Beckhoff EL5102 User Manual
Documentation | EN
EL5102
Incremental Encoder Interface, 5 V, (RS422, TTL, Open Collector)
2021-02-05 | Version: 1.2
Table of contents
Table of contents
1 Foreword ....................................................................................................................................................7
1.1 Notes on the documentation..............................................................................................................7
1.2 Safety instructions .............................................................................................................................8
1.3 Documentation issue status ..............................................................................................................9
1.4 Version identification of EtherCAT devices .....................................................................................10
1.4.1 Beckhoff Identification Code (BIC)................................................................................... 12
2 Product overview.....................................................................................................................................14
2.1 EL5102 - Introduction ......................................................................................................................14
2.2 EL5102 - Technical data..................................................................................................................15
2.3 Start .................................................................................................................................................16
2.4 EL51xx series overview...................................................................................................................17
3 Technology...............................................................................................................................................18
4 Technical properties ...............................................................................................................................20
4.1 Signal types .....................................................................................................................................20
4.2 Latch and Gate/Latch inputs............................................................................................................24
4.3 Status Input .....................................................................................................................................25
4.4 Encoder operating voltage (supply voltage) ....................................................................................26
5 Basics communication ...........................................................................................................................27
5.1 EtherCAT basics..............................................................................................................................27
5.2 EtherCAT cabling – wire-bound.......................................................................................................27
5.3 General notes for setting the watchdog...........................................................................................28
5.4 EtherCAT State Machine.................................................................................................................30
5.5 CoE Interface...................................................................................................................................32
5.6 Distributed Clock .............................................................................................................................37
6 Mounting and wiring................................................................................................................................38
6.1 Instructions for ESD protection........................................................................................................38
6.2 Installation on mounting rails ...........................................................................................................39
6.3 Installation instructions for enhanced mechanical load capacity .....................................................42
6.4 Connection ......................................................................................................................................42
6.4.1 Connection system .......................................................................................................... 42
6.4.2 Wiring............................................................................................................................... 45
6.4.3 Shielding .......................................................................................................................... 46
6.5 Installation positions ........................................................................................................................47
6.6 Positioning of passive Terminals .....................................................................................................49
6.7 EL5102 - Connection.......................................................................................................................50
6.7.1 RS422 mode.................................................................................................................... 52
6.7.2 TTL mode ........................................................................................................................ 54
6.7.3 Open Collector mode....................................................................................................... 56
6.8 EL5102 - LEDs ................................................................................................................................58
7 Commissioning........................................................................................................................................60
7.1 TwinCAT Quick Start .......................................................................................................................60
7.1.1 TwinCAT 2 ....................................................................................................................... 63
7.1.2 TwinCAT 3 ....................................................................................................................... 73
EL5102 3Version: 1.2
Table of contents
7.2 TwinCAT Development Environment ..............................................................................................86
7.2.1 Installation of the TwinCAT real-time driver..................................................................... 87
7.2.2 Notes regarding ESI device description........................................................................... 92
7.2.3 TwinCAT ESI Updater ..................................................................................................... 96
7.2.4 Distinction between Online and Offline............................................................................ 96
7.2.5 OFFLINE configuration creation ...................................................................................... 97
7.2.6 ONLINE configuration creation ...................................................................................... 102
7.2.7 EtherCAT subscriber configuration................................................................................ 110
7.2.8 NC configuration (motion).............................................................................................. 120
7.3 General Notes - EtherCAT Slave Application................................................................................123
8 EL5102 - Commissioning......................................................................................................................132
8.1 Overview of EL5102 functions.......................................................................................................132
8.2 Process data..................................................................................................................................133
8.2.1 Sync Manager (SM)....................................................................................................... 133
8.2.2 PDO assignment............................................................................................................ 134
