Documentation
EL600x, EL602x
Serial Interface Terminals
Version:
Date:
4.6
2018-09-24
Table of contents
Table of contents
1 Foreword ....................................................................................................................................................5
1.1 Overview Serial Interface Terminals..................................................................................................5
1.2 Notes on the documentation..............................................................................................................5
1.3 Safety instructions .............................................................................................................................7
1.4 Documentation Issue Status..............................................................................................................8
1.5 Version identification of EtherCAT devices .......................................................................................9
2 Product overview.....................................................................................................................................14
2.1 EL6001, EL6021..............................................................................................................................18
2.1.1 Introduction ...................................................................................................................... 18
2.1.2 Technical data ................................................................................................................. 19
2.2 EL6002, EL6022..............................................................................................................................20
2.2.1 Introduction ...................................................................................................................... 20
2.2.2 Technical data ................................................................................................................. 21
2.3 Start up ............................................................................................................................................21
3 Basics communication ...........................................................................................................................22
3.1 EtherCAT basics..............................................................................................................................22
3.2 EtherCAT cabling – wire-bound.......................................................................................................22
3.3 General notes for setting the watchdog...........................................................................................23
3.4 EtherCAT State Machine.................................................................................................................25
3.5 CoE Interface...................................................................................................................................27
3.6 Distributed Clock .............................................................................................................................32
4 Mounting and Wiring...............................................................................................................................33
4.1 Instructions for ESD protection........................................................................................................33
4.2 EL6001, EL6021..............................................................................................................................33
4.2.1 Installation on mounting rails ........................................................................................... 33
4.2.2 Connection....................................................................................................................... 36
4.2.3 Positioning of passive Terminals ..................................................................................... 40
4.2.4 LEDs and terminal connector assignments ..................................................................... 41
4.3 EL6002, EL6022..............................................................................................................................43
4.3.1 Mounting and demounting - terminals with front unlocking.............................................. 43
4.3.2 Recommended mounting rails ......................................................................................... 45
4.3.3 LEDs and pin assignment................................................................................................ 46
4.4 Positioning of passive Terminals .....................................................................................................49
4.5 Installation instructions for enhanced mechanical load capacity .....................................................50
4.6 Installation positions ........................................................................................................................51
4.7 UL notice .........................................................................................................................................53
4.8 ATEX - Special conditions (extended temperature range) ..............................................................54
4.9 ATEX Documentation ......................................................................................................................55
5 Commissioning........................................................................................................................................56
5.1 TwinCAT Quick Start .......................................................................................................................56
5.1.1 TwinCAT2 ....................................................................................................................... 58
5.1.2 TwinCAT 3 ....................................................................................................................... 68
5.2 TwinCAT Development Environment ..............................................................................................80
EL600x, EL602x 3Version: 4.6
Table of contents
5.2.1 Installation of the TwinCAT real-time driver..................................................................... 80
5.2.2 Notes regarding ESI device description........................................................................... 86
5.2.3 TwinCAT ESI Updater ..................................................................................................... 90
5.2.4 Distinction between Online and Offline............................................................................ 90
5.2.5 OFFLINE configuration creation ...................................................................................... 91
5.2.6 ONLINE configuration creation ........................................................................................ 96
5.2.7 EtherCAT subscriber configuration................................................................................ 104
5.3 General Notes - EtherCAT Slave Application................................................................................114
5.4 Operating modes and process data ..............................................................................................122
5.5 Hints regarding TcVirtualComDriver..............................................................................................129
5.6 Communication features................................................................................................................131
5.7 LIN Master Feature EL6001 ..........................................................................................................132
5.8 Example programs ........................................................................................................................136
5.8.1 Sample program 1 ......................................................................................................... 136
5.8.2 Sample program 2 ......................................................................................................... 139
5.8.3 Sample program 3 (LIN) ................................................................................................ 141
6 Overview of CoE objects EL6001, EL6021 ..........................................................................................144
6.1 Object description and parameterization .......................................................................................144
6.1.1 Objects for commissioning............................................................................................. 144
6.1.2 Standard objects (0x1000-0x1FFF) ............................................................................... 146
6.1.3 Profile-specific objects (0x6000-0xFFFF) [from hardware version 03] .......................... 162
6.2 Control and status word.................................................................................................................165
7 Overview CoE objects EL6002, EL6022...............................................................................................168
7.1 Object description and parameterization .......................................................................................168
7.1.1 Objects for commissioning............................................................................................. 168
7.1.2 Standard objects (0x1000-0x1FFF) ............................................................................... 169
7.1.3 Profile-specific objects (0x6000-0xFFFF) [from hardware version 03] .......................... 181
7.2 Control and status data .................................................................................................................184
8 Appendix ................................................................................................................................................186
8.1 EtherCAT AL Status Codes...........................................................................................................186
8.2 Firmware compatibility...................................................................................................................186
8.3 Firmware Update EL/ES/EM/EPxxxx ............................................................................................187
8.3.1 Device description ESI file/XML..................................................................................... 188
8.3.2 Firmware explanation .................................................................................................... 191
8.3.3 Updating controller firmware *.efw................................................................................. 192
8.3.4 FPGA firmware *.rbf....................................................................................................... 193
8.3.5 Simultaneous updating of several EtherCAT devices.................................................... 197
8.4 Restoring the delivery state ...........................................................................................................198
8.5 Support and Service ......................................................................................................................199
EL600x, EL602x4 Version: 4.6
Foreword
1 Foreword
1.1 Overview Serial Interface Terminals
EL6001 [}18] (1 channel Serial Interface Terminal, RS232C)
EL6021 [}18] (1 channel Serial Interface Terminal, RS422/RS485)
EL6002 [}20] (2 channel Serial Interface Terminal, RS232C)
EL6022 [}20] (2 channel Serial Interface Terminal, RS422/RS485)
1.2 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®, EtherCATP®, SafetyoverEtherCAT®, TwinSAFE®, XFC® and XTS® are
registered trademarks of and licensed by Beckhoff Automation GmbH.
Other designations used in this publication may be trademarks whose use by third parties for their own
purposes could violate the rights of the owners.
Patent Pending
The EtherCAT Technology is covered, including but not limited to the following patent applications and
patents: EP1590927, EP1789857, DE102004044764, DE102007017835 with corresponding applications or
registrations in various other countries.
The TwinCAT Technology is covered, including but not limited to the following patent applications and
patents: EP0851348, US6167425 with corresponding applications or registrations in various other countries.
EtherCAT® is registered trademark and patented technology, licensed by Beckhoff Automation GmbH,
Germany
EL600x, EL602x 5Version: 4.6
Foreword
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.
EL600x, EL602x6 Version: 4.6
Foreword
1.3 Safety instructions
Safety regulations
Please note the following safety instructions and explanations!
Product-specific safety instructions can be found on following pages or in the areas mounting, wiring,
commissioning etc.
Exclusion of liability
All the components are supplied in particular hardware and software configurations appropriate for the
application. Modifications to hardware or software configurations other than those described in the
documentation are not permitted, and nullify the liability of Beckhoff Automation GmbH & Co. KG.
Personnel qualification
This description is only intended for trained specialists in control, automation and drive engineering who are
familiar with the applicable national standards.
Description of instructions
In this documentation the following instructions are used.
These instructions must be read carefully and followed without fail!
DANGER
Serious risk of injury!
Failure to follow this safety instruction directly endangers the life and health of persons.
WARNING
Risk of injury!
Failure to follow this safety instruction endangers the life and health of persons.
CAUTION
Personal injuries!
Failure to follow this safety instruction can lead to injuries to persons.
NOTE
Damage to environment/equipment or data loss
Failure to follow this instruction can lead to environmental damage, equipment damage or data loss.
Tip or pointer
This symbol indicates information that contributes to better understanding.
EL600x, EL602x 7Version: 4.6
Foreword
1.4 Documentation Issue Status
Version Comment
4.6 • Correction RS232 level
• Update chapter "Technical data"
• Update structure
• Update revision status
4.5 • Update chapter "Commissioning"
• Update revision status
4.4 • Update chapter "Technical data"
• Update chapter "Operating modes and process data"
• Update chapter " Communication features"
• Update structure
• Update revision status
4.3 • Update chapter "Technical data"
• Addenda chapter "Instructions for ESD protection"
• Chapter "ATEX - Special conditions" replaced with chapter "ATEX - Special conditions (extended temperature
range)"
• Addenda chapter "TwinCAT Quickstart"
• Update revision status
4.2 • Update in section ”LEDs and terminal connector assignments”
4.1 • Addenda in section “LEDs and pin assignment”
4.0 • Migration and revision
• Section "Mounting and demounting" in section "EL6002, EL6022" in "Mounting and wiring" complemented with
"Front unlocking"
• Section "Installation instructions for enhanced mechanical load capacity" moved from subsection "EL6001,
EL6021" to section "Mounting and wiring"
• Section "Installation positions" removed from subsection "EL6001, EL6021" (since already present in higher-level
section)
• Section "Configuration with the TwinCAT System Manager" moved from section "Commissioning" to subsection
"TwinCAT 2.1x"
• Section "LIN Feature EL6001" moved to section "Commissioning"
• Sections "Sample program 1" and "Sample program 2" consolidated into new section "Sample programs"; new
section "Sample programs" integrated in section "Commissioning“
• Section "Sample program 3 (LIN)" added to section "Sample programs"
3.8 • "Technical data" section updated
• "Installation instructions for enhanced mechanical load capacity" section supplemented
• Structural update
• Revision version updated
3.7 • Update LED description
• Update revision status
3.6 • Update revision status
• Update structure
3.5 • Update chapter "Technical data"
• Update chapter "Object description and parameterization"
• Update chapter "Communication features"
• Update chapter "Technology"
• Update chapter "Process data"
• Update structure
EL600x, EL602x8 Version: 4.6
Version Comment
3.4 • Update chapter "Technology"
3.3 • Update Technical data
3.2 • Update Technical data
3.1 • Addenda of notes and description of command mode
3.0 • Update chapter "Object description"
2.9 • Addenda chapter "Communication features and TcVirtualComDriver"
2.8 • Update Technical data
2.7 • Update Technical data
2.6 • Update chapter "Technology" and "Process data"
2.5 • Update chapter "Technology"
2.4 • Object description and Technical notes added
2.3 • Firmware compatibility notice, Technical notes added
2.2 • Addenda
2.1 • Addenda
2.0 • First public issue
0.3 • Addenda
0.2 • Corrections and addenda
0.1 • Preliminary documentation for EL60xx
Foreword
1.5 Version identification of EtherCAT devices
Designation
A Beckhoff EtherCAT device has a 14-digit designation, made up of
• family key
• type
• version
• revision
Example Family Type Version Revision
EL3314-0000-0016 EL terminal
(12 mm, nonpluggable connection
level)
ES3602-0010-0017 ES terminal
(12 mm, pluggable
connection level)
CU2008-0000-0000 CU device 2008 (8-port fast ethernet switch) 0000 (basic type) 0000
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
3314 (4-channel thermocouple
terminal)
3602 (2-channel voltage
measurement)
0000 (basic type) 0016
0010 (high-
0017
precision version)
EL600x, EL602x 9Version: 4.6
Foreword
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
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
EL600x, EL602x10 Version: 4.6
Examples of markings
Fig.1: EL5021 EL terminal, standard IP20 IO device with serial/ batch number and revision ID (since
2014/01)
Foreword
Fig.2: EK1100 EtherCAT coupler, standard IP20 IO device with serial/ batch number
Fig.3: CU2016 switch with serial/ batch number
EL600x, EL602x 11Version: 4.6
Foreword
Fig.4: EL3202-0020 with serial/ batch number 26131006 and unique ID-number 204418
Fig.5: EP1258-00001 IP67 EtherCAT Box with batch number/ date code 22090101 and unique serial
number 158102
Fig.6: EP1908-0002 IP67 EtherCAT Safety Box with batch number/ date code 071201FF and unique serial
number 00346070
Fig.7: EL2904 IP20 safety terminal with batch number/ date code 50110302 and unique serial number
00331701
EL600x, EL602x12 Version: 4.6
Foreword
Fig.8: ELM3604-0002 terminal with unique ID number (QR code) 100001051 and serial/ batch number
44160201
EL600x, EL602x 13Version: 4.6
Product overview
2 Product overview
Technology
The EL600x and EL602x serial interface terminals enable the connection of devices with an RS232 (or
RS485 / RS422) interface. In the case of the EL600x, the data is exchanged with the controller in full duplex
mode; in the case of the EL602x, half duplex mode is additionally possible. The terminal has one receive
buffer an one transmit buffer per channel, see technical data. Data transfer between the terminal and the
controller takes place via a handshake.
