Documentation | EN
EL72x1-001x
Servo Motor Terminals with OCT (One Cable Technology)
2020-09-23 | Version: 2.7
Table of contents
Table of contents
1 Product overview Servo Motor Terminals...............................................................................................7
2 Foreword ....................................................................................................................................................8
2.1 Notes on the documentation..............................................................................................................8
2.2 Safety instructions .............................................................................................................................9
2.3 Documentation issue status ............................................................................................................10
2.4 Version identification of EtherCAT devices .....................................................................................11
2.4.1 Beckhoff Identification Code (BIC)................................................................................... 14
3 Product overview.....................................................................................................................................16
3.1 Introduction......................................................................................................................................16
3.2 Technical data .................................................................................................................................18
3.3 Technology ......................................................................................................................................19
3.4 Start-up............................................................................................................................................21
4 Basics communication ...........................................................................................................................22
4.1 EtherCAT basics..............................................................................................................................22
4.2 EtherCAT cabling – wire-bound.......................................................................................................22
4.3 General notes for setting the watchdog...........................................................................................23
4.4 EtherCAT State Machine.................................................................................................................25
4.5 CoE Interface...................................................................................................................................27
4.6 Distributed Clock .............................................................................................................................32
5 Installation................................................................................................................................................33
5.1 Instructions for ESD protection........................................................................................................33
5.2 Installation on mounting rails ...........................................................................................................34
5.3 Installation instructions for enhanced mechanical load capacity .....................................................37
5.4 Connection system ..........................................................................................................................38
5.5 Positioning of passive Terminals .....................................................................................................42
5.6 Installation position for operation with or without fan.......................................................................43
5.7 Shielding concept ............................................................................................................................46
5.8 Notes on current measurements using Hall sensors.......................................................................49
5.9 LEDs and connection ......................................................................................................................50
5.10 UL notice - Compact Motion............................................................................................................54
6 Commissioning........................................................................................................................................55
6.1 TwinCAT Development Environment ..............................................................................................55
6.1.1 Installation of the TwinCAT real-time driver..................................................................... 55
6.1.2 Notes regarding ESI device description........................................................................... 61
6.1.3 TwinCAT ESI Updater ..................................................................................................... 65
6.1.4 Distinction between Online and Offline............................................................................ 65
6.1.5 OFFLINE configuration creation ...................................................................................... 66
6.1.6 ONLINE configuration creation ........................................................................................ 71
6.1.7 EtherCAT subscriber configuration.................................................................................. 79
6.2 Start-up and parameter configuration..............................................................................................88
6.2.1 Integration into the NC configuration ............................................................................... 88
6.2.2 Settings with the Drive Manager...................................................................................... 92
6.2.3 Settings in the CoE register ............................................................................................. 97
EL72x1-001x 3Version: 2.7
Table of contents
6.2.4 Application example....................................................................................................... 101
6.2.5 Commissioning without NC, status word/control word................................................... 105
6.2.6 Settings for the automatic configuration ........................................................................ 109
6.2.7 Configuring the limit switch ........................................................................................... 111
6.2.8 Homing .......................................................................................................................... 111
6.2.9 Touch Probe .................................................................................................................. 115
6.2.10 NC settings .................................................................................................................... 118
6.3 Modes of operation........................................................................................................................125
6.3.1 Overview........................................................................................................................ 125
6.3.2 CSV ............................................................................................................................... 126
6.3.3 CST................................................................................................................................ 129
6.3.4 CSTCA........................................................................................................................... 132
6.3.5 CSP ............................................................................................................................... 136
6.4 Profile MDP 742 or DS 402 ...........................................................................................................140
6.5 MDP742 process data ...................................................................................................................140
6.6 DS402 process data ......................................................................................................................144