8.2.3 Predefined PDO Assignment......................................................................................... 143
8.2.4 Synchronicity mode ....................................................................................................... 147
8.2.5 EtherCAT cycle time ...................................................................................................... 147
8.2.6 "Legacy EL5101" mode ................................................................................................. 148
8.3 Basic functions ..............................................................................................................................149
8.3.1 Counter value ................................................................................................................ 149
8.3.2 Counter value reset ....................................................................................................... 155
8.3.3 Set counter value........................................................................................................... 156
8.3.4 Detect counting direction ............................................................................................... 158
8.3.5 Save counter value ........................................................................................................ 161
8.3.6 Lock counter value......................................................................................................... 165
8.4 Extended functions ........................................................................................................................166
8.4.1 Frequency measurement............................................................................................... 166
8.4.2 Period value measurement............................................................................................ 168
8.4.3 Velocity, speed calculation ............................................................................................ 169
8.4.4 Duty cycle evaluation..................................................................................................... 171
8.4.5 Micro-increments ........................................................................................................... 172
8.4.6 Timestamp function ....................................................................................................... 174
8.4.7 Adjustable interference pulse filters............................................................................... 175
8.4.8 Plausibility check ........................................................................................................... 177
8.5 Inputs.............................................................................................................................................178
8.5.1 Zero pulse C input ......................................................................................................... 178
8.5.2 Latch input (Latch extern) .............................................................................................. 180
8.5.3 Gate/Latch input ............................................................................................................ 182
8.5.4 Status Input.................................................................................................................... 183
8.6 Diagnostics ....................................................................................................................................184
8.6.1 Diagnostics – basic principles of diag messages .......................................................... 184
8.6.2 EL5102 diagnostics ....................................................................................................... 193
8.7 EL5102 - object description and parameterization ........................................................................196
8.7.1 Restore object................................................................................................................ 196
8.7.2 Configuration data ......................................................................................................... 197
EL51024 Version: 1.2
Table of contents
8.7.3 Command object............................................................................................................ 199
8.7.4 Input data....................................................................................................................... 200
8.7.5 Output data .................................................................................................................... 201
8.7.6 Information / diagnostic data (channel specific)............................................................. 202
8.7.7 Information / diagnostic data (device specific)............................................................... 202
8.7.8 Standard objects............................................................................................................ 202
9 Appendix ................................................................................................................................................228
9.1 EtherCAT AL Status Codes...........................................................................................................228
9.2 Firmware compatibility...................................................................................................................228
9.3 Firmware Update EL/ES/EM/ELM/EPxxxx ....................................................................................228
9.3.1 Device description ESI file/XML..................................................................................... 229
9.3.2 Firmware explanation .................................................................................................... 232
9.3.3 Updating controller firmware *.efw................................................................................. 233
9.3.4 FPGA firmware *.rbf....................................................................................................... 235
9.3.5 Simultaneous updating of several EtherCAT devices.................................................... 239
9.4 Restoring the delivery state ...........................................................................................................240
9.5 Support and Service ......................................................................................................................241
EL5102 5Version: 1.2
Table of contents
EL51026 Version: 1.2
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®, EtherCATG®, EtherCATG10®, EtherCATP®, SafetyoverEtherCAT®,
TwinSAFE®, XFC®, XTS® and XPlanar® are registered trademarks of and licensed by Beckhoff Automation
GmbH. Other designations used in this publication may be trademarks whose use by third parties for their
own purposes could violate the rights of the owners.
Patent Pending
The EtherCAT Technology is covered, including but not limited to the following patent applications and
patents: EP1590927, EP1789857, EP1456722, EP2137893, DE102015105702 with corresponding
applications or registrations in various other countries.
EtherCAT® is registered trademark and patented technology, licensed by Beckhoff Automation GmbH,
Germany.
Copyright
© Beckhoff Automation GmbH & Co. KG, Germany.
The reproduction, distribution and utilization of this document as well as the communication of its contents to
others without express authorization are prohibited.
Offenders will be held liable for the payment of damages. All rights reserved in the event of the grant of a
patent, utility model or design.
EL5102 7Version: 1.2
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.
EL51028 Version: 1.2
1.3 Documentation issue status
Version Comment
1.2 • Update chapter “EL51xx series overview”
• Update chapter “EL5102 - object description and parameterization”
1.1 • Update chapter “Predefined PDO”
• Update chapter “Timestamp function”
• Update structure
1.0 • 1st public issue
0.3 • First preliminary documentation for EL5102
Foreword
EL5102 9Version: 1.2
Foreword
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:
Production lot/batch number/serial number/date code/D number
The serial number for Beckhoff IO devices is usually the 8-digit number printed on the device or on a sticker.
The serial number indicates the configuration in delivery state and therefore refers to a whole production
batch, without distinguishing the individual modules of a batch.
