Beckhoff EL6201 Documentation

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Documentation

EL6201

AS-Interface Master Terminal

2.2 2017-03-30

Version: Date:

Table of Contents

EL6201 3Version: 2.2

Table of Contents

1 Foreword ....................................................................................................................................................5

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

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

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

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

2 Product overview.....................................................................................................................................12

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

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

2.3 Technology ................................................................................................................................... 14

2.3.1 • AS-i requirements ..........................................................................................................14

2.3.2 Assembly using the piercing technology..........................................................................14

2.3.3 AS interface for every topology........................................................................................16

2.4 Start .............................................................................................................................................. 16

3 Basics communication ...........................................................................................................................17

3.1 EtherCAT basics........................................................................................................................... 17

3.2 EtherCAT cabling – wire-bound.................................................................................................... 17

3.3 General notes for setting the watchdog ........................................................................................ 18

3.4 EtherCAT State Machine .............................................................................................................. 20

3.5 CoE Interface................................................................................................................................ 22

4 Installation................................................................................................................................................27

4.1 Instructions for ESD protection ..................................................................................................... 27

4.2 Installation on mounting rails ........................................................................................................ 27

4.3 Installation instructions for enhanced mechanical load capacity .................................................. 30

4.4 Connection system ....................................................................................................................... 31

4.5 Prescribed installation position ..................................................................................................... 34

4.6 Mounting of Passive Terminals..................................................................................................... 35

4.7 LEDs and connection.................................................................................................................... 36

5 Commissioning........................................................................................................................................40

5.1 TwinCAT Quick Start .................................................................................................................... 40

5.1.1 TwinCAT2 .......................................................................................................................42

5.1.2 TwinCAT 3 .......................................................................................................................52

5.2 TwinCAT Development Environment............................................................................................ 64

5.2.1 Installation of the TwinCAT real-time driver .....................................................................64

5.2.2 Notes regarding ESI device description...........................................................................70

5.2.3 TwinCAT ESI Updater......................................................................................................74

5.2.4 Distinction between Online and Offline ............................................................................74

5.2.5 OFFLINE configuration creation ......................................................................................75

5.2.6 ONLINE configuration creation ........................................................................................80

5.2.7 EtherCAT subscriber configuration ..................................................................................88

5.3 General Notes - EtherCAT Slave Application ............................................................................... 98

5.4 Functionality of the AS-i master.................................................................................................. 106

5.4.1 AS-i status machine .......................................................................................................106

5.4.2 Lists................................................................................................................................107

5.4.3 Operating modes ...........................................................................................................107

5.4.4 Operating phases...........................................................................................................108

5.4.5 Address assignment of the AS-i slaves .........................................................................109

Table of Contents

EL62014 Version: 2.2

5.4.6 Automatic address assignment......................................................................................109

5.5 Quickstart.................................................................................................................................... 109

5.6 Further notes on commissioning................................................................................................. 124

5.7 Object description and parameterization .................................................................................... 130

5.7.1 Restore object................................................................................................................130

5.7.2 Configuration data..........................................................................................................130

5.7.3 Command object ...........................................................................................................134

5.7.4 Input data .......................................................................................................................137

5.7.5 Output data ....................................................................................................................137

5.7.6 Information data ............................................................................................................137

5.7.7 Diagnostic data .............................................................................................................138

5.7.8 ASI data .........................................................................................................................141

5.8 Object description - standard objects ......................................................................................... 145

6 Appendix ................................................................................................................................................216

6.1 EtherCAT AL Status Codes ........................................................................................................ 216

6.2 Firmware compatibility ................................................................................................................ 216

6.3 Firmware Update EL/ES/EM/EPxxxx.......................................................................................... 216

6.4 Restoring the delivery state ........................................................................................................ 227

6.5 Support and Service ................................................................................................................... 228

Foreword

EL6201 5Version: 2.2

1 Foreword

1.1 Notes on the documentation

Intended audience

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

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

Disclaimer

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

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

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

Trademarks

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

Patent Pending

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

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

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

© 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.

Foreword

EL62016 Version: 2.2

1.2 Safety instructions

Safety regulations

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

Exclusion of liability

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

Personnel qualification

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

Description of symbols

In this documentation the following symbols are used with an accompanying safety instruction or note. The safety instructions must be read carefully and followed without fail!

DANGER

Serious risk of injury!

Failure to follow the safety instructions associated with this symbol directly endangers the life and health of persons.

WARNING

Risk of injury!

Failure to follow the safety instructions associated with this symbol endangers the life and health of persons.

CAUTION

Personal injuries!

Failure to follow the safety instructions associated with this symbol can lead to injuries to persons.

Attention

Damage to the environment or devices

Failure to follow the instructions associated with this symbol can lead to damage to the environment or equipment.

Note

Tip or pointer

This symbol indicates information that contributes to better understanding.