The factory setting of the terminals is:
• 9600 baud
• 8N1: 8 data bits, 1 stop bit, no parity
• in the EL600x the RTS/CTS control is active
• the EL602x operates in full duplex mode with deactivated point-to-point connection.
Basic principles
During transfer of several bytes of data, the data (x bytes or 8*x bits in total) are sent in individual telegrams
containing 7 or 8 bits, based on the coding specification (e.g. 7E2 or 8N1). A telegram consists of:
• Start bit
• Data bits (7 or 8, starting with the LSB [least significant bit])
• Optional: parity bit
◦ "E" EVEN: The parity bit is set by the sender such that the parity is even
◦ "O" ODD: The parity bit is set by the sender such that the parity is odd
◦ "N" NOT: no parity bit
◦ "M" MARK: The parity bit is set to 1 by the sender
◦ "S" SPACE: The parity bit is set to 0 by the sender
• Stop bit (1 or 2)
Accordingly, the coding specification 8N1 means: 8 data bits, no parity bit, 1 stop bit.
If 7-bit coding is selected, of each data byte that is transferred from the PLC to the terminal via the cyclic
process data, only the lower 7 bits are sent. In other words, if 10 bytes of data (consisting of 8 bits) are sent
to the EL60xx, 10 telegrams of 7 bits each are sent.
If 9-bit coding is selected, the 16-bit process data interface must be used. The terminal then expects the 9
useful bits in the lower 9 bits of the 16-bit word.
Frequency
The frequency of the data transfer must be known in the sender and receiver and match within a few
percent, in order to ensure that the receiver can correctly detect any changes in level on the line.
Handshake
An additional handshake between the sender and the receiver can be used so that the receiver can indicate
that it is ready to receive. The EL60xx supports two types of handshake:
• via special RTS/CTS data cables
◦ This features must be activated in the CoE.
◦ Only possible with EL6001/EL6002.
• via special data telegrams
◦ This features must be activated in the CoE.
EL600x, EL602x14 Version: 4.6
Product overview
Level interfaces
The EL6001/6002 devices operate at an RS232 level with reference to GND, the EL6021/6022 devices with
a differential RS485/422 level.
Fig.9: Level interfaces RS232, RS485/422
Termination and topology
The serial RS422 and RS485 communication technologies operate with voltage levels on a 2-wire line.
Reflections at high-resistance line ends can lead to signal distortion. For this reason termination resistors are
required at the receiver. For RS422/485 these are 120Ω resistors, which together with the line resistance
result in a voltage drop over the transmission link.
Permitted cable length
The line resistance together with the termination resistor results in an overall voltage drop over the
transmission link. An unacceptably high number of termination resistors would result in excessive
attenuation of the signal.
The system design should ensure that the voltage does not drop below 200mV at the receiver (see
Fig. ), which is the minimum voltage required.
In RS422 mode each line must be terminated with 120Ω at the receiver.
Fig.10: RS422 termination
In RS485 mode with several devices, termination resistors are only used at the two end devices.
EL600x, EL602x 15Version: 4.6
Product overview
Fig.11: RS485 termination
The background is the different design of RS422/EIA-422 and RS485/EIA-485:
• RS422: 1 Rx → Tx n (maximum 10 receivers)
• RS485: n Rx → Tx m (maximum 32/128 devices, depending on the resulting bus loading)
Components for RS485 usually have a higher input impedance, resulting in lower bus load.
Termination with EL602x and BIAS resistors
The EL602x devices do not have integrated termination resistors, in order to enable operation in
bus mode. Any termination that may be required must be connected outside the terminal.
The EL602x devices feature integrated bias resistors < 1 kOhm, which bring the bus lines to defined
levels, even if the line is disconnected.
If several EL602x devices are connected in a bus, the parallel bias resistors may hamper the data
communication. In this case the EL6021-0021, which has significantly higher bias resistors, should
be used as an intermediate device.
Topology
The termination and the bias resistors generate a load on the bus. However, they are essential for
unambiguous bus levels and therefore have to be positioned with diligence. Ideally the RS422/485 bus
should be configured as a daisy chain or a simple chain, see Fig. [}17] The following topologies may be
problematic:
• Star topologies: each end point should ideally be terminated, but this can lead to excessive bus loading
and ambiguous signal levels. Other potential issues are reflections and runtime variations.
• Intermeshed topologies: no clear end points, which means reflections and circulating currents are
possible.
Shielding/shield
NOTE
Do not use functional earth for discharge of residual currents or potential differences!
The EL60xx units offer a shielded connection for discharging EMC interference via the cable shield (FE,
functional earth). The shield must not be misused for discharging residual currents or potential differences.
The EL60xx units offer a shielded connection for discharging EMC interference via the cable shield (FE,
functional earth). The shield must not be misused for discharging residual currents or potential differences.
EL600x, EL602x16 Version: 4.6
Product overview
Fig.12: EL60xx shield connection
In the 2-channel versions the D-Sub 9 shield is connected with the mounting rail via a high-resistance RC
combination.
EL600x, EL602x 17Version: 4.6
Product overview
2.1 EL6001, EL6021
2.1.1 Introduction
Serial Interface Terminal (RS232C/RS422/RS485), 1 channel
The EL6001 and EL6021 serial interfaces enable the connection of devices with RS-232 or RS422/RS485
interface. The EL6001 operates in conformity with the CCITT V.28/DIN 66 259-1 standards.
The device connected to the EL6001 EtherCAT Terminal communicates with the automation device via the
coupler. The active communication channel operates independently of the higher-level bus system in full
duplex mode or selectable half duplex mode (EL6021) at up to 115.2kbaud.
The RS232 interface guarantees high immunity to interference through electrically isolated signals, which is
additionally guaranteed for the EL6021 through differential signal transmission.
In conjunction with the TwinCAT Virtual Serial COM Driver (see TwinCAT Supplements – Communication)
the EL6001/EL6021 can be used as a normal Windows COM interface.
Quick links
• EtherCAT basics [}22]
• Technology Serial Interface Terminals [}14]
• Commissioning [}56]
• Process data, general notes [}122]
• CoE object description and parameterization EL60x1 [}144]
• Control and status data EL60x1 [}165]
EL600x, EL602x18 Version: 4.6
Product overview
2.1.2 Technical data
Technical data EL6001 EL6021
Data transfer channels TxD and RxD, full duplex TxD and RxD, full/half duplex
Data transfer rate 2400...115200baud,
default: 9600baud, 8data bits,
no parity, 1 stop bit
from firmware 07 [}186]:
also 12000baud and
14400baud
from firmware 11 [}186]:
any integer baud rate 1000…
115200Baud
Data buffer 864byte receive buffer, 128byte transmit buffer
EL6001 from FW08: 250byte transmit buffer
Bit transfer - with differential signal
Level interface RS232 RS485/422
Bit distortion < 3 % -
Cable length max. 15m max. 1000m (Twisted Pair)
Line impedance - 120Ω
Providing external supply - -
Diagnosis Status LEDs
Power supply via the E-Bus
Current consumption via E-bus typ. 120mA typ. 170mA
Electrical isolation 500 V
(E-bus/RS232C)
Bit width in process image 1 x 8bit Control/Status, Inputs/Outputs: 3 x 8bit user data or
1 x 8bit Control/Status, Inputs/Outputs: 5 x 8bit user data or
1 x 16bit Control/Status, Inputs/Outputs: 22 x 8bit user data
(configurable)
Configuration no address setting required
configuration via TwinCAT System Manager
Weight approx. 55g
Permissible ambient temperature range
during operation
Permissible ambient temperature range
during storage
Permissible relative humidity 95%, no condensation
Dimensions (W x H x D) approx. 15mm x 100mm x 70mm (width aligned: 12mm)
Mounting on 35mm mounting rail conforms 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
Approval CE
-25°C ... +60°C (extended temperature range)
-40°C ... +85°C
see also installation instructions [}50] for enhanced mechanical
load capacity
ATEX [}54]
cULus [}53]
2400...115200baud,
default: 9600baud, 8data bits,
no parity, 1stop bit
(in case of short circuit: typ.
250mA)
500 V
(E-bus/RS422, E-bus/RS485)
CE
ATEX [}54]
cULus [}53]
IECEx
EL600x, EL602x 19Version: 4.6
Product overview
2.2 EL6002, EL6022
2.2.1 Introduction
Serial Interface Terminal (RS232C/RS422/RS485), 2 channel
The EL6002 and EL6022 serial interfaces enable the connection of devices with two RS232 or two RS422/
RS485 interfaces each with one D-Sub connector (9 pin). The interfaces are electrically isolated from each
other and from the EtherCAT.
The devices connected to the EL6002/EL6022 EtherCAT Terminals communicate with the automation
device via the Coupler. The active communication channel operates independently of the higher-level
EtherCAT system in full duplex mode with 300 baud up to 115.2 kbaud.
The RS232/RS422/RS485 interfaces guarantee high interference immunity through electrically isolated
signals. The EL6022 can provide 2 x 5 V/20 mA from the E-bus supply (electrically isolated, short-circuitproof) as supply for external devices.
In conjunction with the TwinCAT Virtual Serial COM Driver, the EL60xx can be used as a normal Windows
COM interface.
Quick links
• EtherCAT basics [}22]
• Technology Serial Interface Terminals [}14]
• Commissioning [}56]
• Process data, general notes [}122]
• CoE object description and parameterization EL60x1 [}168]
• Control and status data EL60x1 [}184]
EL600x, EL602x20 Version: 4.6
Product overview
2.2.2 Technical data
Technical data EL6002 EL6022
Data transfer channels 2, TxD and RxD, full duplex 2, TXD and RXD, full/half duplex
Connection 2 x D-sub connector (DE9), 9-pin 2 x D-sub connector (DE9), 9-pin
Data transfer rate 300...115200 baud
default: 9600 baud, 8 data bits, no parity, 1 stop bit
Data buffer 864 byte receive buffer, 128 byte transmit buffer per channel
Level interface RS232 RS485/422
Cable length max. 15 m max. 1000 m (Twisted Pair)
Providing external supply - 2x typ. 5V (± 20%),
from E-bus supply (electrically
isolated), max. 20 mA,
short-circuit-proof
Diagnosis Status LEDs
Power supply via the E-Bus
Current consumption via E-bus typ. 170 mA typ. 250 mA
(in case of short circuit: typ.