Structure of the serial number: KKYYFFHH
KK - week of production (CW, calendar week)
YY - year of production
FF - firmware version
HH - hardware version
EL510210 Version: 1.2
Foreword
Example with
Ser. no.: 12063A02: 12 - production week 12 06 - production year 2006 3A - firmware version 3A 02 hardware version 02
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)
Fig.2: EK1100 EtherCAT coupler, standard IP20 IO device with serial/ batch number
Fig.3: EL3202-0020 with serial/ batch number 26131006 and unique ID-number 204418
EL5102 11Version: 1.2
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
(ANSIMH10.8.2-2016). 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:
EL510212 Version: 1.2
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.
EL5102 13Version: 1.2
Product overview
2 Product overview
2.1 EL5102 - Introduction
2-channel incremental encoder interface terminal
Fig.5: EL5102
The EL5102 EtherCAT Terminal is an interface for the direct connection of two incremental encoders with
differential inputs (RS422) or single-ended inputs (TTL and Open Collector), parameterizable per channel.
The encoders can be supplied with power directly from the terminal. The EL5102 offers two separate
encoder supply voltages, which can be switched between 5VDC, 12VDC or 24VDC.
A 32-bit counter with quadrature decoder is available for each channel. Furthermore, the counter value can
be stored separately or set to a preset value via the inputs (latch, gate/latch and zero pulse C input). In
addition, it is possible to lock the counter, either via the Gate/Latch input or directly via the process data. A
status signal from the incremental encoder can be connected to the status input of the terminal.
The EL5102 enables measurement of a period, a frequency and a speed with a resolution of 10ns. Duty
cycle measurement of the incoming signal is also implemented.
Due to the optional interpolating micro-increment function, the EL5102 can supply even more precise axis
positions for dynamic axes. In addition to that it supports the synchronous reading of the encoder value
together with other input data in the EtherCAT system via high-precision EtherCAT Distributed Clocks (DC).
In addition, the EL5102 offers a timestamp function, so that the last registered incremental edge, i.e. the
edge at the latch input and the zero pulse track C, can be output with a timestamp.
Quick links
Basics communication [}27]
Creation of the TwinCAT configuration [}102]
EL5102 - Process data [}133]
Configuration data [}197]
EL5102 - Object description [}196]
LEDs [}58] and connection [}50]
EL510214 Version: 1.2
Product overview
2.2 EL5102 - Technical data
Technical data EL5102
Encoder type Incremental, differential (RS422), single-ended (TTL, open collector), counter, pulse gen-
Encoder connection Differential inputs (RS422): A, A, B, B, C, C
Number of channels 2 x A, B, C
Additional inputs Latch, Gate/Latch (24VDC, t
Encoder operating voltage 5V
Counter 32bit (default) or 16bit switchable
Cut-off frequency RS422 mode: 20million increments/s with 4-fold evaluation, corresponds to 5MHz
Quadrature decoder 4-fold evaluation (preset), 2-fold, 1-fold evaluation switchable
Micro-increments resolution 1/256bit micro-increments
Broken wire detection to sensor Yes for RS422 encoder
Distributed Clocks Yes
Timestamp Resolution 1ns
Special functions Frequency, period duration and duty cycle measurement, micro increments, adjustable in-
Cycle time min. 100µs
Current consumption via E-bus typ. 210mA
Current consumption from power contacts typ.20mA+load
Electrical isolation 500V (E-bus/field voltage)
Configuration
Weight approx.100g
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. 27mm x 100mm x 70mm (width aligned: 24mm)
Mounting [}39]
Vibration/shock resistance conforms to EN60068-2-6 / EN60068-2-27,
EMC immunity/emission conforms to EN61000-6-2/ EN61000-6-4
Protection class IP20
Installation position variable
Approval CE
erator
Single-ended connection (TTL, Open Collector): A, B, C
Counters, pulse generators: A, B
>1µs) per channel,
ON
Status Input input (max. 5VDC, negative switching, t
(preset), 12VDC, 24V
DC
power contacts)
switchable, 0.3A per channel (generated from the 24V
DC
>10µs) per channel
ON
TTL mode: 4million increments/s with 4-fold evaluation, corresponds to 1MHz
Open Collector: 400,000 increments/s with 4-fold evaluation, corresponds to 100kHz
terference pulse filters,
Timestamp on: last incremental edge, zero pulse C, Latch input and Gate/Latch input
via TwinCAT System Manager [}110]
0°C ... +55°C
-25°C ... +85°C
on 35mm mounting rail according to EN60715
see also Installation instructions [}42] for enhanced mechanical load capacity
DC
EL5102 15Version: 1.2
Product overview
2.3 Start
For commissioning:
• mount the EL5102 as described in the chapter Mounting and wiring [}38]
• configure the EL5102 in TwinCAT as described in the chapter Commissioning [}60].
