Documentation
EL34xx
3-phase energy and power measurement terminals
Version:
Date:
1.5
2019-09-05
Table of contents
Table of contents
1 Product overview – Power measurement terminals ..............................................................................5
2 Foreword ....................................................................................................................................................6
2.1 Notes on the documentation..............................................................................................................6
2.2 Safety instructions .............................................................................................................................7
2.3 Documentation issue status ..............................................................................................................8
2.4 Version identification of EtherCAT devices .......................................................................................9
2.4.1 Beckhoff Identification Code (BIC)................................................................................... 13
3 Product overview.....................................................................................................................................15
3.1 EL34xx – Introduction......................................................................................................................15
3.2 Technical data .................................................................................................................................19
3.3 Basic function principles ..................................................................................................................23
3.4 Current transformers .......................................................................................................................29
3.5 Start .................................................................................................................................................31
4 Basics communication ...........................................................................................................................32
4.1 EtherCAT basics..............................................................................................................................32
4.2 EtherCAT cabling – wire-bound.......................................................................................................32
4.3 General notes for setting the watchdog...........................................................................................33
4.4 EtherCAT State Machine.................................................................................................................35
4.5 CoE Interface...................................................................................................................................37
4.6 Distributed Clock .............................................................................................................................42
5 Mounting and wiring................................................................................................................................43
5.1 Instructions for ESD protection........................................................................................................43
5.2 Installation on mounting rails ...........................................................................................................44
5.3 Connection ......................................................................................................................................47
5.3.1 Connection system .......................................................................................................... 47
5.3.2 Wiring............................................................................................................................... 49
5.3.3 Shielding .......................................................................................................................... 50
5.4 Installation positions ........................................................................................................................51
5.5 Positioning of passive Terminals .....................................................................................................53
5.6 EL34xx - LEDs and connection .......................................................................................................54
6 Commissioning........................................................................................................................................63
6.1 TwinCAT Quick Start .......................................................................................................................63
6.1.1 TwinCAT2 ....................................................................................................................... 66
6.1.2 TwinCAT 3 ....................................................................................................................... 76
6.2 TwinCAT Development Environment ..............................................................................................88
6.2.1 Installation of the TwinCAT real-time driver..................................................................... 88
6.2.2 Notes regarding ESI device description........................................................................... 94
6.2.3 TwinCAT ESI Updater ..................................................................................................... 98
6.2.4 Distinction between Online and Offline............................................................................ 98
6.2.5 OFFLINE configuration creation ...................................................................................... 99
6.2.6 ONLINE configuration creation ...................................................................................... 104
6.2.7 EtherCAT subscriber configuration................................................................................ 112
6.3 General Notes - EtherCAT Slave Application................................................................................121
EL34xx 3Version: 1.5
Table of contents
6.4 Process data..................................................................................................................................129
6.4.1 Sync Manager................................................................................................................ 129
6.4.2 Settings.......................................................................................................................... 137
6.4.3 Timestamp Distributed Clocks ....................................................................................... 143
6.5 Scaling factors ...............................................................................................................................144
6.6 Notices on analog specifications ...................................................................................................145
6.6.1 Full scale value (FSV).................................................................................................... 145
6.6.2 Measuring error/ measurement deviation ...................................................................... 145
6.6.3 Temperature coefficient tK [ppm/K] ............................................................................... 146
6.6.4 Single-ended/differential typification .............................................................................. 147
6.6.5 Common-mode voltage and reference ground (based on differential inputs)................ 152
6.6.6 Dielectric strength .......................................................................................................... 152
6.6.7 Temporal aspects of analog/digital conversion.............................................................. 153
6.7 Object description and parameterization .......................................................................................157
6.7.1 Restore object................................................................................................................ 157
6.7.2 EL3423 .......................................................................................................................... 158
6.7.3 EL3443-00xx.................................................................................................................. 181
6.7.4 EL3453 .......................................................................................................................... 211
6.7.5 EL3483-00xx.................................................................................................................. 248
7 Application examples............................................................................................................................259
7.1 Power measurement on motor with 2 or 3 current transformers ...................................................260
7.2 Power measurement at a machine................................................................................................262
7.3 Power measurement in a single-phase mains network with ohmic consumers ............................264
7.4 Power measurement at a fieldbus station .....................................................................................265
7.5 Power measurement at three-phase motors controlled by a frequency converter ........................266
7.6 Power measurement including differential current measurement .................................................267
7.7 Example Function Blocks for Evaluation .......................................................................................269
8 Appendix ................................................................................................................................................273
8.1 TcEventLogger and IO ..................................................................................................................273
8.2 EtherCAT AL Status Codes...........................................................................................................276
8.3 Firmware compatibility...................................................................................................................276
8.4 Firmware Update EL/ES/EM/ELM/EPxxxx ....................................................................................278
8.4.1 Device description ESI file/XML..................................................................................... 279
8.4.2 Firmware explanation .................................................................................................... 282
8.4.3 Updating controller firmware *.efw................................................................................. 283
8.4.4 FPGA firmware *.rbf....................................................................................................... 284
8.4.5 Simultaneous updating of several EtherCAT devices.................................................... 288
8.5 Restoring the delivery state ...........................................................................................................289
8.6 Support and Service ......................................................................................................................290
EL34xx4 Version: 1.5
Product overview – Power measurement terminals
1 Product overview – Power measurement
terminals
EL3423 [}16]
3-phase power measurement terminal, Economy; 480VAC, 1A
EL3443 [}15]
3-phase power measurement terminal with extended functionality; 480VAC, 1A
EL3443-0010 [}15]
3-phase power measurement terminal with extended functionality; 480VAC, 5A
EL3443-0011 [}15]
3-phase power measurement terminal with extended functionality; 480VAC, 100mA
EL3443-0013 [}15]
3-phase power measurement terminal with extended functionality; 480VAC, 333mV
EL3453 [}18]
3-phase power measurement terminal with extended functionality; 690VAC, 5A
EL3483 [}17]
3-phase mains monitoring terminal for voltage, frequency and phase; 480V
AC
EL3483-0060 [}17]
3-phase mains monitoring terminal with voltage measurement; 480V
AC
EL34xx 5Version: 1.5
Foreword
2 Foreword
2.1 Notes on the documentation
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®, EtherCATG®, EtherCATG10®, EtherCATP®, SafetyoverEtherCAT®,
TwinSAFE®, XFC®, XTS® and XPlanar® 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, EP1456722, EP2137893, DE102015105702 with corresponding
applications or registrations in various other countries.
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.
EL34xx6 Version: 1.5
Foreword
2.2 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.
