "Restart TwinCAT system in Run mode" with "OK". The
corresponding assignments can be seen in the project folder explorer:

A few seconds later the corresponding status of the Run mode is displayed in the form of a rotating symbol

at the bottom right of the VS shell development environment. The PLC system can then be started as

described below.

Starting the controller

Select the menu option "PLC" → "Login" or click on to link the PLC with the real-time system and load
the control program for execution. This results in the message "No program on the controller! Should the
new program be loaded?", which should be acknowledged with "Yes". The runtime environment is ready for

program start by click on symbol , the "F5" key or via "PLC" in the menu selecting “Start”. The started
programming environment shows the runtime values of individual variables:

Fig.81: TwinCAT development environment (VS shell): logged-in, after program startup

The two operator control elements for stopping and logout result in the required action
(accordingly also for stop "Shift + F5", or both actions can be selected via the PLC menu).

EL34x386 Version: 4.4

Commissioning

5.2 TwinCAT Development Environment

The Software for automation TwinCAT (The Windows Control and Automation Technology) will be
distinguished into:

• TwinCAT2: System Manager (Configuration) & PLC Control (Programming)

• TwinCAT3: Enhancement of TwinCAT2 (Programming and Configuration takes place via a common
Development Environment)

Details:

• TwinCAT2:

◦ Connects I/O devices to tasks in a variable-oriented manner
◦ Connects tasks to tasks in a variable-oriented manner
◦ Supports units at the bit level
◦ Supports synchronous or asynchronous relationships
◦ Exchange of consistent data areas and process images
◦ Datalink on NT - Programs by open Microsoft Standards (OLE, OCX, ActiveX, DCOM+, etc.)
◦ Integration of IEC 61131-3-Software-SPS, Software- NC and Software-CNC within Windows

NT/2000/XP/Vista, Windows 7, NT/XP Embedded, CE

◦ Interconnection to all common fieldbusses
◦ More…

Additional features:

• TwinCAT3 (eXtended Automation):

◦ Visual-Studio®-Integration
◦ Choice of the programming language
◦ Supports object orientated extension of IEC 61131-3
◦ Usage of C/C++ as programming language for real time applications
◦ Connection to MATLAB®/Simulink®
◦ Open interface for expandability
◦ Flexible run-time environment
◦ Active support of Multi-Core- und 64-Bit-Operatingsystem
◦ Automatic code generation and project creation with the TwinCAT Automation Interface

◦ More…

Within the following sections commissioning of the TwinCAT Development Environment on a PC System for
the control and also the basically functions of unique control elements will be explained.

Please see further information to TwinCAT2 and TwinCAT3 at http://infosys.beckhoff.com.

5.2.1 Installation of the TwinCAT real-time driver

In order to assign real-time capability to a standard Ethernet port of an IPC controller, the Beckhoff real-time
driver has to be installed on this port under Windows.

This can be done in several ways. One option is described here.

In the System Manager call up the TwinCAT overview of the local network interfaces via Options → Show
Real Time Ethernet Compatible Devices.

EL34x3 87Version: 4.4

Commissioning

Fig.82: System Manager “Options” (TwinCAT2)

This have to be called up by the Menü “TwinCAT” within the TwinCAT3 environment:

Fig.83: Call up under VS Shell (TwinCAT3)

The following dialog appears:

Fig.84: Overview of network interfaces

Interfaces listed under “Compatible devices” can be assigned a driver via the “Install” button. A driver should
only be installed on compatible devices.

A Windows warning regarding the unsigned driver can be ignored.