• Parameterize the EL5102 as described in chapter EL5102 - Commissioning [}132].
EL510216 Version: 1.2
2.4 EL51xx series overview
Product overview
Technical data EL5102
2 x A, B, C
Number of channels 2 1 2 2 1
Encoder
type,
incremental
Number of digital inputs per
channel
Number of digital outputs per
channel
Encoder operating voltage
switchable between 5VDC,
12VDC, 24V
Encoder output current per
channel
Cut-off frequency 20 million in-
Differential RS422 X X X / X
Single-ended TTL X X X X X
OpenCollector X X X X X
Counter / pulse
generator
DC
X X X X X
2 2 1 1 2
/ / / / 2
X X X X X
0.3 A 0.3 A Sum current
crements,
correspond-
ing to 5 MHz
1 x A, B, C 2 x A, B
20 million in-
crements,
correspond-
ing to 5 MHz
EL5112 EL5122
2 x A, B
Sum current
0.3 A
20 million in-
crements,
correspond-
ing to 5 MHz
0.3 A
4 million in-
crements,
correspond-
ing to 1 MHz
EL5131
1 x A, B, C
0.3 A
20 million in-
crements,
correspond-
ing to 5 MHz
Functions EL5102
2 x A, B, C
Reset
counter
value via
Set counter
value via
Save
counter
value via
Lock counter
value via
Switching at comparison values
(Counter / Frequency / Period
value)
Detect counting direction X X / / X
Detect reversion of rotation X X / / X
Frequency measurement X X X X X
Period value measurement X X X X X
Velocity, speed calculation X X X X X
Duty cycle evaluation X X / / X
Micro-increments X X / / X
Timestamp function X X / / X
Adjustable interference pulse
filters
Plausibility check X X X X X
zero pulse C X X / / X
Latch input X X X X X
PLC variable X X X X X
zero pulse C X X / / X
Latch input X X X / X
Gate/Latch input / / X X /
zero pulse C X X / / X
Latch input X X X / X
Gate/Latch input X X / X X
PLC variable X X X X X
Gate/Latch input X X X X X
/ / / / X
X X X X X
1 x A, B, C 2 x A, B
EL5112 EL5122
2 x A, B
EL5131
1 x A, B, C
EL5102 17Version: 1.2
Technology
3 Technology
The incremental encoder interface terminals of the EL51xx series enable the connection of incremental
encoders to Bus Couplers or the PLC.
Incremental encoder basics
Incremental encoders divide a 360° rotation of the encoder axis into individual steps (increments) and mark a
full revolution by means of a special mark (zero pulse). An RS422 encoder transmits the signal symmetrically
as a differential line pair. TTL and Open Collector encoders use single signal lines (single-ended).
The terminal evaluates the 90° phase-shifted square wave signals of an incremental encoder on tracks A
and B. The zero pulse is captured on track C. With a differential connection, the inverted signals (A, B, C)
are also recorded.
These signals are converted by means of the quadrature decoder and the 32-bit counter into a position value
with optional quadruple, double or single evaluation. The digital inputs enable latch, reset and set
functionalities and thus exact and speed-independent referencing and storage of the counter value.
Encoder type Incremental signals
RS422 encoder with zero pulse A, A, B, B, C, C
RS422 encoder without zero pulse A, A, B, B
RS422 counter or pulse generator with zero pulse A, A, C, C;
Counting direction specification via track B (B, B)
RS422 counter or pulse generator without zero pulse A, A;
Counting direction specification via track B (B, B)
TTL, Open Collector encoder with zero pulse A, B, C
TTL, Open Collector encoder without zero pulse A, B
TTL, Open Collector counter or pulse generator with zero pulse A, C;
Counting direction specification via B
TTL, Open Collector counter or pulse generator without zero pulse A,
Counting direction specification via B
The phase position between the signals on track A and track B determines the counting direction.
Forward (cw): Signal on track A leads track B by 90°
Reverse (ccw): Signal on track A lags track B by 90°.
With single evaluation the rising edges on track A are counted.