Foreword

EL6201 7Version: 2.2

1.3 Documentation issue status

Version Comment

2.2 • Update chapter "Object description and parameterization"

• Update structure

2.1 • Update chapter "Notes on the documentation"

• Correction of Technical data

• Addenda chapter "TwinCAT Quick Start"

2.0 • Migration

• Amendments in section "Commissioning"

• Amendments in section "Technical data"

• Amendments in section "Object description and parameterization"

• Update structure

1.5 • Update chapter "Technical data"

• Addenda chapter "Installation instructions for enhanced mechanical load capacity"

• Update revision status

1.4 • Update chapter "Technical data"

• Section "Connection" updated

• Update revision status

1.3 • Update chapter "Technical data"

• Update chapter "Object description and parameterization"

• Update structure

• Update revision status

1.2 • Update chapter "Technical data"

1.1 • Amendments re commissioning

1.0 • First public issue

0.8 • Amendments & corrections in section "Quickstart"

0.7 • Amendments & corrections in section "AS-iMaster functionality"

0.6 • Addenda & corrections

0.5 • Addenda & corrections

0.4 • Addenda

0.3 • Addenda

0.2 • Addenda

0.1 • Provisional documentation for EL6201

1.4 Version identification of EtherCAT devices

Designation

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

• family key

• type

• version

• revision

Foreword

EL62018 Version: 2.2

Example Family Type Version Revision

EL3314-0000-0016 EL terminal

(12 mm, nonpluggable connection level)

3314 (4-channel thermocouple terminal)

0000 (basic type) 0016

CU2008-0000-0000CU device 2008 (8-port fast

ethernet switch)

0000 (basic type) 0000

ES3602-0010-0017 ES terminal

(12 mm, pluggable connection level)

3602 (2-channel voltage measurement)

0010 (highprecision version)

0017

Notes

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

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

• The order identifier is made up of

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

- type (3314)

- version (-0000)

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

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

Identification number

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

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

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

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

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

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

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

Syntax: D ww yy x y z u

D - prefix designation ww - calendar week yy - year x - firmware version of the bus PCB

Foreword

EL6201 9Version: 2.2

y - hardware version of the bus PCB z - firmware version of the I/O PCB u - hardware version of the I/O PCB

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

Unique serial number/ID, ID number

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

See also the further documentation in the area

• IP67: EtherCAT Box

• Safety: TwinSafe

• Terminals with factory calibration certificate and other measuring terminals

Examples of markings:

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

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

Foreword

EL620110 Version: 2.2

Fig.3: CU2016 switch with batch number

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

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

Fig.6: EP1908-0002 IP76 EtherCAT Safety Box with batch number 071201FF and unique serial number

00346070

Foreword

EL6201 11Version: 2.2

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

00331701

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

Product overview

EL620112 Version: 2.2

2 Product overview

2.1 Introduction

Fig.9: EL6201

Fig.10: AS-i logo

AS-Interface master terminal

The EL6201 AS interface master terminal enables the direct connection of AS interface slaves. The AS-Interface-compliant interface supports digital and analog slaves according to version 3.0 (master profile M3).

Quick links

• EtherCAT basics

• Technology [}14]

• Technical data [}13]

• Quick start [}109]

Product overview

EL6201 13Version: 2.2

2.2 Technical data

Technical data EL6201-0000

AS-Interface channels 1

Number of slaves up to 31 in V 2.0; up to 62 in V 2.11, V 3.0

AS-Interface versions V 2.0, V 2.11, V 3.0 (Rev. 4)

Slave types Standard: digital and analog,

extended: Type 1 (CTT1): S-7.3, S-7.4, Type 2 (CTT2): S-7.5.5, S-7.A.5, S-B.A.5, Type 3 (CTT3): S-7.A.7, S-7.A.A, Type 4 (CTT4): S-7.A.8, S-7.A.9, Type 5 (CTT5): S-6.0, Safety at work: S-0.B, S-7.B

Diagnostics power failure, slave failure, parameterization fault

AS-Interface address assignment via configuration or automatic

Cycle time max. 5ms (with 31 or 62 slaves)

Connection 2 lines via spring force technology

Data transfer rates 167 kbit/s

Distributed clocks -

Power contacts no

Electrical isolation 500V (AS-Interface/E-bus)

Supply voltage for electronics via the E-bus

Current consumption 120mA (E-Bus), typ. 40mA/max. 60mA (AS-Interface)

Configuration via TwinCAT System Manager

Dimensions (W x H x D) approx. 27 mm x 100 mm x 70 mm (width aligned: 24

mm)

Weight approx. 55 g

Assembly [}27]

on 35 mm mounting rail conforms to EN 60715

Operating temperature 0°C...+55°C

Storage temperature -25°C...+85°C

Relative humidity 95 % no condensation

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

see also installation instructions [}30] for enhanced mechanical load capacity

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

Protect. class / installation pos.