250mA)
Electrical isolation 500 V
(E-bus/RS232C)
Bit width in process image 1 x 16 bit Control/Status, Inputs/Outputs: 22 x 8 bit user data
Configuration no address setting required
configuration via TwinCAT System Manager
Permissible ambient temperature
range during operation
Permissible ambient temperature
range during storage
Permissible relative humidity 95%, no condensation
Weight approx. 70 g
Dimensions (W x H x D) approx. 26 mm x 100 mm x 52 mm (width aligned: 23 mm)
Mounting [}43]
Vibration/shock resistance conforms to EN 60068-2-6 / EN 60068-2-27
-25°C ... +60°C (extended temperature range)
-40°C ... +85°C
on 35 mm mounting rail conforms to EN 60715
500 V
(E-bus/RS422, E-bus/RS485)
EMC immunity/emission conforms to EN 61000-6-2 / EN 61000-6-4
Protection class IP20
Installation position variable
Approval CE
ATEX [}54]
cULus [}53]
2.3 Start up
Start
For commissioning:
• mount the EL600x / EL602x as described in the chapter Mounting and wiring [}33]
• configure the EL600x / EL602x in TwinCAT as described in the chapter Commissioning [}56]
EL600x, EL602x 21Version: 4.6
Basics communication
3 Basics communication
3.1 EtherCAT basics
Please refer to the chapter EtherCAT System Documentation for the EtherCAT fieldbus basics.
3.2 EtherCAT cabling – wire-bound
The cable length between two EtherCAT devices must not exceed 100 m. This results from the FastEthernet
technology, which, above all for reasons of signal attenuation over the length of the cable, allows a maximum
link length of 5 + 90 + 5 m if cables with appropriate properties are used. See also the Design
recommendations for the infrastructure for EtherCAT/Ethernet.
Cables and connectors
For connecting EtherCAT devices only Ethernet connections (cables + plugs) that meet the requirements of
at least category 5 (CAt5) according to EN 50173 or ISO/IEC 11801 should be used. EtherCAT uses 4 wires
for signal transfer.
EtherCAT uses RJ45 plug connectors, for example. The pin assignment is compatible with the Ethernet
standard (ISO/IEC 8802-3).
Pin Color of conductor Signal Description
1 yellow TD + Transmission Data +
2 orange TD - Transmission Data -
3 white RD + Receiver Data +
6 blue RD - Receiver Data -
Due to automatic cable detection (auto-crossing) symmetric (1:1) or cross-over cables can be used between
EtherCAT devices from Beckhoff.
Recommended cables
Suitable cables for the connection of EtherCAT devices can be found on the Beckhoff website!
E-Bus supply
A bus coupler can supply the EL terminals added to it with the E-bus system voltage of 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.
EL600x, EL602x22 Version: 4.6
Basics communication
Fig.13: System manager current calculation
NOTE
Malfunction possible!
The same ground potential must be used for the E-Bus supply of all EtherCAT terminals in a terminal block!
3.3 General notes for setting the watchdog
ELxxxx terminals are equipped with a safety feature (watchdog) that switches off the outputs after a
specifiable time e.g. in the event of an interruption of the process data traffic, depending on the device and
settings, e.g. in OFF state.
The EtherCAT slave controller (ESC) in the EL2xxx terminals features 2 watchdogs:
• SM watchdog (default: 100 ms)
• PDI watchdog (default: 100 ms)
SM watchdog (SyncManager Watchdog)
The SyncManager watchdog is reset after each successful EtherCAT process data communication with the
terminal. If no EtherCAT process data communication takes place with the terminal for longer than the set
and activated SM watchdog time, e.g. in the event of a line interruption, the watchdog is triggered and the
outputs are set to FALSE. The OP state of the terminal is unaffected. The watchdog is only reset after a
successful EtherCAT process data access. Set the monitoring time as described below.
The SyncManager watchdog monitors correct and timely process data communication with the ESC from the
EtherCAT side.
PDI watchdog (Process Data Watchdog)
If no PDI communication with the EtherCAT slave controller (ESC) takes place for longer than the set and
activated PDI watchdog time, this watchdog is triggered.
PDI (Process Data Interface) is the internal interface between the ESC and local processors in the EtherCAT
slave, for example. The PDI watchdog can be used to monitor this communication for failure.
The PDI watchdog monitors correct and timely process data communication with the ESC from the
application side.
The settings of the SM- and PDI-watchdog must be done for each slave separately in the TwinCAT System
Manager.
EL600x, EL602x 23Version: 4.6
Basics communication
Fig.14: EtherCAT tab -> Advanced Settings -> Behavior -> Watchdog
Notes:
• the multiplier is valid for both watchdogs.
• each watchdog has its own timer setting, the outcome of this in summary with the multiplier is a
resulting time.
• Important: the multiplier/timer setting is only loaded into the slave at the start up, if the checkbox is
activated.
If the checkbox is not activated, nothing is downloaded and the ESC settings remain unchanged.
Multiplier
Multiplier
Both watchdogs receive their pulses from the local terminal cycle, divided by the watchdog multiplier:
1/25 MHz * (watchdog multiplier + 2) = 100 µs (for default setting of 2498 for the multiplier)
The standard setting of 1000 for the SM watchdog corresponds to a release time of 100 ms.
The value in multiplier + 2 corresponds to the number of basic 40 ns ticks representing a watchdog tick.
The multiplier can be modified in order to adjust the watchdog time over a larger range.
EL600x, EL602x24 Version: 4.6
Basics communication
Example "Set SM watchdog"
This checkbox enables manual setting of the watchdog times. If the outputs are set and the EtherCAT
communication is interrupted, the SM watchdog is triggered after the set time and the outputs are erased.
This setting can be used for adapting a terminal to a slower EtherCAT master or long cycle times. The
default SM watchdog setting is 100 ms. The setting range is 0..65535. Together with a multiplier with a range
of 1..65535 this covers a watchdog period between 0..~170 seconds.
Calculation
Multiplier = 2498 → watchdog base time = 1 / 25MHz * (2498 + 2) = 0.0001seconds = 100µs
SM watchdog = 10000 → 10000 * 100µs = 1second watchdog monitoring time
CAUTION
Undefined state possible!
The function for switching off of the SM watchdog via SM watchdog = 0 is only implemented in terminals
from version -0016. In previous versions this operating mode should not be used.
CAUTION
Damage of devices and undefined state possible!
If the SM watchdog is activated and a value of 0 is entered the watchdog switches off completely. This is
the deactivation of the watchdog! Set outputs are NOT set in a safe state, if the communication is interrupted.
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.
EL600x, EL602x 25Version: 4.6
Basics communication
Fig.15: States of the EtherCAT State Machine
Init
After switch-on the EtherCAT slave in the Init state. No mailbox or process data communication is possible.
The EtherCAT master initializes sync manager channels 0 and 1 for mailbox communication.
Pre-Operational (Pre-Op)
During the transition between Init and Pre-Op the EtherCAT slave checks whether the mailbox was initialized
correctly.
In Pre-Op state mailbox communication is possible, but not process data communication. The EtherCAT
master initializes the sync manager channels for process data (from sync manager channel 2), the FMMU
channels and, if the slave supports configurable mapping, PDO mapping or the sync manager PDO
assignment. In this state the settings for the process data transfer and perhaps terminal-specific parameters
that may differ from the default settings are also transferred.
Safe-Operational (Safe-Op)
During transition between Pre-Op and Safe-Op the EtherCAT slave checks whether the sync manager
channels for process data communication and, if required, the distributed clocks settings are correct. Before
it acknowledges the change of state, the EtherCAT slave copies current input data into the associated DPRAM areas of the EtherCAT slave controller (ECSC).
In Safe-Op state mailbox and process data communication is possible, although the slave keeps its outputs
in a safe state, while the input data are updated cyclically.
Outputs in SAFEOP state
The default set watchdog [}23] 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.
EL600x, EL602x26 Version: 4.6
Basics communication
Boot
In the Boot state the slave firmware can be updated. The Boot state can only be reached via the Init state.
In the Boot state mailbox communication via the file access over EtherCAT (FoE) protocol is possible, but no
other mailbox communication and no process data communication.
3.5 CoE Interface
General description
The CoE interface (CANopen over EtherCAT) is used for parameter management of EtherCAT devices.
EtherCAT slaves or the EtherCAT master manage fixed (read only) or variable parameters which they
require for operation, diagnostics or commissioning.
CoE parameters are arranged in a table hierarchy. In principle, the user has read access via the fieldbus.
The EtherCAT master (TwinCAT System Manager) can access the local CoE lists of the slaves via
EtherCAT in read or write mode, depending on the attributes.
Different CoE parameter types are possible, including string (text), integer numbers, Boolean values or larger
byte fields. They can be used to describe a wide range of features. Examples of such parameters include
manufacturer ID, serial number, process data settings, device name, calibration values for analog
measurement or passwords.
The order is specified in 2 levels via hexadecimal numbering: (main)index, followed by subindex. The value
ranges are
• Index: 0x0000 …0xFFFF (0...65535
• SubIndex: 0x00…0xFF (0...255
dez
)
dez
)
A parameter localized in this way is normally written as 0x8010:07, with preceding "x" to identify the
hexadecimal numerical range and a colon between index and subindex.
The relevant ranges for EtherCAT fieldbus users are:
• 0x1000: This is where fixed identity information for the device is stored, including name, manufacturer,
serial number etc., plus information about the current and available process data configurations.
• 0x8000: This is where the operational and functional parameters for all channels are stored, such as
filter settings or output frequency.
Other important ranges are:
• 0x4000: In some EtherCAT devices the channel parameters are stored here (as an alternative to the
0x8000 range).
• 0x6000: Input PDOs ("input" from the perspective of the EtherCAT master)
• 0x7000: Output PDOs ("output" from the perspective of the EtherCAT master)
Availability
Not every EtherCAT device must have a CoE list. Simple I/O modules without dedicated processor
usually have no variable parameters and therefore no CoE list.
If a device has a CoE list, it is shown in the TwinCAT System Manager as a separate tab with a listing of the
elements:
EL600x, EL602x 27Version: 4.6
Basics communication
Fig.16: "CoE Online " tab
The figure above shows the CoE objects available in device "EL2502", ranging from 0x1000 to 0x1600. The
subindices for 0x1018 are expanded.
Data management and function "NoCoeStorage"
Some parameters, particularly the setting parameters of the slave, are configurable and writeable. This can
be done in write or read mode
• via the System Manager (Fig. "CoE Online " tab) by clicking
This is useful for commissioning of the system/slaves. Click on the row of the index to be
parameterised and enter a value in the "SetValue" dialog.
• from the control system/PLC via ADS, e.g. through blocks from the TcEtherCAT.lib library
This is recommended for modifications while the system is running or if no System Manager or
operating staff are available.
Data management
If slave CoE parameters are modified online, Beckhoff devices store any changes in a fail-safe
manner in the EEPROM, i.e. the modified CoE parameters are still available after a restart.
The situation may be different with other manufacturers.
An EEPROM is subject to a limited lifetime with respect to write operations. From typically 100,000
write operations onwards it can no longer be guaranteed that new (changed) data are reliably saved
or are still readable. This is irrelevant for normal commissioning. However, if CoE parameters are
continuously changed via ADS at machine runtime, it is quite possible for the lifetime limit to be
reached. Support for the NoCoeStorage function, which suppresses the saving of changed CoE values, depends on the firmware version.