Alternatively an EtherCAT-device can be inserted first of all as described in chapter Offline configuration
creation, section “Creating the EtherCAT device” [}98] in order to view the compatible ethernet ports via its

EtherCAT properties (tab „Adapter“, button „Compatible Devices…“):

EL34x388 Version: 4.4

Commissioning

Fig.85: EtherCAT device properties(TwinCAT2): click on „Compatible Devices…“ of tab “Adapter”

TwinCAT 3: the properties of the EtherCAT device can be opened by double click on “Device .. (EtherCAT)”
within the Solution Explorer under “I/O”:

After the installation the driver appears activated in the Windows overview for the network interface
(Windows Start → System Properties → Network)

Fig.86: Windows properties of the network interface

A correct setting of the driver could be:

EL34x3 89Version: 4.4

Commissioning

Fig.87: Exemplary correct driver setting for the Ethernet port

Other possible settings have to be avoided:

EL34x390 Version: 4.4

Commissioning

Fig.88: Incorrect driver settings for the Ethernet port

EL34x3 91Version: 4.4

Commissioning

IP address of the port used

IP address/DHCP

In most cases an Ethernet port that is configured as an EtherCAT device will not transport general
IP packets. For this reason and in cases where an EL6601 or similar devices are used it is useful to
specify a fixed IP address for this port via the “Internet Protocol TCP/IP” driver setting and to disable
DHCP. In this way the delay associated with the DHCP client for the Ethernet port assigning itself a
default IP address in the absence of a DHCP server is avoided. A suitable address space is

192.168.x.x, for example.

Fig.89: TCP/IP setting for the Ethernet port

EL34x392 Version: 4.4

Commissioning

5.2.2 Notes regarding ESI device description

Installation of the latest ESI device description

The TwinCAT EtherCAT master/System Manager needs the device description files for the devices to be
used in order to generate the configuration in online or offline mode. The device descriptions are contained
in the so-called ESI files (EtherCAT Slave Information) in XML format. These files can be requested from the
respective manufacturer and are made available for download. An *.xml file may contain several device
descriptions.

The ESI files for Beckhoff EtherCAT devices are available on the Beckhoff website.

The ESI files should be stored in the TwinCAT installation directory.

Default settings:

• TwinCAT2: C:\TwinCAT\IO\EtherCAT

• TwinCAT3: C:\TwinCAT\3.1\Config\Io\EtherCAT

The files are read (once) when a new System Manager window is opened, if they have changed since the
last time the System Manager window was opened.

A TwinCAT installation includes the set of Beckhoff ESI files that was current at the time when the TwinCAT
build was created.

For TwinCAT2.11/TwinCAT3 and higher, the ESI directory can be updated from the System Manager, if the
programming PC is connected to the Internet; by

• TwinCAT2: Option → “Update EtherCAT Device Descriptions”

• TwinCAT3: TwinCAT → EtherCAT Devices → “Update Device Descriptions (via ETG Website)…”

The TwinCAT ESI Updater [}97] is available for this purpose.

ESI

The *.xml files are associated with *.xsd files, which describe the structure of the ESI XML files. To
update the ESI device descriptions, both file types should therefore be updated.

Device differentiation

EtherCAT devices/slaves are distinguished by four properties, which determine the full device identifier. For
example, the device identifier EL2521-0025-1018 consists of:

• family key “EL”

• name “2521”

• type “0025”

• and revision “1018”

Fig.90: Identifier structure

The order identifier consisting of name + type (here: EL2521-0010) describes the device function. The
revision indicates the technical progress and is managed by Beckhoff. In principle, a device with a higher
revision can replace a device with a lower revision, unless specified otherwise, e.g. in the documentation.

Each revision has its own ESI description. See further notes [}11].

EL34x3 93Version: 4.4

Commissioning

Online description

If the EtherCAT configuration is created online through scanning of real devices (see section Online setup)
and no ESI descriptions are available for a slave (specified by name and revision) that was found, the
System Manager asks whether the description stored in the device should be used. In any case, the System
Manager needs this information for setting up the cyclic and acyclic communication with the slave correctly.

Fig.91: OnlineDescription information window (TwinCAT2)

In TwinCAT3 a similar window appears, which also offers the Web update:

Fig.92: Information window OnlineDescription (TwinCAT3)

If possible, the Yes is to be rejected and the required ESI is to be requested from the device manufacturer.
After installation of the XML/XSD file the configuration process should be repeated.

NOTE

Changing the ‘usual’ configuration through a scan

ü If a scan discovers a device that is not yet known to TwinCAT, distinction has to be made between two

cases. Taking the example here of the EL2521-0000 in the revision 1019

a) no ESI is present for the EL2521-0000 device at all, either for the revision 1019 or for an older revision.