IP20 / see note [}34]!

AS-Interface certificate yes, cert. no. 97701

Approvals CE

Product overview

EL620114 Version: 2.2

2.3 Technology

This section provides a short general technical introduction to the technology of the AS interface. Please refer to the following sections for further details.

(Source: (AS-INTERNATIONAL ASSOCIATION e.V.)

Fig.11: AS-i logo

2.3.1 • AS-i requirements

The industry places many different demands on modern automation systems. It demands that the necessary functions are fulfilled at an optimum price-performance ratio. AS-Interface, or AS-i for short, does precisely that. The system is focused on the lower field level. The goal of the development was not a universal fieldbus for all areas of automation, but rather an economically practical system for the lower field level, with which binary sensors and actuators can be simply, reliably and economically networked and connected to the higher control level.

The sensors and actuators can be networked and supplied with power via the AS-i-specific twin-core cable. The cable harnesses of traditional cabling are dispensed with. A massive cost reduction due to the simple wiring, which is possible without extensive training thanks to the proven click-and-go technology. Due to its cost effectiveness the AS-Interface system proves to be a technically and economically practical supplement to the normal fieldbus.

The freely selectable network topology and its simple configuration facilitate the installation of an AS-i network. The susceptibility to faults of other systems frequently leads to delays in the installation, for which reason care was taken with the AS-Interface system to reduce sources of error. Reverse voltage protection by means of the profiled cable is just one corresponding measure.

2.3.2 Assembly using the piercing technology

The simple assembly of the AS-interface is made possible by the special assembly method, which is also called the piercing technology or, less frequently, the click-and-go method. The technology is based on the use of the usually yellow AS-i cable, a cable with two cores that is protected against polarity reversal. When assembling, the piercing pins of the device to be connected penetrate into the cores of the cable and reliably make the contact. Some advantages:

• Direct, simple connection of sensors/actuators or modules

• Flat cable with reverse voltage protection

• Data and energy in one cable

• Piercing technology

• Very simple connection method

• Secure contacting

• Protection class IP67

• Cutting to length and stripping of insulation are not necessary

• Can be mounted in any place

• Trouble-free shifting is possible thanks to the self-healing capability of the cable for each type of cable

Product overview

EL6201 15Version: 2.2

Fig.12: Profiled twin-core cable for use with the AS-i technology

Assembly example

Fig.13: Upper and lower half of the AS-i component are disassembled.

Fig.14: The AS-i cable is placed – always without error thanks to its profiling – in the lower half of the AS-i component.

Fig.15: Upper and lower halves are assembled using a simple tool.

Fig.16: Finished assembled junction

Product overview

EL620116 Version: 2.2

Fig.17: The piercing technology ensures the reliable connection of the AS-i component to the AS-i network cable.

2.3.3 AS interface for every topology

The AS-i protocol guarantees simple expandability. The AS-interface network can be configured like every conventional electrical installation. Every AS-i slave is freely addressable and can be connected to the bus cable in any place. This enables a modular structure and, due to the robust principle of operation, there are no limits to the structure. Any desired network topology may be used, i.e. including star or tree topologies.

Fail-safe

The data are transmitted reliably on the AS-i network. Each AS-Interface telegram is monitored in the receiver with regard to a parity bit and several further independent variables. This ensures extremely high reliability in the detection of single and multiple errors. The use of the AS-Interface in very noisy environments such as welding plants and frequency converters is thus possible without problems.

Standardized economic efficiency

All AS-Interface products conform to the European standard EN 50295 and the world standard IEC 62026-2.

Certified: Economic and reliable

The certification of the AS-i products guarantees the user maximum system security. The products are fully compatible and interchangeable with one another. As a user you can recognize the tested and certified products by the AS-Interface “shadow logo” and the associated test number.

2.4 Start

For commissioning:

• mount the EL6201 as described in the chapter Mounting and wiring [}27]

• configure the EL6201 in TwinCAT as described in the chapter Commissioning [}109].

Basics communication

EL6201 17Version: 2.2

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.

Note

Recommended cables

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

E-Bus supply

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

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

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

Basics communication

EL620118 Version: 2.2

Fig.18: System manager current calculation

Attention

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.

Basics communication

EL6201 19Version: 2.2

Fig.19: EtherCAT tab -> Advanced Settings -> Behavior -> Watchdog

Notes:

• the multiplier is valid for both watchdogs.

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

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

Multiplier

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

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

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

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

Basics communication

EL620120 Version: 2.2

Example "Set SM watchdog"

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

Calculation

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

CAUTION

Undefined state possible!

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

CAUTION

Damage of devices and undefined state possible!

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

3.4 EtherCAT State Machine

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

A distinction is made between the following states:

• Init

• Pre-Operational

• Safe-Operational and

• Operational

• Boot

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

Basics communication

EL6201 21Version: 2.2

Fig.20: 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.