EL34xx 7Version: 1.5
Foreword
2.3 Documentation issue status
Version Comment
1.4 • EL3443-0011, EL3443-0013, EL3483-0060 added
• Update structure
• Update revision status
1.3 • EL3453 added
• Update structure
• Update revision status
1.2 • Addenda chapter “TcEventLogger and IO” (Appendix)
1.1 • Chapter “Technical data” updated
1.0 • 1st public release
0.2 – 0.5 • Complements, corrections
0.1 • Provisional documentation for EL34xx
EL34xx8 Version: 1.5
Foreword
2.4 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 (highprecision version)
0017
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: KKYYFFHH
KK - week of production (CW, calendar week)
YY - year of production
FF - firmware version
HH - hardware version
EL34xx 9Version: 1.5
Foreword
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
• 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)
EL34xx10 Version: 1.5
Fig.2: EK1100 EtherCAT coupler, standard IP20 IO device with serial/ batch number
Foreword
Fig.3: CU2016 switch with serial/ batch number
Fig.4: EL3202-0020 with serial/ batch number 26131006 and unique ID-number 204418
EL34xx 11Version: 1.5
Foreword
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
Fig.8: ELM3604-0002 terminal with unique ID number (QR code) 100001051 and serial/ batch number
44160201
EL34xx12 Version: 1.5
Foreword
2.4.1 Beckhoff Identification Code (BIC)
The Beckhoff Identification Code (BIC) is increasingly being applied to Beckhoff products to uniquely identify
the product. The BIC is represented as a Data Matrix Code (DMC, code scheme ECC200), the content is
based on the ANSI standard MH10.8.2-2016.
Fig.9: BIC as data matrix code (DMC, code scheme ECC200)
The BIC will be introduced step by step across all product groups.
Depending on the product, it can be found in the following places:
• on the packaging unit
• directly on the product (if space suffices)
• on the packaging unit and the product
The BIC is machine-readable and contains information that can also be used by the customer for handling
and product management.
Each piece of information can be uniquely identified using the so-called data identifier (ANSI
MH10.8.2-2016). The data identifier is followed by a character string. Both together have a maximum length
according to the table below. If the information is shorter, it shall be replaced by spaces. The data under
positions 1-4 are always available.
The following information is contained:
EL34xx 13Version: 1.5
Foreword
Item
no.
1 Beckhoff order
2 Beckhoff
3 Article description Beckhoff article
4 Quantity Quantity in packaging
5 Batch number Optional: Year and week of
6 ID/serial number Optional: Present-day serial
7 Variant number Optional: Product variant
...
Further types of information and data identifiers are used by Beckhoff and serve internal processes.
Type of information
number
Traceability
Number (BTN)
Explanation Data identifier Number of
digits incl.
data identifier
Beckhoff order number 1P 8 1P072222
Unique serial number,
see note below
description, e.g. EL1008
unit, e.g. 1, 10, etc.
production
number system, e.g. with
safety products
number on the basis of
standard products
S 12 SBTNk4p562d7
1K 32 1KEL1809
Q 6 Q1
2P 14 2P40150318001
51S 12 51S678294104
30P 32 30PF971 ,
Example
6
2*K183
Structure of the BIC
Example of composite information from items 1 - 4 and 6. The data identifiers are marked in red for better
display:
BTN
An important component of the BIC is the Beckhoff Traceability Number (BTN, item no. 2). The BTN is a
unique serial number consisting of eight characters that will replace all other serial number systems at
Beckhoff in the long term (e.g. batch designations on IO components, previous serial number range for
safety products, etc.). The BTN will also be introduced step by step, so it may happen that the BTN is not yet
coded in the BIC
Notice
This information has been carefully prepared. However, the procedure described is constantly being further
developed. We reserve the right to revise and change procedures and documentation at any time and
without prior notice. No claims for changes can be made from the information, illustrations and descriptions
in this information.
EL34xx14 Version: 1.5
3 Product overview
3.1 EL34xx – Introduction
EL3443 | 3-phase power measurement terminal with extended functionality
Product overview
Fig.10: EL3443
The EL3443 EtherCAT Terminal enables measurement of all relevant electrical data of the mains supply and
performs simple pre-evaluations. The voltage is measured via the direct connection of L1, L2, L3 and N. The
current of the three phases L1, L2 and L3 is fed via simple current transformers.
All measured currents and voltages are available as RMS values. In the EL3443 version, the active power
and the energy consumption for each phase are calculated. The RMS values of voltage U and current I as
well as active power P, apparent power S, reactive power Q, frequency f, phase shift angle cos φ and
harmonics are available. The EL3443 offers options for comprehensive grid analysis and energy
management.
Variants:
• EL3443-0000: Version with direct current measurement up to 1 A
• EL3443-0010: Version with direct current measurement up to 5 A
• EL3443-0011: Version with direct current measurement 100 mA
• EL3443-0013: Version with direct voltage measurement 333 mV
EL34xx 15Version: 1.5
Product overview
EL3423 | 3-phase power measurement terminal, Economy
Fig.11: EL3423
The EL3423 EtherCAT Terminal enables measurement of relevant data for an efficient energy management
system. The voltage is measured internally via direct connection of L1, L2, L3 and N. The current of the three
phases L1, L2 and L3 is fed via simple current transformers. The measured energy values are available
separately as generated and accepted values. In the EL3423 version, the active power and the energy
consumption for each phase are calculated. In addition, an internally calculated power quality factor provides
information about the quality of the monitored power supply. The EL3423 offers basic functionality for mains
analysis and energy management.
EL34xx16 Version: 1.5
EL3483 | 3-phase mains monitoring terminal for voltage, frequency and phase
Product overview
Fig.12: EL3483
The EL3483 EtherCAT Terminal enables monitoring of relevant electrical data of the supply network. The
voltage is measured internally via direct connection of L1, L2, L3 and N. The internal measured values are
compared with threshold values preset by the user. The result is available as digital information in the
process image.
The EL3483 monitors the correct phase sequence L1, L2, L3, phase failure, undervoltage and overvoltage
and possible phase imbalance. An error bit is set in case of an incorrect phase sequence or phase failure. If,
for example, an imbalance or voltage fault occurs, only a warning bit is set initially. In addition, an internally
calculated power quality factor provides information about the quality of the monitored power supply. The
EL3483 offers options for simple mains analysis and network control.
The EL3483-0060 variant also outputs the current effective voltage values in the process image.
EL34xx 17Version: 1.5
Product overview
EL3453 | 3-phase power measurement terminal up to 690 V AC with extended functionality
Fig.13: EL3453
The EL3453 EtherCAT power measurement terminal is an advancement based on the EL3413. With up to
690 V AC, the voltage inputs are optimised for the direct monitoring of high-capacity generators, as in the
wind power industry, for example. No upstream voltage transformer is required.
The four 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
incl. neutral conductor current measurement. The EL3453 can be used for simple grid analysis up to the
63rd harmonics analysis. Alternatively, all readings can be combined in a power quality factor for simplified
diagnostics. Like all measured terminal data, the harmonic content can be read via the process data.