7 EL72x1-0010 (MDP742) - Object description and parameterization .................................................149
7.1 Restore object ...............................................................................................................................149
7.2 Configuration data .........................................................................................................................149
7.3 Configuration data (vendor-specific)..............................................................................................156
7.4 Command object ...........................................................................................................................156
7.5 Input data.......................................................................................................................................156
7.6 Output data....................................................................................................................................158
7.7 Information / diagnosis data .........................................................................................................160
7.8 Standard objects............................................................................................................................163
8 EL72x1-0011 (DS402) - Object description and parameterization ....................................................172
8.1 Configuration data .........................................................................................................................173
8.2 Configuration data (vendor-specific)..............................................................................................178
8.3 Command object ..........................................................................................................................178
8.4 Input/output data............................................................................................................................179
8.5 Information / diagnosis data .........................................................................................................184
8.6 Standard objects............................................................................................................................187
9 Error correction .....................................................................................................................................194
9.1 Diagnostics – basic principles of diag messages ..........................................................................194
9.2 Notes on Diag Messages associated with Motor Terminals..........................................................203
10 Appendix ................................................................................................................................................204
10.1 EtherCAT AL Status Codes...........................................................................................................204
10.2 Firmware compatibility...................................................................................................................204
10.3 Firmware Update EL/ES/EM/ELM/EPxxxx....................................................................................205
10.3.1 Device description ESI file/XML..................................................................................... 206
10.3.2 Firmware explanation .................................................................................................... 209
10.3.3 Updating controller firmware *.efw................................................................................. 210
10.3.4 FPGA firmware *.rbf....................................................................................................... 212
10.3.5 Simultaneous updating of several EtherCAT devices.................................................... 216
10.4 Restoring the delivery state...........................................................................................................217
EL72x1-001x4 Version: 2.7
Table of contents
10.5 Support and Service......................................................................................................................218
EL72x1-001x 5Version: 2.7
Table of contents
EL72x1-001x6 Version: 2.7
Product overview Servo Motor Terminals
1 Product overview Servo Motor Terminals
EL7201-0010 [}16], Servo Motor Terminal (MDP742 profile), 48 VDC with OCT, 2.8 A
EL7201-0011 [}16], Servo Motor Terminal (DS402 profile), 48 VDC with OCT, 2.8 A
rms
EL7211-0010 [}16], Servo Motor Terminal (MDP742 profile), 48 VDC with OCT, 4.5 A
EL7211-0011 [}16], Servo Motor Terminal (DS402 profile), 48 VDC with OCT, 4.5 A
rms
rms
rms
EL72x1-001x 7Version: 2.7
Foreword
2 Foreword
2.1 Notes on the documentation
Intended audience
This description is only intended for the use of trained specialists in control and automation engineering who
are familiar with the applicable national standards.
It is essential that the documentation and the following notes and explanations are followed when installing
and commissioning these components.
It is the duty of the technical personnel to use the documentation published at the respective time of each
installation and commissioning.
The responsible staff must ensure that the application or use of the products described satisfy all the
requirements for safety, including all the relevant laws, regulations, guidelines and standards.
Disclaimer
The documentation has been prepared with care. The products described are, however, constantly under
development.
We reserve the right to revise and change the documentation at any time and without prior announcement.
No claims for the modification of products that have already been supplied may be made on the basis of the
data, diagrams and descriptions in this documentation.
Trademarks
Beckhoff®, TwinCAT®, EtherCAT®, EtherCATG®, EtherCATG10®, EtherCATP®, SafetyoverEtherCAT®,
TwinSAFE®, XFC®, XTS® and XPlanar® are registered trademarks of and licensed by Beckhoff Automation
GmbH. Other designations used in this publication may be trademarks whose use by third parties for their
own purposes could violate the rights of the owners.
Patent Pending
The EtherCAT Technology is covered, including but not limited to the following patent applications and
patents: EP1590927, EP1789857, EP1456722, EP2137893, DE102015105702 with corresponding
applications or registrations in various other countries.
EtherCAT® is registered trademark and patented technology, licensed by Beckhoff Automation GmbH,
Germany.
Copyright
© Beckhoff Automation GmbH & Co. KG, Germany.
The reproduction, distribution and utilization of this document as well as the communication of its contents to
others without express authorization are prohibited.
Offenders will be held liable for the payment of damages. All rights reserved in the event of the grant of a
patent, utility model or design.
EL72x1-001x8 Version: 2.7
Foreword
2.2 Safety instructions
Safety regulations
Please note the following safety instructions and explanations!
Product-specific safety instructions can be found on following pages or in the areas mounting, wiring,
commissioning etc.
Exclusion of liability
All the components are supplied in particular hardware and software configurations appropriate for the
application. Modifications to hardware or software configurations other than those described in the
documentation are not permitted, and nullify the liability of Beckhoff Automation GmbH & Co. KG.
Personnel qualification
This description is only intended for trained specialists in control, automation and drive engineering who are
familiar with the applicable national standards.
Description of instructions
In this documentation the following instructions are used.
These instructions must be read carefully and followed without fail!
DANGER
Serious risk of injury!
Failure to follow this safety instruction directly endangers the life and health of persons.
WARNING
Risk of injury!
Failure to follow this safety instruction endangers the life and health of persons.
CAUTION
Personal injuries!
Failure to follow this safety instruction can lead to injuries to persons.
NOTE
Damage to environment/equipment or data loss
Failure to follow this instruction can lead to environmental damage, equipment damage or data loss.