Note

Outputs in SAFEOP state

The default set watchdog [}18] 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.

Basics communication

EL620122 Version: 2.2

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

dez

)

• SubIndex: 0x00…0xFF (0...255

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)

Note

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:

Basics communication

EL6201 23Version: 2.2

Fig.21: "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.

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.

Basics communication

EL620124 Version: 2.2

Note

Data management

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

• 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.

Note

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 parameterised with the specifications of the user.

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

Recommended approach for manual modification of CoE parameters

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

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

Fig.22: 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.

Basics communication

EL6201 25Version: 2.2

Online/offline list

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

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

• If the slave is offline

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

possible.

◦ The configured status is shown under Identity.

◦ No firmware or hardware version is displayed, since these are features of the physical device.

◦ Offline is shown in red.

Fig.23: 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.

Basics communication

EL620126 Version: 2.2

Fig.24: Online list

Channel-based order

The CoE list is available in EtherCAT devices that usually feature several functionally equivalent channels. For example, a 4-channel analog 0..10 V input terminal also has 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

hex

steps. The parameter range

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.

Installation

EL6201 27Version: 2.2

4 Installation

4.1 Instructions for ESD protection

Attention

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 directly.

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 bus end cap,

to ensure the protection class and ESD protection.

Fig.25: Spring contacts of the Beckhoff I/O components

4.2 Installation on mounting rails

WARNING

Risk of electric shock and damage of device!

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

Installation

EL620128 Version: 2.2

Assembly

Fig.26: Attaching on mounting rail

The Bus Coupler and Bus Terminals are attached to commercially available 35mm mounting rails (DIN rails according to EN60715) by applying slight pressure:

1. First attach the Fieldbus Coupler to the mounting rail.

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

Note

Fixing of mounting rails

The locking mechanism of the terminals and couplers extends to the profile of the mounting rail. At the installation, the locking mechanism of the components must not come into conflict with the fixing bolts of the mounting rail. To mount the mounting rails with a height of

7.5mm under the terminals and couplers, you should use flat mounting connections (e.g. countersunk screws or blind rivets).

Installation

EL6201 29Version: 2.2

Disassembly

Fig.27: Disassembling of terminal

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

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

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

Connections within a bus terminal block

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

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

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

Note

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 4channel Bus Terminals) do not or not fully loop through the power contacts. Power Feed Terminals (KL91xx, KL92xx or EL91xx, EL92xx) interrupt the power contacts and thus represent the start of a new supply rail.

PE power contact

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

Installation

EL620130 Version: 2.2

Fig.28: Power contact on left side

Attention

Possible damage of the device

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

WARNING

Risk of electric shock!

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

4.3 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

60.1Hz<f<500Hz acceleration 5g, constant amplitude

Shocks 1000 shocks in each direction, in 3 axes

25 g, 6 ms

Installation

EL6201 31Version: 2.2

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.

4.4 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 KLxxxx and ELxxxx series with standard wiring include electronics and connection level in a single enclosure.

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

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

Standard wiring

Fig.29: Standard wiring

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

Installation

EL620132 Version: 2.2

Pluggable wiring

Fig.30: Pluggable wiring

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

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

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

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

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

High Density Terminals (HD Terminals)

Fig.31: High Density Terminals

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

Note

Wiring HD Terminals

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

Ultrasonically "bonded" (ultrasonically welded) conductors

Note

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 concern-

ing the wire-size width [}33] below!

Installation

EL6201 33Version: 2.2

Wiring

Terminals for standard wiring ELxxxx / KLxxxx and terminals for steady wiring ESxxxx / KSxxxx

Fig.32: Mounting a cable on a terminal connection

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

1. Open a spring-loaded terminal by slightly pushing with a screwdriver or a rod into the square opening above the terminal.

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

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

Terminal housing ELxxxx, KLxxxx ESxxxx, KSxxxx

Wire size width 0.08 ... 2,5mm

0.08 ... 2.5mm

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

High Density Terminals ELx8xx, KLx8xx (HD)

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 contact 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 (conductors with a wire end sleeve) 0.14... 0.75mm

Wire size width (single core wires) 0.08 ... 1.5mm

Wire size width (fine-wire conductors) 0.25 ... 1.5mm

Wire size width (ultrasonically “bonded" conductors)

only 1.5mm2 (see notice [}32]!)

Wire stripping length 8 ... 9mm

Installation

EL620134 Version: 2.2

Shielding

Note

Shielding

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

4.5 Prescribed installation position

Attention

Constraints regarding installation position and operating temperature range

When installing the terminals ensure that an adequate spacing is maintained between other components above and below the terminal in order to guarantee adequate ventilation!