Please refer to the technical data in this documentation as to whether this applies to the respective
device.
• If the function is supported: the function is activated by entering the code word 0x12345678 once
in CoE 0xF008 and remains active as long as the code word is not changed. After switching the
device on it is then inactive. Changed CoE values are not saved in the EEPROM and can thus
be changed any number of times.
• Function is not supported: continuous changing of CoE values is not permissible in view of the
lifetime limit.
EL600x, EL602x28 Version: 4.6
Startup list
Changes in the local CoE list of the terminal are lost if the terminal is replaced. If a terminal is replaced with a new Beckhoff terminal, it will have the default settings. It is therefore advisable to link
all changes in the CoE list of an EtherCAT slave with the Startup list of the slave, which is processed whenever the EtherCAT fieldbus is started. In this way a replacement EtherCAT slave can
automatically be parameterized with the specifications of the user.
If EtherCAT slaves are used which are unable to store local CoE values permanently, the Startup
list must be used.
Recommended approach for manual modification of CoE parameters
• Make the required change in the System Manager
The values are stored locally in the EtherCAT slave
• If the value is to be stored permanently, enter it in the Startup list.
The order of the Startup entries is usually irrelevant.
Basics communication
Fig.17: 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.
EL600x, EL602x 29Version: 4.6
Basics communication
Fig.18: Offline list
• If the slave is online
◦ The actual current slave list is read. This may take several seconds, depending on the size and
cycle time.
◦ The actual identity is displayed
◦ The firmware and hardware version of the equipment according to the electronic information is
displayed
◦ Online is shown in green.
Fig.19: Online list
EL600x, EL602x30 Version: 4.6
Basics communication
Channel-based order
The CoE list is available in EtherCAT devices that usually feature several functionally equivalent channels.
For example, a 4-channel analog 0..10 V input terminal also has 4 logical channels and therefore 4 identical
sets of parameter data for the channels. In order to avoid having to list each channel in the documentation,
the placeholder "n" tends to be used for the individual channel numbers.
In the CoE system 16 indices, each with 255 subindices, are generally sufficient for representing all channel
parameters. The channel-based order is therefore arranged in 16
dec
/10
steps. The parameter range
hex
0x8000 exemplifies this:
• Channel 0: parameter range 0x8000:00 ... 0x800F:255
• Channel 1: parameter range 0x8010:00 ... 0x801F:255
• Channel 2: parameter range 0x8020:00 ... 0x802F:255
• ...
This is generally written as 0x80n0.
Detailed information on the CoE interface can be found in the EtherCAT system documentation on the
Beckhoff website.
EL600x, EL602x 31Version: 4.6
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.
EL600x, EL602x32 Version: 4.6
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.
ü Please ensure you are electrostatically discharged and avoid touching the contacts of the device di-
rectly.
a) Avoid contact with highly insulating materials (synthetic fibers, plastic film etc.).
b) Surroundings (working place, packaging and personnel) should by grounded probably, when handling
with the devices.
c) Each assembly must be terminated at the right hand end with an EL9011 or EL9012 bus end cap, to en-
sure the protection class and ESD protection.
Fig.20: Spring contacts of the Beckhoff I/O components
4.2 EL6001, EL6021
4.2.1 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!
EL600x, EL602x 33Version: 4.6
Mounting and Wiring
Assembly
Fig.21: Attaching on mounting rail
The bus coupler and bus terminals are attached to commercially available 35mm mounting rails (DIN rails
according to EN60715) by applying slight pressure:
1. First attach the fieldbus coupler to the mounting rail.
2. The bus terminals are now attached on the right-hand side of the fieldbus coupler. Join the components with tongue and groove and push the terminals against the mounting rail, until the lock clicks
onto the mounting rail.
If the terminals are clipped onto the mounting rail first and then pushed together without tongue and
groove, the connection will not be operational! When correctly assembled, no significant gap should
be visible between the housings.
Fixing of mounting rails
The locking mechanism of the terminals and couplers extends to the profile of the mounting rail. At
the installation, the locking mechanism of the components must not come into conflict with the fixing
bolts of the mounting rail. To mount the mounting rails with a height of 7.5mm under the terminals
and couplers, you should use flat mounting connections (e.g. countersunk screws or blind rivets).
EL600x, EL602x34 Version: 4.6
Mounting and Wiring
Disassembly
Fig.22: Disassembling of terminal
Each terminal is secured by a lock on the mounting rail, which must be released for disassembly:
1. Pull the terminal by its orange-colored lugs approximately 1cm away from the mounting rail. In doing
so for this terminal the mounting rail lock is released automatically and you can pull the terminal out of
the bus terminal block easily without excessive force.
2. Grasp the released terminal with thumb and index finger simultaneous at the upper and lower grooved
housing surfaces and pull the terminal out of the bus terminal block.
Connections within a bus terminal block
The electric connections between the Bus Coupler and the Bus Terminals are automatically realized by
joining the components:
• The six spring contacts of the K-Bus/E-Bus deal with the transfer of the data and the supply of the Bus
Terminal electronics.
• The power contacts deal with the supply for the field electronics and thus represent a supply rail within
the bus terminal block. The power contacts are supplied via terminals on the Bus Coupler (up to 24V)
or for higher voltages via power feed terminals.
Power Contacts
During the design of a bus terminal block, the pin assignment of the individual Bus Terminals must
be taken account of, since some types (e.g. analog Bus Terminals or digital 4-channel Bus Terminals) do not or not fully loop through the power contacts. Power Feed Terminals (KL91xx, KL92xx
or EL91xx, EL92xx) interrupt the power contacts and thus represent the start of a new supply rail.
PE power contact
The power contact labeled PE can be used as a protective earth. For safety reasons this contact mates first
when plugging together, and can ground short-circuit currents of up to 125A.
EL600x, EL602x 35Version: 4.6
Mounting and Wiring
Fig.23: Power contact on left side
NOTE
Possible damage of the device
Note that, for reasons of electromagnetic compatibility, the PE contacts are capacitatively coupled to the
mounting rail. This may lead to incorrect results during insulation testing or to damage on the terminal (e.g.
disruptive discharge to the PE line during insulation testing of a consumer with a nominal voltage of 230V).
For insulation testing, disconnect the PE supply line at the Bus Coupler or the Power Feed Terminal! In order to decouple further feed points for testing, these Power Feed Terminals can be released and pulled at
least 10mm from the group of terminals.
WARNING
Risk of electric shock!
The PE power contact must not be used for other potentials!
4.2.2 Connection
4.2.2.1 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.
EL600x, EL602x36 Version: 4.6
Standard wiring (ELxxxx / KLxxxx)
Fig.24: 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)
Mounting and Wiring
Fig.25: Pluggable wiring
The terminals of ESxxxx and KSxxxx series feature a pluggable connection level.
The assembly and wiring procedure is the same as for the ELxxxx and KLxxxx series.
The pluggable connection level enables the complete wiring to be removed as a plug connector from the top
of the housing for servicing.
The lower section can be removed from the terminal block by pulling the unlocking tab.
Insert the new component and plug in the connector with the wiring. This reduces the installation time and
eliminates the risk of wires being mixed up.
The familiar dimensions of the terminal only had to be changed slightly. The new connector adds about 3
mm. The maximum height of the terminal remains unchanged.
A tab for strain relief of the cable simplifies assembly in many applications and prevents tangling of individual
connection wires when the connector is removed.
Conductor cross sections between 0.08mm2 and 2.5mm2 can continue to be used with the proven spring
force technology.
The overview and nomenclature of the product names for ESxxxx and KSxxxx series has been retained as
known from ELxxxx and KLxxxx series.
High Density Terminals (HD Terminals)
Fig.26: High Density Terminals
The Bus Terminals from these series with 16 terminal points are distinguished by a particularly compact
design, as the packaging density is twice as large as that of the standard 12mm Bus Terminals. Massive
conductors and conductors with a wire end sleeve can be inserted directly into the spring loaded terminal
point without tools.
EL600x, EL602x 37Version: 4.6
Mounting and Wiring
Wiring HD Terminals
The High Density (HD) Terminals of the ELx8xx and KLx8xx series doesn't support pluggable
wiring.
Ultrasonically "bonded" (ultrasonically welded) conductors
Ultrasonically “bonded" conductors
It is also possible to connect the Standard and High Density Terminals with ultrasonically
"bonded" (ultrasonically welded) conductors. In this case, please note the tables concerning the
wire-size width below!
4.2.2.2 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.27: 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.
EL600x, EL602x38 Version: 4.6
Mounting and Wiring
Terminal housing ELxxxx, KLxxxx ESxxxx, KSxxxx
Wire size width (single core wires) 0.08 ... 2.5mm
Wire size width (fine-wire conductors) 0.08 ... 2.5mm
Wire size width (conductors with a wire end sleeve) 0.14 ... 1.5mm
2
2
2
0.08 ... 2.5mm
0,08 ... 2.5mm
0.14 ... 1.5mm
2
2
2
Wire stripping length 8 ... 9mm 9 ... 10mm
High Density Terminals (HD Terminals [}37]) 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.
Terminal housing High Density Housing
Wire size width (single core wires) 0.08 ... 1.5mm
Wire size width (fine-wire conductors) 0.25 ... 1.5mm
Wire size width (conductors with a wire end sleeve) 0.14 ... 0.75mm
Wire size width (ultrasonically “bonded" conductors) only 1.5mm
2
2
2
2
Wire stripping length 8 ... 9mm
4.2.2.3 Shielding
Shielding
Encoder, analog sensors and actors should always be connected with shielded, twisted paired
wires.
EL600x, EL602x 39Version: 4.6
Mounting and Wiring
4.2.3 Positioning of passive Terminals
Hint for positioning of passive terminals in the bus terminal block
EtherCAT Terminals (ELxxxx / ESxxxx), which do not take an active part in data transfer within the
bus terminal block are so called passive terminals. The passive terminals have no current consumption out of the E-Bus.
To ensure an optimal data transfer, you must not directly string together more than 2 passive terminals!
Examples for positioning of passive terminals (highlighted)
Fig.28: Correct positioning
Fig.29: Incorrect positioning
EL600x, EL602x40 Version: 4.6
4.2.4 LEDs and terminal connector assignments
LEDs
Mounting and Wiring
Fig.30: EL6001, EL6021 - LEDs and Connection
LED Color Meaning
RUN Green This LED indicates the terminal's operating state:
Off
flashing State of the EtherCAT state machine: PREOP = function for mailbox
Single flash
On State of the EtherCAT State Machine: OP = normal operating state;
TxD Green State of the transmit signal line (on: HI signal level on transmit line)
RxD Green State of the receive signal line (on: HI signal level on receive line)
State of the EtherCAT State Machine [}25]: INIT = initialization of the
terminal or BOOTSTRAP = function for firmware updates [}187] of the
terminal
communication and variant standard settings
State of the EtherCAT state machine: SAFEOP = verification of the Sync
Manager [}105] channels and the distributed clocks.