Tip or pointer
This symbol indicates information that contributes to better understanding.
EL72x1-001x 9Version: 2.7
Foreword
2.3 Documentation issue status
Version Comment
2.7 • Update chapter “Introduction”
• Update chapter “Technical data”
• Update chapter “Technology”
• Update revision structure
• Update chapter “LEDs and connection”
• Update structure
2.6 • Update chapter “Object description”
• Update structure
2.5 • Note for fuse protection of the supply voltage added
• Update revision status
• Update structure
2.4 • Update chapter “Technical data”
• Addenda chapter “ESD protection”
• Update chapter “UL notice”
• Update structure
• Update revision status
2.3 • Update chapter “Technical data”
• Update structure
2.2 • Update chapter “Introduction”
• Update chapter “Technical data”
• Update chapter “Object description”
• Update structure
• Update revision status
2.1 • Update chapter “Technical data”
• Update chapter “Installation”
• Update chapter “Shielding concept”
• Update chapter “Operating mode CSP”
• Update chapter “Object description”
• Addenda note “Diag messages”
• Update structure
• Update revision status
2.0 • Migration
• Update structure
• Update revision status
EL72x1-001x10 Version: 2.7
Version Comment
1.4 • Update chapter "Technical data"
• Addenda chapter "Installation instructions for enhanced mechanical load capacity"
• Update structure
• Update revision status
1.3 • Addenda EL7211-0010
• Update structure
1.2 • Addenda chapter "Limit switches"
1.1 • Update MDP object description
1.0 • First public issue
• Corrections and addenda
0.2 • Corrections and addenda
0.1 • Provisional documentation for EL72x1-0010
2.4 Version identification of EtherCAT devices
Designation
Foreword
A Beckhoff EtherCAT device has a 14-digit designation, made up of
• family key
• type
• version
• revision
Example Family Type Version Revision
EL3314-0000-0016 EL terminal
(12 mm, nonpluggable connection
level)
ES3602-0010-0017 ES terminal
(12 mm, pluggable
connection level)
CU2008-0000-0000 CU device 2008 (8-port fast ethernet switch) 0000 (basic type) 0000
Notes
• The elements mentioned above result in the technical designation. EL3314-0000-0016 is used in the
example below.
• EL3314-0000 is the order identifier, in the case of “-0000” usually abbreviated to EL3314. “-0016” is the
EtherCAT revision.
• The order identifier is made up of
- family key (EL, EP, CU, ES, KL, CX, etc.)
- type (3314)
- version (-0000)
• The revision -0016 shows the technical progress, such as the extension of features with regard to the
EtherCAT communication, and is managed by Beckhoff.
In principle, a device with a higher revision can replace a device with a lower revision, unless specified
otherwise, e.g. in the documentation.
Associated and synonymous with each revision there is usually a description (ESI, EtherCAT Slave
Information) in the form of an XML file, which is available for download from the Beckhoff web site.
From 2014/01 the revision is shown on the outside of the IP20 terminals, see Fig. “EL5021 EL terminal,
standard IP20 IO device with batch number and revision ID (since 2014/01)”.
• The type, version and revision are read as decimal numbers, even if they are technically saved in
hexadecimal.
3314 (4-channel thermocouple
terminal)
3602 (2-channel voltage
measurement)
0000 (basic type) 0016
0010 (highprecision version)
0017
EL72x1-001x 11Version: 2.7
Foreword
Identification number
Beckhoff EtherCAT devices from the different lines have different kinds of identification numbers:
Production lot/batch number/serial number/date code/D number
The serial number for Beckhoff IO devices is usually the 8-digit number printed on the device or on a sticker.
The serial number indicates the configuration in delivery state and therefore refers to a whole production
batch, without distinguishing the individual modules of a batch.
Structure of the serial number: KKYYFFHH
KK - week of production (CW, calendar week)
YY - year of production
FF - firmware version
HH - hardware version
Example with
Ser. no.: 12063A02: 12 - production week 12 06 - production year 2006 3A - firmware version 3A 02 hardware version 02
Examples of markings
Fig.1: EL5021 EL terminal, standard IP20 IO device with serial/ batch number and revision ID (since
2014/01)
Fig.2: EK1100 EtherCAT coupler, standard IP20 IO device with serial/ batch number
EL72x1-001x12 Version: 2.7
Fig.3: EL3202-0020 with serial/ batch number 26131006 and unique ID-number 204418
Foreword
EL72x1-001x 13Version: 2.7
Foreword
2.4.1 Beckhoff Identification Code (BIC)
The Beckhoff Identification Code (BIC) is increasingly being applied to Beckhoff products to uniquely identify
the product. The BIC is represented as a Data Matrix Code (DMC, code scheme ECC200), the content is
based on the ANSI standard MH10.8.2-2016.