Prescribed installation position

The prescribed 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.33: Recommended minimum distances for standard installation position

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

Installation

EL6201 35Version: 2.2

4.6 Mounting of Passive Terminals

Note

Hint for mounting passive terminals

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 mounting passive terminals (highlighted)

Fig.34: Correct configuration

Fig.35: Incorrect configuration

Installation

EL620136 Version: 2.2

4.7 LEDs and connection

Fig.36: EL6201 LEDs

LEDs

LED Color Meaning

RUN green These LEDs indicate the terminal's operating state:

off

State of the EtherCAT State Machine [}20]: INIT=initialization of the terminal

flashing State of the EtherCAT State Machine: PREOP = function for mailbox

communication and different standard-settings set

Single flash

State of the EtherCAT State Machine: SAFEOP = verification of the Sync Manager [}88] channels and the distributed clocks.

Outputs remain in safe state

on State of the EtherCAT State Machine: OP = normal operating state;

mailbox and process data communication is possible

flickering State of the EtherCAT State Machine: BOOTSTRAP=function for

terminal firmware updates [}216]

AS-i Diag green This LED lights up during the AS-i data exchange phase (it flickers in regular

operation).

Set switch green This LED is on as long as both set inputs are short-circuited.

AS-i Power green This LED is on as long as the AS-i power supply is connected and at least one AS-i

slave was found.

AS-i fault diagnostics

red This LED flashes if the nominal and actual configuration do not match.

Possible causes:

• AS-i ID code of one or several slaves does not match the currently projected values.

• The AS-i I/O code of one or several slaves does not match the currently projected values.

• The currently projected AS-i slave was not found.

Protected mode

green This LED lights up as long as the two protected mode inputs are short-circuited.

AS-i installation

WARNING

Risk of injury through electric shock and damage to the device!

Bring the Bus Terminals system into a safe, de-energized state before starting mounting, disassembly or wiring of the Bus Terminals.

Installation

EL6201 37Version: 2.2

Connection of the AS interface

Fig.37: Connection of EL6201 AS-i master

Terminal contact

Name Use

1 and 5 SCM Setting of the configuration mode by briefly bridging contacts 1 and 5

2 and 6 ASi+ ASi+ connection (brown). Both terminal points identified with ASi+ are

connected internally.

3 and 7 ASi- ASi- connection (blue). Both terminal points identified with ASi- are

connected internally.

4 and 8 SPM The detected slaves from the list of detected slaves can be projected for

the protected mode by briefly bridging the two SPM contacts 4 and 8.

Installation

EL620138 Version: 2.2

Connection AS-i potential supply terminal EL9520

Fig.38: Connection AS-i potential supply terminal EL9520

Terminal contact Name Use

1 Uin+ Positive voltage input 24V..35V

2 ASi+ Connection AS-i+

Both terminal points identified with ASi+ are connected internally.

3 ASi- Connection AS-i-

Both terminal points identified with ASi- are connected internally.

4 not used

5 Uin- Negative voltage input 24V..35V

6 ASi+ Connection AS-i+

Both terminal points identified with ASi+ are connected internally.

7 ASi- Connection AS-i-

Both terminal points identified with ASi- are connected internally.

8 not used

Installation

EL6201 39Version: 2.2

Wiring of the AS interface

Fig.39: Wiring diagram (example) for EL6201 AS-i master: connection to EL9520 (left), connection to AS-i power supply unit (right)

Since the user data are modulated on the power supply line with the AS-Interface, a special AS-i power supply unit (30.5VDC) is required.

A further possibility is offered by the EL9520 AS-i potential supply terminal, which provides the supply direct from the EtherCAT Terminal network.

Commissioning

EL620140 Version: 2.2

5 Commissioning

5.1 TwinCAT Quick Start

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

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

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

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

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

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

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

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

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

• "online": The existing hardware configuration is read

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

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

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

Commissioning

EL6201 41Version: 2.2

Fig.40: Relationship between user side (commissioning) and installation

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

Sample configuration (actual configuration)

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

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

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

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

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

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

Commissioning

EL620142 Version: 2.2

Fig.41: 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 TwinCAT2

Startup

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

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

Fig.42: Initial TwinCAT2 user interface

Commissioning

EL6201 43Version: 2.2

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 [}44]".

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.43: 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.44: 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):

Commissioning

EL620144 Version: 2.2

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

Adding devices

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

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

Fig.45: Select "Scan Devices..."