Quick links
Also see about this
2 Basic function principles [}23]
2 Technical data [}19]
2 Object description and parameterization [}157]
2 Process data [}129]
2 Application examples [}259]
EL34xx18 Version: 1.5
3.2 Technical data
EL3423
Technical data EL3423
Number of inputs 3 x current, 3 x voltage
Technology 3-phase power measurement
Oversampling factor –
Distributed clocks –
Update interval >10 s adjustable
Measured values energy, power, power quality factor
Measuring voltage max. 480 V AC 3~ (ULX-N: max. 277 V AC; max. 240 V DC)
Measuring current max. 1 A (AC/DC), via measuring transformers x A/1 A
Measuring error 0.5% relative to full scale value (U/I), 1% calculated values
Update time mains-synchronous
Frequency range 0 (direct current) and 12 ... 400 Hz
Electrical isolation 2500 V
Current consumption power contacts -
Current consumption E -Bus typ. 120 mA
Special features single-phase operation possible, mains monitoring functionality
Configuration via TwinCAT System Manager
Weight approx. 75 g
Dimensions (WxHxD) approx. 15mmx100mmx70mm (width aligned: 12mm)
Mounting on 35 mm mounting rail according to EN 60715
Permissible ambient temperature range
during operation
Permissible ambient temperature range
during storage
Relative humidity 95% no condensation
Vibration/shock resistance conforms to EN60068-2-6 / EN60068-2-27
EMC immunity/emission conforms to EN61000-6-2/EN 61000-6-4
Protect. class / installation pos. IP20/any
Approvals CE
-25°C ... +60°C (extended temperature range)
-40°C ... +85°C
Product overview
EL34xx 19Version: 1.5
Product overview
EL3443-00xx
Technical data EL3443-0000 EL3443-0010 EL3443-0011 EL3443-0013
Number of inputs 3 x current, 3 x voltage
Technology 3-phase power measurement
Oversampling factor –
Distributed clocks Optional (for determining the zero crossing time)
Activation interval one mains period (20 ms at 50 Hz)
Measured values Current, voltage, active power, reactive power, apparent power, active energy, reactive energy, apparent
Measuring voltage max. 480 V AC 3~ (ULX-N: max. 277 V AC; max 240 V DC)
Measuring current max. 1 A (AC/DC),
Measuring error 0.3% relative to the full scale value (U/I),
Threshold frequency 3000 Hz
Electrical isolation 2500 V
Update time mains-synchronous
Current consumption
power contacts
Current consumption via
E-bus
Special features Single-phase operation possible, mains monitoring functionality, precise voltage zero crossing determina-
Weight approx. 75 g
Dimensions (WxHxD) approx. 15mmx100mmx70mm (width aligned: 12mm)
Mounting on 35 mm mounting rail according to EN 60715
Permissible ambient temperature range during operation
Permissible ambient temperature range during
storage
Relative humidity 95% no condensation
Vibration/shock resistance
EMC immunity/emission conforms to EN61000-6-2/EN 61000-6-4
Protect. class / installation
pos.
Approvals CE
energy, cos φ, frequency, THD, harmonics (up to 40th harmonic), power quality factor
via measuring transformers x A/1 A
0.6% calculated values (see documentation)
–
typ. 120mA
tion
-25°C ... +60°C (extended temperature range)
-40°C ... +85°C
conforms to EN60068-2-6 / EN60068-2-27
IP20/any
max. 5 A (AC/DC),
via measuring transformers x A/5 A
max. 100 mA (AC/DC),
via measuring transformers x A/5 A
max. 333 mV (AC/DC),
via measuring transformers x A/333 mV
EL34xx20 Version: 1.5
Product overview
EL3453
Technical data EL3453
Number of inputs 4 x current, 3 x voltage
Technology 3-phase power measurement
Oversampling-factor –
Distributed-Clocks Optional (for zero crossing time determination)
Accuracy of Distributed Clocks << 1 µs
Update time with every half-wave (10 ms at 50 Hz)
Measured values Current, voltage, active power, reactive power, apparent power, active energy, reactive en-
Measuring error 0.3 % relative to full scale value (U/I)
Mains voltage
(Nominal voltage range)
Technical measuring range Voltage 520 V
Maximum permissible overvoltage max. ±736 V (peak value, ULX-N, corresponds to 520 V
Internal resolution 24 bits
Input resistance Voltage path typ. 1,5 MΩ
Nominal current range corresponding to AC:
Technical measuring range current 2.25 A (peak value, corresponds to 1.59 A
Maximum permissible overcurrent max. ±10 A peak value, corresponds to 7 A
Peak overload capacity 60 A (sinusoidal) for 1 second, upstream use of current-limiting current transformers recom-
Largest short-term deviation during a
specified electrical disturbance test
Input resistance Current path typ. 3 mΩ
Frequency range 15 … 400 Hz
Threshold frequency 4000 Hz
Electrical isolation 4500 V
Current consumption power contacts –
Current consumption E-Bus 260 mA typ.
Weight approx. 100 g
Dimensions (WxHxD) approx. 27mmx100mmx70mm (width aligned: 24mm)
Mounting on 35 mm mounting rail according to EN 60715
Permissible ambient temperature range
during operation
Permissible ambient temperature range
during storage
Relative humidity 95% no condensation
Vibration/shock resistance conforms to EN60068-2-6 / EN60068-2-27
EMC immunity/emission conforms to EN61000-6-2/EN 61000-6-4
Protect. class / installation pos. IP20/any
Approvals CE
ergy, apparent energy, fundamental wave power and energy, cos φ, frequency, THD, harmonics (up to 63rd harmonic), power quality factor
0.6 % calculated values (see documentation)
corresponding to AC:
400 V
(ULX-N) or 690 V
rms
(ULX-N) or 897 V
rms
common reference potential N/GND
max. time for voltages above 500 V
or 863 V
(ULx-ULy): t
rms
max. ±1270 V (peak value, ULX-ULY, corresponds to 897 V
100 mA
recommended via measuring transformer x A AC/1 A AC
;1 A
rms
(default); 5 A
rms
9.6 A (peak value, corresponds to 6.8 A
max. total current (I1+I2+I3+IN) ±20 A peak value, corresponds to 14 A
(ULX-ULY) (TN-system: 600 V
rms
(ULX-ULY)
rms
(ULX-N)
< 10s *
max
rms
rms
) or.