Fig.4: BIC as data matrix code (DMC, code scheme ECC200)
The BIC will be introduced step by step across all product groups.
Depending on the product, it can be found in the following places:
• on the packaging unit
• directly on the product (if space suffices)
• on the packaging unit and the product
The BIC is machine-readable and contains information that can also be used by the customer for handling
and product management.
Each piece of information can be uniquely identified using the so-called data identifier
(ANSIMH10.8.2-2016). The data identifier is followed by a character string. Both together have a maximum
length according to the table below. If the information is shorter, spaces are added to it. The data under
positions 1 to 4 are always available.
The following information is contained:
EL72x1-001x14 Version: 2.7
Item
Type of
no.
information
1 Beckhoff order
number
2 Beckhoff Traceability
Number (BTN)
3 Article description Beckhoff article
4 Quantity Quantity in packaging
5 Batch number Optional: Year and week
6 ID/serial number Optional: Present-day
7 Variant number Optional: Product variant
...
Explanation Data
Beckhoff order number 1P 8 1P072222
Unique serial number,
see note below
description, e.g.
EL1008
unit, e.g. 1, 10, etc.
of production
serial number system,
e.g. with safety products
number on the basis of
standard products
Foreword
Number of digits
identifier
S 12 SBTNk4p562d7
1K 32 1KEL1809
Q 6 Q1
2P 14 2P401503180016
51S 12 51S678294104
30P 32 30PF971, 2*K183
incl. data identifier
Example
Further types of information and data identifiers are used by Beckhoff and serve internal processes.
Structure of the BIC
Example of composite information from item 1 to 4 and 6. The data identifiers are marked in red for better
display:
BTN
An important component of the BIC is the Beckhoff Traceability Number (BTN, item no.2). The BTN is a
unique serial number consisting of eight characters that will replace all other serial number systems at
Beckhoff in the long term (e.g. batch designations on IO components, previous serial number range for
safety products, etc.). The BTN will also be introduced step by step, so it may happen that the BTN is not yet
coded in the BIC.
NOTE
This information has been carefully prepared. However, the procedure described is constantly being further
developed. We reserve the right to revise and change procedures and documentation at any time and without prior notice. No claims for changes can be made from the information, illustrations and descriptions in
this information.
EL72x1-001x 15Version: 2.7
Product overview
3 Product overview
3.1 Introduction
Fig.5: EL7201-0010
Fig.6: EL7211-0010
EL72x1-001x16 Version: 2.7
Servomotor terminals with OCT
Product overview
The servomotor EtherCAT Terminals EL7201-0010 (MDP742 profile, 48VDC, 2.8 A
(DS402 profile, 48VDC, 2.8 A
profile, 48VDC, 4.5 A
) with integrated absolute value interface offer high servo performance with a very
rms
) and EL7211-0010 (MDP742 profile, 48VDC, 4.5 A
rms
) / EL7201-0011
rms
) / EL7211-0011 (DS402
rms
compact design. The EL72x1-001x was designed for the motor types of the AM81xx series from Beckhoff
Automation.
The fast control technology, based on field-orientated current and PI speed control, supports fast and highly
dynamic positioning tasks. The monitoring of numerous parameters, such as overvoltage and undervoltage,
overcurrent, terminal temperature or motor load via the calculation of a I²T model, offers maximum
operational reliability.
EtherCAT, as a high-performance system communication, and CAN-over-EtherCAT (CoE), as the
application layer, enable ideal interfacing with PC-based control technology.
The latest power semiconductors guarantee minimum power loss and enable feedback into the DC link when
braking.
The LEDs indicate status, warning and error messages as well as possibly active limitations.
With the One Cable Technology (OCT) the encoder cable is omitted by transmitting the signals of the
encoder digitally via the existing motor cable. The option to read the electronic type plates of suitable motors
from the AM81xx series enables a plug-and-play solution for maximum convenience during commissioning.
The EL72x1-xx1x terminals provide 2 digital inputs, which can be used for the Touch Probe functionality. The
state of these inputs can be read out of the Select Info Data object (profile MDP 742 [}151] and DS 402
[}173]).
Recommended TwinCAT version
In order to be able to utilize the full power of the EL72x1-001x, we recommend using the
EL72x1-0010 with TwinCAT 2.11 R3 or higher!
Mandatory hardware
The EL72x1-001x must be operated with a real-time capable computer and distributed clocks.
Approved motors
Trouble-free operation can only be guaranteed with motors approved by Beckhoff.