Outputs remain in safe state
mailbox and process data communication is possible
EL600x, EL602x 41Version: 4.6
Mounting and Wiring
Connection
Fig.31: EL6001, EL6021 - LEDs and Connection
EL6001 terminal connector assignments
Terminal point Name Signal
1 TxD Signal line (Transmit Data)
5 RxD Signal line (Receive Data)
2 RTS Control line (Request To Send)
6 CTS Control line (Clear To Send)
3 GND Ground (internally bridged with terminal 7)
7 GND Ground (internally bridged with terminal 3)
4 Shield Shield (internally bridged with terminal 8)
8 Shield Shield (internally bridged with terminal 4)
EL6021 terminal connector assignments
Terminal point Name Signal
1 TxD+ Signal line + (Transmit Data)
5 TxD- Signal line - (Transmit Data)
2 RxD+ Signal line + (Receive Data)
6 RxD- Signal line - (Receive Data)
3 GND Ground (internally bridged with terminal 7)
7 GND Ground (internally bridged with terminal 3)
4 Shield Shield (internally bridged with terminal 8)
8 Shield Shield (internally bridged with terminal 4)
EL600x, EL602x42 Version: 4.6
Mounting and Wiring
Connection for RS422 transfer
In RS422 mode, data can be transferred in full duplex mode. Only point to point connections can be
established.
Fig.32: Connection for RS422 transfer
Connection for RS485 transfer
In RS485 mode, data are exchanged in half duplex mode. A bus structure can be created in this mode of
operation.
Fig.33: Connection for RS485 transfer
The transmit and receive lines are connected to one another in RS485 operating mode. As a result, the
terminal receives not only the data from other devices, but also its own transmitted data. This can be
suppressed with the index 0x8000:06 “Enable half duplex” in the Settings object.
In operating mode RS485, the reception of new data is only possible if transmission is complete.
“Enable half duplex” “Enable point to
point connection
(RS422)”
0 0 RS485:
0 1 RS422:
1 0 RS485:
1 1 RS422:
Mode
The terminal receives its own data and the data from other
devices
Normal operating mode; the terminal operates in full duplex
mode.
The terminal only receives data from other devices
The receiver is only enabled after the last data has been
transmitted.
4.3 EL6002, EL6022
4.3.1 Mounting and demounting - terminals with front unlocking
The terminal modules are fastened to the assembly surface with the aid of a 35 mm mounting rail (e.g.
mounting rail TH 35-15).
EL600x, EL602x 43Version: 4.6
Mounting and Wiring
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 recommended mounting rails under the terminals and couplers, you should use flat mounting connections (e.g. countersunk screws or blind rivets).
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!
Mounting
• Fit the mounting rail to the planned assembly location.
and press (1) the terminal module against the mounting rail until it latches in place on the mounting
rail (2).
• Attach the cables.
Demounting
• Remove all the cables.
• Lever the unlatching hook back with thumb and forefinger (3). An internal mechanism pulls the two
latching lugs (3a) from the top hat rail back into the terminal module.
EL600x, EL602x44 Version: 4.6
Mounting and Wiring
• Pull (4) the terminal module away from the mounting surface.
Avoid canting of the module; you should stabilize the module with the other hand, if required.
4.3.2 Recommended mounting rails
Terminal Modules und EtherCAT Modules of KMxxxx and EMxxxx series, same as the terminals of the
EL66xx and EL67xx series can be snapped onto the following recommended mounting rails:
DIN Rail TH 35-7.5 with 1 mm material thickness (according to EN 60715)
DIN Rail TH 35-15 with 1,5 mm material thickness
Pay attention to the material thickness of the DIN Rail
Terminal Modules und EtherCAT Modules of KMxxxx and EMxxxx series, same as the terminals of
the EL66xx and EL67xx series does not fit to the DIN Rail TH 35-15 with 2,2 to 2,5 mm material
thickness (according to EN 60715)!
EL600x, EL602x 45Version: 4.6
Mounting and Wiring
4.3.3 LEDs and pin assignment
Fig.34: EL6002, EL6022 - LEDs
LEDs
LED Color Meaning
RUN Green This LED indicates the terminal's operating state:
Off
flashing State of the EtherCAT State Machine: PREOP = function for mailbox
Single flash
On State of the EtherCAT State Machine: OP = normal operating state; mailbox
TxCh. 1 Orange Serial port at this connection sends data (channel 1)
RxCh. 1 Green Serial port at this connection receives data (channel 1)
TxCh. 2 Orange Serial port at this connection sends data (channel 2)
RxCh. 2 Green Serial port at this connection receives data (channel 2)
State of the EtherCAT State Machine [}25]: INIT = initialization of the
terminal or BOOTSTRAP = function for firmware updates [}187] of the
terminal
communication and variant standard settings
State of the EtherCAT State Machine: SAFEOP = verification of the Sync
Manager [}105] channels and the distributed clocks.
Outputs remain in safe state
and process data communication is possible
EL600x, EL602x46 Version: 4.6
EL6002 pin assignment
2 x D-Sub connector, male; 9-pin
Mounting and Wiring
D-Sub connector, male
(plan view)
GND connections
GND for both channels is internally connected via a high-resistance RC combination
Pin assignment channel 1 Pin assignment channel 2
Pin RS232 Pin RS232
1 DCD (internally bridged with
pins 4 and 6)
2 RxCH1 2 RxCH2
3 TxCH1 3 TxCH2
4 DTR (internally bridged with
pins 1 and 6)
5 GND 5 GND
6 DSR (internally bridged with
pins 1 and 4)
7 RTS CH1 7 RTS CH2
8 CTS CH1 8 CTS CH2
9 - 9 -
1 DCD (internally bridged with pins
4 and 6)
4 DTR (internally bridged with pins
1 and 6)
6 DSR (internally bridged with pins
1 and 4)
EL6022 pin assignment
2 x D-Sub connection socket, 9-pin
D-Sub connector, female
(plan view)
Pin assignment channel 1 Pin assignment channel 2
Pin RS485/RS422 Pin RS485/RS422
1 - 1 -
2 Tx+ CH1 2 Tx+ CH2
3 Rx+ CH1 3 Rx+ CH2
4 - 4 -
5 GND 5 GND
6 +5V 6 +5V
7 Tx- CH1 7 Tx- CH2
8 Rx- CH1 8 Rx- CH2
9 - 9 -
GND connections
GND for both channels is internally connected via a high-resistance RC combination
EL600x, EL602x 47Version: 4.6
Mounting and Wiring
Connection for RS422 transfer
In RS422 mode, data can be transferred in full duplex mode. Only point to point connections can be
established.
Fig.35: Connection for RS422 transfer
Connection for RS485 transfer
In RS485 mode, data are exchanged in half duplex mode. A bus structure can be created in this mode of
operation.
Fig.36: Connection for RS485 transfer
The transmit and receive lines are connected to one another in RS485 operating mode. As a result, the
terminal receives not only the data from other devices, but also its own transmitted data. This can be
suppressed with the index 0x8000:06 “Enable half duplex” in the Settings object.
In operating mode RS485, the reception of new data is only possible if transmission is complete.
“Enable half duplex” “Enable point to
point connection
(RS422)”
0 0 RS485:
0 1 RS422:
1 0 RS485:
1 1 RS422:
Mode
The terminal receives its own data and the data from other
devices
Normal operating mode; the terminal operates in full duplex
mode.
The terminal only receives data from other devices
The receiver is only enabled after the last data has been
transmitted.
EL600x, EL602x48 Version: 4.6
4.4 Positioning of passive Terminals
Hint for positioning of passive terminals in the bus terminal block
EtherCAT Terminals (ELxxxx / ESxxxx), which do not take an active part in data transfer within the
bus terminal block are so called passive terminals. The passive terminals have no current consumption out of the E-Bus.
To ensure an optimal data transfer, you must not directly string together more than 2 passive terminals!
Examples for positioning of passive terminals (highlighted)
Mounting and Wiring
Fig.37: Correct positioning
Fig.38: Incorrect positioning
EL600x, EL602x 49Version: 4.6
Mounting and Wiring
4.5 Installation instructions for enhanced mechanical load capacity
WARNING
Risk of injury through electric shock and damage to the device!
Bring the Bus Terminal system into a safe, de-energized state before starting mounting, disassembly or
wiring of the Bus Terminals!
Additional checks
The terminals have undergone the following additional tests:
Verification Explanation
Vibration 10 frequency runs in 3 axes
6 Hz < f < 60 Hz displacement 0.35 mm, constant amplitude
60.1Hz<f<500Hz acceleration 5g, constant amplitude
Shocks 1000 shocks in each direction, in 3 axes
25 g, 6 ms
Additional installation instructions
For terminals with enhanced mechanical load capacity, the following additional installation instructions apply:
• The enhanced mechanical load capacity is valid for all permissible installation positions
• Use a mounting rail according to EN 60715 TH35-15
• Fix the terminal segment on both sides of the mounting rail with a mechanical fixture, e.g. an earth
terminal or reinforced end clamp
• The maximum total extension of the terminal segment (without coupler) is:
64 terminals (12 mm mounting with) or 32 terminals (24 mm mounting with)
• Avoid deformation, twisting, crushing and bending of the mounting rail during edging and installation of
the rail
• The mounting points of the mounting rail must be set at 5 cm intervals
• Use countersunk head screws to fasten the mounting rail
• The free length between the strain relief and the wire connection should be kept as short as possible. A
distance of approx. 10 cm should be maintained to the cable duct.
EL600x, EL602x50 Version: 4.6
Mounting and Wiring
4.6 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.39: 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.
EL600x, EL602x 51Version: 4.6
Mounting and Wiring
Fig.40: Other installation positions
EL600x, EL602x52 Version: 4.6
Mounting and Wiring
4.7 UL notice
Application
Beckhoff EtherCAT modules are intended for use with Beckhoff’s UL Listed EtherCAT System only.
Examination
For cULus examination, the Beckhoff I/O System has only been investigated for risk of fire
and electrical shock (in accordance with UL508 and CSAC22.2 No.142).
For devices with Ethernet connectors
Not for connection to telecommunication circuits.
Basic principles
Two UL certificates are met in the Beckhoff EtherCAT product range, depending upon the components:
1. UL certification according to UL508. Devices with this kind of certification are marked by this sign:
2. UL certification according to UL508 with limited power consumption. The current consumed by the device is limited to a max. possible current consumption of 4A. Devices with this kind of certification are
marked by this sign:
Almost all current EtherCAT products (as at 2010/05) are UL certified without restrictions.
Application
If terminals certified with restrictions are used, then the current consumption at 24VDC must be limited
accordingly by means of supply
• from an isolated source protected by a fuse of max. 4A (according to UL248) or
• from a voltage supply complying with NECclass2.
A voltage source complying with NECclass2 may not be connected in series or parallel with another
NECclass2compliant voltage supply!
These requirements apply to the supply of all EtherCAT bus couplers, power adaptor terminals, Bus
Terminals and their power contacts.
EL600x, EL602x 53Version: 4.6
Mounting and Wiring
4.8 ATEX - Special conditions (extended temperature range)
WARNING
Observe the special conditions for the intended use of Beckhoff fieldbus components with
extended temperature range (ET) in potentially explosive areas (directive 94/9/EU)!
• The certified components are to be installed in a suitable housing that guarantees a protection class of at
least IP54 in accordance with EN 60529! The environmental conditions during use are thereby to be
taken into account!
• If the temperatures during rated operation are higher than 70°C at the feed-in points of cables, lines or
pipes, or higher than 80°C at the wire branching points, then cables must be selected whose temperature data correspond to the actual measured temperature values!
• Observe the permissible ambient temperature range of -25 to 60°C for the use of Beckhoff fieldbus components with extended temperature range (ET) in potentially explosive areas!
