Beckhoff EL5072 Users manual

Documentation | EN

EL5072

2 Channel LVDT Interface

2021-04-07 | Version: 1.0

Table of contents

Table of contents

1 Foreword ....................................................................................................................................................5

1.1 Notes on the documentation..............................................................................................................5

1.2 Safety instructions .............................................................................................................................6

1.3 Documentation issue status ..............................................................................................................7

1.4 Version identification of EtherCAT devices .......................................................................................7

1.4.1 Beckhoff Identification Code (BIC)................................................................................... 10

2 Product description.................................................................................................................................12

2.1 Introduction......................................................................................................................................12

2.2 Technical data .................................................................................................................................13

2.3 Basics of inductive measuring probes .............................................................................................14

3 Basics communication ...........................................................................................................................16

3.1 EtherCAT basics..............................................................................................................................16

3.2 EtherCAT cabling – wire-bound.......................................................................................................16

3.3 General notes for setting the watchdog...........................................................................................17

3.4 EtherCAT State Machine.................................................................................................................19

3.5 CoE Interface...................................................................................................................................20

3.6 Distributed Clock .............................................................................................................................25

4 Mounting and wiring................................................................................................................................26

4.1 Instructions for ESD protection........................................................................................................26

4.2 Installation on mounting rails ...........................................................................................................26

4.3 Connection ......................................................................................................................................30

4.3.1 Connection system .......................................................................................................... 30

4.3.2 Wiring............................................................................................................................... 32

4.3.3 Shielding .......................................................................................................................... 33

4.4 Installation positions ........................................................................................................................34

4.5 Positioning of passive Terminals .....................................................................................................36

4.6 EL5072 - Connection.......................................................................................................................37

4.6.1 Notes on the electrical connection of inductive measuring probes.................................. 38

4.6.2 LVDT connection ............................................................................................................. 39

4.6.3 Half bridge - Connection .................................................................................................. 41

4.6.4 Variable input impedances .............................................................................................. 42

4.7 EL5072 - LEDs ................................................................................................................................43

5 Commissioning........................................................................................................................................44

5.1 TwinCAT Development Environment ..............................................................................................44

5.1.1 Installation of the TwinCAT real-time driver..................................................................... 44

5.1.2 Notes regarding ESI device description........................................................................... 50

5.1.3 TwinCAT ESI Updater ..................................................................................................... 54

5.1.4 Distinction between Online and Offline............................................................................ 54

5.1.5 OFFLINE configuration creation ...................................................................................... 55

5.1.6 ONLINE configuration creation ........................................................................................ 60

5.1.7 EtherCAT subscriber configuration.................................................................................. 68

5.1.8 Import/Export of EtherCAT devices with SCI and XTI ..................................................... 77

5.2 General Notes - EtherCAT Slave Application..................................................................................83

EL5072 3Version: 1.0

Table of contents

6 EL5072 - Commissioning........................................................................................................................91

6.1 Overview of functions ......................................................................................................................91

6.2 Process data....................................................................................................................................92

6.2.1 Sync Manager (SM)......................................................................................................... 92

6.2.2 PDO assignment.............................................................................................................. 93

6.2.3 Predefined PDO Assignment........................................................................................... 95

6.2.4 Synchronicity mode ......................................................................................................... 96

6.2.5 EtherCAT cycle time ........................................................................................................ 97

6.3 Functions .........................................................................................................................................98

6.3.1 Parameterization for evaluation of the measuring probe ............................................... 100

6.3.2 Position value output ..................................................................................................... 108

6.3.3 Application notes on measurement deviations .............................................................. 108

6.3.4 Set position value .......................................................................................................... 109

6.3.5 Save position value........................................................................................................ 111

6.3.6 Timestamp for the stored position value........................................................................ 112

6.3.7 Digital input .................................................................................................................... 113

7 Diagnostics ............................................................................................................................................115

7.1 EL5072 - Diagnostics ....................................................................................................................115

7.2 Diagnostics – basic principles of diag messages ..........................................................................117

8 Object description and parameterization............................................................................................127

8.1 Restore object ...............................................................................................................................127

8.2 Configuration data .........................................................................................................................127

8.3 Configuration data (vendor-specific)..............................................................................................129

8.4 Command object ...........................................................................................................................129

8.5 Input data.......................................................................................................................................130

8.6 Output data....................................................................................................................................131

8.7 Information / diagnostic data (channel specific) ............................................................................131

8.8 Diagnosis History data...................................................................................................................131

8.9 Standard objects............................................................................................................................131

9 Appendix ................................................................................................................................................138

9.1 Firmware compatibility...................................................................................................................138

9.2 Firmware Update EL/ES/EM/ELM/EPxxxx ....................................................................................138

9.2.1 Device description ESI file/XML..................................................................................... 139

9.2.2 Firmware explanation .................................................................................................... 142

9.2.3 Updating controller firmware *.efw................................................................................. 143

9.2.4 FPGA firmware *.rbf....................................................................................................... 145

9.2.5 Simultaneous updating of several EtherCAT devices.................................................... 149

9.3 Restoring the delivery state ...........................................................................................................150

9.4 Support and Service ......................................................................................................................151

EL50724 Version: 1.0

Foreword

1 Foreword

1.1 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®, EtherCATG®, EtherCATG10®, EtherCATP®, SafetyoverEtherCAT®,
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.

EL5072 5Version: 1.0

Foreword

1.2 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.

EL50726 Version: 1.0

Foreword

1.3 Documentation issue status

Version Comment

1.0 • First release

0.2 • Modifications

0.1 • Provisional documentation for EL5072

1.4 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:

EL5072 7Version: 1.0

Foreword

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

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

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

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

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

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

Syntax: D ww yy x y z u

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

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

Unique serial number/ID, ID number

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

See also the further documentation in the area

• 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)

EL50728 Version: 1.0

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

Foreword

Fig.3: EL3202-0020 with serial/ batch number 26131006 and unique ID-number 204418

EL5072 9Version: 1.0

Foreword

1.4.1 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.4: 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, spaces are added to it. The data under
positions 1 to 4 are always available.

The following information is contained:

EL507210 Version: 1.0

Item

Type of

no.

information

1 Beckhoff order

number

2 Beckhoff Traceability

Number (BTN)

3 Article description Beckhoff article

4 Quantity Quantity in packaging

5 Batch number Optional: Year and week

6 ID/serial number Optional: Present-day

7 Variant number Optional: Product variant

...

Explanation Data

Beckhoff order number 1P 8 1P072222

Unique serial number,
see note below

description, e.g.
EL1008

unit, e.g. 1, 10, etc.

of production

serial number system,
e.g. with safety products
or calibrated terminals

number on the basis of
standard products

Foreword

Number of digits

identifier

S 12 SBTNk4p562d7

1K 32 1KEL1809

Q 6 Q1

2P 14 2P401503180016

51S 12 51S678294104

30P 32 30PF971, 2*K183

incl. data identifier

Example

Further types of information and data identifiers are used by Beckhoff and serve internal processes.

Structure of the BIC

Example of composite information from item 1 to 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.

NOTE

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.

EL5072 11Version: 1.0

Product description

2 Product description

2.1 Introduction

Fig.5: EL5072

2-channel inductive displacement sensor interface (LVDT, half bridge, RVDT)

The EL5072 EtherCAT Terminal is used for direct connection of up to two inductive displacement sensors,
including measuring probes in LVDT and half bridge design or inductive angular position sensors in RVDT
design. The integrated excitation source provides a wide range with different adjustable excitation
frequencies and voltages. Through internal switching and switchable input impedances, commercially
available inductive sensors such as LVDT in 4-, 5-, 6-wire design or half bridge in 3- and 5-wire design can
be connected and evaluated.

All sensor parameters such as excitation frequency, excitation voltage, measuring range and sensitivity are
set directly in the terminal. The measuring signal range is automatically adjusted; the measured value is
directly output as a 32-bit position value. Inversion of the measuring signal and a reference position can be
parameterized via the process data. Furthermore, short circuit or overload of the excitation source, as well as
amplitude errors of the input signal are diagnosed for each channel and indicated via signal LEDs.

Precision measuring tasks in the area of position and distance measurement with inductive measuring
probes can be successfully solved in this way with the EL5072.

Quick links

• Basic Function Principles [}14]

• EL5072 - Connection [}37]

• EL5072 - LEDs [}43]

• EL5072 - Functions [}98]

EL507212 Version: 1.0

Product description

2.2 Technical data

Technical data EL5072

Technology Inductive displacement sensor interface

Input connections LVDT (ratiometric & differential), inductive half bridge, RVDT

2 x digital input (5VDC to 24VDC, 2-wire, switching threshold
typically 5V at 3mA)

Number of channels 2

Distributed clocks yes, timestamp for position value can be saved via digital input

Excitation voltage U

exc

Total excitation current max. 50mA

Excitation frequency (sine) 1kHz to 20kHz, adjustable, common for both channels

Resolution 24bit, 32 bit representation

Measuring signal range U

SIG

Conversion time 100µs/10kSps at max. 13kHz

Electrical isolation 500V (E-bus/field voltage)

Current consumption power contacts 40mA typ.+ load

Current consumption via E-bus 200 mAtyp.

Special features Short circuit and overload detection, amplitude error per

Weight app.60g

Permissible ambient temperature range
during operation

Permissible ambient temperature range
during storage

Permissible relative air humidity 95%, no condensation

Dimensions (W x H x D) approx. 15mm x 100mm x 70mm (width aligned: 12mm)

Mounting on 35mm support rail according to EN60715

Vibration/shock resistance conforms to EN60068-2-6/ EN60068-2-27

EMC immunity/emission conforms to EN61000-6-2/ EN61000-6-4

Protection class IP20

Installation position variable

Approvals CE

optionally 0.5V

to 7V

rms

(1.5VPP to 20VPP), common for

rms

both channels

(140mAPP)

rms

max. 7V

(automatic setting)

rms

channel, set and save digital input for position value

0°C ... +55°C

-25°C... +85°C

EL5072 13Version: 1.0

Product description

2.3 Basics of inductive measuring probes

Inductive displacement sensors are transformers with a special design that are used for displacement
recording / path length measurement. They are passive components that are available with different circuit
options. A basic common feature is that an alternating voltage excites a coil system. A moving ferromagnetic
core affects the inductance in the coils. The inductance change is proportional to the movement of the core
and can be evaluated.