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

Fig.46: 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 [}41] described at the beginning of this section, the result is as follows:

Commissioning

EL6201 45Version: 2.2

Fig.47: Mapping of the configuration in the TwinCAT2 System Manager

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

Fig.48: 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)

Commissioning

EL620146 Version: 2.2

• 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.49: TwinCAT PLC Control after startup

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

Commissioning

EL6201 47Version: 2.2

Fig.50: 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.51: Appending the TwinCAT PLC Control project

Commissioning

EL620148 Version: 2.2

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.52: 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.53: 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:

Commissioning

EL6201 49Version: 2.2

Fig.54: 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.55: 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:

Commissioning

EL620150 Version: 2.2

Fig.56: 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…":

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EL6201 51Version: 2.2

Fig.57: 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:

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EL620152 Version: 2.2

Fig.58: PLC Control logged in, ready for program startup

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

5.1.2 TwinCAT 3

Startup

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

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

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EL6201 53Version: 2.2

Fig.59: Initial TwinCAT3 user interface

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

Fig.60: Create new TwinCAT project

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

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EL620154 Version: 2.2

Fig.61: New TwinCAT3 project in the project folder explorer

next step is "Insert Device [}55]".

expand the pull-down menu:

and open the following window:

Fig.62: Selection dialog: Choose the target system

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EL6201 55Version: 2.2

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.63: 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.64: Select "Scan"

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

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EL620156 Version: 2.2

Fig.65: Automatic detection of I/O devices: selection the devices to be integrated

Based on the sample configuration [}41] described at the beginning of this section, the result is as follows:

Fig.66: Mapping of the configuration in VS shell of the TwinCAT3 environment

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EL6201 57Version: 2.2

Fig.67: Reading of individual terminals connected to a device

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

Programming the PLC

• 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….":

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EL620158 Version: 2.2

Fig.68: 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.69: 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:

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EL6201 59Version: 2.2

Fig.70: Initial "Main" program of the standard PLC project

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

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EL620160 Version: 2.2

Fig.71: 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.72: 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:

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EL6201 61Version: 2.2

Fig.73: 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.74: Selecting PDO of type BOOL

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EL620162 Version: 2.2

Fig.75: Selecting several PDOs simultaneously: activate "Continuous" and "All types"

Fig.76: Application of a "Goto Link" variable, using "MAIN.bEL1004_Ch4" as a sample

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EL6201 63Version: 2.2

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.77: 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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EL620164 Version: 2.2

5.2 TwinCAT Development Environment

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

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

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

Details:

• TwinCAT2:

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

◦ Connects tasks to tasks in a variable-oriented manner

◦ Supports units at the bit level

◦ Supports synchronous or asynchronous relationships

◦ Exchange of consistent data areas and process images

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

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

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

◦ Interconnection to all common fieldbusses

◦ More…

Additional features:

• TwinCAT3 (eXtended Automation):

◦ Visual-Studio®-Integration

◦ Choice of the programming language

◦ Supports object orientated extension of IEC 61131-3

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

◦ Connection to MATLAB®/Simulink®

◦ Open interface for expandability

◦ Flexible run-time environment

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

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

◦ More…

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

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

5.2.1 Installation of the TwinCAT real-time driver

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

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

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

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EL6201 65Version: 2.2

Fig.78: System Manager “Options” (TwinCAT2)

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

Fig.79: Call up under VS Shell (TwinCAT3)

The following dialog appears:

Fig.80: 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” [}75] in order to view the compatible ethernet ports via its

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

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EL620166 Version: 2.2

Fig.81: EtherCAT device properties(TwinCAT2): click on „Compatible Devices…“ of tab “Adapter”

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

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

Fig.82: Windows properties of the network interface

A correct setting of the driver could be:

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EL6201 67Version: 2.2

Fig.83: Exemplary correct driver setting for the Ethernet port

Other possible settings have to be avoided:

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EL620168 Version: 2.2

Fig.84: Incorrect driver settings for the Ethernet port

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EL6201 69Version: 2.2

IP address of the port used

Note

IP address/DHCP

In most cases an Ethernet port that is configured as an EtherCAT device will not transport general IP packets. For this reason and in cases where an EL6601 or similar devices are used it is useful to specify a fixed IP address for this port via the “Internet Protocol TCP/IP” driver setting and to disable DHCP. In this way the delay associated with the DHCP client for the Ethernet port assigning itself a default IP address in the absence of a DHCP server is avoided. A suitable address space is 192.168.x.x, for example.

Fig.85: TCP/IP setting for the Ethernet port

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EL620170 Version: 2.2

5.2.2 Notes regarding ESI device description

Installation of the latest ESI device description

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

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

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

Default settings:

• TwinCAT2: C:\TwinCAT\IO\EtherCAT

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

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

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

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

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

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

The TwinCAT ESI Updater [}74] is available for this purpose.

Note

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.86: 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 [}7].

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EL6201 71Version: 2.2

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.87: OnlineDescription information window (TwinCAT2)

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

Fig.88: Information window OnlineDescription (TwinCAT3)

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

Attention

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’ [}75].

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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EL620172 Version: 2.2

Fig.89: 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.90: 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

Note

OnlineDescription for TwinCAT3.x

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

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

Faulty ESI file

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

Fig.91: Information window for faulty ESI file (left: TwinCAT2; right: TwinCAT3)

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EL6201 73Version: 2.2

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

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EL620174 Version: 2.2

5.2.3 TwinCAT ESI Updater

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

Fig.92: Using the ESI Updater (>= TwinCAT2.11)

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

Selection under TwinCAT3:

Fig.93: Using the ESI Updater (TwinCAT3)

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

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

5.2.4 Distinction between Online and Offline

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

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

In any case, during each startup the EtherCAT master checks whether the slaves it finds match the configuration. This test can be parameterised in the extended slave settings. Refer to note “Installation of the latest ESI-XML device description” [}70].