• Measures must be taken to protect against the rated operating voltage being exceeded by more than
40% due to short-term interference voltages!
• The individual terminals may only be unplugged or removed from the Bus Terminal system if the supply
voltage has been switched off or if a non-explosive atmosphere is ensured!
• The connections of the certified components may only be connected or disconnected if the supply voltage has been switched off or if a non-explosive atmosphere is ensured!
• The fuses of the KL92xx/EL92xx power feed terminals may only be exchanged if the supply voltage has
been switched off or if a non-explosive atmosphere is ensured!
• Address selectors and ID switches may only be adjusted if the supply voltage has been switched off or if
a non-explosive atmosphere is ensured!
Standards
The fundamental health and safety requirements are fulfilled by compliance with the following standards:
• EN 60079-0:2012+A11:2013
• EN 60079-15:2010
Marking
The Beckhoff fieldbus components with extended temperature range (ET) certified for potentially explosive
areas bear the following marking:
II 3GKEMA 10ATEX0075 X Ex nA IIC T4 GcTa: -25…60°C
or
II 3GKEMA 10ATEX0075 X Ex nC IIC T4 GcTa: -25…60°C
EL600x, EL602x54 Version: 4.6
4.9 ATEX Documentation
Notes about operation of the Beckhoff terminal systems in potentially explosive areas (ATEX)
Pay also attention to the continuative documentation
Notes about operation of the Beckhoff terminal systems in potentially explosive areas (ATEX)
that is available in the download area of the Beckhoff homepage http:\\www.beckhoff.com!
Mounting and Wiring
EL600x, EL602x 55Version: 4.6
Commissioning
5 Commissioning
5.1 TwinCAT Quick Start
TwinCAT is a development environment for real-time control including multi-PLC system, NC axis control,
programming and operation. The whole system is mapped through this environment and enables access to a
programming environment (including compilation) for the controller. Individual digital or analog inputs or
outputs can also be read or written directly, in order to verify their functionality, for example.
For further information please refer to http://infosys.beckhoff.com:
• EtherCAT Systemmanual:
Fieldbus Components → EtherCAT Terminals → EtherCAT System Documentation → Setup in the
TwinCAT System Manager
• TwinCAT2 → TwinCAT System Manager → I/O - Configuration
• In particular, TwinCAT driver installation:
Fieldbus components → Fieldbus Cards and Switches → FC900x – PCI Cards for Ethernet →
Installation
Devices contain the terminals for the actual configuration. All configuration data can be entered directly via
editor functions (offline) or via the "Scan" function (online):
• "offline": The configuration can be customized by adding and positioning individual components.
These can be selected from a directory and configured.
◦ The procedure for offline mode can be found under http://infosys.beckhoff.com:
TwinCAT2 → TwinCAT System Manager → IO - Configuration → Adding an I/O Device
• "online": The existing hardware configuration is read
◦ See also http://infosys.beckhoff.com:
Fieldbus components → Fieldbus cards and switches → FC900x – PCI Cards for Ethernet →
Installation → Searching for devices
The following relationship is envisaged from user PC to the individual control elements:
EL600x, EL602x56 Version: 4.6
Commissioning
Fig.41: Relationship between user side (commissioning) and installation
The user inserting of certain components (I/O device, terminal, box...) is the same in TwinCAT2 and
TwinCAT3. The descriptions below relate to the online procedure.
Sample configuration (actual configuration)
Based on the following sample configuration, the subsequent subsections describe the procedure for
TwinCAT2 and TwinCAT3:
• Control system (PLC) CX2040 including CX2100-0004 power supply unit
• Connected to the CX2040 on the right (E-bus):
EL1004 (4-channel analog input terminal -10…+10V)
• Linked via the X001 port (RJ-45): EK1100 EtherCAT Coupler
• Connected to the EK1100 EtherCAT coupler on the right (E-bus):
EL2008 (8-channel digital output terminal 24VDC;0.5A)
• (Optional via X000: a link to an external PC for the user interface)
EL600x, EL602x 57Version: 4.6
Commissioning
Fig.42: Control configuration with Embedded PC, input (EL1004) and output (EL2008)
Note that all combinations of a configuration are possible; for example, the EL1004 terminal could also be
connected after the coupler, or the EL2008 terminal could additionally be connected to the CX2040 on the
right, in which case the EK1100 coupler wouldn’t be necessary.
5.1.1 TwinCAT2
Startup
TwinCAT basically uses two user interfaces: the TwinCAT System Manager for communication with the
electromechanical components and TwinCAT PLC Control for the development and compilation of a
controller. The starting point is the TwinCAT System Manager.
After successful installation of the TwinCAT system on the PC to be used for development, the TwinCAT2
System Manager displays the following user interface after startup:
Fig.43: Initial TwinCAT2 user interface
EL600x, EL602x58 Version: 4.6
Commissioning
Generally, TwinCAT can be used in local or remote mode. Once the TwinCAT system including the user
interface (standard) is installed on the respective PLC, TwinCAT can be used in local mode and thereby the
next step is "Insert Device [}60]".
If the intention is to address the TwinCAT runtime environment installed on a PLC as development
environment remotely from another system, the target system must be made known first. In the menu under
"Actions" → "Choose Target System...", via the symbol " " or the "F8" key, open the following window:
Fig.44: Selection of the target system
Use "Search (Ethernet)..." to enter the target system. Thus a next dialog opens to either:
• enter the known computer name after "Enter Host Name / IP:" (as shown in red)
• perform a "Broadcast Search" (if the exact computer name is not known)
• enter the known computer IP or AmsNetID.
Fig.45: Specify the PLC for access by the TwinCAT System Manager: selection of the target system
Once the target system has been entered, it is available for selection as follows (a password may have to be
entered):
EL600x, EL602x 59Version: 4.6
Commissioning
After confirmation with "OK" the target system can be accessed via the System Manager.
Adding devices
In the configuration tree of the TwinCAT2 System Manager user interface on the left, select "I/ODevices”
and then right-click to open a context menu and select "ScanDevices…", or start the action in the menu bar
via . The TwinCAT System Manager may first have to be set to "Configmode" via or via menu
“Actions" → "Set/Reset TwinCAT to Config Mode…" (Shift + F4).
Fig.46: Select "Scan Devices..."
Confirm the warning message, which follows, and select "EtherCAT" in the dialog:
Fig.47: Automatic detection of I/O devices: selection the devices to be integrated
Confirm the message "Find new boxes", in order to determine the terminals connected to the devices. "Free
Run" enables manipulation of input and output values in "Config mode" and should also be acknowledged.
Based on the sample configuration [}57] described at the beginning of this section, the result is as follows:
EL600x, EL602x60 Version: 4.6
Commissioning
Fig.48: Mapping of the configuration in the TwinCAT2 System Manager
The whole process consists of two stages, which may be performed separately (first determine the devices,
then determine the connected elements such as boxes, terminals, etc.). A scan can also be initiated by
selecting "Device ..." from the context menu, which then reads the elements present in the configuration
below:
Fig.49: Reading of individual terminals connected to a device
This functionality is useful if the actual configuration is modified at short notice.
Programming and integrating the PLC
TwinCAT PLC Control is the development environment for the creation of the controller in different program
environments: TwinCAT PLC Control supports all languages described in IEC 61131-3. There are two textbased languages and three graphical languages.
• Text-based languages
◦ Instruction List (IL)
◦ Structured Text (ST)
EL600x, EL602x 61Version: 4.6
Commissioning
• Graphical languages
◦ Function Block Diagram (FBD)
◦ Ladder Diagram (LD)
◦ The Continuous Function Chart Editor (CFC)
◦ Sequential Function Chart (SFC)
The following section refers to Structured Text (ST).
After starting TwinCAT PLC Control, the following user interface is shown for an initial project:
Fig.50: TwinCAT PLC Control after startup
Sample variables and a sample program have been created and stored under the name "PLC_example.pro":
EL600x, EL602x62 Version: 4.6
Commissioning
Fig.51: Sample program with variables after a compile process (without variable integration)
Warning 1990 (missing "VAR_CONFIG") after a compile process indicates that the variables defined as
external (with the ID "AT%I*" or "AT%Q*") have not been assigned. After successful compilation, TwinCAT
PLC Control creates a "*.tpy" file in the directory in which the project was stored. This file (*.tpy) contains
variable assignments and is not known to the System Manager, hence the warning. Once the System
Manager has been notified, the warning no longer appears.
First, integrate the TwinCAT PLC Control project in the System Manager via the context menu of the PLC
configuration; right-click and select "Append PLC Project…":
Fig.52: Appending the TwinCAT PLC Control project
EL600x, EL602x 63Version: 4.6
Commissioning
Select the PLC configuration "PLC_example.tpy" in the browser window that opens. The project including the
two variables identified with "AT" are then integrated in the configuration tree of the System Manager:
Fig.53: PLC project integrated in the PLC configuration of the System Manager
The two variables "bEL1004_Ch4" and "nEL2008_value" can now be assigned to certain process objects of
the I/O configuration.
Assigning variables
Open a window for selecting a suitable process object (PDO) via the context menu of a variable of the
integrated project "PLC_example" and via "Modify Link..." "Standard":
Fig.54: Creating the links between PLC variables and process objects
In the window that opens, the process object for the variable “bEL1004_Ch4” of type BOOL can be selected
from the PLC configuration tree:
EL600x, EL602x64 Version: 4.6
Commissioning
Fig.55: Selecting PDO of type BOOL
According to the default setting, certain PDO objects are now available for selection. In this sample the input
of channel 4 of the EL1004 terminal is selected for linking. In contrast, the checkbox "All types" must be
ticked for creating the link for the output variables, in order to allocate a set of eight separate output bits to a
byte variable. The following diagram shows the whole process:
Fig.56: Selecting several PDOs simultaneously: activate "Continuous" and "All types"
Note that the "Continuous" checkbox was also activated. This is designed to allocate the bits contained in the
byte of the variable "nEL2008_value" sequentially to all eight selected output bits of the EL2008 terminal. In
this way it is possible to subsequently address all eight outputs of the terminal in the program with a byte
corresponding to bit 0 for channel 1 to bit 7 for channel 8 of the PLC. A special symbol ( ) at the yellow or
red object of the variable indicates that a link exists. The links can also be checked by selecting a "Goto Link
Variable” from the context menu of a variable. The object opposite, in this case the PDO, is automatically
selected:
EL600x, EL602x 65Version: 4.6
Commissioning
Fig.57: Application of a "Goto Link" variable, using "MAIN.bEL1004_Ch4" as a sample
The process of assigning variables to the PDO is completed via the menu selection "Actions" → "Generate
Mappings”, key Ctrl+M or by clicking on the symbol in the menu.
This can be visualized in the configuration:
The process of creating links can also take place in the opposite direction, i.e. starting with individual PDOs
to variable. However, in this example it would then not be possible to select all output bits for the EL2008,
since the terminal only makes individual digital outputs available. If a terminal has a byte, word, integer or
similar PDO, it is possible to allocate this a set of bit-standardised variables (type "BOOL"). Here, too, a
"Goto Link Variable” from the context menu of a PDO can be executed in the other direction, so that the
respective PLC instance can then be selected.