The EL5072 can evaluate the following inductive displacement sensors:

• Inductive half bridge [}14]

• LVDT (Linear Variable Differential Transformer) [}15]

• RVDT (Rotary Variable Differential Transformer) [}15]

Operating principle of inductive half bridge position transducers

Electrically, inductive half bridges (differential chokes) represent a Wheatstone half bridge with variable,
complex resistances. This consists of:

• two measuring coils

• a movable ferromagnetic core that moves inside the coils

Fig.6: Inductive half bridge - operating principle

Principle of operation:

An alternating voltage is applied to the two coils connected in series. The ferromagnetic core changes the
inductance of the coils when the measuring probe is deflected. In a symmetrical configuration and in the zero
position of the position transducer, the impedance of the two coils is the same. If the core is moved from its
center position, the impedance in the two coils changes in opposite directions. This results in a linear and
absolute displacement signal, which can be measured with the EL5072.

EL507214 Version: 1.0

Operating principle of Linear Variable Differential Transformers (LVDTs)

inductive LVDT displacement sensors generally consist of:

• a primary coil used for excitation

• two secondary coils, which are arranged in phase opposition to each other.

• a movable ferromagnetic core, which serves to couple the primary and secondary coils

Product description

Fig.7: LVDT - Operating principle

Principle of operation:

The primary coil fed with an alternating voltage induces a secondary voltage in the secondary winding. In a
symmetrical configuration, the secondary voltages are equal in magnitude in the zero position of the position
transducer but phase-inverted. The resulting signal voltage is zero. If the core is deflected, the induced
voltage increases in one secondary coil and decreases in the other. This results in a linear and absolute
displacement signal, which can be measured with the EL5072.

The deflection direction of the inductive measuring probe is determined by the movement of the core and the
resulting phase shift between the excitation voltage U

and the measured signal voltage U

exc

. The general

sig

rule is:

• Negative deflection direction of the core relative to the zero position:
excitation voltage U

and signal voltage U

exc

are in phase

sig

• Positive deflection direction of the core relative to the zero position:
excitation voltage U

and signal voltage U

exc

are phase-shifted by 180°

sig

• Zero position of the core:
phase jump between excitation voltage U

and signal voltage U

exc

sig

In addition to the usual 4-wire connection, LVDT probes are also available as 5- or 6-wire versions. The 5­wire version allows ratiometric measurement on the secondary side.

With the 6-wire version, the excitation voltage fed in is measured back from the sensor, thus minimizing
influences on the voltage measurement which could be caused by a voltage drop along the supply lines.

Operating principle of Rotary Variable Differential Transformers (RVDT)

An RVDT rotary encoder represents a special design of the LVDT measuring principle. The main difference
is that the LVDT uses a linear displacement of the core, whereas the RVDT uses a cam-shaped rotating core
to measure the angular displacement.

To ensure correct output of the measured value, special Notes for RVDTs [}104] must be observed.

EL5072 15Version: 1.0

Basics communication

3 Basics communication

3.1 EtherCAT basics

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

3.2 EtherCAT cabling – wire-bound

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

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

Cables and connectors

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

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

Pin Color of conductor Signal Description

1 yellow TD + Transmission Data +

2 orange TD - Transmission Data -

3 white RD + Receiver Data +

6 blue RD - Receiver Data -

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

Recommended cables

It is recommended to use the appropriate Beckhoff components e.g.

- cable sets ZK1090-9191-xxxx respectively

- RJ45 connector, field assembly ZS1090-0005

- EtherCAT cable, field assembly ZB9010, ZB9020

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

E-Bus supply

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

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

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

EL507216 Version: 1.0

Basics communication

Fig.8: System manager current calculation

NOTE

Malfunction possible!

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

3.3 General notes for setting the watchdog

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

The EtherCAT slave controller (ESC) in the EL2xxx terminals features two 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.

EL5072 17Version: 1.0

Basics communication

Fig.9: 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

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.

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.

EL507218 Version: 1.0

Basics communication

Calculation

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

CAUTION

Undefined state possible!

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

CAUTION

Damage of devices and undefined state possible!

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

3.4 EtherCAT State Machine

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

A distinction is made between the following states:

• Init

• Pre-Operational

• Safe-Operational and

• Operational

• Boot

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

Fig.10: States of the EtherCAT State Machine

EL5072 19Version: 1.0

Basics communication

Init

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

Pre-Operational (Pre-Op)

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

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

Safe-Operational (Safe-Op)

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

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

Outputs in SAFEOP state

The default set watchdog [}17] 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.

Boot

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

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

3.5 CoE Interface

General description

The CoE interface (CAN application protocol 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.

EL507220 Version: 1.0

Basics communication

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 two 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 “0x” 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: here are the channel parameters for some EtherCAT devices. Historically, this was the first
parameter area before the 0x8000 area was introduced. EtherCAT devices that were previously
equipped with parameters in 0x4000 and changed to 0x8000 support both ranges for compatibility
reasons and mirror internally.

• 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:

Fig.11: “CoE Online” tab

EL5072 21Version: 1.0

Basics communication

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
parameterized 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.

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.

EL507222 Version: 1.0

Basics communication

Fig.12: 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.

Fig.13: Offline list

EL5072 23Version: 1.0

Basics communication

• 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.14: Online list

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 four logical channels and therefore four
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.

EL507224 Version: 1.0

Basics communication

3.6 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.

EL5072 25Version: 1.0

Mounting and wiring

4 Mounting and wiring

4.1 Instructions for ESD protection

NOTE

Destruction of the devices by electrostatic discharge possible!

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

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

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

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

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

Fig.15: Spring contacts of the Beckhoff I/O components

4.2 Installation on mounting rails

WARNING

Risk of electric shock and damage of device!

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

EL507226 Version: 1.0

Assembly

Mounting and wiring

Fig.16: Attaching on mounting rail

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

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

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

Fixing of mounting rails

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

EL5072 27Version: 1.0

Mounting and wiring

Disassembly

Fig.17: Disassembling of terminal

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

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

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

Connections within a bus terminal block

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

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

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

Power Contacts

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

PE power contact

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

EL507228 Version: 1.0

Fig.18: Power contact on left side

Mounting and wiring

NOTE

Possible damage of the device

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

WARNING

Risk of electric shock!

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

EL5072 29Version: 1.0

Mounting and wiring

4.3 Connection

4.3.1 Connection system

WARNING

Risk of electric shock and damage of device!

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

Overview

The bus terminal system offers different connection options for optimum adaptation to the respective
application:

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

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

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

Standard wiring (ELxxxx / KLxxxx)

Fig.19: 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.20: 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.

EL507230 Version: 1.0

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

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

High Density Terminals (HD Terminals)

Fig.21: High Density Terminals

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

Wiring HD Terminals

The High Density 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!

EL5072 31Version: 1.0

Mounting and wiring

4.3.2 Wiring

WARNING

Risk of electric shock and damage of device!

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

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

Fig.22: Connecting a cable on a terminal point

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

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

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

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

See the following table for the suitable wire size width.

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

2

2

2

0.08 ... 2.5mm

0,08 ... 2.5mm

0.14 ... 1.5mm

2

2

2

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

High Density Terminals (HD Terminals [}31]) 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.

EL507232 Version: 1.0

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

2

2

2

2

Wire stripping length 8 ... 9mm

4.3.3 Shielding

Shielding

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

Mounting and wiring

EL5072 33Version: 1.0

Mounting and wiring

4.4 Installation positions

NOTE

Constraints regarding installation position and operating temperature range

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

Optimum installation position (standard)

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

Fig.23: 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.

EL507234 Version: 1.0

Mounting and wiring

Fig.24: Other installation positions

EL5072 35Version: 1.0

Mounting and wiring

4.5 Positioning of passive Terminals

Hint for positioning of passive terminals in the bus terminal block

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

Examples for positioning of passive terminals (highlighted)

Fig.25: Correct positioning

Fig.26: Incorrect positioning

EL507236 Version: 1.0

4.6 EL5072 - Connection

Mounting and wiring

Fig.27: EL5072

Terminal point No. Comment

DI+ Ch 1 1 + digital input 24 VDC channel 1

DI- Ch 1 9 - digital input channel1

U

Ch 1 2 + input reference voltage channel 1

sens+

U

Ch 1 10 - input reference voltage channel 1

sens-

U

Ch 1 3 + input measuring voltage channel 1

sig+

U

Ch 1 11 - input measuring voltage channel 1

sig-

U

Ch 1 4 + input excitation voltage channel 1

exc+

U

Ch 1 12 - input excitation voltage channel 1

exc-

U

Ch 2 5 + input excitation voltage channel 2

exc+

U

Ch 2 13 - input excitation voltage channel 2

exc-

U

Ch 2 6 + input measuring voltage channel 2

sig+

U

Ch 2 14 - input measuring voltage channel 2

sig-

U

Ch 2 7 + input reference voltage channel 2

sens+

U

Ch 2 15 - input reference voltage channel 2

sens-

DI+ Ch 2 8 + digital input 24 VDC channel 2

DI- Ch 2 16 - digital input channel2

Automatic switching of the bridges

All necessary bridges are automatically switched in the terminal. The user therefore only has to con­nect the lines shown in the following diagrams and make the corresponding settings in the CoE con­figuration data (index 0x80n1:12 "Connection type").

EL5072 37Version: 1.0

Mounting and wiring

NOTE

Setting and activating the excitation frequency and excitation voltage

• Set the excitation frequency index 0x8001:14 "Excitation frequency" and excitation voltage index
0x8001:15 "Excitation voltage" centrally via the first channel. These settings are then valid for both chan­nels.

• Before switching, make sure that both sensors support the set range!

• The excitation voltage is switched off in the delivery state and must be switched on by setting index
0x8000:08 "Enable excitation" to TRUE.