With double evaluation the rising and falling edges on track A are counted.
With quadruple evaluation the rising and falling edges on track A and track B are counted.
Fig.6: Incremental signals
Absolute value encoders provide an absolute position value directly after switch-on, which is unambiguous
over the entire travel path. With incremental encoders, homing must be performed after switch-on in order to
be able to determine an unambiguous position.
Referencing can be carried out, for example, with the aid of referencing cams or using the zero pulse of the
encoder.
EL510218 Version: 1.2
Technology
NOTE
Differential and single-ended connection
• The RS422 signal transmits a differential voltage, which makes the signal less sensitive to interference
compared to a single-ended signal.
ð If the encoder signal is to be transmitted over longer distances or at higher frequencies, an encoder
with RS422 signals is recommended.
ð Shielded and twisted pair cables should be used.
EL5102 19Version: 1.2
Technical properties
4 Technical properties
The EL51xx series incremental encoder interface terminals enable connection of incremental encoders. In
addition to the encoder inputs A, B and optional zero pulse C, up to two additional 24VDC inputs are available
(latch and gate/latch), which can be used for resetting, setting, blocking and storing the counter value. If the
incremental encoder has a fault signal output, this can be connected to the Status Input input (5VDC).
The following inputs are available with the respective technical characteristics:
• Encoder connection: differential signals according to RS422 and single-ended signals from TTL
encoders and Open Collector encoders are supported.
• Latch input and Gate/Latch input
• Status Input
The terminal also provides a parameterizable encoder supply.
• Encoder operating voltage
NOTE
Fast digital inputs – interference from interfering devices
Please note that the input wiring has very little filtering. It has been optimized for fast signal transmission
from the input to the evaluation unit. In other words, rapid level changes/pulses in the µs range and/or highfrequency interference signals from devices (e.g. proportional valves, stepper motor or DC motor output
stages) arrive at the evaluation unit almost unfiltered/unattenuated. These interferences can be incorrectly
detected as a signal.
To suppress interference, an additional input filter can be parameterized. Furthermore, EMC-compliant cabling and the use of separate power supply units for the terminal and the devices causing interference are
recommended.
4.1 Signal types
Supported encoders / signal types
Differential signals according to RS422 are provided as encoder connection. Single-ended signals from TTL
encoders and also signals from Open Collector encoders are possible through internal pull-up resistors.
The following signal types are supported:
Encoder Signal type Setting in
Encoder
with or without zero pulse track C
Counter/pulse generator
with or without zero pulse track C
Encoder
with or without zero pulse track C
Counter/pulse generator
with or without zero pulse track C
Encoder
with or without zero pulse track C
Counter/pulse generator
with or without zero pulse track C
RS422
(diff. input)
TTL
(single ended)
open collector 4 400,000 increments
index 0x80n1:1D
"Counter mode"
0 20 million increments
1
2 4 million increments
3
5
The correct wiring for the respective encoder can be found in chapter Connection [}50].
Cut-off frequency Comments
with 4-fold evaluation,
corresponds to 5MHz per
track
with 4-fold evaluation,
corresponds to 1MHz per
track
with 4-fold evaluation,
corresponds to 100kHz per
track
Signal levels according to
RS422 are expected
Detection of
broken wire and short circuit
A voltage level of nominally
2.0V to 6.0V with a current
of 2.1mA or higher is expected.
No broken wire detection
No broken wire detection
Signal type RS422 (diff. input)
The terminal expects the differential signal levels according to RS422 with the following settings in "Counter
mode" (0x80n1:1D):
EL510220 Version: 1.2
Technical properties
• 0: Encoder RS422 (diff. input)
• 1: Counter RS422 (diff. input)
A cut-off frequency of up to 20million increments per second is permissible with 4-fold evaluation. This
corresponds to 5MHz.
Fig.7: RS422 signal level
Key:
V
CM
V
ID
V
IDLow
A, B, C Signals A, B, C
A, B, C
Common mode voltage range
Differential voltage
Differential voltage too low
Inverted signals A, B, C
NOTE
Exceeding of Common Mode range
Exceeding the Common Mode voltage range can lead to destruction of the device.
EL5102 21Version: 1.2
Technical properties
RS422 - broken wire and short-circuit detection (open circuit)
In the RS422 (differential input) modes it is possible to detect a broken wire or short circuit at the individual
encoder inputs.