The ESI must then be requested from the manufacturer (in this case Beckhoff).

b) an ESI is present for the EL2521-0000 device, but only in an older revision, e.g. 1018 or 1017.

In this case an in-house check should first be performed to determine whether the spare parts stock al­lows the integration of the increased revision into the configuration at all. A new/higher revision usually
also brings along new features. If these are not to be used, work can continue without reservations with
the previous revision 1018 in the configuration. This is also stated by the Beckhoff compatibility rule.

Refer in particular to the chapter ‘General notes on the use of Beckhoff EtherCAT IO components’ and for
manual configuration to the chapter ‘Offline configuration creation’ [}98].

If the OnlineDescription is used regardless, the System Manager reads a copy of the device description from
the EEPROM in the EtherCAT slave. In complex slaves the size of the EEPROM may not be sufficient for the
complete ESI, in which case the ESI would be incomplete in the configurator. Therefore it’s recommended
using an offline ESI file with priority in such a case.

The System Manager creates for online recorded device descriptions a new file
“OnlineDescription0000...xml” in its ESI directory, which contains all ESI descriptions that were read online.

EL34x394 Version: 4.4

Commissioning

Fig.93: File OnlineDescription.xml created by the System Manager

Is a slave desired to be added manually to the configuration at a later stage, online created slaves are
indicated by a prepended symbol “>” in the selection list (see Figure “Indication of an online recorded ESI of
EL2521 as an example”).

Fig.94: Indication of an online recorded ESI of EL2521 as an example

If such ESI files are used and the manufacturer's files become available later, the file OnlineDescription.xml
should be deleted as follows:

• close all System Manager windows

• restart TwinCAT in Config mode

• delete "OnlineDescription0000...xml"

• restart TwinCAT System Manager

This file should not be visible after this procedure, if necessary press <F5> to update

OnlineDescription for TwinCAT3.x

In addition to the file described above "OnlineDescription0000...xml" , a so called EtherCAT cache
with new discovered devices is created by TwinCAT3.x, e.g. under Windows 7:

(Please note the language settings of the OS!)
You have to delete this file, too.

Faulty ESI file

If an ESI file is faulty and the System Manager is unable to read it, the System Manager brings up an
information window.

Fig.95: Information window for faulty ESI file (left: TwinCAT2; right: TwinCAT3)

EL34x3 95Version: 4.4

Commissioning

Reasons may include:

• Structure of the *.xml does not correspond to the associated *.xsd file → check your schematics

• Contents cannot be translated into a device description → contact the file manufacturer

EL34x396 Version: 4.4

Commissioning

5.2.3 TwinCAT ESI Updater

For TwinCAT2.11 and higher, the System Manager can search for current Beckhoff ESI files automatically, if
an online connection is available:

Fig.96: Using the ESI Updater (>= TwinCAT2.11)

The call up takes place under:
“Options” → "Update EtherCAT Device Descriptions"

Selection under TwinCAT3:

Fig.97: Using the ESI Updater (TwinCAT3)

The ESI Updater (TwinCAT3) is a convenient option for automatic downloading of ESI data provided by
EtherCAT manufacturers via the Internet into the TwinCAT directory (ESI = EtherCAT slave information).
TwinCAT accesses the central ESI ULR directory list stored at ETG; the entries can then be viewed in the
Updater dialog, although they cannot be changed there.

The call up takes place under:
“TwinCAT“ → „EtherCAT Devices“ → “Update Device Description (via ETG Website)…“.

5.2.4 Distinction between Online and Offline

The distinction between online and offline refers to the presence of the actual I/O environment (drives,
terminals, EJ-modules). If the configuration is to be prepared in advance of the system configuration as a
programming system, e.g. on a laptop, this is only possible in “Offline configuration” mode. In this case all
components have to be entered manually in the configuration, e.g. based on the electrical design.

If the designed control system is already connected to the EtherCAT system and all components are
energised and the infrastructure is ready for operation, the TwinCAT configuration can simply be generated
through “scanning” from the runtime system. This is referred to as online configuration.