NOTE

Wiring the digital input

To ensure correct function of the digital input, in addition to the 24V signal at connection point 1 for DI+
Ch1 or connection point 8 for DI+ Ch2, the corresponding ground connection must also be connected to
connection point 10 for DI- Ch1 or connection point 16 for DI- Ch2.

4.6.1 Notes on the electrical connection of inductive measuring probes

Observe the following instructions to achieve an optimum measurement result:

• The use of suitable low-capacitance cables is recommended. Depending on the measuring method,
parasitic capacitances of the individual cables have a direct influence on the accuracy of the
measurement result

• If separate cables are used for the secondary coils, it is recommended to connect two cables to a
center tap as close as possible to the measuring probe, so that a 5-wire LVDT signal can be evaluated
at the EL5072.

• For medium cable lengths it is usually sufficient to shield only the signal line of the secondary winding.

• For longer cable lengths (> 20m) and in cases with strong interference, the supply cable for excitation
of the primary coil and the cable of the secondary winding for measurement of the signal should be
routed in separate shields

• As a general rule, the supply line and the signal line should not be routed in a multi-core, jointly
shielded line.

• The shield should be placed over a large area using a shielding bracket.

EL507238 Version: 1.0

4.6.2 LVDT connection

4-wire LVDT connection

Mounting and wiring

Fig.28: Connection 4-wire LVDT

5-wire LVDT connection

Fig.29: Connection 5-wire LVDT

EL5072 39Version: 1.0

Mounting and wiring

6-wire LVDT connection

Fig.30: Connection 6-wire LVDT

5-wire LVDT Mahr connection

Fig.31: Connection for 5-wire LVDT Mahr circuit

NOTE

Setting for Mahr®-compatible sensors

Mahr®-compatible sensors are connected using 5 wires. Since the fifth line is not a signal line but a virtual
ground, use the 4-wire LVDT mode in index 0x80n1:12 "Connection type".

EL507240 Version: 1.0

4.6.3 Half bridge - Connection

3-wire half bridge connection

Mounting and wiring

Fig.32: Connection for 3-wire inductive half bridge

5-wire half bridge connection

Fig.33: Connection for 5-wire inductive half bridge

EL5072 41Version: 1.0

Mounting and wiring

4.6.4 Variable input impedances

Different input impedances are required, depending on the sensor type and manufacturer. This information
can be found in the respective sensor data sheet or can be obtained directly from the manufacturer.

The EL5072 provides three different input impedances for connecting various sensors. In each case the
selection is made via the CoE configuration data (0x80n1:13 Sensor Impedance). The bridges are switched
automatically.

The following diagrams show the terminal designations of the EL5072 as an example for channel 1.

High impedance / Mahrposs® impedance

Fig.34: Block diagram of high input impedance / Mahrposs® (channel1)

Tesa® impedance

Fig.35: Block diagram for Tesa® input impedance (channel 1)

Mahr® impedance

Fig.36: Block diagram for Mahr® input impedance (channel 1)

EL507242 Version: 1.0

Mounting and wiring

4.7 EL5072 - LEDs

Fig.37: EL5072 - LEDs

LED No. Color Description

Run LED 1 green This LED indicates the terminal's operating state:

Off State of the EtherCAT State Machine:

INIT=initialization of the terminal

Flashing State of the EtherCAT State Machine: PREOP =

function for mailbox communication and different default
settings set

Single
flash

On State of the EtherCAT State Machine: OP = normal

flickering State of the EtherCAT State Machine:

Up LED 2 green Off Supply voltage Up not present

On Supply voltage Up is present, excitation voltage U

Flashing Supply voltage Up is present, excitation voltage U

Digital Input Ch1 LED 9 green On Digital input is active

Excitation Error Ch1 LED 10 red On Short circuit on primary side on channel 1 or overload of

Amplitude Error Ch1 LED 11 red On Amplitude error on secondary side on channel 1 was

Excitation Error Ch 2 LED 12 red On Short circuit on primary side on channel 2 or overload of

Amplitude Error Ch 2 LED 13 red On Amplitude error on secondary side on channel 2 was

Digital Input Ch 2 LED 14 green On Digital input is active

State of the EtherCAT State Machine: SAFEOP =
verification of the sync manager channels and the
distributed clocks. Outputs remain in safe state

operating state; mailbox and process data
communication is possible

BOOTSTRAP=function for terminal firmware updates

is

exc

switched on

is

exc

switched off

excitation source was detected

detected

excitation source was detected

detected

EL5072 43Version: 1.0

Commissioning

5 Commissioning

5.1 TwinCAT Development Environment

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

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

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

Details:

• TwinCAT2:

◦ Connects I/O devices to tasks in a variable-oriented manner

◦ Connects tasks to tasks in a variable-oriented manner

◦ Supports units at the bit level

◦ Supports synchronous or asynchronous relationships

◦ Exchange of consistent data areas and process images

◦ Datalink on NT - Programs by open Microsoft Standards (OLE, OCX, ActiveX, DCOM+, etc.)

◦ Integration of IEC 61131-3-Software-SPS, Software- NC and Software-CNC within Windows

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

◦ Interconnection to all common fieldbusses

◦ More…

Additional features:

• TwinCAT3 (eXtended Automation):

◦ Visual-Studio®-Integration

◦ Choice of the programming language

◦ Supports object orientated extension of IEC 61131-3

◦ Usage of C/C++ as programming language for real time applications

◦ Connection to MATLAB®/Simulink®

◦ Open interface for expandability

◦ Flexible run-time environment

◦ Active support of Multi-Core- und 64-Bit-Operatingsystem

◦ Automatic code generation and project creation with the TwinCAT Automation Interface

◦ More…

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

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

5.1.1 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.

EL507244 Version: 1.0

Fig.38: System Manager “Options” (TwinCAT2)

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

Commissioning

Fig.39: Call up under VS Shell (TwinCAT3)

The following dialog appears:

Fig.40: 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” [}55] in order to view the compatible ethernet ports via its

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

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Fig.41: EtherCAT device properties(TwinCAT2): click on “Compatible Devices…” of tab “Adapte””

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.42: Windows properties of the network interface

A correct setting of the driver could be:

EL507246 Version: 1.0

Fig.43: Exemplary correct driver setting for the Ethernet port

Other possible settings have to be avoided:

Commissioning

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Fig.44: Incorrect driver settings for the Ethernet port

EL507248 Version: 1.0

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.45: TCP/IP setting for the Ethernet port

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5.1.2 Notes regarding ESI device description

Installation of the latest ESI device description

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

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

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

Default settings:

• TwinCAT2: C:\TwinCAT\IO\EtherCAT

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

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

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

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

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

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

The TwinCAT ESI Updater [}54] 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.46: 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.

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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.47: OnlineDescription information window (TwinCAT2)

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

Fig.48: Information window OnlineDescription (TwinCAT3)

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

NOTE

Changing the “usual” configuration through a scan

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

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

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

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

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

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

Refer in particular to the chapter “General notes on the use of Beckhoff EtherCAT IO components” and for
manual configuration to the chapter “Offline configuration creation [}55]”.

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.

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Fig.49: 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.50: Indication of an online recorded ESI of EL2521 as an example

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

• close all System Manager windows

• restart TwinCAT in Config mode

• delete “OnlineDescription0000...xml”

• restart TwinCAT System Manager

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

OnlineDescription for TwinCAT3.x

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

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

Faulty ESI file

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

Fig.51: Information window for faulty ESI file (left: TwinCAT2; right: TwinCAT3)

EL507252 Version: 1.0

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

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5.1.3 TwinCAT ESI Updater

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

Fig.52: Using the ESI Updater (>= TwinCAT2.11)

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

Selection under TwinCAT3:

Fig.53: Using the ESI Updater (TwinCAT3)

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

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

5.1.4 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” [}50].

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

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• 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 [}60] (Ethernet port at the IPC)

• detecting the connected EtherCAT devices [}61]. This step can be carried out independent of the
preceding step

• troubleshooting [}64]

The scan with existing configuration [}65] can also be carried out for comparison.

5.1.5 OFFLINE configuration creation

Creating the EtherCAT device

Create an EtherCAT device in an empty System Manager window.

Fig.54: Append EtherCAT device (left: TwinCAT2; right: TwinCAT3)

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

Fig.55: Selecting the EtherCAT connection (TwinCAT2.11, TwinCAT3)

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

Fig.56: Selecting the Ethernet port

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

Fig.57: EtherCAT device properties (TwinCAT2)

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

Selecting the Ethernet port

Ethernet ports can only be selected for EtherCAT devices for which the TwinCAT real-time driver is
installed. This has to be done separately for each port. Please refer to the respective installation
page [}44].

Defining EtherCAT slaves

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

Fig.58: Appending EtherCAT devices (left: TwinCAT2; right: TwinCAT3)

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

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

Overview of physical layer

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

EL507256 Version: 1.0

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

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

Commissioning

Fig.59: Selection dialog for new EtherCAT device

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

Fig.60: Display of device revision

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

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Fig.61: Display of previous revisions

Device selection based on revision, compatibility

The ESI description also defines the process image, the communication type between master and
slave/device and the device functions, if applicable. The physical device (firmware, if available) has
to support the communication queries/settings of the master. This is backward compatible, i.e.
newer devices (higher revision) should be supported if the EtherCAT master addresses them as an
older revision. The following compatibility rule of thumb is to be assumed for Beckhoff EtherCAT
Terminals/ Boxes/ EJ-modules:

device revision in the system >= device revision in the configuration

This also enables subsequent replacement of devices without changing the configuration (different
specifications are possible for drives).

Example

If an EL2521-0025-1018 is specified in the configuration, an EL2521-0025-1018 or higher (-1019, -1020) can
be used in practice.

Fig.62: Name/revision of the terminal

If current ESI descriptions are available in the TwinCAT system, the last revision offered in the selection
dialog matches the Beckhoff state of production. It is recommended to use the last device revision when
creating a new configuration, if current Beckhoff devices are used in the real application. Older revisions
should only be used if older devices from stock are to be used in the application.