rms
)
rms
rms
)
rms
or
rms)
)*
rms
* per channel and
*
rms
mended
< ±0.5% of full scale value for current measurement
0°C ... +55°C
-25°C ... +85°C
*) prolonged operation above the nominal range can lead to impairment of function and/or shortening of operating life
EL34xx 21Version: 1.5
Product overview
EL3483
Technical data EL3483
Number of inputs 3 x voltage
Technology 3-phase mains monitor
Oversampling factor –
Distributed clocks –
Update interval 10 mains periods (200 ms at 50 Hz)
Measured values digital thresholds and power quality factor
Measuring voltage max. 480 V AC 3~ (ULX-N: max. 277 V AC; max. 240 V DC)
Measuring procedure True RMS, True RMS calculation
Update time mains-synchronous
Electrical isolation 2500 V
Current consumption power contacts –
Current consumption E-Bus typ. 120 mA
Special features operation as voltage monitor, frequency monitor and phase monitor also possible in single-
Monitoring function phase sequence, phase failure, phase imbalance, undervoltage/overvoltage (adjustable)
Weight approx. 75 g
Dimensions (WxHxD) approx. 15mmx100mmx70mm (width aligned: 12mm)
Mounting on 35 mm mounting rail according to EN 60715
Permissible ambient temperature range
during operation
Permissible ambient temperature range
during storage
Relative humidity 95% no condensation
Vibration/shock resistance conforms to EN60068-2-6 / EN60068-2-27
EMC immunity/emission conforms to EN61000-6-2/EN 61000-6-4
Protect. class / installation pos. IP20/any
Approvals CE
phase operation
-25°C ... +60°C (extended temperature range)
-40°C ... +85°C
EL34xx22 Version: 1.5
Product overview
3.3 Basic function principles
Measuring principle
The EL3443 works with 6 analog/digital converters for recording the current and voltage values of all 3
phases.
Recording and processing is synchronous and identical for the 3 phases. The signal processing for one
phase is described below. This description applies correspondingly for all 3 phases.
Fig.14: Voltage u and current i curves
RMS value calculation
The RMS value for voltage and current is calculated during the period T. The following equations are used:
u
: instantaneous voltage value
(t)
i
: instantaneous current value
(t)
n:number of measured values
The instantaneous values for current and voltage are low-pass filtered with a cut-off frequency of 2.5 kHz for
the EL3443, EL3423 and EL3483.
Active power measurement
The EL34xx measures the active power P according to the following equation
P: active power
n: number of samples
u
: instantaneous voltage value
(t)
i
: instantaneous current value
(t)
EL34xx 23Version: 1.5
Product overview
Fig.15: Power s
In the first step, the power s
curve
(t)
is calculated at each sampling instant:
(t)
The mean value is calculated over a period.
The power frequency is twice that of the corresponding voltages and currents.
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 active power is different: Here, the product of RMS voltage and RMS current is the
apparent power.
The active power is smaller than the apparent power.
S: apparent power
P: active power
Q: reactive power
φ: Phase shift angle
EL34xx24 Version: 1.5
Product overview
Fig.16: u, i, p curves with phase shift angle (t) (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 EL3443 determines the following values:
• RMS voltage U and RMS current I
• Active power P and active energy E
• Apparent power S and apparent energy
• Reactive power Q and reactive energy
• Power factor and cos(φ)
• Distortion factors for current THDI and voltage THD
• Calculated RMS neutral conductor current I
N
U
• Voltage imbalance
• Power quality factor (details see below)
• In "DC synchronous" mode, the distributed clock time of the voltage zero crossing is also available.
EL34xx 25Version: 1.5
Product overview
Sign for power measurement
The sign of the (fundamental wave) active power P and the power factor cos φ provides information about
the direction of the energy flow. A positive sign indicates the motor mode, a negative sign indicates
generator mode.
Furthermore, the sign of the fundamental harmonic reactive power Q provides information about the direction
of the phase shift between current and voltage. Fig. Four-quadrant representation of active/fundamental
harmonic reactive power in motor and generator mode illustrates this. In motor mode (quadrant I + IV), a
positive fundamental harmonic reactive power indicates an inductive load, a negative fundamental harmonic
reactive power indicates a capacitive load. The information about a capacitive or inductive load behavior is
also shown in the sign of the phase angle φ, which is already contained in the EL3443.
In generator mode (quadrant II & III), an inductive generator is indicated by a positive fundamental harmonic
reactive power, a capacitive generator by a negative fundamental harmonic reactive power.
Since the total reactive power is defined as the quadratic difference between apparent and active power, it
has no sign. For the total active power, signs are permitted, as described above.
Fig.17: Four-quadrant representation of active power/fundamental harmonic reactive power in motor and
generator mode
Frequency measurement
The EL34xx can measure the frequency for a voltage path input signal and a current path input signal. CoE
objects "Reference" and "Frequency Source" (F800:11 [}159] and F800:13 [}159]) can be used to set which
frequency is to be output as PDO.
Power quality factor
The EL34xx calculates a PQF (power quality factor), which reflects the quality of the voltage supply as a
simplified analog value between 1.0 and 0.
To calculate this factor, the measured values, frequency, RMS voltage, distortion factor and voltage
imbalance are calculated and combined as shown in the following diagram.
EL34xx26 Version: 1.5
Product overview
Fig.18: Representation of the power quality factor calculation
As can be seen for the time value 120, the calculation method is chosen in such a way that even very short
voltage drops cause a clear signal deflection.
The value above which the power supply is to be regarded as "sufficiently good" is strongly dependent on the
connected application. The more sensitive the application, the higher the minimum limit value of the PQF
should be.
To adapt the power quality factor to your mains supply, enter the nominal voltage and frequency in CoE
object "0xF801 PMX Total Settings PQF [}159]". This can also be done via the "Settings" tab, which
summarizes all the important terminal setting options in a user-friendly manner.
Voltage zero crossing
The EL3443 and EL3453 have the ability to determine the exact time of a voltage zero crossing. However, in
order for this to be transmitted to a higher-level controller in a meaningful manner, the controller and the
EtherCAT Terminal must have the same time base. Using distributed clocks technology, an EtherCAT
system provides such a common time base (for details see EtherCAT system description). In order to be able
to use these, the EL3443 must be in "DC synchronous" mode and the EtherCAT master must support the
corresponding function.
Once these basic requirements have been met, the EL3443 and EL3453 provide the DC time of the
penultimate zero crossing. In order to facilitate exact determination of the fundamental wave, the voltage
signal to be evaluated must first be filtered, which inevitably entails a delay. In addition to the time of the
voltage zero crossing, the EL3453 also determines the respective current zero crossings.
Statistical evaluation
In addition to the cyclic data, the EL34xx terminals also produce statistical evaluations over longer periods
(can be set in the CoE: "F803 PMX Time Settings [}162]"). By default, the "F803:12 Measurement Interval
[}162]" is set to 15 minutes. The clock available for this purpose in the terminal can not only be read out via
the CoE object "F803:13 Actual System Time [}162]", it can also be actively influenced. Depending on the
EL34xx 27Version: 1.5
Product overview
application, it may make sense to regularly synchronize the clock with an external clock. By default, the clock
is set once at system startup based on the local Windows system time, taking into account the set time zone,
usually UTC.