• In case of a broken wire, e.g. between input A and input A,
◦ the differential voltage VID is almost 0V,
◦ which leads to an error with low differential voltage.
• In case of a short circuit, e.g. between input A and input A, the error behavior is similar to a broken wire
and also leads to error detection.
Activation of error detection for each channel
Index (hex) Name Description
80n0:0B Error detection A TRUE Broken wire and short circuit detection for encoder input A enabled
FALSE Broken wire and short circuit detection for encoder input A disabled
80n0:0C Error detection B TRUE Broken wire and short circuit detection for encoder input B enabled
FALSE Broken wire and short circuit detection for encoder input B disabled
80n0:0D Error detection C TRUE Broken wire and short circuit detection for encoder input C enabled
FALSE Broken wire and short circuit detection for encoder input C disabled
Error detection using the example of a broken wire or short circuit between inputs A and A.
Error diagnosis Display Description
LED A1 Green A TRUE level is present
Red An error (open circuit) was detected
0x60n07 "Open circuit" TRUE Group error message for "Open circuit"
FALSE There is no "open circuit" error.
0xA0n0:01 "Error A" TRUE An "open circuit" error (broken wire or short circuit) has occurred at encoder input A.
FALSE There is no "open circuit" error.
A broken wire or short circuit has occurred at one of the encoder inputs
NOTE
Differential and single-ended connection
• The RS422 signal transmits a differential voltage, which makes the signal less sensitive to interference
compared to a single-ended signal.
ð If the encoder signal is to be transmitted over longer distances or at higher frequencies, an encoder
with RS422 signals is recommended.
ð Shielded and twisted pair cables should be used.
EL510222 Version: 1.2
Technical properties
Signal type TTL (single-ended) and Open Collector
With the following settings in "Counter mode" (0x80n1:1D), a voltage level of nominally 2.0V to 6.0V with a
current of 2.1mA or higher is expected:
• 2: Encoder TTL (single-ended)
• 3: Counter TTL (single-ended)
• 4: Encoder open collector
• 5: Counter open collector
For TTL encoders a cut-off frequency of up to 4 million increments per second is permissible with 4-fold
evaluation. This corresponds to 1MHz.
For Open Collector encoders, a cut-off frequency of up to 400,000 increments per second is permissible with
4-fold evaluation. This corresponds to 100kHz.
Fig.8: TTL, Open Collector signal level (single-ended signal)
Key:
V
IN
A, B, C Encoder signals A, B, C
Single-ended input voltage
NOTE
Open circuit detection
Open circuit detection inherently does not work with single-ended lines: TTL and Open Collector encoders
and counters/pulse generators.
NOTE
Open Collector wiring
When selecting an Open Collector encoder under "Counter mode" (0x80n1:1D), the inputs A, B, C are connected to 5V via pull-up resistors (1kΩ).
EL5102 23Version: 1.2
Technical properties
4.2 Latch and Gate/Latch inputs
The terminal provides two digital 24VDC inputs. The function of these inputs is described in the respective
chapter.
• Latch input [}180] (Latch extern)
• Gate/latch input [}182] (Latch extern 2)
Both inputs are type 3 inputs according to EN61131-2, with a minimum pulse duration of tON>1µs.
Digital input type 3, according to
EN61131-2
Signal voltage "0 - LOW" -3V ... +5V typ. 0mA ... 2.6mA typ.
Signal voltage "1 - HIGH" 11V ... 30V typ. typ. 2.5mA
Fig.9: Characteristic 24VDC Input type 3
Voltage [V] Input current [mA]
NOTE
Be aware of bouncing when using electromechanical switches and push buttons
When using electromechanical switches and push buttons, repeated closing and opening of the switch or
push button can occur when the switch or push button is actuated, which is referred to as bouncing.
• If the function 0x80n0:22 "Enable continuous latch extern" or 0x80n0:23 "Enable continuous latch extern
2" is active, the stored value is overwritten several times due to the bouncing. As a result, parameter
0x60n0: 12 "Latch value" or 0x60n0: 22 "Latch value 2" contains the value that was saved last, not the
value that was saved first.
• If the function is deactivated, only the first opening or closing of the switch or push button is detected and
saved as a value in the corresponding parameter. No other transactions are taken into account.
EL510224 Version: 1.2
Technical properties
4.3 Status Input
The terminal provides a Status Input. The function is described in chapter Status Input. [}183]
The input is 5V compatible.