In this case the process image of the device is shown in the configuration tree and can be parameterized as
follows: linking with the task, CoE/DC settings, plug-in definition, startup settings, ...

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Fig.63: EtherCAT terminal in the TwinCAT tree (left: TwinCAT2; right: TwinCAT3)

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5.1.6 ONLINE configuration creation

Detecting/scanning of the EtherCAT device

The online device search can be used if the TwinCAT system is in CONFIG mode. This can be indicated by
a symbol right below in the information bar:

• on TwinCAT2 by a blue display “Config Mode” within the System Manager window: .

• on TwinCAT3 within the user interface of the development environment by a symbol .

TwinCAT can be set into this mode:

• TwinCAT2: by selection of in the Menubar or by “Actions” → “Set/Reset TwinCATtoConfig
Mode…”

• TwinCAT3: by selection of in the Menubar or by “TwinCAT” → “RestartTwinCAT(ConfigMode)”

Online scanning in Config mode

The online search is not available in RUN mode (production operation). Note the differentiation be­tween TwinCAT programming system and TwinCAT target system.

The TwinCAT2 icon ( ) or TwinCAT3 icon ( ) within the Windows-Taskbar always shows the
TwinCAT mode of the local IPC. Compared to that, the System Manager window of TwinCAT2 or the user
interface of TwinCAT3 indicates the state of the target system.

Fig.64: Differentiation local/target system (left: TwinCAT2; right: TwinCAT3)

Right-clicking on “I/O Devices” in the configuration tree opens the search dialog.

Fig.65: Scan Devices (left: TwinCAT2; right: TwinCAT3)

This scan mode attempts to find not only EtherCAT devices (or Ethernet ports that are usable as such), but
also NOVRAM, fieldbus cards, SMB etc. However, not all devices can be found automatically.

Fig.66: Note for automatic device scan (left: TwinCAT2; right: TwinCAT3)

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Ethernet ports with installed TwinCAT real-time driver are shown as “RT Ethernet” devices. An EtherCAT
frame is sent to these ports for testing purposes. If the scan agent detects from the response that an
EtherCAT slave is connected, the port is immediately shown as an “EtherCAT Device” .

Fig.67: Detected Ethernet devices

Via respective checkboxes devices can be selected (as illustrated in Fig. “Detected Ethernet devices” e.g.
Device 3 and Device 4 were chosen). After confirmation with “OK” a device scan is suggested for all selected
devices, see Fig.: “Scan query after automatic creation of an EtherCAT device”.

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 [}44].

Detecting/Scanning the EtherCAT devices

Online scan functionality

During a scan the master queries the identity information of the EtherCAT slaves from the slave
EEPROM. The name and revision are used for determining the type. The respective devices are lo­cated in the stored ESI data and integrated in the configuration tree in the default state defined
there.

Fig.68: Example default state

NOTE

Slave scanning in practice in series machine production

The scanning function should be used with care. It is a practical and fast tool for creating an initial configu­ration as a basis for commissioning. In series machine production or reproduction of the plant, however, the

function should no longer be used for the creation of the configuration, but if necessary for comparison
[}65] with the defined initial configuration.Background: since Beckhoff occasionally increases the revision

version of the delivered products for product maintenance reasons, a configuration can be created by such
a scan which (with an identical machine construction) is identical according to the device list; however, the
respective device revision may differ from the initial configuration.

Example:

Company A builds the prototype of a machine B, which is to be produced in series later on. To do this the
prototype is built, a scan of the IO devices is performed in TwinCAT and the initial configuration “B.tsm” is
created. The EL2521-0025 EtherCAT terminal with the revision 1018 is located somewhere. It is thus built
into the TwinCAT configuration in this way:

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Fig.69: Installing EthetCAT terminal with revision -1018

Likewise, during the prototype test phase, the functions and properties of this terminal are tested by the
programmers/commissioning engineers and used if necessary, i.e. addressed from the PLC “B.pro” or the
NC. (the same applies correspondingly to the TwinCAT3 solution files).

The prototype development is now completed and series production of machine B starts, for which Beckhoff
continues to supply the EL2521-0025-0018. If the commissioning engineers of the series machine production
department always carry out a scan, a B configuration with the identical contents results again for each
machine. Likewise, A might create spare parts stores worldwide for the coming series-produced machines
with EL2521-0025-1018 terminals.

After some time Beckhoff extends the EL2521-0025 by a new feature C. Therefore the FW is changed,
outwardly recognizable by a higher FW version and a new revision -1019. Nevertheless the new device
naturally supports functions and interfaces of the predecessor version(s); an adaptation of “B.tsm” or even
“B.pro” is therefore unnecessary. The series-produced machines can continue to be built with “B.tsm” and

“B.pro”; it makes sense to perform a comparative scan [}65] against the initial configuration “B.tsm” in order
to check the built machine.

However, if the series machine production department now doesn’t use “B.tsm”, but instead carries out a
scan to create the productive configuration, the revision -1019 is automatically detected and built into the
configuration:

Fig.70: Detection of EtherCAT terminal with revision -1019

This is usually not noticed by the commissioning engineers. TwinCAT cannot signal anything either, since
virtually a new configuration is created. According to the compatibility rule, however, this means that no
EL2521-0025-1018 should be built into this machine as a spare part (even if this nevertheless works in the
vast majority of cases).

In addition, it could be the case that, due to the development accompanying production in company A, the
new feature C of the EL2521-0025-1019 (for example, an improved analog filter or an additional process
data for the diagnosis) is discovered and used without in-house consultation. The previous stock of spare
part devices are then no longer to be used for the new configuration “B2.tsm” created in this way. Þ if series
machine production is established, the scan should only be performed for informative purposes for
comparison with a defined initial configuration. Changes are to be made with care!

If an EtherCAT device was created in the configuration (manually or through a scan), the I/O field can be
scanned for devices/slaves.

Fig.71: Scan query after automatic creation of an EtherCAT device (left: TwinCAT2; right: TwinCAT3)

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Fig.72: Manual triggering of a device scan on a specified EtherCAT device (left: TwinCAT2; right:
TwinCAT3)

In the System Manager (TwinCAT2) or the User Interface (TwinCAT3) the scan process can be monitored
via the progress bar at the bottom in the status bar.

Fig.73: Scan progressexemplary by TwinCAT2

The configuration is established and can then be switched to online state (OPERATIONAL).

Fig.74: Config/FreeRun query (left: TwinCAT2; right: TwinCAT3)

In Config/FreeRun mode the System Manager display alternates between blue and red, and the EtherCAT
device continues to operate with the idling cycle time of 4ms (default setting), even without active task (NC,
PLC).

Fig.75: Displaying of “Free Run” and “Config Mode” toggling right below in the status bar

Fig.76: TwinCAT can also be switched to this state by using a button (left: TwinCAT2; right: TwinCAT3)

The EtherCAT system should then be in a functional cyclic state, as shown in Fig. Online display example.

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Fig.77: Online display example

Please note:

• all slaves should be in OP state

• the EtherCAT master should be in “Actual State” OP

• “frames/sec” should match the cycle time taking into account the sent number of frames

• no excessive “LostFrames” or CRC errors should occur

The configuration is now complete. It can be modified as described under manual procedure [}55].

Troubleshooting

Various effects may occur during scanning.

• An unknown device is detected, i.e. an EtherCAT slave for which no ESI XML description is available.
In this case the System Manager offers to read any ESI that may be stored in the device. This case is
described in the chapter “Notes regarding ESI device description”.

• Device are not detected properly
Possible reasons include:

◦ faulty data links, resulting in data loss during the scan

◦ slave has invalid device description

The connections and devices should be checked in a targeted manner, e.g. via the emergency
scan.
Then re-run the scan.

Fig.78: Faulty identification

In the System Manager such devices may be set up as EK0000 or unknown devices. Operation is not
possible or meaningful.

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Scan over existing Configuration

NOTE

Change of the configuration after comparison

With this scan (TwinCAT2.11 or 3.1) only the device properties vendor (manufacturer), device name and
revision are compared at present! A “ChangeTo” or “Copy” should only be carried out with care, taking into
consideration the Beckhoff IO compatibility rule (see above). The device configuration is then replaced by
the revision found; this can affect the supported process data and functions.

If a scan is initiated for an existing configuration, the actual I/O environment may match the configuration
exactly or it may differ. This enables the configuration to be compared.

Fig.79: Identical configuration (left: TwinCAT2; right: TwinCAT3)

If differences are detected, they are shown in the correction dialog, so that the user can modify the
configuration as required.

Fig.80: Correction dialog

It is advisable to tick the “Extended Information” check box to reveal differences in the revision.

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Color Explanation

green This EtherCAT slave matches the entry on the other side. Both type and revision match.

blue This EtherCAT slave is present on the other side, but in a different revision. This other revision can

have other default values for the process data as well as other/additional functions.
If the found revision is higher than the configured revision, the slave may be used provided
compatibility issues are taken into account.

If the found revision is lower than the configured revision, it is likely that the slave cannot be used.
The found device may not support all functions that the master expects based on the higher
revision number.

light
blue

red • This EtherCAT slave is not present on the other side.

This EtherCAT slave is ignored (“Ignore” button)

• It is present, but in a different revision, which also differs in its properties from the one specified.
The compatibility principle then also applies here: if the found revision is higher than the
configured revision, use is possible provided compatibility issues are taken into account, since
the successor devices should support the functions of the predecessor devices.
If the found revision is lower than the configured revision, it is likely that the slave cannot be
used. The found device may not support all functions that the master expects based on the
higher revision number.

Device selection based on revision, compatibility

The ESI description also defines the process image, the communication type between master and
slave/device and the device functions, if applicable. The physical device (firmware, if available) has
to support the communication queries/settings of the master. This is backward compatible, i.e.
newer devices (higher revision) should be supported if the EtherCAT master addresses them as an
older revision. The following compatibility rule of thumb is to be assumed for Beckhoff EtherCAT
Terminals/ Boxes/ EJ-modules:

device revision in the system >= device revision in the configuration

This also enables subsequent replacement of devices without changing the configuration (different
specifications are possible for drives).