In addition, the interval can also be restarted manually via the "Reset Interval" output bit or directly from the
application, for example to obtain statistics on a process that varies over time.
Calculation of the neutral current
Since the EL34xx terminals have direct access to the instantaneous current values of all three phases, the
neutral current can be calculated or estimated, assuming that no current is lost to the system (in other words:
the differential current is zero). The calculated (i.e. not measured) current value is output in index "F601:13
Calculated Neutral Line Current [}188]".
Since in the worst case all measurement errors add up, the maximum measurement error is correspondingly
higher.
The additional possibility of measuring a fourth current value in the EL3453 means that either the differential
current or the neutral current can be calculated. The other current can be measured directly using the fourth
current channel. Due to the usual conditions and the corresponding measurement tolerances, however, it
makes much more sense to measure the differential current with the aid of a summation current transformer
and have the neutral conductor current calculated. Further information on this can be found in the chapter
Application examples [}259] under the section Power measurement including residual current measurement
[}267].
Harmonic calculation
The EL34xx terminals perform an internal harmonic analysis for all current and voltage channels. For this
purpose, a fundamental wave in the frequency range from 45 to 65 Hz is determined at the beginning
(separately from the system frequency). The frequency value determined for the voltage harmonics can be
read, for example, from index 99 (plus channel offset) of the variable output values and the amplitude in volts
from index 98. The same applies to the current values - see "Variable output values".
The actual harmonic measured values are output as a percentage of the fundamental wave amplitude. It
should also be noted that the zero harmonic indicates the DC component of the signal.
EL34xx28 Version: 1.5
Product overview
3.4 Current transformers
In principle, the choice of current transformer for the EL34xx is not critical. The internal resistance within the
current circuit of the EL34xx is so small that it is negligible for the calculation of the total resistances of the
current loop. The transformers should be able to produce a secondary rated current of 1A. The primary
rated current Ipn can be selected arbitrarily. The common permissible overload of 1.2xIpn is no problem for
the EL34xx, but may lead to small measuring inaccuracies.
Accuracy
Please note that the overall accuracy of the set-up consisting of EL34xx and current transformers to a large
degree depends on the accuracy class of the transformers.
No approval as a billing meter
Even an arrangement with a current transformer of class 0.5 or better is not subject to approval and
certification. The EL34xx is not an approved billing meter within the meaning of the standard for
electricity meters (DIN 43 856).
NOTE
DC currents with the EL3453
DC currents can lead to saturation of the internal current transformers and thus to measurement errors!
Current types
The EL34xx can measure any current type up to a limiting proportion of 400Hz. Since such currents are
frequently created by inverters and may contain frequencies of less than 50Hz 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.
NOTE
Attention! Risk of damage to the device!
The EL34xx-xxxx must not be subjected to continuous loads that exceed the current values specified in the
technical data! In systems, in which the overcurrent limiting factors of the transformers allow higher secondary currents, additional intermediate transformers with a suitable ratio should be used.
NOTE
Attention! Risk of damage to the device!
The EL3453-xxxx must not be permanently loaded with more than I1 + I2 + I3 + IN = 20 A total current across
all channels!
Protection against dangerous touch voltages
During appropriate operation of the EL34xx 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 EL34xx
• General insulation fault
EL34xx 29Version: 1.5
Product overview
WARNING
WARNING Risk of electric shock!
The complete wiring of the EL34xx 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 EL34xx allows a maximum voltage of 480V for normal operating conditions. The conductor voltage on
the current side must not exceed this value! For higher voltages, an intermediate transformer stage should
be used!
An EL34xx is equipped with a protection impedance of typically 1.2MΩ on the voltage measurement side. If
the neutral conductor is not connected and only one connection on the side of the voltage measurement is
live, the resulting voltage against earth in a 3-phase system with a phase-to-phase voltage of 400VAC is
230VAC. This should also be measured on the side of the current measurement using a multimeter with an
internal resistance of 10MΩ, which does not represent an insulation fault.
Connection cable for current transformers
Please note the following minimum power values for current transformers to be connected:
Rated secondary transformer current
1 A 1 A 1 A 1 A 5 A 5 A 5 A 5 A
Cross-section 0.5 mm² 1 mm² 1.5 mm² 2.5 mm² 0.5 mm² 1 mm² 1.5 mm² 2.5 mm²
1 m 0.3 0.2 0.2 0.2 2.4 1.3 0.9 0.6
2 m 0.4 0.3 0.3 0.2 4.6 2.4 1.7 1.1
3 m 0.5 0.3 0.3 0.3 6.8 3.5 2.4 1.5
4 m 0.6 0.4 0.3 0.3 9.0 4.6 3.1 2.0
5 m 0.6 0.4 0.3 0.3 11.2 5.7 3.9 2.4
10 m 1.1 0.6 0.5 0.4 22.2 11.2 7.5 4.6
20 m 2.0 1.1 0.8 0.6 44.2 22.2 14.9 9.0
30 m 2.8 1.5 1.1 0.7 66.2 33.2 22.2 13.4
40 m 3.7 2.0 1.4 0.9 88.2 44.2 29.5 17.8
50 m 4.6 2.4 1.7 1.1 110.2 55.2 36.9 22.2
100 m 9.0 4.6 3.1 2.0 220.2 110.2 73.5 44.2
Cable length Minimum operating load in VA for current transformers with copper cables and 80°C
operating temperature
Additional measuring devices in the current circuit
Please note that the addition of additional measuring devices (e.g.ammeters) in the current circuit can lead
to a significant increase in the total apparent power.
Furthermore, connection IN of the EL34xx must represent a star point for the three secondary windings.
Additional measuring devices therefore have to be potential-free and must be wired accordingly.
EL34xx30 Version: 1.5
3.5 Start
For commissioning:
• mount the EL34xx as described in the chapter Mounting and wiring [}44]
• configure the EL34xx in TwinCAT as described in the chapter Commissioning [}88].
Product overview
EL34xx 31Version: 1.5
Basics communication
4 Basics communication
4.1 EtherCAT basics
Please refer to the EtherCAT System Documentation for the EtherCAT fieldbus basics.
4.2 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 5V; a coupler is
thereby loadable up to 2A 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.
EL34xx32 Version: 1.5
Basics communication
Fig.19: 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!
4.3 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.
EL34xx 33Version: 1.5
Basics communication
Fig.20: 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.
EL34xx34 Version: 1.5
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 / 25MHz * (2498 + 2) = 0.0001seconds = 100µs
SM watchdog = 10000 → 10000 * 100µs = 1second 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.
4.4 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.
EL34xx 35Version: 1.5
Basics communication
Fig.21: States of the EtherCAT State Machine
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 [}33] 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.
EL34xx36 Version: 1.5
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.
4.5 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:
EL34xx 37Version: 1.5
Basics communication
Fig.22: "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.