Quick links
Connection instructions
• Chapter "Mounting and wiring",
- LEDs and pin assignment [}50]
- Shielding concept [}46]
- Notes on current measurement via Hall sensor [}49]
Configuration instructions
• Chapter "Commissioning",
- Configuration of the main parameters [}88]
• Chapter "Configuration with the TwinCAT System Manager",
- Object description and parameterization [}149]
Application example
• Chapter "Commissioning",
- Application example [}101]
EL72x1-001x 17Version: 2.7
Product overview
3.2 Technical data
Technical data EL7201-001x EL7211-001x
Number of outputs 3 motor phases, 2 motor holding brake
Number of inputs 2 (4) DC link voltage, 2 absolute feedback,
DC link supply voltage 8...48V
Supply voltage 24VDC via the power contacts / via the E-bus
Output current
Peak current
Rated power
Motor holding brake output voltage 24V (+ 6 %, - 10 %)
Max. motor holding brake output current max. 0.5A
Load type permanently excited synchronous motors, inductive
PWM switching frequency 16kHz
Current controller frequency double PWM switching frequency
Velocity controller frequency 16kHz
Diagnostics LED Status, warning, errors and limits
Power loss typ. 1.6W
Current consumption via E-bus typ. 120mA
Current consumption from the 24 V typ. 55mA + holding brake
Supports NoCoeStorage [}27] function
Reverse voltage protection 24 V power supply yes, through the body diode of the overvoltage protection device
Fusing
(to be carried out by the user)
Electrical isolation 500 V (E-bus/signal voltage)
Possible EtherCAT cycle times Multiple of 125µs
Configuration no address setting required
Weight approx. 60 g approx. 95 g
Permissible ambient temperature range dur-
ing operation
Permissible ambient temperature range dur-
ing storage
Permissible relative humidity 95%, no condensation
Dimensions (W x H x D) approx. 15 mm x 100 mm x 70 mm (width
Mounting [}34]
Vibration/shock resistance conforms to EN 60068-2-6 / EN 60068-2-27,
EMC immunity/emission conforms to EN 61000-6-2 / EN 61000-6-4
EMC category Category C3 - standard
Protection class IP20
Installation position
Approval CE
2 digital inputs
DC
2.8A
(without fan cartridge ZB8610)
rms
4.5A
(with fan cartridge ZB8610)
rms
5.7A
for 1 second 2.8A
rms
(without fan car-
rms
4.5A
9A
rms
rms
for 1 second
tridge ZB8610)
9A
for 1 second 2.8A
rms
(with fan cartridge
rms
ZB8610)
170 W (without fan cartridge ZB8610)
276 W
276 W (with fan cartridge ZB8610)
(series AM81xx)
Yes
50 V power supply yes, through the body diode of the overvoltage protection device
24 V power supply 10A
50 V power supply 10A
configuration via TwinCAT System Manager
0°C ... + 55°C
-25°C ... + 85°C
approx. 27 mm x 100 mm x 70 mm
aligned: 12 mm)
(width aligned: 24 mm)
on 35 mm mounting rail conforms to EN 60715
see also installation instructions [}37] for enhanced mechanical load capacity
according to IEC/EN 61800-3
Category C2, C1 - auxiliary filter required
without fan cartridge ZB8610: standard installing position
with fan cartridge ZB8610: standard installing position, other installing positions (example
1 & 2)
see notice [}43]
cULus [}54]
EL72x1-001x18 Version: 2.7
Product overview
3.3 Technology
The very compact EL72x1-xxxx servomotor terminal integrates a complete servo drive for servomotors up to
276W.
Servomotor
The servomotor is an electrical motor. Together with a servo amplifier the servomotor forms a servo drive.
The servomotor is operated in a closed control loop with position, torque or speed control.
The servo terminal EL72x1-xxxx supports control of permanent magnet synchronous motors. These consist
of 3 coils which are offset by 120° and a permanent magnet rotor.
Fig.7: Three synchronous motor coils, each offset by 120°
Servomotors particularly demonstrate their advantages in highly dynamic and precise positioning
applications:
• very high positioning accuracy in applications where maximum precision is required through integrated
position feedback
• high efficiency and high acceleration capacity
• servomotors are overload-proof and therefore have far greater dynamics than stepper motors, for
example.
• load-independent high torque right up to the higher speed ranges
• maintenance requirements reduced to a minimum
The EtherCAT servomotor terminal offers users the option to configure compact and cost-effective systems
without having to give up the benefits of a servomotor.