Example

If an EL2521-0025-1018 is specified in the configuration, an EL2521-0025-1018 or higher (-1019, -1020) can
be used in practice.

Fig.81: Name/revision of the terminal

If current ESI descriptions are available in the TwinCAT system, the last revision offered in the selection
dialog matches the Beckhoff state of production. It is recommended to use the last device revision when
creating a new configuration, if current Beckhoff devices are used in the real application. Older revisions
should only be used if older devices from stock are to be used in the application.

In this case the process image of the device is shown in the configuration tree and can be parameterized as
follows: linking with the task, CoE/DC settings, plug-in definition, startup settings, ...

EL507266 Version: 1.0

Fig.82: Correction dialog with modifications

Commissioning

Once all modifications have been saved or accepted, click “OK” to transfer them to the real *.tsm
configuration.

Change to Compatible Type

TwinCAT offers a function Change to Compatible Type… for the exchange of a device whilst retaining the
links in the task.

Fig.83: Dialog “Change to Compatible Type…” (left: TwinCAT2; right: TwinCAT3)

This function is preferably to be used on AX5000 devices.

Change to Alternative Type

The TwinCAT System Manager offers a function for the exchange of a device: Change to Alternative Type

Fig.84: TwinCAT2 Dialog Change to Alternative Type

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If called, the System Manager searches in the procured device ESI (in this example: EL1202-0000) for
details of compatible devices contained there. The configuration is changed and the ESI-EEPROM is
overwritten at the same time – therefore this process is possible only in the online state (ConfigMode).

5.1.7 EtherCAT subscriber configuration

In the left-hand window of the TwinCAT2 System Manager or the Solution Explorer of the TwinCAT3
Development Environment respectively, click on the element of the terminal within the tree you wish to
configure (in the example: EL3751 Terminal 3).

Fig.85: Branch element as terminal EL3751

In the right-hand window of the TwinCAT System Manager (TwinCAT2) or the Development Environment
(TwinCAT3), various tabs are now available for configuring the terminal. And yet the dimension of
complexity of a subscriber determines which tabs are provided. Thus as illustrated in the example above the
terminal EL3751 provides many setup options and also a respective number of tabs are available. On the
contrary by the terminal EL1004 for example the tabs “General”, “EtherCAT”, “Process Data” and “Online“
are available only. Several terminals, as for instance the EL6695 provide special functions by a tab with its
own terminal name, so “EL6695” in this case. A specific tab “Settings” by terminals with a wide range of
setup options will be provided also (e.g. EL3751).

“General” tab

Fig.86: “General” tab

Name Name of the EtherCAT device
Id Number of the EtherCAT device
Type EtherCAT device type
Comment Here you can add a comment (e.g. regarding the system).
Disabled Here you can deactivate the EtherCAT device.
Create symbols Access to this EtherCAT slave via ADS is only available if this control box is

activated.

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“EtherCAT” tab

Fig.87: “EtherCAT” tab

Type EtherCAT device type
Product/Revision Product and revision number of the EtherCAT device
Auto Inc Addr. Auto increment address of the EtherCAT device. The auto increment address can

be used for addressing each EtherCAT device in the communication ring through
its physical position. Auto increment addressing is used during the start-up phase
when the EtherCAT master allocates addresses to the EtherCAT devices. With
auto increment addressing the first EtherCAT slave in the ring has the address
0000

. For each further slave the address is decremented by 1 (FFFF

hex

, FFFE

hex

etc.).

EtherCAT Addr. Fixed address of an EtherCAT slave. This address is allocated by the EtherCAT

master during the start-up phase. Tick the control box to the left of the input field in
order to modify the default value.

Previous Port Name and port of the EtherCAT device to which this device is connected. If it is

possible to connect this device with another one without changing the order of the
EtherCAT devices in the communication ring, then this combination field is
activated and the EtherCAT device to which this device is to be connected can be
selected.

Advanced Settings This button opens the dialogs for advanced settings.

hex

The link at the bottom of the tab points to the product page for this EtherCAT device on the web.

“Process Data” tab

Indicates the configuration of the process data. The input and output data of the EtherCAT slave are
represented as CANopen process data objects (Process Data Objects, PDOs). The user can select a PDO
via PDO assignment and modify the content of the individual PDO via this dialog, if the EtherCAT slave
supports this function.

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Fig.88: “Process Data” tab

The process data (PDOs) transferred by an EtherCAT slave during each cycle are user data which the
application expects to be updated cyclically or which are sent to the slave. To this end the EtherCAT master
(Beckhoff TwinCAT) parameterizes each EtherCAT slave during the start-up phase to define which process
data (size in bits/bytes, source location, transmission type) it wants to transfer to or from this slave. Incorrect
configuration can prevent successful start-up of the slave.

For Beckhoff EtherCAT EL, ES, EM, EJ and EP slaves the following applies in general:

• The input/output process data supported by the device are defined by the manufacturer in the ESI/XML
description. The TwinCAT EtherCAT Master uses the ESI description to configure the slave correctly.

• The process data can be modified in the System Manager. See the device documentation.
Examples of modifications include: mask out a channel, displaying additional cyclic information, 16-bit
display instead of 8-bit data size, etc.

• In so-called “intelligent” EtherCAT devices the process data information is also stored in the CoE
directory. Any changes in the CoE directory that lead to different PDO settings prevent successful
startup of the slave. It is not advisable to deviate from the designated process data, because the
device firmware (if available) is adapted to these PDO combinations.

If the device documentation allows modification of process data, proceed as follows (see Figure Configuring
the process data).

• A: select the device to configure

• B: in the “Process Data” tab select Input or Output under SyncManager (C)

• D: the PDOs can be selected or deselected

• H: the new process data are visible as linkable variables in the System Manager
The new process data are active once the configuration has been activated and TwinCAT has been
restarted (or the EtherCAT master has been restarted)

• E: if a slave supports this, Input and Output PDO can be modified simultaneously by selecting a so­called PDO record (“predefined PDO settings”).

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Fig.89: Configuring the process data

Manual modification of the process data

According to the ESI description, a PDO can be identified as “fixed” with the flag “F” in the PDO
overview (Fig. Configuring the process data, J). The configuration of such PDOs cannot be
changed, even if TwinCAT offers the associated dialog (“Edit”). In particular, CoE content cannot be
displayed as cyclic process data. This generally also applies in cases where a device supports
download of the PDO configuration, “G”. In case of incorrect configuration the EtherCAT slave usu­ally refuses to start and change to OP state. The System Manager displays an “invalid SM cfg” log­ger message: This error message (“invalid SM IN cfg” or “invalid SM OUT cfg”) also indicates the
reason for the failed start.

A detailed description [}76] can be found at the end of this section.

“Startup” tab

The Startup tab is displayed if the EtherCAT slave has a mailbox and supports the CANopen over EtherCAT
(CoE) or Servo drive over EtherCAT protocol. This tab indicates which download requests are sent to the
mailbox during startup. It is also possible to add new mailbox requests to the list display. The download
requests are sent to the slave in the same order as they are shown in the list.

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Fig.90: “Startup” tab

Column Description

Transition Transition to which the request is sent. This can either be

• the transition from pre-operational to safe-operational (PS), or

• the transition from safe-operational to operational (SO).

If the transition is enclosed in “<>” (e.g. <PS>), the mailbox request is fixed and cannot be
modified or deleted by the user.

Protocol Type of mailbox protocol

Index Index of the object

Data Date on which this object is to be downloaded.

Comment Description of the request to be sent to the mailbox

Move Up This button moves the selected request up by one position in the list.
Move Down This button moves the selected request down by one position in the list.
New This button adds a new mailbox download request to be sent during startup.
Delete This button deletes the selected entry.
Edit This button edits an existing request.

“CoE - Online” tab

The additional CoE - Online tab is displayed if the EtherCAT slave supports the CANopen over EtherCAT
(CoE) protocol. This dialog lists the content of the object list of the slave (SDO upload) and enables the user
to modify the content of an object from this list. Details for the objects of the individual EtherCAT devices can
be found in the device-specific object descriptions.

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Fig.91: “CoE - Online” tab

Object list display

Column Description

Index Index and sub-index of the object

Name Name of the object

Flags RW The object can be read, and data can be written to the object (read/write)

RO The object can be read, but no data can be written to the object (read only)

P An additional P identifies the object as a process data object.

Value Value of the object

Update List The Update list button updates all objects in the displayed list
Auto Update If this check box is selected, the content of the objects is updated automatically.
Advanced The Advanced button opens the Advanced Settings dialog. Here you can specify which

objects are displayed in the list.

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Fig.92: Dialog “Advanced settings”

Online - via SDO Information If this option button is selected, the list of the objects included in the object

list of the slave is uploaded from the slave via SDO information. The list
below can be used to specify which object types are to be uploaded.

Offline - via EDS File If this option button is selected, the list of the objects included in the object

list is read from an EDS file provided by the user.

“Online” tab

Fig.93: “Online” tab

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State Machine

Init This button attempts to set the EtherCAT device to the Init state.
Pre-Op This button attempts to set the EtherCAT device to the pre-operational state.
Op This button attempts to set the EtherCAT device to the operational state.
Bootstrap This button attempts to set the EtherCAT device to the Bootstrap state.
Safe-Op This button attempts to set the EtherCAT device to the safe-operational state.
Clear Error This button attempts to delete the fault display. If an EtherCAT slave fails during

change of state it sets an error flag.

Example: An EtherCAT slave is in PREOP state (pre-operational). The master now
requests the SAFEOP state (safe-operational). If the slave fails during change of
state it sets the error flag. The current state is now displayed as ERR PREOP.
When the Clear Error button is pressed the error flag is cleared, and the current
state is displayed as PREOP again.

Current State Indicates the current state of the EtherCAT device.
Requested State Indicates the state requested for the EtherCAT device.

DLL Status

Indicates the DLL status (data link layer status) of the individual ports of the EtherCAT slave. The DLL status
can have four different states:

Status Description

No Carrier / Open No carrier signal is available at the port, but the port is open.

No Carrier / Closed No carrier signal is available at the port, and the port is closed.

Carrier / Open A carrier signal is available at the port, and the port is open.