EL34xx38 Version: 1.5
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.
Basics communication
Fig.23: 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.
EL34xx 39Version: 1.5
Basics communication
Fig.24: 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.25: Online list
EL34xx40 Version: 1.5
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.
EL34xx 41Version: 1.5
Basics communication
4.6 Distributed Clock
The distributed clock represents a local clock in the EtherCAT slave controller (ESC) with the following
characteristics:
• Unit 1 ns
• Zero point 1.1.2000 00:00
• Size 64 bit (sufficient for the next 584 years; however, some EtherCAT slaves only offer 32-bit support,
i.e. the variable overflows after approx. 4.2 seconds)
• The EtherCAT master automatically synchronizes the local clock with the master clock in the EtherCAT
bus with a precision of < 100 ns.
For detailed information please refer to the EtherCAT system description.
EL34xx42 Version: 1.5
Mounting and wiring
5 Mounting and wiring
5.1 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.26: Spring contacts of the Beckhoff I/O components
EL34xx 43Version: 1.5
Mounting and wiring
5.2 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!
Assembly
Fig.27: Attaching on mounting rail
The bus coupler and bus terminals are attached to commercially available 35mm mounting rails (DIN rails
according to EN60715) 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 7.5mm under the terminals
and couplers, you should use flat mounting connections (e.g. countersunk screws or blind rivets).
EL34xx44 Version: 1.5
Mounting and wiring
Disassembly
Fig.28: 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 1cm 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 24V)
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 125A.
EL34xx 45Version: 1.5
Mounting and wiring
Fig.29: Power contact on left side
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 230V).
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 10mm from the group of terminals.
WARNING
Risk of electric shock!
The PE power contact must not be used for other potentials!
EL34xx46 Version: 1.5
Mounting and wiring
5.3 Connection
5.3.1 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.
Standard wiring (ELxxxx / KLxxxx)
Fig.30: 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.31: 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.
EL34xx 47Version: 1.5
Mounting and wiring
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 0.08mm2 and 2.5mm2 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.32: 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 12mm Bus Terminals. Massive
conductors and conductors with a wire end sleeve can be inserted directly into the spring loaded terminal
point without tools.
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!
EL34xx48 Version: 1.5
Mounting and wiring
5.3.2 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.33: 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 ... 2.5mm
Wire size width (fine-wire conductors) 0.08 ... 2.5mm
Wire size width (conductors with a wire end sleeve) 0.14 ... 1.5mm
2
2
2
0.08 ... 2.5mm
0,08 ... 2.5mm
0.14 ... 1.5mm
2
2
2
Wire stripping length 8 ... 9mm 9 ... 10mm
High Density Terminals (HD Terminals [}48]) 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.
EL34xx 49Version: 1.5
Mounting and wiring
Terminal housing High Density Housing
Wire size width (single core wires) 0.08 ... 1.5mm
Wire size width (fine-wire conductors) 0.25 ... 1.5mm
Wire size width (conductors with a wire end sleeve) 0.14 ... 0.75mm
Wire size width (ultrasonically “bonded" conductors) only 1.5mm
2
2
2
2
Wire stripping length 8 ... 9mm
5.3.3 Shielding
Shielding
Encoder, analog sensors and actors should always be connected with shielded, twisted paired
wires.
EL34xx50 Version: 1.5
Mounting and wiring
5.4 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.
Fig.34: 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.
EL34xx 51Version: 1.5
Mounting and wiring
Fig.35: Other installation positions
EL34xx52 Version: 1.5
5.5 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)
Mounting and wiring
Fig.36: Correct positioning
Fig.37: Incorrect positioning
EL34xx 53Version: 1.5
Mounting and wiring
5.6 EL34xx - LEDs and connection
WARNING
Caution: Risk of electric shock!
If you do not connect the terminal point N with the neutral conductor of your mains supply (e.g.if the
EL3443/EL3453 is used purely for current measurements), terminal point N should be earthed, in order to
avoid dangerous overvoltages in the event of a current transformer fault!
WARNING
Caution: Risk of electric shock!
Please note that many vendors do not permit their current transformers to be operated in no-load mode!
Connect the EL3443/EL3453 to the secondary windings of the current transformers before using the current
transformer!
EL3423 - LEDs and connection
Fig.38: EL3423 LEDs
EL34xx54 Version: 1.5
LED Color Meaning
RUN green This LED indicates the terminal's operating state:
off
flashing rapidly
flashing
Single flash
on
System OK green on System OK,
L1 - L3
OK
green on Voltage in the normal range
flashes Voltage in the critical range
State of the EtherCAT State Machine [}35]:
INIT=initialization of the terminal
State of the EtherCAT State Machine [}35]:
BOOTSTRAP=function for terminal firmware updates [}278]
State of the EtherCAT State Machine [}35]:
PREOP = function for mailbox communication and different default settings set
State of the EtherCAT State Machine [}35]:
SAFEOP = verification of the Sync Manager [}113] channels and the distributed
clocks.
Outputs remain in safe state.
State of the EtherCAT State Machine [}35]:
OP = normal operating state; mailbox and process data communication is possible
L1 L2 L3
(warning threshold exceeded)
Mounting and wiring
L1 L2 L3
off Voltage in prohibited range
L1 - L3
Error
Terminal point Description Comment
Name No.
L1 1 Phase L1 Connections for the voltage measurement
L2 2 Phase L2
L3 3 Phase L3
N 4 Neutral conductor N
IL1 5 Consumer at phase L1 Connections for the current transformers. Note
IL2 6 Consumer at phase L2
IL3 7 Consumer at phase L3
N 8 Neutral conductor N
red on
(internally connected to terminal point 8)
(internally connected to terminal point 4)
(error threshold exceeded)
L1 L2 L3
Note the Warnings [}54] above " Caution: Risk
of electric shock! "
the Warnings [}54] above " Caution: Risk of
electric shock!"
EL34xx 55Version: 1.5
Mounting and wiring
EL3443 - LEDs and connection
Fig.39: EL3443 LEDs
LED Color Meaning
RUN green This LED indicates the terminal's operating state:
off
flashing rapidly
flashing
Single flash
on
System OK green on System OK,
L1 - L3
OK
green on Voltage in the normal range
flashes Voltage in the critical range
State of the EtherCAT State Machine [}35]:
INIT=initialization of the terminal
State of the EtherCAT State Machine [}35]:
BOOTSTRAP=function for terminal firmware updates [}278]
State of the EtherCAT State Machine [}35]:
PREOP = function for mailbox communication and different default settings set
State of the EtherCAT State Machine [}35]:
SAFEOP = verification of the Sync Manager [}113] channels and the distributed
clocks.
Outputs remain in safe state.