Digital input,
5V TTL input characteristic
Signal voltage "0 - LOW" -6V … + 0.8V typ. 5mA
Signal voltage "1 - HIGH" +2V … +6V typ. 0mA
Voltage [V] Input current [mA]
NOTE
Wiring of the Status Input
In the terminal the Status Input is internally connected to 5V via a pull-up resistor (1kΩ). The encoder output must actively pull the signal against GND. The resistance must be dimensioned so that it is less than
120Ω.
External power supply is not recommended. If an external supply is used, the maximum permitted voltage
is 5V against GND.
EL5102 25Version: 1.2
Technical properties
4.4 Encoder operating voltage (supply voltage)
The encoder supply is generated internally from the 24V of the power contacts. The encoder supply can be
set in index 0x80n1:17 "Supply voltage". An operating voltage of 5VDC is preset. Voltage values of 5VDC,
12VDC and 24VDC can be selected. The settings are made separately for each channel.
The following tolerances apply
Voltage range Tolerance
5V
DC
12V
DC
24V
DC
Setting the encoder supply voltage
• Before switching to a higher voltage, make sure that the connected encoder supports the selected voltage range!
• To write to 0x80n1:17 "Supply voltage" you have to set the value 0x72657375 (ASCII: "user") in index
0xF008 [}227] "Code word".
+/- 5% (4.75V … 5.25V)
+/- 10% (10.8V … 13.2V)
-15% to +20% (20.4V … 28.8V)
NOTE
EL510226 Version: 1.2
Basics communication
5 Basics communication
5.1 EtherCAT basics
Please refer to the EtherCAT System Documentation for the EtherCAT fieldbus basics.
5.2 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 5V; a coupler is
thereby loadable up to 2A as a rule (see details in respective device documentation).
Information on how much current each EL terminal requires from the E-bus supply is available online and in
the catalogue. If the added terminals require more current than the coupler can supply, then power feed
terminals (e.g. EL9410) must be inserted at appropriate places in the terminal strand.
The pre-calculated theoretical maximum E-Bus current is displayed in the TwinCAT System Manager. A
shortfall is marked by a negative total amount and an exclamation mark; a power feed terminal is to be
placed before such a position.
EL5102 27Version: 1.2
Basics communication
Fig.10: 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!
5.3 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.
EL510228 Version: 1.2
Basics communication
Fig.11: EtherCAT tab -> Advanced Settings -> Behavior -> Watchdog
Notes:
• the multiplier is valid for both watchdogs.
• each watchdog has its own timer setting, the outcome of this in summary with the multiplier is a
resulting time.
• Important: the multiplier/timer setting is only loaded into the slave at the start up, if the checkbox is
activated.
If the checkbox is not activated, nothing is downloaded and the ESC settings remain unchanged.
Multiplier
Multiplier
Both watchdogs receive their pulses from the local terminal cycle, divided by the watchdog multiplier:
1/25 MHz * (watchdog multiplier + 2) = 100µs (for default setting of 2498 for the multiplier)
The standard setting of 1000 for the SM watchdog corresponds to a release time of 100ms.
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.
EL5102 29Version: 1.2
Basics communication
Example “Set SM watchdog”
This checkbox enables manual setting of the watchdog times. If the outputs are set and the EtherCAT
communication is interrupted, the SM watchdog is triggered after the set time and the outputs are erased.
This setting can be used for adapting a terminal to a slower EtherCAT master or long cycle times. The
default SM watchdog setting is 100ms. The setting range is 0...65535. Together with a multiplier with a
range of 1...65535 this covers a watchdog period between 0...~170 seconds.
Calculation
Multiplier = 2498 → watchdog base time = 1 / 25MHz * (2498 + 2) = 0.0001seconds = 100µs
SM watchdog = 10000 → 10000 * 100µs = 1second watchdog monitoring time
CAUTION
Undefined state possible!
The function for switching off of the SM watchdog via SM watchdog = 0 is only implemented in terminals
from version -0016. In previous versions this operating mode should not be used.
CAUTION
Damage of devices and undefined state possible!
If the SM watchdog is activated and a value of 0 is entered the watchdog switches off completely. This is
the deactivation of the watchdog! Set outputs are NOT set in a safe state, if the communication is interrupted.
5.4 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.
EL510230 Version: 1.2
Loading...