The Beckhoff servo terminal
The EL72x1-xxxx is a fully capable servo drive for direct connection to servomotors in the lower performance
range. There is no need for further modules or cabling to make a connection to the control system. This
results in a very compact control system solution. The E-Bus connection of the EL72x1-xxxx makes the full
functionality of EtherCAT available to the user. This includes in particular the short cycle time, low jitter,
simultaneity and easy diagnostics provided by EtherCAT. With this performance from EtherCAT the
dynamics that a servomotor can achieve can be used optimally.
EL72x1-001x 19Version: 2.7
Product overview
With a rated voltage up to 48VDC and a rated current of up to 4.5A, this enables the user to operate a
servomotor with a power of up to 276W. Permanent magnet synchronous motors with a rated current of up
to 4.5A can be connected as loads. The monitoring of numerous parameters, such as overvoltage and
undervoltage, overcurrent, terminal temperature or motor load, offers maximum operational reliability.
Modern power semiconductors guarantee minimum power loss and enable feedback into the DC link when
braking.
With the integration of a complete servo drive into a standard EL7201 EtherCAT Terminal only 12mm wide,
Beckhoff is setting new standards in matters of size. This small manufactured size is possible thanks to the
latest semiconductor technology and the resulting very high power factor. And yet, despite the small
dimensions, nothing has to be sacrificed.
The integrated fast control technology, with a field-orientated current and PI speed control, supports highly
dynamic positioning tasks. Apart from the direct connection of motor and resolver, the connection of a motor
holding brake is also possible.
The EL72x1-xx1x EtherCAT terminal has two digital inputs that can be used for the “Touch Probe” function.
The status of the inputs can be read by “Select Info Data” (MDP742 profile and DS402 profile).
Connection to the control system
A further big advantage of the EL72x1-xxxx is the easy incorporation into the control solution. The complete
integration into the control system simplifies commissioning and parameterization. As with all the other
Beckhoff terminals, the EL72x1-xxxx is simply inserted into the terminal network. Then the full terminal
network can be scanned by the TwinCAT System Manager or manually added by the application engineer.
In the System Manager the EL72x1-xxxx can be linked with the TwinCAT NC and parameterized.
Scalable motion solution
The servo terminal complements the product range of compact drive technology for Beckhoff I/O systems
that are available for stepper motors, AC and DC motors. With the EL72x1-xxxx, the range of servo drives
becomes even more finely scalable: from the miniature servo drive up to 170 W in the EtherCAT Terminal
through to the AX5000 servo drive with 118 KW, Beckhoff offers a wide range including the servomotors.
The AM81xx series was specially developed for the servomotor terminal EL72x1-xxxx.
One Cable Technology (OCT)
In the servomotors from the AM8100-xF2 x series the feedback signals are transmitted directly via the power
supply cable, so that power and feedback system are combined in a single motor connection cable. With the
use of the One Cable technology, the information is sent reliably and without interference through a digital
interface. Since a cable and plug are omitted at both the motor and controller end, the component and
commissioning costs are reduced.
Thermal I²T motor model
The thermal I²T motor model represents the thermal behavior of the motor winding taking into account the
absolute thermal resistance Rth and the thermal capacity Cth of motor and the stator winding.
The model assumes that the motor reaches its maximum continuous operating temperature T
continuous operation with rated current I
. This temperature corresponds to 100% motor load. During
nom
nom
during
operation at rated current the motor model reaches a load of 63% after a time of τth=Rth∙Cth and slowly
reaches its continuous operating temperature.
If the motor is operated with a current that is greater than the rated current, the model reaches 100% load
more quickly.
If the load of the I²T model exceeds 100%, the requested set current is limited to the rated current, in order to
protect the motor winding thermally. The load reduces to a maximum of 100%. If the current falls below the
rated current, the load falls below 100% and the set current limitation is cancelled.
For a motor that has been cooled to ambient temperature, the time for reaching 100% load with a set current
that exceeds the rated current can be estimated with τth∙I
nom
²/I
actual
².
The actual load must be known for exact calculation of the time when the 100% load threshold is exceeded.
EL72x1-001x20 Version: 2.7
Fig.8: Limitation to the rated motor current
3.4 Start-up
Product overview
For commissioning:
• mount the EL72x1-901x as described in the chapter Installation.
• configure the EL72x1-901x in TwinCAT as described in the chapter Commissioning.
EL72x1-001x 21Version: 2.7
Basics communication
4 Basics communication
4.1 EtherCAT basics
Please refer to the EtherCAT System Documentation for the EtherCAT fieldbus basics.
4.2 EtherCAT cabling – wire-bound
The cable length between two EtherCAT devices must not exceed 100 m. This results from the FastEthernet
technology, which, above all for reasons of signal attenuation over the length of the cable, allows a maximum
link length of 5 + 90 + 5 m if cables with appropriate properties are used. See also the Design
recommendations for the infrastructure for EtherCAT/Ethernet.