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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EL6201 75Version: 2.2

• 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 [}80] (Ethernet port at the IPC)

• detecting the connected EtherCAT devices [}81]. This step can be carried out independent of the preceding step

• troubleshooting [}84]

The scan with existing configuration [}85] 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.94: Append EtherCAT device (left: TwinCAT2; right: TwinCAT3)

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

Fig.95: Selecting the EtherCAT connection (TwinCAT2.11, TwinCAT3)

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

Fig.96: Selecting the Ethernet port

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EL620176 Version: 2.2

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

Fig.97: EtherCAT device properties (TwinCAT2)

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

Note

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 respec-

tive installation page [}64].

Defining EtherCAT slaves

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

Fig.98: Appending EtherCAT devices (left: TwinCAT2; right: TwinCAT3)

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

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

Overview of physical layer

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

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EL6201 77Version: 2.2

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

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

Fig.99: 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.100: 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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EL620178 Version: 2.2

Fig.101: Display of previous revisions

Note

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.102: 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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EL6201 79Version: 2.2

Fig.103: EtherCAT terminal in the TwinCAT tree (left: TwinCAT2; right: TwinCAT3)

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EL620180 Version: 2.2

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

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

TwinCAT can be set into this mode:

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

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

Note

Online scanning in Config mode

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

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

Fig.104: Differentiation local/target system (left: TwinCAT2; right: TwinCAT3)

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

Fig.105: Scan Devices (left: TwinCAT2; right: TwinCAT3)

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

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EL6201 81Version: 2.2

Fig.106: Note for automatic device scan (left: TwinCAT2; right: TwinCAT3)

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.107: 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”.

Note

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 respec-

tive installation page [}64].

Detecting/Scanning the EtherCAT devices

Note

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.108: Example default state

Attention

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 con-

figuration, but if necessary for comparison [}85] 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.

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EL620182 Version: 2.2

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:

Fig.109: Installing EthetCAT terminal with revision -1018

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

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

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

‘B.pro’; it makes sense to perform a comparative scan [}85] 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.110: 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.

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EL6201 83Version: 2.2

Fig.111: Scan query after automatic creation of an EtherCAT device (left: TwinCAT2; right: TwinCAT3)

Fig.112: Manual triggering of a device scan on a specified EtherCAT device (left: TwinCAT2; right:

TwinCAT3)

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

Fig.113: Scan progressexemplary by TwinCAT2

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

Fig.114: Config/FreeRun query (left: TwinCAT2; right: TwinCAT3)

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

Fig.115: Displaying of “Free Run” and “Config Mode” toggling right below in the status bar

Fig.116: TwinCAT can also be switched to this state by using a button (left: TwinCAT2; right: TwinCAT3)

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

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EL620184 Version: 2.2

Fig.117: 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 [}75].

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.118: Faulty identification

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

Commissioning

EL6201 85Version: 2.2

Scan over existing Configuration

Attention

Change of the configuration after comparison

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

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

Fig.119: Identical configuration (left: TwinCAT2; right: TwinCAT3)

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

Fig.120: Correction dialog

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

Commissioning

EL620186 Version: 2.2

Colour Explanation

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

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

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

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

light blue This EtherCAT slave is ignored (“Ignore” button)

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

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

Note

Device selection based on revision, compatibility

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.121: Name/revision of the terminal

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, ...

Commissioning

EL6201 87Version: 2.2

Fig.122: Correction dialog with modifications

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

Change to compatible device

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

Fig.123: Dialog “Change to Compatible Type…” (left: TwinCAT2; right: TwinCAT3)

This function is preferably to be used on AX5000 devices. If called, the System Manager suggests the devices that it finds in the associated sub-folder; in the case of the AX5000, for example, in \TwinCAT\IO

\EtherCAT\Beckhoff AX5xxx.

Change to Alternative Type

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

Fig.124: TwinCAT2 Dialog Change to Alternative Type

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EL620188 Version: 2.2

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

5.2.7 EtherCAT subscriber configuration

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

Fig.125: Branch element as terminal EL3751

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

„General“ tab

Fig.126: “General” tab

Name Name of the EtherCAT device Id Number of the EtherCAT device Type EtherCAT device type Comment Here you can add a comment (e.g. regarding the

system).

Disabled Here you can deactivate the EtherCAT device. Create symbols Access to this EtherCAT slave via ADS is only

available if this control box is activated.

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EL6201 89Version: 2.2

„EtherCAT“ tab

Fig.127: „EtherCAT“ tab

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

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

hex

. For each further slave the address is

decremented by 1 (FFFF

hex

, FFFE

hex

etc.).