Carrier / Closed A carrier signal is available at the port, but the port is closed.

File Access over EtherCAT

Download With this button a file can be written to the EtherCAT device.
Upload With this button a file can be read from the EtherCAT device.

“DC” tab (Distributed Clocks)

Fig.94: “DC” tab (Distributed Clocks)

Operation Mode Options (optional):

• FreeRun

• SM-Synchron

• DC-Synchron (Input based)

• DC-Synchron

Advanced Settings… Advanced settings for readjustment of the real time determinant TwinCAT-clock

Detailed information to Distributed Clocks is specified on http://infosys.beckhoff.com:

Fieldbus Components → EtherCAT Terminals → EtherCAT System documentation → EtherCAT basics →
Distributed Clocks

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5.1.7.1 Detailed description of Process Data tab

Sync Manager

Lists the configuration of the Sync Manager (SM).
If the EtherCAT device has a mailbox, SM0 is used for the mailbox output (MbxOut) and SM1 for the mailbox
input (MbxIn).
SM2 is used for the output process data (outputs) and SM3 (inputs) for the input process data.

If an input is selected, the corresponding PDO assignment is displayed in the PDO Assignment list below.

PDO Assignment

PDO assignment of the selected Sync Manager. All PDOs defined for this Sync Manager type are listed
here:

• If the output Sync Manager (outputs) is selected in the Sync Manager list, all RxPDOs are displayed.

• If the input Sync Manager (inputs) is selected in the Sync Manager list, all TxPDOs are displayed.

The selected entries are the PDOs involved in the process data transfer. In the tree diagram of the System
Manager these PDOs are displayed as variables of the EtherCAT device. The name of the variable is
identical to the Name parameter of the PDO, as displayed in the PDO list. If an entry in the PDO assignment
list is deactivated (not selected and greyed out), this indicates that the input is excluded from the PDO
assignment. In order to be able to select a greyed out PDO, the currently selected PDO has to be deselected
first.

Activation of PDO assignment

ü If you have changed the PDO assignment, in order to activate the new PDO assignment,

a) the EtherCAT slave has to run through the PS status transition cycle (from pre-operational to

safe-operational) once (see Online tab [}74]),

b) and the System Manager has to reload the EtherCAT slaves

( button for TwinCAT2 or button for TwinCAT3)

PDO list

List of all PDOs supported by this EtherCAT device. The content of the selected PDOs is displayed in the
PDO Content list. The PDO configuration can be modified by double-clicking on an entry.

Column Description

Index PDO index.

Size Size of the PDO in bytes.

Name Name of the PDO.

If this PDO is assigned to a Sync Manager, it appears as a variable of the slave with this
parameter as the name.

Flags F Fixed content: The content of this PDO is fixed and cannot be changed by the

System Manager.

M Mandatory PDO. This PDO is mandatory and must therefore be assigned to a

Sync Manager! Consequently, this PDO cannot be deleted from the PDO
Assignment list

SM Sync Manager to which this PDO is assigned. If this entry is empty, this PDO does not take

part in the process data traffic.

SU Sync unit to which this PDO is assigned.

PDO Content

Indicates the content of the PDO. If flag F (fixed content) of the PDO is not set the content can be modified.

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Download

If the device is intelligent and has a mailbox, the configuration of the PDO and the PDO assignments can be
downloaded to the device. This is an optional feature that is not supported by all EtherCAT slaves.

PDO Assignment

If this check box is selected, the PDO assignment that is configured in the PDO Assignment list is
downloaded to the device on startup. The required commands to be sent to the device can be viewed in the

Startup [}71] tab.

PDO Configuration

If this check box is selected, the configuration of the respective PDOs (as shown in the PDO list and the
PDO Content display) is downloaded to the EtherCAT slave.

5.1.8 Import/Export of EtherCAT devices with SCI and XTI

SCI and XTI Export/Import – Handling of user-defined modified EtherCAT slaves

5.1.8.1 Basic principles

An EtherCAT slave is basically parameterized through the following elements:

• Cyclic process data (PDO)

• Synchronization (Distributed Clocks, FreeRun, SM-Synchron)

• CoE parameters (acyclic object dictionary)

Note: Not all three elements may be present, depending on the slave.

For a better understanding of the export/import function, let's consider the usual procedure for IO
configuration:

• The user/programmer processes the IO configuration in the TwinCAT system environment. This
involves all input/output devices such as drives that are connected to the fieldbuses used.
Note: In the following sections, only EtherCAT configurations in the TwinCAT system environment are
considered.

• For example, the user manually adds devices to a configuration or performs a scan on the online
system.

• This results in the IO system configuration.

• On insertion, the slave appears in the system configuration in the default configuration provided by the
vendor, consisting of default PDO, default synchronization method and CoE StartUp parameter as
defined in the ESI (XMLdevice description).

• If necessary, elements of the slave configuration can be changed, e.g. the PDO configuration or the
synchronization method, based on the respective device documentation.

It may become necessary to reuse the modified slave in other projects in this way, without having to make
equivalent configuration changes to the slave again. To accomplish this, proceed as follows:

• Export the slave configuration from the project,

• Store and transport as a file,

• Import into another EtherCAT project.

TwinCAT offers two methods for this purpose:

• within the TwinCAT environment: Export/Import as xti file or

• outside, i.e. beyond the TwinCAT limits: Export/Import as sci file.

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An example is provided below for illustration purposes: an EL3702 terminal with standard setting is switched
to 2-fold oversampling (blue) and the optional PDO "StartTimeNextLatch" is added (red):

The two methods for exporting and importing the modified terminal referred to above are demonstrated
below.

5.1.8.2 Procedure within TwinCAT with xti files

Each IO device can be exported/saved individually:

The xti file can be stored:

and imported again in another TwinCAT system via "Insert Existing item":

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5.1.8.3 Procedure within and outside TwinCAT with sci file

Note regarding availability (2021/01)

The SCI method is available from TwinCAT 3.1 build 4024.14.

The Slave Configuration Information (SCI) describes a specific complete configuration for an EtherCAT slave
(terminal, box, drive...) based on the setting options of the device description file (ESI, EtherCAT Slave
Information). That is, it includes PDO, CoE, synchronization.

Export:

• select a single device via the menu (multiple selection is also possible):
TwinCAT→EtherCATDevices→ExportSCI.

• If TwinCAT is offline (i.e. if there is no connection to an actual running controller) a warning message
may appear, because after executing the function the system attempts to reload the EtherCAT
segment. However, in this case this is not relevant for the result and can be acknowledged by clicking
OK:

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• A description may also be provided:

• Explanation of the dialog box:

Name Name of the SCI, assigned by the user.

Description Description of the slave configuration for the use case, assigned by the user.

Options Keep modules If a slave supports modules/slots, the user can decide whether these are to be exported or

AoE | Set AmsNetId The configured AmsNetId is exported. Usually this is network-dependent and cannot al-

EoE | Set MAC and IP The configured virtual MAC and IP addresses are stored in the SCI. Usually these are net-

CoE | Set cycle
time(0x1C3x.2)

ESI Reference to the original ESI file.

Export Save SCI file.

whether the module and device data are to be combined during export.

ways be determined in advance.

work-dependent and cannot always be determined in advance.

The configured cycle time is exported. Usually this is network-dependent and cannot al­ways be determined in advance.

• A list view is available for multiple selections (Export multiple SCI files):

• Selection of the slaves to be exported:

◦ All:

All slaves are selected for export.

EL507280 Version: 1.0

◦ None:

All slaves are deselected.

• The sci file can be saved locally:

• The export takes place:

Commissioning

Import

• An sci description can be inserted manually into the TwinCAT configuration like any normal Beckhoff
device description.

• The sci file must be located in the TwinCAT ESI path, usually under:
C:\TwinCAT\3.1\Config\Io\EtherCAT

• Open the selection dialog:

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• Display SCI devices and select and insert the desired device:

Additional Notes

• Settings for the SCI function can be made via the general Options dialog
(Tools→Options→TwinCAT→ExportSCI):

Explanation of the settings:

Default export
options

Generic Reload Devices Setting whether the Reload Devices command is executed before the SCI ex-

AoE | Set AmsNetId Default setting whether the configured AmsNetId is exported.

CoE | Set cycle time(0x1C3x.2) Default setting whether the configured cycle time is exported.

EoE | Set MAC and IP Default setting whether the configured MAC and IP addresses are exported.

Keep modules Default setting whether the modules persist.

port.
This is strongly recommended to ensure a consistent slave configuration.

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SCI error messages are displayed in the TwinCAT logger output window if required:

5.2 General Notes - EtherCAT Slave Application

This summary briefly deals with a number of aspects of EtherCAT Slave operation under TwinCAT. More
detailed information on this may be found in the corresponding sections of, for instance, the EtherCAT
System Documentation.

Diagnosis in real time: WorkingCounter, EtherCAT State and Status

Generally speaking an EtherCAT Slave provides a variety of diagnostic information that can be used by the
controlling task.

This diagnostic information relates to differing levels of communication. It therefore has a variety of sources,
and is also updated at various times.

Any application that relies on I/O data from a fieldbus being correct and up to date must make diagnostic
access to the corresponding underlying layers. EtherCAT and the TwinCAT System Manager offer
comprehensive diagnostic elements of this kind. Those diagnostic elements that are helpful to the controlling
task for diagnosis that is accurate for the current cycle when in operation (not during commissioning) are
discussed below.

Fig.95: Selection of the diagnostic information of an EtherCAT Slave

In general, an EtherCAT Slave offers

• communication diagnosis typical for a slave (diagnosis of successful participation in the exchange of
process data, and correct operating mode)
This diagnosis is the same for all slaves.

as well as

• function diagnosis typical for a channel (device-dependent)
See the corresponding device documentation

The colors in Fig. Selection of the diagnostic information of an EtherCAT Slave also correspond to the
variable colors in the System Manager, see Fig. Basic EtherCAT Slave Diagnosis in the PLC.