Cables and connectors
For connecting EtherCAT devices only Ethernet connections (cables + plugs) that meet the requirements of
at least category 5 (CAt5) according to EN 50173 or ISO/IEC 11801 should be used. EtherCAT uses 4 wires
for signal transfer.
EtherCAT uses RJ45 plug connectors, for example. The pin assignment is compatible with the Ethernet
standard (ISO/IEC 8802-3).
Pin Color of conductor Signal Description
1 yellow TD + Transmission Data +
2 orange TD - Transmission Data 3 white RD + Receiver Data +
6 blue RD - Receiver Data -
Due to automatic cable detection (auto-crossing) symmetric (1:1) or cross-over cables can be used between
EtherCAT devices from Beckhoff.
Recommended cables
Suitable cables for the connection of EtherCAT devices can be found on the Beckhoff website!
E-Bus supply
A bus coupler can supply the EL terminals added to it with the E-bus system voltage of 5V; a coupler is
thereby loadable up to 2A as a rule (see details in respective device documentation).
Information on how much current each EL terminal requires from the E-bus supply is available online and in
the catalogue. If the added terminals require more current than the coupler can supply, then power feed
terminals (e.g. EL9410) must be inserted at appropriate places in the terminal strand.
The pre-calculated theoretical maximum E-Bus current is displayed in the TwinCAT System Manager. A
shortfall is marked by a negative total amount and an exclamation mark; a power feed terminal is to be
placed before such a position.
EL72x1-001x22 Version: 2.7
Basics communication
Fig.9: System manager current calculation
NOTE
Malfunction possible!
The same ground potential must be used for the E-Bus supply of all EtherCAT terminals in a terminal block!
4.3 General notes for setting the watchdog
ELxxxx terminals are equipped with a safety feature (watchdog) that switches off the outputs after a
specifiable time e.g. in the event of an interruption of the process data traffic, depending on the device and
settings, e.g. in OFF state.
The EtherCAT slave controller (ESC) in the EL2xxx terminals features two watchdogs:
• SM watchdog (default: 100 ms)
• PDI watchdog (default: 100 ms)
SM watchdog (SyncManager Watchdog)
The SyncManager watchdog is reset after each successful EtherCAT process data communication with the
terminal. If no EtherCAT process data communication takes place with the terminal for longer than the set
and activated SM watchdog time, e.g. in the event of a line interruption, the watchdog is triggered and the
outputs are set to FALSE. The OP state of the terminal is unaffected. The watchdog is only reset after a
successful EtherCAT process data access. Set the monitoring time as described below.
The SyncManager watchdog monitors correct and timely process data communication with the ESC from the
EtherCAT side.
PDI watchdog (Process Data Watchdog)
If no PDI communication with the EtherCAT slave controller (ESC) takes place for longer than the set and
activated PDI watchdog time, this watchdog is triggered.
PDI (Process Data Interface) is the internal interface between the ESC and local processors in the EtherCAT
slave, for example. The PDI watchdog can be used to monitor this communication for failure.
The PDI watchdog monitors correct and timely process data communication with the ESC from the
application side.
The settings of the SM- and PDI-watchdog must be done for each slave separately in the TwinCAT System
Manager.
EL72x1-001x 23Version: 2.7
Basics communication
Fig.10: EtherCAT tab -> Advanced Settings -> Behavior -> Watchdog
Notes:
• the multiplier is valid for both watchdogs.
• each watchdog has its own timer setting, the outcome of this in summary with the multiplier is a
resulting time.
• Important: the multiplier/timer setting is only loaded into the slave at the start up, if the checkbox is
activated.
If the checkbox is not activated, nothing is downloaded and the ESC settings remain unchanged.
Multiplier
Multiplier
Both watchdogs receive their pulses from the local terminal cycle, divided by the watchdog multiplier:
1/25 MHz * (watchdog multiplier + 2) = 100µs (for default setting of 2498 for the multiplier)
The standard setting of 1000 for the SM watchdog corresponds to a release time of 100ms.
The value in multiplier + 2 corresponds to the number of basic 40 ns ticks representing a watchdog tick.
The multiplier can be modified in order to adjust the watchdog time over a larger range.
EL72x1-001x24 Version: 2.7
Basics communication
Example “Set SM watchdog”
This checkbox enables manual setting of the watchdog times. If the outputs are set and the EtherCAT
communication is interrupted, the SM watchdog is triggered after the set time and the outputs are erased.