Activation of the configuration
The allocation of PDO to PLC variables has now established the connection from the controller to the inputs
and outputs of the terminals. The configuration can now be activated. First, the configuration can be verified
via (or via "Actions" → "Check Configuration”). If no error is present, the configuration can be
activated via (or via "Actions" → "Activate Configuration…") to transfer the System Manager settings
to the runtime system. Confirm the messages "Old configurations are overwritten!" and "Restart TwinCAT
system in Run mode" with "OK".
A few seconds later the real-time status is displayed at the bottom right in the System Manager.
The PLC system can then be started as described below.
Starting the controller
Starting from a remote system, the PLC control has to be linked with the Embedded PC over Ethernet via
"Online" → “Choose Run-Time System…":
EL600x, EL602x66 Version: 4.6
Commissioning
Fig.58: Choose target system (remote)
In this sample "Runtime system 1 (port 801)" is selected and confirmed. Link the PLC with the real-time
system via menu option "Online" → "Login", the F11 key or by clicking on the symbol .The control
program can then be loaded for execution. This results in the message "No program on the controller!
Should the new program be loaded?", which should be acknowledged with "Yes". The runtime environment
is ready for the program start:
EL600x, EL602x 67Version: 4.6
Commissioning
Fig.59: PLC Control logged in, ready for program startup
The PLC can now be started via "Online" → "Run", F5 key or .
5.1.2 TwinCAT 3
Startup
TwinCAT makes the development environment areas available together with Microsoft Visual Studio: after
startup, the project folder explorer appears on the left in the general window area (cf. "TwinCAT System
Manager" of TwinCAT2) for communication with the electromechanical components.
After successful installation of the TwinCAT system on the PC to be used for development, TwinCAT3
(shell) displays the following user interface after startup:
EL600x, EL602x68 Version: 4.6
Commissioning
Fig.60: Initial TwinCAT3 user interface
First create a new project via (or under "File"→“New"→ "Project…"). In the
following dialog make the corresponding entries as required (as shown in the diagram):
Fig.61: Create new TwinCAT project
The new project is then available in the project folder explorer:
EL600x, EL602x 69Version: 4.6
Commissioning
Fig.62: New TwinCAT3 project in the project folder explorer
Generally, TwinCAT can be used in local or remote mode. Once the TwinCAT system including the user
interface (standard) is installed on the respective PLC, TwinCAT can be used in local mode and thereby the
next step is "Insert Device [}71]".
If the intention is to address the TwinCAT runtime environment installed on a PLC as development
environment remotely from another system, the target system must be made known first. Via the symbol in
the menu bar:
expand the pull-down menu:
and open the following window:
Fig.63: Selection dialog: Choose the target system
EL600x, EL602x70 Version: 4.6
Use "Search (Ethernet)..." to enter the target system. Thus a next dialog opens to either:
• enter the known computer name after "Enter Host Name / IP:" (as shown in red)
• perform a "Broadcast Search" (if the exact computer name is not known)
• enter the known computer IP or AmsNetID.
Commissioning
Fig.64: Specify the PLC for access by the TwinCAT System Manager: selection of the target system
Once the target system has been entered, it is available for selection as follows (a password may have to be
entered):
After confirmation with "OK" the target system can be accessed via the Visual Studio shell.
Adding devices
In the project folder explorer of the Visual Studio shell user interface on the left, select "Devices" within
element “I/O”, then right-click to open a context menu and select "Scan" or start the action via in the
menu bar. The TwinCAT System Manager may first have to be set to "Config mode" via or via the
menu "TwinCAT" → "Restart TwinCAT (Config mode)".
Fig.65: Select "Scan"
Confirm the warning message, which follows, and select "EtherCAT" in the dialog:
EL600x, EL602x 71Version: 4.6
Commissioning
Fig.66: Automatic detection of I/O devices: selection the devices to be integrated
Confirm the message "Find new boxes", in order to determine the terminals connected to the devices. "Free
Run" enables manipulation of input and output values in "Config mode" and should also be acknowledged.
Based on the sample configuration [}57] described at the beginning of this section, the result is as follows:
Fig.67: Mapping of the configuration in VS shell of the TwinCAT3 environment
The whole process consists of two stages, which may be performed separately (first determine the devices,
then determine the connected elements such as boxes, terminals, etc.). A scan can also be initiated by
selecting "Device ..." from the context menu, which then reads the elements present in the configuration
below:
EL600x, EL602x72 Version: 4.6
Commissioning
Fig.68: Reading of individual terminals connected to a device
This functionality is useful if the actual configuration is modified at short notice.
Programming the PLC
TwinCAT PLC Control is the development environment for the creation of the controller in different program
environments: TwinCAT PLC Control supports all languages described in IEC 61131-3. There are two textbased languages and three graphical languages.
• Text-based languages
◦ Instruction List (IL)
◦ Structured Text (ST)
• Graphical languages
◦ Function Block Diagram (FBD)
◦ Ladder Diagram (LD)
◦ The Continuous Function Chart Editor (CFC)
◦ Sequential Function Chart (SFC)
The following section refers to Structured Text (ST).
In order to create a programming environment, a PLC subproject is added to the project sample via the
context menu of "PLC" in the project folder explorer by selecting "Add New Item….":
EL600x, EL602x 73Version: 4.6
Commissioning
Fig.69: Adding the programming environment in "PLC"
In the dialog that opens select "Standard PLC project" and enter "PLC_example" as project name, for
example, and select a corresponding directory:
Fig.70: Specifying the name and directory for the PLC programming environment
The "Main" program, which already exists by selecting "Standard PLC project", can be opened by doubleclicking on "PLC_example_project" in "POUs”. The following user interface is shown for an initial project:
EL600x, EL602x74 Version: 4.6
Commissioning
Fig.71: Initial "Main" program of the standard PLC project
To continue, sample variables and a sample program have now been created:
EL600x, EL602x 75Version: 4.6
Commissioning
Fig.72: Sample program with variables after a compile process (without variable integration)
The control program is now created as a project folder, followed by the compile process:
Fig.73: Start program compilation
The following variables, identified in the ST/ PLC program with "AT%", are then available in under
"Assignments" in the project folder explorer:
Assigning variables
Via the menu of an instance - variables in the "PLC” context, use the "Modify Link…" option to open a
window for selecting a suitable process object (PDO) for linking:
EL600x, EL602x76 Version: 4.6
Commissioning
Fig.74: Creating the links between PLC variables and process objects
In the window that opens, the process object for the variable "bEL1004_Ch4" of type BOOL can be selected
from the PLC configuration tree:
Fig.75: Selecting PDO of type BOOL
According to the default setting, certain PDO objects are now available for selection. In this sample the input
of channel 4 of the EL1004 terminal is selected for linking. In contrast, the checkbox "All types" must be
ticked for creating the link for the output variables, in order to allocate a set of eight separate output bits to a
byte variable. The following diagram shows the whole process:
EL600x, EL602x 77Version: 4.6
Commissioning
Fig.76: Selecting several PDOs simultaneously: activate "Continuous" and "All types"
Note that the "Continuous" checkbox was also activated. This is designed to allocate the bits contained in the
byte of the variable "nEL2008_value" sequentially to all eight selected output bits of the EL2008 terminal. In
this way it is possible to subsequently address all eight outputs of the terminal in the program with a byte
corresponding to bit 0 for channel 1 to bit 7 for channel 8 of the PLC. A special symbol ( ) at the yellow or
red object of the variable indicates that a link exists. The links can also be checked by selecting a "Goto Link
Variable” from the context menu of a variable. The object opposite, in this case the PDO, is automatically
selected:
Fig.77: Application of a "Goto Link" variable, using "MAIN.bEL1004_Ch4" as a sample
The process of creating links can also take place in the opposite direction, i.e. starting with individual PDOs
to variable. However, in this example it would then not be possible to select all output bits for the EL2008,
since the terminal only makes individual digital outputs available. If a terminal has a byte, word, integer or
similar PDO, it is possible to allocate this a set of bit-standardised variables (type "BOOL"). Here, too, a
"Goto Link Variable” from the context menu of a PDO can be executed in the other direction, so that the
respective PLC instance can then be selected.
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Activation of the configuration
The allocation of PDO to PLC variables has now established the connection from the controller to the inputs
and outputs of the terminals. The configuration can now be activated with or via the menu under
"TwinCAT" in order to transfer settings of the development environment to the runtime system. Confirm the
messages "Old configurations are overwritten!" and "Restart TwinCAT system in Run mode" with "OK". The
corresponding assignments can be seen in the project folder explorer:
A few seconds later the corresponding status of the Run mode is displayed in the form of a rotating symbol
at the bottom right of the VS shell development environment. The PLC system can then be started as
described below.
Starting the controller
Select the menu option "PLC" → "Login" or click on to link the PLC with the real-time system and load
the control program for execution. This results in the message "No program on the controller! Should the
new program be loaded?", which should be acknowledged with "Yes". The runtime environment is ready for
program start by click on symbol , the "F5" key or via "PLC" in the menu selecting “Start”. The started
programming environment shows the runtime values of individual variables:
Fig.78: TwinCAT development environment (VS shell): logged-in, after program startup
The two operator control elements for stopping and logout result in the required action
(accordingly also for stop "Shift + F5", or both actions can be selected via the PLC menu).
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5.2 TwinCAT Development Environment
The Software for automation TwinCAT (The Windows Control and Automation Technology) will be
distinguished into:
• TwinCAT2: System Manager (Configuration) & PLC Control (Programming)
• TwinCAT3: Enhancement of TwinCAT2 (Programming and Configuration takes place via a common
Development Environment)
Details:
• TwinCAT2:
◦ Connects I/O devices to tasks in a variable-oriented manner
◦ Connects tasks to tasks in a variable-oriented manner
◦ Supports units at the bit level
◦ Supports synchronous or asynchronous relationships
◦ Exchange of consistent data areas and process images
◦ Datalink on NT - Programs by open Microsoft Standards (OLE, OCX, ActiveX, DCOM+, etc.)
◦ Integration of IEC 61131-3-Software-SPS, Software- NC and Software-CNC within Windows
NT/2000/XP/Vista, Windows 7, NT/XP Embedded, CE
◦ Interconnection to all common fieldbusses
◦ More…
Additional features:
• TwinCAT3 (eXtended Automation):
◦ Visual-Studio®-Integration
◦ Choice of the programming language
◦ Supports object orientated extension of IEC 61131-3
◦ Usage of C/C++ as programming language for real time applications
◦ Connection to MATLAB®/Simulink®
◦ Open interface for expandability
◦ Flexible run-time environment
◦ Active support of Multi-Core- und 64-Bit-Operatingsystem
◦ Automatic code generation and project creation with the TwinCAT Automation Interface
◦ More…
Within the following sections commissioning of the TwinCAT Development Environment on a PC System for
the control and also the basically functions of unique control elements will be explained.
Please see further information to TwinCAT2 and TwinCAT3 at http://infosys.beckhoff.com.
5.2.1 Installation of the TwinCAT real-time driver
In order to assign real-time capability to a standard Ethernet port of an IPC controller, the Beckhoff real-time
driver has to be installed on this port under Windows.
This can be done in several ways. One option is described here.
In the System Manager call up the TwinCAT overview of the local network interfaces via Options → Show
Real Time Ethernet Compatible Devices.