State of the EtherCAT State Machine [}35]:
OP = normal operating state; mailbox and process data communication is possible
L1 L2 L3
(warning threshold exceeded)
L1 - L3
Error
off Voltage in prohibited range
red on
L1 L2 L3
(error threshold exceeded)
L1 L2 L3
EL34xx56 Version: 1.5
Mounting and wiring
Terminal point Description Comment
Name No.
L1 1 Phase L1 Connections for the voltage measurement
L2 2 Phase L2
L3 3 Phase L3
N 4 Neutral conductor N
(internally connected to terminal point 8)
IL1 5 Consumer at phase L1 Connections for the current transformers. Note
IL2 6 Consumer at phase L2
IL3 7 Consumer at phase L3
N 8 Neutral conductor N
(internally connected to terminal point 4)
Note the Warnings [}54] above " Caution: Risk
of electric shock! "
the Warnings [}54] above " Caution: Risk of
electric shock!"
EL34xx 57Version: 1.5
Mounting and wiring
EL3453 - LEDs and connection
Fig.40: EL3453 LED's
EL34xx58 Version: 1.5
LED Color Meaning
RUN green This LED indicates the terminal's operating state:
off
State of the EtherCAT State Machine [}35]:
INIT=initialization of the terminal
flashing
rapidly
flashing
State of the EtherCAT State Machine [}35]:
BOOTSTRAP=function for terminal firmware updates [}278]
State of the EtherCAT State Machine [}35]:
PREOP = function for mailbox communication and different default
settings set
Single flash
State of the EtherCAT State Machine [}35]:
SAFEOP = verification of the Sync Manager [}113] channels and the
distributed clocks.
Outputs remain in safe state.
on
State of the EtherCAT State Machine [}35]:
OP = normal operating state; mailbox and process data
communication is possible
System OK green on System OK,
L1 - L3
OK
green on Right prism:
Voltage in normal range
Mounting and wiring
L1 - L3
Error
IL1 - I
L3
OK
L1 L2 L3
flashes Right prism:
Voltage in the critical range
(warning threshold exceeded)
L1 L2 L3
off Right prism:
red on
Voltage in prohibited range
(error threshold exceeded)
L1 L2 L3
green on Left prism:
Current in normal range
IL1 IL2 IL3 IN
flashes Left prism:
Current in the critical range
(warning threshold exceeded)
IL1 IL2 IL3 IN
off Left prism:
IL1 - I
Error
L3
red on
Current in prohibited range
(error threshold exceeded
IL1 IL2 IL3 IN
EL34xx 59Version: 1.5
Mounting and wiring
Terminal point Description Comment
Name No.
I
L1
I
L2
I
L3
I
N
1 Phase L1 current measurement input Connections for the current
2 Phase L2 current measurement input
3 Phase L3 current measurement input
4 Neutral conductor current measurement input
transformers. Note the Warnings
[}54] above " Caution: Risk of electric
shock!"
(star point)
IL1‘ 5 Phase L1 current measurement output
IL2‘ 6 Phase L2 current measurement output
IL3‘ 7 Phase L3 current measurement output
IN‘ 8 Neutral conductor current measurement
output (star point)
L1 1‘ Phase L1 Connections for the voltage
2‘ n.c.
L3 3‘ Phase L3
N 4‘ Neutral conductor
measurement
Note the Warnings [}54] above "
Caution: Risk of electric shock!
(internally connected with terminal point 8‘)
5‘ n.c.
L2 6‘ Phase L2
7‘ n.c.
N 8‘ Neutral conductor
(internally connected with terminal point 4‘)
EL34xx60 Version: 1.5
EL3483 - LEDs and connection
Mounting and wiring
Fig.41: EL3483 LEDs
LED Color Meaning
RUN green This LED indicates the terminal's operating state:
off
flashing rapidly
flashing
Single flash
on
System OK green on System OK,
L1 - L3
OK
green on Voltage in the normal range
flashes Voltage in the critical range
State of the EtherCAT State Machine [}35]:
INIT=initialization of the terminal
State of the EtherCAT State Machine [}35]:
BOOTSTRAP=function for terminal firmware updates [}278]
State of the EtherCAT State Machine [}35]:
PREOP = function for mailbox communication and different default settings set
State of the EtherCAT State Machine [}35]:
SAFEOP = verification of the Sync Manager [}113] channels and the distributed
clocks.
Outputs remain in safe state.
State of the EtherCAT State Machine [}35]:
OP = normal operating state; mailbox and process data communication is possible
L1 L2 L3
(warning threshold exceeded)
L1 L2 L3
L1 - L3
Error
off Voltage in prohibited range
red on
(error threshold exceeded)
L1 L2 L3
EL34xx 61Version: 1.5
Mounting and wiring
Terminal point Description Comment
Name No.
L1 1 Phase L1 Connections for the voltage measurement
L2 2 Phase L2
L3 3 Phase L3
N 4 Neutral conductor N
Note the Warnings [}54] above " Caution: Risk
of electric shock! "
EL34xx62 Version: 1.5
Commissioning
6 Commissioning
6.1 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
• TwinCAT2 → 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:
TwinCAT2 → 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:
EL34xx 63Version: 1.5
Commissioning
Fig.42: Relationship between user side (commissioning) and installation
The user inserting of certain components (I/O device, terminal, box...) is the same in TwinCAT2 and
TwinCAT3. 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
TwinCAT2 and TwinCAT3:
• Control system (PLC) CX2040 including CX2100-0004 power supply unit
• Connected to the CX2040 on the right (E-bus):
EL1004 (4-channel digital input terminal 24 V DC)
• 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 24VDC;0.5A)
• (Optional via X000: a link to an external PC for the user interface)
EL34xx64 Version: 1.5
Commissioning
Fig.43: 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.
EL34xx 65Version: 1.5
Commissioning
6.1.1 TwinCAT2
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 TwinCAT2
System Manager displays the following user interface after startup:
Fig.44: Initial TwinCAT2 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 [}68]".
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:
EL34xx66 Version: 1.5
Fig.45: Selection of the target system
Use "Search (Ethernet)..." to enter the target system. Thus a next dialog opens to either:
Commissioning
• 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.46: 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.
EL34xx 67Version: 1.5
Commissioning
Adding devices
In the configuration tree of the TwinCAT2 System Manager user interface on the left, select "I/ODevices”
and then right-click to open a context menu and select "ScanDevices…", or start the action in the menu bar
via . The TwinCAT System Manager may first have to be set to "Configmode" via or via menu
“Actions" → "Set/Reset TwinCAT to Config Mode…" (Shift + F4).
Fig.47: Select "Scan Devices..."