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Colour Meaning

yellow Input variables from the Slave to the EtherCAT Master, updated in every cycle

red Output variables from the Slave to the EtherCAT Master, updated in every cycle

green Information variables for the EtherCAT Master that are updated acyclically. This means that

it is possible that in any particular cycle they do not represent the latest possible status. It is
therefore useful to read such variables through ADS.

Fig. Basic EtherCAT Slave Diagnosis in the PLC shows an example of an implementation of basic EtherCAT
Slave Diagnosis. A Beckhoff EL3102 (2-channel analogue input terminal) is used here, as it offers both the
communication diagnosis typical of a slave and the functional diagnosis that is specific to a channel.
Structures are created as input variables in the PLC, each corresponding to the process image.

Fig.96: Basic EtherCAT Slave Diagnosis in the PLC

The following aspects are covered here:

EL507284 Version: 1.0

Code Function Implementation Application/evaluation

A The EtherCAT Master's diagnostic infor-

mation

updated acyclically (yellow) or provided
acyclically (green).

B In the example chosen (EL3102) the

EL3102 comprises two analogue input
channels that transmit a single function
status for the most recent cycle.

C For every EtherCAT Slave that has cyclic

process data, the Master displays, using
what is known as a WorkingCounter,
whether the slave is participating success­fully and without error in the cyclic ex­change of process data. This important, el­ementary information is therefore provided
for the most recent cycle in the System
Manager

1. at the EtherCAT Slave, and, with
identical contents

2. as a collective variable at the
EtherCAT Master (see Point A)

for linking.

D Diagnostic information of the EtherCAT

Master which, while it is represented at the
slave for linking, is actually determined by
the Master for the Slave concerned and
represented there. This information cannot
be characterized as real-time, because it

• is only rarely/never changed,
except when the system starts up

• is itself determined acyclically (e.g.
EtherCAT Status)

Status

• the bit significations may be
found in the device
documentation

• other devices may supply
more information, or none
that is typical of a slave

WcState (Working Counter)

0: valid real-time communication in
the last cycle

1: invalid real-time communication

This may possibly have effects on
the process data of other Slaves
that are located in the same Syn­cUnit

State

current Status (INIT..OP) of the
Slave. The Slave must be in OP
(=8) when operating normally.

AdsAddr

The ADS address is useful for
communicating from the PLC/task
via ADS with the EtherCAT Slave,
e.g. for reading/writing to the CoE.
The AMS-NetID of a slave corre­sponds to the AMS-NetID of the
EtherCAT Master; communication
with the individual Slave is possible
via the port (= EtherCAT address).

At least the DevState is to be evaluated for
the most recent cycle in the PLC.

The EtherCAT Master's diagnostic informa­tion offers many more possibilities than are
treated in the EtherCAT System Documenta­tion. A few keywords:

• CoE in the Master for communication
with/through the Slaves

• Functions from TcEtherCAT.lib

• Perform an OnlineScan

In order for the higher-level PLC task (or cor­responding control applications) to be able to
rely on correct data, the function status must
be evaluated there. Such information is
therefore provided with the process data for
the most recent cycle.

In order for the higher-level PLC task (or cor­responding control applications) to be able to
rely on correct data, the communication sta­tus of the EtherCAT Slave must be evaluated
there. Such information is therefore provided
with the process data for the most recent cy­cle.

Information variables for the EtherCAT Mas­ter that are updated acyclically. This means
that it is possible that in any particular cycle
they do not represent the latest possible sta­tus. It is therefore possible to read such vari­ables through ADS.

Commissioning

NOTE

Diagnostic information

It is strongly recommended that the diagnostic information made available is evaluated so that the applica­tion can react accordingly.

CoE Parameter Directory

The CoE parameter directory (CanOpen-over-EtherCAT) is used to manage the set values for the slave
concerned. Changes may, in some circumstances, have to be made here when commissioning a relatively
complex EtherCAT Slave. It can be accessed through the TwinCAT System Manager, see Fig. EL3102, CoE
directory:

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Fig.97: EL3102, CoE directory

EtherCAT System Documentation

The comprehensive description in the EtherCAT System Documentation (EtherCAT Basics --> CoE
Interface) must be observed!

A few brief extracts:

• Whether changes in the online directory are saved locally in the slave depends on the device. EL
terminals (except the EL66xx) are able to save in this way.

• The user must manage the changes to the StartUp list.

Commissioning aid in the TwinCAT System Manager

Commissioning interfaces are being introduced as part of an ongoing process for EL/EP EtherCAT devices.
These are available in TwinCAT System Managers from TwinCAT 2.11R2 and above. They are integrated
into the System Manager through appropriately extended ESI configuration files.

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Fig.98: Example of commissioning aid for a EL3204

This commissioning process simultaneously manages

• CoE Parameter Directory

• DC/FreeRun mode

• the available process data records (PDO)

Although the “Process Data”, “DC”, “Startup” and “CoE-Online” that used to be necessary for this are still
displayed, it is recommended that, if the commissioning aid is used, the automatically generated settings are
not changed by it.

The commissioning tool does not cover every possible application of an EL/EP device. If the available setting
options are not adequate, the user can make the DC, PDO and CoE settings manually, as in the past.

EtherCAT State: automatic default behaviour of the TwinCAT System Manager and manual operation

After the operating power is switched on, an EtherCAT Slave must go through the following statuses

• INIT

• PREOP

• SAFEOP

• OP

to ensure sound operation. The EtherCAT Master directs these statuses in accordance with the initialization
routines that are defined for commissioning the device by the ES/XML and user settings (Distributed Clocks

(DC), PDO, CoE). See also the section on "Principles of Communication, EtherCAT State Machine [}19]" in
this connection. Depending how much configuration has to be done, and on the overall communication,
booting can take up to a few seconds.

The EtherCAT Master itself must go through these routines when starting, until it has reached at least the
OP target state.

The target state wanted by the user, and which is brought about automatically at start-up by TwinCAT, can
be set in the System Manager. As soon as TwinCAT reaches the status RUN, the TwinCAT EtherCAT
Master will approach the target states.

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Standard setting

The advanced settings of the EtherCAT Master are set as standard:

• EtherCAT Master: OP

• Slaves: OP
This setting applies equally to all Slaves.

Fig.99: Default behaviour of the System Manager

In addition, the target state of any particular Slave can be set in the “Advanced Settings” dialogue; the
standard setting is again OP.

Fig.100: Default target state in the Slave

Manual Control

There are particular reasons why it may be appropriate to control the states from the application/task/PLC.
For instance:

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• for diagnostic reasons

• to induce a controlled restart of axes

• because a change in the times involved in starting is desirable

In that case it is appropriate in the PLC application to use the PLC function blocks from the TcEtherCAT.lib,
which is available as standard, and to work through the states in a controlled manner using, for instance,
FB_EcSetMasterState.

It is then useful to put the settings in the EtherCAT Master to INIT for master and slave.

Fig.101: PLC function blocks

Note regarding E-Bus current

EL/ES terminals are placed on the DIN rail at a coupler on the terminal strand. A Bus Coupler can supply the
EL terminals added to it with the E-bus system voltage of 5V; a coupler is thereby loadable up to 2A as a
rule. 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 as a
column value. 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.

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Fig.102: Illegally exceeding the E-Bus current

From TwinCAT 2.11 and above, a warning message “E-Bus Power of Terminal...” is output in the logger
window when such a configuration is activated:

Fig.103: Warning message for exceeding E-Bus current

NOTE

Caution! Malfunction possible!

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

EL507290 Version: 1.0

EL5072 - Commissioning

6 EL5072 - Commissioning

6.1 Overview of functions

The functionality of the EL5072 is summarized in the following table. A detailed description can be found in
the individual chapters.

Function Description

Parameterization for evaluation of the mea­suring probe [}100]

Filter function for mechanical cut-off fre­quency [}105]

Direction inversion [}107]

Position value output [}108]

Position value overflow / underflow [}108]

Set position value [}109]

Save position value [}111]

User calibration [}106]

Diagnostic data [}115]

LVDT, inductive half bridges and RVDT sensors can be connected and evaluated.

The input signal can be filtered by specifying a mechanical cut-off frequency.

The position direction can be adapted to the application.

The measured value is output as a position value.

Exceeding and falling below the maximum counter depth are displayed in a separate
process data.

The position value can be set to a specified value at runtime via the process data or the
digital input.

The current position value can be saved, independent of the cycle time, in a separate
process data via an edge at the digital input.

It is possible to parameterize a user calibration via offset and gain values or via a lookup
table.

Different diagnostic data are available. In this way, a short circuit on the primary side
and an amplitude error on the secondary side can be detected.

Process data Description

Operation modes [}95]

Synchronicity mode [}96]

Digital input Description

Digital input [}113]

The scope of the process data can be selected via "Predefined PDO Assignment".

Frame-triggered operating mode (SM mode) and time-synchronous recording of the
latch timestamp signal (DC latch active) are available.

The digital input can be used to set and save the position value.

EL5072 91Version: 1.0

EL5072 - Commissioning

6.2 Process data

6.2.1 Sync Manager (SM)

The scope of process data offered can be modified via the "Process Data" tab (see Fig. Process Data tab
SM3, EL5112 (default) below).

A detailed description for setting the process data can be found in chapter EtherCAT subscriber configuration
[}69].