In any case, during each startup the EtherCAT master checks whether the slaves it finds match the
configuration. This test can be parameterised in the extended slave settings. Refer to note “Installation of
the latest ESI-XML device description” [}93].

For preparation of a configuration:

• the real EtherCAT hardware (devices, couplers, drives) must be present and installed

• the devices/modules must be connected via EtherCAT cables or in the terminal/ module strand in the
same way as they are intended to be used later

EL34x3 97Version: 4.4

Commissioning

• the devices/modules be connected to the power supply and ready for communication

• TwinCAT must be in CONFIG mode on the target system.

The online scan process consists of:

• detecting the EtherCAT device [}103] (Ethernet port at the IPC)

• detecting the connected EtherCAT devices [}104]. This step can be carried out independent of the
preceding step

• troubleshooting [}107]

The scan with existing configuration [}108] can also be carried out for comparison.

5.2.5 OFFLINE configuration creation

Creating the EtherCAT device

Create an EtherCAT device in an empty System Manager window.

Fig.98: Append EtherCAT device (left: TwinCAT2; right: TwinCAT3)

Select type ‘EtherCAT’ for an EtherCAT I/O application with EtherCAT slaves. For the present publisher/
subscriber service in combination with an EL6601/EL6614 terminal select “EtherCAT Automation Protocol
via EL6601”.

Fig.99: Selecting the EtherCAT connection (TwinCAT2.11, TwinCAT3)

Then assign a real Ethernet port to this virtual device in the runtime system.

Fig.100: Selecting the Ethernet port

EL34x398 Version: 4.4

Commissioning

This query may appear automatically when the EtherCAT device is created, or the assignment can be set/
modified later in the properties dialog; see Fig. “EtherCAT device properties (TwinCAT2)”.

Fig.101: EtherCAT device properties (TwinCAT2)

TwinCAT 3: the properties of the EtherCAT device can be opened by double click on “Device .. (EtherCAT)”
within the Solution Explorer under “I/O”:

Selecting the Ethernet port

Ethernet ports can only be selected for EtherCAT devices for which the TwinCAT real-time driver is
installed. This has to be done separately for each port. Please refer to the respective installation
page [}87].

Defining EtherCAT slaves

Further devices can be appended by right-clicking on a device in the configuration tree.

Fig.102: Appending EtherCAT devices (left: TwinCAT2; right: TwinCAT3)

The dialog for selecting a new device opens. Only devices for which ESI files are available are displayed.

Only devices are offered for selection that can be appended to the previously selected device. Therefore the
physical layer available for this port is also displayed (Fig. “Selection dialog for new EtherCAT device”, A). In
the case of cable-based Fast-Ethernet physical layer with PHY transfer, then also only cable-based devices
are available, as shown in Fig. “Selection dialog for new EtherCAT device”. If the preceding device has
several free ports (e.g. EK1122 or EK1100), the required port can be selected on the right-hand side (A).

Overview of physical layer

• “Ethernet”: cable-based 100BASE-TX: EK couplers, EP boxes, devices with RJ45/M8/M12 connector

EL34x3 99Version: 4.4

Commissioning

• “E-Bus”: LVDS “terminal bus”, “EJ-module”: EL/ES terminals, various modular modules

The search field facilitates finding specific devices (since TwinCAT2.11 or TwinCAT3).

Fig.103: Selection dialog for new EtherCAT device

By default only the name/device type is used as selection criterion. For selecting a specific revision of the
device the revision can be displayed as “Extended Information”.

Fig.104: Display of device revision

In many cases several device revisions were created for historic or functional reasons, e.g. through
technological advancement. For simplification purposes (see Fig. “Selection dialog for new EtherCAT
device”) only the last (i.e. highest) revision and therefore the latest state of production is displayed in the
selection dialog for Beckhoff devices. To show all device revisions available in the system as ESI
descriptions tick the “Show Hidden Devices” check box, see Fig. “Display of previous revisions”.

EL34x3100 Version: 4.4