EL600x, EL602x80 Version: 4.6
Fig.79: System Manager “Options” (TwinCAT2)
This have to be called up by the Menü “TwinCAT” within the TwinCAT3 environment:
Commissioning
Fig.80: Call up under VS Shell (TwinCAT3)
The following dialog appears:
Fig.81: 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” [}91] in order to view the compatible ethernet ports via its
EtherCAT properties (tab „Adapter“, button „Compatible Devices…“):
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Fig.82: EtherCAT device properties(TwinCAT2): click on „Compatible Devices…“ of tab “Adapter”
TwinCAT 3: the properties of the EtherCAT device can be opened by double click on “Device .. (EtherCAT)”
within the Solution Explorer under “I/O”:
After the installation the driver appears activated in the Windows overview for the network interface
(Windows Start → System Properties → Network)
Fig.83: Windows properties of the network interface
A correct setting of the driver could be:
EL600x, EL602x82 Version: 4.6
Fig.84: Exemplary correct driver setting for the Ethernet port
Other possible settings have to be avoided:
Commissioning
EL600x, EL602x 83Version: 4.6
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Fig.85: Incorrect driver settings for the Ethernet port
EL600x, EL602x84 Version: 4.6
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.86: TCP/IP setting for the Ethernet port
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5.2.2 Notes regarding ESI device description
Installation of the latest ESI device description
The TwinCAT EtherCAT master/System Manager needs the device description files for the devices to be
used in order to generate the configuration in online or offline mode. The device descriptions are contained
in the so-called ESI files (EtherCAT Slave Information) in XML format. These files can be requested from the
respective manufacturer and are made available for download. An *.xml file may contain several device
descriptions.
The ESI files for Beckhoff EtherCAT devices are available on the Beckhoff website.
The ESI files should be stored in the TwinCAT installation directory.
Default settings:
• TwinCAT2: C:\TwinCAT\IO\EtherCAT
• TwinCAT3: C:\TwinCAT\3.1\Config\Io\EtherCAT
The files are read (once) when a new System Manager window is opened, if they have changed since the
last time the System Manager window was opened.
A TwinCAT installation includes the set of Beckhoff ESI files that was current at the time when the TwinCAT
build was created.
For TwinCAT2.11/TwinCAT3 and higher, the ESI directory can be updated from the System Manager, if the
programming PC is connected to the Internet; by
• TwinCAT2: Option → “Update EtherCAT Device Descriptions”
• TwinCAT3: TwinCAT → EtherCAT Devices → “Update Device Descriptions (via ETG Website)…”
The TwinCAT ESI Updater [}90] 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.87: Identifier structure
The order identifier consisting of name + type (here: EL2521-0010) describes the device function. The
revision indicates the technical progress and is managed by Beckhoff. In principle, a device with a higher
revision can replace a device with a lower revision, unless specified otherwise, e.g. in the documentation.
Each revision has its own ESI description. See further notes [}9].
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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.88: OnlineDescription information window (TwinCAT2)
In TwinCAT3 a similar window appears, which also offers the Web update:
Fig.89: Information window OnlineDescription (TwinCAT3)
If possible, the Yes is to be rejected and the required ESI is to be requested from the device manufacturer.
After installation of the XML/XSD file the configuration process should be repeated.
NOTE
Changing the ‘usual’ configuration through a scan
ü If a scan discovers a device that is not yet known to TwinCAT, distinction has to be made between two
cases. Taking the example here of the EL2521-0000 in the revision 1019
a) no ESI is present for the EL2521-0000 device at all, either for the revision 1019 or for an older revision.
The ESI must then be requested from the manufacturer (in this case Beckhoff).
b) an ESI is present for the EL2521-0000 device, but only in an older revision, e.g. 1018 or 1017.
In this case an in-house check should first be performed to determine whether the spare parts stock allows the integration of the increased revision into the configuration at all. A new/higher revision usually
also brings along new features. If these are not to be used, work can continue without reservations with
the previous revision 1018 in the configuration. This is also stated by the Beckhoff compatibility rule.
Refer in particular to the chapter ‘General notes on the use of Beckhoff EtherCAT IO components’ and for
manual configuration to the chapter ‘Offline configuration creation’ [}91].
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.90: 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.91: Indication of an online recorded ESI of EL2521 as an example
If such ESI files are used and the manufacturer's files become available later, the file OnlineDescription.xml
should be deleted as follows:
• close all System Manager windows
• restart TwinCAT in Config mode
• delete "OnlineDescription0000...xml"
• restart TwinCAT System Manager
This file should not be visible after this procedure, if necessary press <F5> to update
OnlineDescription for TwinCAT3.x
In addition to the file described above "OnlineDescription0000...xml" , a so called EtherCAT cache
with new discovered devices is created by TwinCAT3.x, e.g. under Windows 7:
(Please note the language settings of the OS!)
You have to delete this file, too.
Faulty ESI file
If an ESI file is faulty and the System Manager is unable to read it, the System Manager brings up an
information window.
Fig.92: Information window for faulty ESI file (left: TwinCAT2; right: TwinCAT3)
EL600x, EL602x88 Version: 4.6
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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5.2.3 TwinCAT ESI Updater
For TwinCAT2.11 and higher, the System Manager can search for current Beckhoff ESI files automatically, if
an online connection is available:
Fig.93: Using the ESI Updater (>= TwinCAT2.11)
The call up takes place under:
“Options” → "Update EtherCAT Device Descriptions"
Selection under TwinCAT3:
Fig.94: Using the ESI Updater (TwinCAT3)
The ESI Updater (TwinCAT3) is a convenient option for automatic downloading of ESI data provided by
EtherCAT manufacturers via the Internet into the TwinCAT directory (ESI = EtherCAT slave information).
TwinCAT accesses the central ESI ULR directory list stored at ETG; the entries can then be viewed in the
Updater dialog, although they cannot be changed there.
The call up takes place under:
“TwinCAT“ → „EtherCAT Devices“ → “Update Device Description (via ETG Website)…“.
5.2.4 Distinction between Online and Offline
The distinction between online and offline refers to the presence of the actual I/O environment (drives,
terminals, EJ-modules). If the configuration is to be prepared in advance of the system configuration as a
programming system, e.g. on a laptop, this is only possible in “Offline configuration” mode. In this case all
components have to be entered manually in the configuration, e.g. based on the electrical design.
If the designed control system is already connected to the EtherCAT system and all components are
energised and the infrastructure is ready for operation, the TwinCAT configuration can simply be generated
through “scanning” from the runtime system. This is referred to as online configuration.
In any case, during each startup the EtherCAT master checks whether the slaves it finds match the
configuration. This test can be parameterised in the extended slave settings. Refer to note “Installation of
the latest ESI-XML device description” [}86].
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 [}96] (Ethernet port at the IPC)
• detecting the connected EtherCAT devices [}97]. This step can be carried out independent of the
preceding step
• troubleshooting [}100]
The scan with existing configuration [}101] can also be carried out for comparison.
5.2.5 OFFLINE configuration creation
Creating the EtherCAT device
Create an EtherCAT device in an empty System Manager window.
Fig.95: Append EtherCAT device (left: TwinCAT2; right: TwinCAT3)
Select type ‘EtherCAT’ for an EtherCAT I/O application with EtherCAT slaves. For the present publisher/
subscriber service in combination with an EL6601/EL6614 terminal select “EtherCAT Automation Protocol
via EL6601”.
Fig.96: Selecting the EtherCAT connection (TwinCAT2.11, TwinCAT3)
Then assign a real Ethernet port to this virtual device in the runtime system.
Fig.97: 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 (TwinCAT2)”.
Fig.98: EtherCAT device properties (TwinCAT2)
TwinCAT 3: the properties of the EtherCAT device can be opened by double click on “Device .. (EtherCAT)”
within the Solution Explorer under “I/O”:
Selecting the Ethernet port
Ethernet ports can only be selected for EtherCAT devices for which the TwinCAT real-time driver is
installed. This has to be done separately for each port. Please refer to the respective installation
page [}80].
Defining EtherCAT slaves
Further devices can be appended by right-clicking on a device in the configuration tree.
Fig.99: Appending EtherCAT devices (left: TwinCAT2; right: TwinCAT3)
The dialog for selecting a new device opens. Only devices for which ESI files are available are displayed.
Only devices are offered for selection that can be appended to the previously selected device. Therefore the
physical layer available for this port is also displayed (Fig. “Selection dialog for new EtherCAT device”, A). In
the case of cable-based Fast-Ethernet physical layer with PHY transfer, then also only cable-based devices
are available, as shown in Fig. “Selection dialog for new EtherCAT device”. If the preceding device has
several free ports (e.g. EK1122 or EK1100), the required port can be selected on the right-hand side (A).
Overview of physical layer
• “Ethernet”: cable-based 100BASE-TX: EK couplers, EP boxes, devices with RJ45/M8/M12 connector
EL600x, EL602x92 Version: 4.6
• “E-Bus”: LVDS “terminal bus”, “EJ-module”: EL/ES terminals, various modular modules
The search field facilitates finding specific devices (since TwinCAT2.11 or TwinCAT3).
Commissioning
Fig.100: 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.101: 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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Commissioning
Fig.102: 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.103: 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 parameterised as
follows: linking with the task, CoE/DC settings, plug-in definition, startup settings, ...
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Fig.104: EtherCAT terminal in the TwinCAT tree (left: TwinCAT2; right: TwinCAT3)
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5.2.6 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 TwinCAT2 by a blue display “Config Mode” within the System Manager window: .
• on TwinCAT3 within the user interface of the development environment by a symbol .
TwinCAT can be set into this mode:
• TwinCAT2: by selection of in the Menubar or by “Actions” → “Set/Reset TwinCATtoConfig
Mode…”
• TwinCAT3: by selection of in the Menubar or by „TwinCAT“ → “RestartTwinCAT(ConfigMode)“
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 TwinCAT2 icon ( ) or TwinCAT3 icon ( ) within the Windows-Taskbar always shows the
TwinCAT mode of the local IPC. Compared to that, the System Manager window of TwinCAT2 or the user
interface of TwinCAT3 indicates the state of the target system.
Fig.105: Differentiation local/target system (left: TwinCAT2; right: TwinCAT3)
Right-clicking on “I/O Devices” in the configuration tree opens the search dialog.
Fig.106: Scan Devices (left: TwinCAT2; right: TwinCAT3)
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.107: Note for automatic device scan (left: TwinCAT2; right: TwinCAT3)
EL600x, EL602x96 Version: 4.6
Commissioning
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.108: 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 [}80].
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.109: 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
[}101] 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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Commissioning
Fig.110: 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 TwinCAT3 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 [}101] 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.111: 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.112: Scan query after automatic creation of an EtherCAT device (left: TwinCAT2; right: TwinCAT3)
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Commissioning
Fig.113: Manual triggering of a device scan on a specified EtherCAT device (left: TwinCAT2; right:
TwinCAT3)
In the System Manager (TwinCAT2) or the User Interface (TwinCAT3) the scan process can be monitored
via the progress bar at the bottom in the status bar.
Fig.114: Scan progressexemplary by TwinCAT2
The configuration is established and can then be switched to online state (OPERATIONAL).
Fig.115: Config/FreeRun query (left: TwinCAT2; right: TwinCAT3)
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.116: Displaying of “Free Run” and “Config Mode” toggling right below in the status bar
Fig.117: TwinCAT can also be switched to this state by using a button (left: TwinCAT2; right: TwinCAT3)
The EtherCAT system should then be in a functional cyclic state, as shown in Fig. “Online display example”.
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Fig.118: 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 [}91].
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.119: Faulty identification
In the System Manager such devices may be set up as EK0000 or unknown devices. Operation is not
possible or meaningful.
EL600x, EL602x100 Version: 4.6
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