Fig.104: EL5072 - Process data tab SM3 (default)

EL507292 Version: 1.0

6.2.2 PDO assignment

6.2.2.1 SM3 - Inputs (0x1A00 - 0x1A03)

0x1A00 - IND Inputs Channel 1 (10.0)

Contents
Index - name size (byte.bit)

0x6000:01 [}130] - Status_Underrange (0.1)
0x6000:02 [}130] - Status_Overrange (0.1)
0x6000:03 [}130] - Status_Excitation error (0.1)
0x6000:04 [}130] - Status_Input error (0.1)
0x6000:08 [}130] - Status_Digital input (0.1)
0x6000:0A [}130] - Status_Latch extern valid (0.1)
0x6000:0B [}130] - Status_Set position done (0.1)
0x6000:0D [}130] - Status_Diag (0.1)
0x6000:0E [}130] - Status_TxPDO State (0.1)
0x6000:0F [}130] - Status_Input cycle counter (0.2)

0x6001:01 [}130] - Position (4.0)
0x6001:02 [}130] - Latch value (4.0)

0x1A01 - IND Latch Timestamp Channel 1 (8.0)

Contents
Index - name size (byte.bit)

0x6002:01 [}130] - Latch event Timestamp (8.0)

EL5072 - Commissioning

Excluded PDOs
Index - name size (byte.bit)

-

Excluded PDOs
Index - name size (byte.bit)

-

0x1A02 - IND Inputs Channel 2 (10.0)

Contents
Index - name size (byte.bit)

0x6010:01 [}130] - Status_Underrange (0.1)
0x6010:02 [}130] - Status_Overrange (0.1)
0x6010:03 [}130] - Status_Excitation error (0.1)
0x6010:04 [}130] - Status_Input error (0.1)
0x6010:08 [}130] - Status_Digital input (0.1)
0x6010:0A [}130] - Status_Latch extern valid (0.1)
0x6010:0B [}130] - Status_Set position done (0.1)
0x6010:0D [}130] - Status_Diag (0.1)
0x6010:0E [}130] - Status_TxPDO State (0.1)
0x6010:0F [}130] - Status_Input cycle counter (0.2)

0x6011:01 [}130] - Position (4.0)
0x6011:02 [}130] - Latch value (4.0)

0x1A03 - IND Latch Timestamp Channel 2 (8.0)

Contents
Index - name size (byte.bit)

0x6012:01 [}130] - Latch event Timestamp (8.0)

6.2.2.2 SM2 - Outputs (0x1600, 0x1601)

0x1600 - IND Outputs Channel 1 (8.0)

Contents
Index - name size (byte.bit)

0x7000:01 [}131] - Set position (0.1)
0x7000:02 [}131] - Set position on digital input (0.1)
0x7000:03 [}131] - Enable latch on digital input (0.1)

0x7000:11 [}131] - Set position value (4.0)

Excluded PDOs
Index - name size (byte.bit)

-

Excluded PDOs
Index - name size (byte.bit)

-

Excluded PDOs
Index - name size (byte.bit)

-

EL5072 93Version: 1.0

EL5072 - Commissioning

0x1601 - IND Outputs Channel 2 (8.0)

Contents
Index - name size (byte.bit)

0x7010:01 [}131] - Set position (0.1)
0x7010:02 [}131] - Set position on digital input (0.1)
0x7010:03 [}131] - Enable latch on digital input (0.1)

0x7010:11 [}131] - Set position value (4.0)

Excluded PDOs
Index - name size (byte.bit)

-

EL507294 Version: 1.0

EL5072 - Commissioning

6.2.3 Predefined PDO Assignment

The "Predefined PDO Assignment" enables a simplified selection of the process data. The desired function is
selected on the lower part of the Process Data tab. As a result, all necessary PDOs are automatically
enabled and the unnecessary PDOs are disabled.

Fig.105: EL5072 - Process data, Predefined PDO (default: 2 Ch. Standard)

Four PDO assignments are available for selection:

Predefined PDO Assignment PDO assignment (SM3) PDO assignment (SM2)

1 Channel

2 Channel

1 Channel, Timestamp

2 Channel, Timestamp

0x1A00 [}133] - IND Inputs Channel 1 (10.0) 0x1600 [}132] - IND Outputs Channel 1 (8.0)

0x1A00 [}133] - IND Inputs Channel 1 (10.0)
0x1A02 [}134] - IND Inputs Channel 2 (10.0)

0x1A00 [}133] - IND Inputs Channel 1 (10.0)
0x1A01 [}133] - IND Latch Timestamp Channel 1 (8.0)

0x1A00 [}133] - IND Inputs Channel 1 (10.0)
0x1A01 [}133] - IND Latch Timestamp Channel 1 (8.0)
0x1A02 [}134] - IND Inputs Channel 2 (10.0)
0x1A03 [}134] - IND Latch Timestamp Channel 2 (8.0)

0x1600 [}132] - IND Outputs Channel 1 (8.0)
0x1601 [}133] - IND Outputs Channel 2 (8.0)

0x1600 [}132] - IND Outputs Channel 1 (8.0)

0x1600 [}132] - IND Outputs Channel 1 (8.0)
0x1601 [}133] - IND Outputs Channel 2 (8.0)

EL5072 95Version: 1.0

EL5072 - Commissioning

6.2.4 Synchronicity mode

The terminal can be operated in two different operation modes. Further information can be found in the
EtherCAT system documentation in chapter Distributed Clocks -> Basics.

The following operating modes are available for selection in the "DC" tab:

Fig.106: EL5072 - "DC" tab

Operation mode Description

FreeRun/SM Synchron Cyclic, frame-triggered exchange of process data. An Ethernet frame triggers the

process data provision for the next retrieving frame.

DC Latch Active In addition to the cyclic, frame-triggered exchange of process data, a timestamp is

provided for saving the position value (latch event timestamp). An Ethernet frame
triggers the process data provision for the next retrieving frame. The timestamp is
determined cyclically by the integrated distributed clocks unit.

EL507296 Version: 1.0

EL5072 - Commissioning

6.2.5 EtherCAT cycle time

The EtherCAT cycle time depends on the selection of the process data to be transmitted and the set
excitation frequency 0x8001:14 "Excitation frequency".

The following table provides an overview of the recommended cycle time, depending on the "Predefined
PDO Assignment" and the excitation frequency.

• The specifications refer to a multiple of the "Base Time" to be set via the TwinCAT Master.

• If a faster cycle time is used, the process data 0x60n0:0F "Input Cycle Counter" must be used to
monitor when new process data are delivered.

EL5072 – Predefined PDO Assignment 0x8001:14 "Excitation frequency" Min. EtherCAT cycle time

2. Ch. Standard 1kHz typical 66.6 µs

2kHz typical 66.6 µs

2.5kHz typical 66.6 µs

4kHz typical 66.6 µs

5kHz typical 71.4 µs

7.5kHz typical 71.4 µs

10kHz typical 76.9 µs

12.5kHz typical 83.3 µs

13kHz typical 83.3 µs

15kHz typical 100 µs

19.4kHz typical 200 µs

20kHz typical 230.7 µs

2. Ch. Standard, Timestamp 1kHz typical 66.6 µs

2kHz typical 71.4 µs

2.5kHz typical 71.4 µs

4kHz typical 76.9 µs

5kHz typical 83.3 µs

7.5kHz typical 83.3 µs

10kHz typical 100 µs

12.5kHz typical 100 µs

13kHz typical 100 µs

15kHz typical 125 µs

19.4kHz typical 214.2 µs

20kHz typical 285.6 µs

EL5072 97Version: 1.0

EL5072 - Commissioning

6.3 Functions

Basics of data acquisition and evaluation

The measuring functions of the EL5072 can be described as follows:

1. Feeding the alternating voltage into the measuring probe

• The alternating voltage is fed into the measuring probe via the connection points U

◦ The excitation frequency (0x8001:14 [}128] "Excitation frequency") and

the excitation voltage (0x8001:15 [}128] "Excitation voltage") can be set via the CoE objects. The
setting simultaneously applies to both channels.

◦ First switch on the supply voltage (0x8000:08 [}127] "Enable excitation"). It is switched off in the

delivery state.

2. Measurement

• In the EL5072 the measuring principle is defined via:

◦ the selection of the connection (0x80n1:12 [}128] "Connection type") and the

◦ input impedance for the sensor (0x80n1:13 [}128] "Sensor impedance").

• For the maximum input voltage to be measured, the internal gain factors are determined from the
information provided below. This automatically adjusts the measuring signal range.

exc+

and U

exc

.

◦ Excitation voltage (0x80n1:15 [}128] "Excitation voltage"),

◦ Sensitivity (0x80n1:16 [}128] "Sensitivity"),

◦ Maximum measuring range of the measuring probe (0x80n1:18 [}128] "Overall sensor range")

• Depending on the measuring probe version, the measuring voltage is measured via the connection
points U

and U

sig

sens

.

3. Output of the measured value

• The measured value is output in the process data 0x60n1:01 [}130] "Position" in the unit nm.

NOTE

Observe the notes on application and parameterization

• For correct measured value output, parameterize the EL5072 according to the measur-

ing probe used, as described in chapter Parameterization for evaluation of the measur-
ing probe [}100].

• During commissioning observe the Application notes on measurement deviations
[}108]!

EL507298 Version: 1.0

Data flow

EL5072 - Commissioning

Fig.107: EL5072 - Data flow

EL5072 99Version: 1.0

EL5072 - Commissioning

6.3.1 Parameterization for evaluation of the measuring probe

The EL5072 offers the option to evaluate measuring probes in LVDT and half bridge design or inductive
angular position sensors in RVDT design. The measuring signal range is adjusted automatically. The

measured value is output directly as a position value via the process data 0x60n01:01 [}130] "Position".

For correct output of the measured value, all sensor parameters must be entered in the configuration data.

Index (hex) Name Meaning

80n1:12 [}128]

80n1:13 [}128]

80n1:14 [}128]

80n1:15 [}128]

80n1:16 [}128]

80n1:18 [}128]

Please refer to the data sheet or the specification of the measuring probe used. For the commissioning an
RVDT follow the corresponding instructions [}104].

Other available parameterization options: filter function; user calibration via offset and gain values or via a
lookup table; reversal of the measuring direction.

Connection type

Sensor impedance

Excitation frequency

Excitation voltage

Sensitivity

Overall sensor range

Selecting the connection [}101]

Selecting the input impedance [}101]

Excitation frequency [}102]

Excitation voltage [}102]

Sensitivity [}103]

Maximum measuring probe travel path [}103]

Index (hex) Name Meaning

80n1:19 Mech. operating frequency

80n1:1C User offset

80n1:1D User gain

80n5:0 IND Scaler Settings Ch.n

80n0:05 Sign inversion

Selecting the mechanical cut-off frequency [}105]

User offset compensation of the position value [}106]

User gain compensation of the position value [}106]

Optional lookup table for user calibration [}107]

Selection for direction inversion [}107]

EL5072100 Version: 1.0