EtherCAT Addr. Fixed address of an EtherCAT slave. This address is

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

Previous Port Name and port of the EtherCAT device to which this

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

Advanced Settings This button opens the dialogs for advanced settings.

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

“Process Data” tab

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

Commissioning

EL620190 Version: 2.2

Fig.128: “Process Data” tab

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

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

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

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

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

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

• A: select the device to configure

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

• D: the PDOs can be selected or deselected

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

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

Commissioning

EL6201 91Version: 2.2

Fig.129: Configuring the process data

Note

Manual modification of the process data

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

A detailed description [}96] can be found at the end of this section.

„Startup“ tab

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

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EL620192 Version: 2.2

Fig.130: „Startup“ tab

Column Description

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

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

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

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

Protocol Type of mailbox protocol

Index Index of the object

Data Date on which this object is to be downloaded.

Comment Description of the request to be sent to the mailbox

Move Up This button moves the selected request up by one

position in the list.

Move Down This button moves the selected request down by one

position in the list.

New This button adds a new mailbox download request to

be sent during startup.

Delete This button deletes the selected entry. Edit This button edits an existing request.

“CoE – Online” tab

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

Commissioning

EL6201 93Version: 2.2

Fig.131: “CoE – Online” tab

Object list display

Column Description

Index Index and sub-index of the object

Name Name of the object

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

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

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

Value Value of the object

Commissioning

EL620194 Version: 2.2

Update List The Update list button updates all objects in the

displayed list

Auto Update If this check box is selected, the content of the

objects is updated automatically.

Advanced The Advanced button opens the Advanced Settings

dialog. Here you can specify which objects are displayed in the list.

Fig.132: Dialog “Advanced settings”

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

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

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

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

Commissioning

EL6201 95Version: 2.2

„Online“ tab

Fig.133: „Online“ tab

State Machine

Init This button attempts to set the EtherCAT device to

the Init state.

Pre-Op This button attempts to set the EtherCAT device to

the pre-operational state.

Op This button attempts to set the EtherCAT device to

the operational state.

Bootstrap This button attempts to set the EtherCAT device to

the Bootstrap state.

Safe-Op This button attempts to set the EtherCAT device to

the safe-operational state.

Clear Error This button attempts to delete the fault display. If an

EtherCAT slave fails during change of state it sets an error flag.

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

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

device.

DLL Status

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

Commissioning

EL620196 Version: 2.2

Status Description

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

is open.

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

is closed.

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

open.

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

closed.

File Access over EtherCAT

Download With this button a file can be written to the EtherCAT

device.

Upload With this button a file can be read from the EtherCAT

device.

"DC" tab (Distributed Clocks)

Fig.134: "DC" tab (Distributed Clocks)

Operation Mode Options (optional):

• FreeRun

• SM-Synchron

• DC-Synchron (Input based)

• DC-Synchron

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

clock

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

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

5.2.7.1 Detailed description of Process Data tab

Sync Manager

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

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

PDO Assignment

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

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EL6201 97Version: 2.2

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

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

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

Note

Activation of PDO assignment

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

ment,

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

tional to safe-operational) once (see Online tab [}95]),

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

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

PDO list

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

Column Description

Index PDO index.

Size Size of the PDO in bytes.

Name Name of the PDO.

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

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

System Manager.

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

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

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

part in the process data traffic.

SU Sync unit to which this PDO is assigned.

PDO Content

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

Download

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

PDO Assignment

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

Startup [}91] tab.

PDO Configuration

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

Commissioning

EL620198 Version: 2.2

5.3 General Notes - EtherCAT Slave Application

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

Diagnosis in real time: WorkingCounter, EtherCAT State and Status

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

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

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

Fig.135: Selection of the diagnostic information of an EtherCAT Slave

In general, an EtherCAT Slave offers

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

as well as

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

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

Colour Meaning

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

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

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

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

Commissioning

EL6201 99Version: 2.2

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

Fig.136: Basic EtherCAT Slave Diagnosis in the PLC

The following aspects are covered here:

Commissioning

EL6201100 Version: 2.2

Code Function Implementation Application/evaluation

A The EtherCAT Master's diagnostic infor-

mation

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

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

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

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

• Functions from TcEtherCAT.lib

• Perform an OnlineScan

B In the example chosen (EL3102) the

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

Status

• the bit significations may be found in the device documentation

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

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

C For every EtherCAT Slave that has cyclic

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

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

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

for linking.

WcState (Working Counter)

0: valid real-time communication in the last cycle

1: invalid real-time communication

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

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

D Diagnostic information of the EtherCAT

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

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

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

State

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

AdsAddr

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

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

Attention

Diagnostic information

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

CoE Parameter Directory

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

Beckhoff EL6201 Documentation

Specifications and Main Features

Frequently Asked Questions

User Manual