Confirm the warning message, which follows, and select "EtherCAT" in the dialog:
Fig.48: 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 [}64] described at the beginning of this section, the result is as follows:
EL34xx68 Version: 1.5
Commissioning
Fig.49: Mapping of the configuration in the TwinCAT2 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.50: 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)
EL34xx 69Version: 1.5
Commissioning
◦ 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:
Fig.51: TwinCAT PLC Control after startup
Sample variables and a sample program have been created and stored under the name "PLC_example.pro":
EL34xx70 Version: 1.5
Commissioning
Fig.52: 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.53: Appending the TwinCAT PLC Control project
EL34xx 71Version: 1.5
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.54: 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.55: 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:
EL34xx72 Version: 1.5
Commissioning
Fig.56: 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.57: 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:
EL34xx 73Version: 1.5
Commissioning
Fig.58: 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…":
EL34xx74 Version: 1.5
Commissioning
Fig.59: 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:
EL34xx 75Version: 1.5
Commissioning
Fig.60: PLC Control logged in, ready for program startup
The PLC can now be started via "Online" → "Run", F5 key or .
6.1.2 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 TwinCAT2) for communication with the electromechanical components.
After successful installation of the TwinCAT system on the PC to be used for development, TwinCAT3
(shell) displays the following user interface after startup:
EL34xx76 Version: 1.5
Commissioning
Fig.61: Initial TwinCAT3 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.62: Create new TwinCAT project
The new project is then available in the project folder explorer:
EL34xx 77Version: 1.5
Commissioning
Fig.63: 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 [}79]".
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.64: Selection dialog: Choose the target system
EL34xx78 Version: 1.5
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.
Commissioning
Fig.65: 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.66: Select "Scan"
Confirm the warning message, which follows, and select "EtherCAT" in the dialog:
EL34xx 79Version: 1.5
Commissioning
Fig.67: 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 [}64] described at the beginning of this section, the result is as follows:
Fig.68: 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:
EL34xx80 Version: 1.5
Commissioning
Fig.69: 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….":
EL34xx 81Version: 1.5
Commissioning
Fig.70: Adding the programming environment in "PLC"
In the dialog that opens select "Standard PLC project" and enter "PLC_example" as project name, for
example, and select a corresponding directory:
Fig.71: 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:
EL34xx82 Version: 1.5
Commissioning
Fig.72: Initial "Main" program of the standard PLC project
To continue, sample variables and a sample program have now been created:
EL34xx 83Version: 1.5
Commissioning
Fig.73: 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.74: 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:
EL34xx84 Version: 1.5
Commissioning
Fig.75: 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.76: 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:
EL34xx 85Version: 1.5
Commissioning
Fig.77: 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.78: 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.
EL34xx86 Version: 1.5
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.79: 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).
EL34xx 87Version: 1.5
Commissioning
6.2 TwinCAT Development Environment
The Software for automation TwinCAT (The Windows Control and Automation Technology) will be
distinguished into:
• TwinCAT2: System Manager (Configuration) & PLC Control (Programming)
• TwinCAT3: Enhancement of TwinCAT2 (Programming and Configuration takes place via a common
Development Environment)
Details:
• TwinCAT2:
◦ 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:
• TwinCAT3 (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 TwinCAT2 and TwinCAT3 at http://infosys.beckhoff.com.
6.2.1 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.
EL34xx88 Version: 1.5
Fig.80: System Manager “Options” (TwinCAT2)
This have to be called up by the Menü “TwinCAT” within the TwinCAT3 environment:
Commissioning
Fig.81: Call up under VS Shell (TwinCAT3)
The following dialog appears:
Fig.82: 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” [}99] in order to view the compatible ethernet ports via its
EtherCAT properties (tab „Adapter“, button „Compatible Devices…“):
EL34xx 89Version: 1.5
Commissioning
Fig.83: EtherCAT device properties(TwinCAT2): 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.84: Windows properties of the network interface
A correct setting of the driver could be:
EL34xx90 Version: 1.5
Fig.85: Exemplary correct driver setting for the Ethernet port
Other possible settings have to be avoided:
Commissioning
EL34xx 91Version: 1.5
Commissioning
Fig.86: Incorrect driver settings for the Ethernet port
EL34xx92 Version: 1.5
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.
Commissioning
Fig.87: TCP/IP setting for the Ethernet port
EL34xx 93Version: 1.5
Commissioning
6.2.2 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:
• TwinCAT2: C:\TwinCAT\IO\EtherCAT
• TwinCAT3: 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 TwinCAT2.11/TwinCAT3 and higher, the ESI directory can be updated from the System Manager, if the
programming PC is connected to the Internet; by
• TwinCAT2: Option → “Update EtherCAT Device Descriptions”
• TwinCAT3: TwinCAT → EtherCAT Devices → “Update Device Descriptions (via ETG Website)…”
The TwinCAT ESI Updater [}98] 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.88: 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 [}9].
EL34xx94 Version: 1.5
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.89: OnlineDescription information window (TwinCAT2)
In TwinCAT3 a similar window appears, which also offers the Web update:
Fig.90: Information window OnlineDescription (TwinCAT3)
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’ [}99].
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.
EL34xx 95Version: 1.5
Commissioning
Fig.91: 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.92: 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 TwinCAT3.x
In addition to the file described above "OnlineDescription0000...xml" , a so called EtherCAT cache
with new discovered devices is created by TwinCAT3.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.93: Information window for faulty ESI file (left: TwinCAT2; right: TwinCAT3)
EL34xx96 Version: 1.5
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
Commissioning
EL34xx 97Version: 1.5
Commissioning
6.2.3 TwinCAT ESI Updater
For TwinCAT2.11 and higher, the System Manager can search for current Beckhoff ESI files automatically, if
an online connection is available:
Fig.94: Using the ESI Updater (>= TwinCAT2.11)
The call up takes place under:
“Options” → "Update EtherCAT Device Descriptions"
Selection under TwinCAT3:
Fig.95: Using the ESI Updater (TwinCAT3)
The ESI Updater (TwinCAT3) 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)…“.
6.2.4 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” [}94].
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
EL34xx98 Version: 1.5
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 [}104] (Ethernet port at the IPC)
• detecting the connected EtherCAT devices [}105]. This step can be carried out independent of the
preceding step
• troubleshooting [}108]
The scan with existing configuration [}109] can also be carried out for comparison.
6.2.5 OFFLINE configuration creation
Creating the EtherCAT device
Create an EtherCAT device in an empty System Manager window.
Fig.96: Append EtherCAT device (left: TwinCAT2; right: TwinCAT3)
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.97: Selecting the EtherCAT connection (TwinCAT2.11, TwinCAT3)
Then assign a real Ethernet port to this virtual device in the runtime system.
Fig.98: Selecting the Ethernet port
EL34xx 99Version: 1.5
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 (TwinCAT2)”.
Fig.99: EtherCAT device properties (TwinCAT2)
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 [}88].
Defining EtherCAT slaves
Further devices can be appended by right-clicking on a device in the configuration tree.
Fig.100: Appending EtherCAT devices (left: TwinCAT2; right: TwinCAT3)
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
EL34xx100 Version: 1.5
Loading...