This setting can be used for adapting a terminal to a slower EtherCAT master or long cycle times. The
default SM watchdog setting is 100ms. The setting range is 0...65535. Together with a multiplier with a
range of 1...65535 this covers a watchdog period between 0...~170 seconds.
Calculation
Multiplier = 2498 → watchdog base time = 1 / 25MHz * (2498 + 2) = 0.0001seconds = 100µs
SM watchdog = 10000 → 10000 * 100µs = 1second watchdog monitoring time
CAUTION
Undefined state possible!
The function for switching off of the SM watchdog via SM watchdog = 0 is only implemented in terminals
from version -0016. In previous versions this operating mode should not be used.
CAUTION
Damage of devices and undefined state possible!
If the SM watchdog is activated and a value of 0 is entered the watchdog switches off completely. This is
the deactivation of the watchdog! Set outputs are NOT set in a safe state, if the communication is interrupted.
4.4 EtherCAT State Machine
The state of the EtherCAT slave is controlled via the EtherCAT State Machine (ESM). Depending upon the
state, different functions are accessible or executable in the EtherCAT slave. Specific commands must be
sent by the EtherCAT master to the device in each state, particularly during the bootup of the slave.
A distinction is made between the following states:
• Init
• Pre-Operational
• Safe-Operational and
• Operational
• Boot
The regular state of each EtherCAT slave after bootup is the OP state.
EL72x1-001x 25Version: 2.7
Basics communication
Fig.11: States of the EtherCAT State Machine
Init
After switch-on the EtherCAT slave in the Init state. No mailbox or process data communication is possible.
The EtherCAT master initializes sync manager channels 0 and 1 for mailbox communication.
Pre-Operational (Pre-Op)
During the transition between Init and Pre-Op the EtherCAT slave checks whether the mailbox was initialized
correctly.
In Pre-Op state mailbox communication is possible, but not process data communication. The EtherCAT
master initializes the sync manager channels for process data (from sync manager channel 2), the FMMU
channels and, if the slave supports configurable mapping, PDO mapping or the sync manager PDO
assignment. In this state the settings for the process data transfer and perhaps terminal-specific parameters
that may differ from the default settings are also transferred.
Safe-Operational (Safe-Op)
During transition between Pre-Op and Safe-Op the EtherCAT slave checks whether the sync manager
channels for process data communication and, if required, the distributed clocks settings are correct. Before
it acknowledges the change of state, the EtherCAT slave copies current input data into the associated DPRAM areas of the EtherCAT slave controller (ECSC).
In Safe-Op state mailbox and process data communication is possible, although the slave keeps its outputs
in a safe state, while the input data are updated cyclically.
Outputs in SAFEOP state
The default set watchdog [}23] monitoring sets the outputs of the module in a safe state - depending on the settings in SAFEOP and OP - e.g. in OFF state. If this is prevented by deactivation of the
watchdog monitoring in the module, the outputs can be switched or set also in the SAFEOP state.
Operational (Op)
Before the EtherCAT master switches the EtherCAT slave from Safe-Op to Op it must transfer valid output
data.
In the Op state the slave copies the output data of the masters to its outputs. Process data and mailbox
communication is possible.
EL72x1-001x26 Version: 2.7
Basics communication
Boot
In the Boot state the slave firmware can be updated. The Boot state can only be reached via the Init state.
In the Boot state mailbox communication via the file access over EtherCAT (FoE) protocol is possible, but no
other mailbox communication and no process data communication.
4.5 CoE Interface
General description
The CoE interface (CAN application protocol over EtherCAT)) is used for parameter management of
EtherCAT devices. EtherCAT slaves or the EtherCAT master manage fixed (read only) or variable
parameters which they require for operation, diagnostics or commissioning.
CoE parameters are arranged in a table hierarchy. In principle, the user has read access via the fieldbus.
The EtherCAT master (TwinCAT System Manager) can access the local CoE lists of the slaves via
EtherCAT in read or write mode, depending on the attributes.
Different CoE parameter types are possible, including string (text), integer numbers, Boolean values or larger
byte fields. They can be used to describe a wide range of features. Examples of such parameters include
manufacturer ID, serial number, process data settings, device name, calibration values for analog
measurement or passwords.
The order is specified in two levels via hexadecimal numbering: (main)index, followed by subindex. The
value ranges are
• Index: 0x0000 …0xFFFF (0...65535
• SubIndex: 0x00…0xFF (0...255
dez
)
dez
)
A parameter localized in this way is normally written as 0x8010:07, with preceding “0x” to identify the
hexadecimal numerical range and a colon between index and subindex.
The relevant ranges for EtherCAT fieldbus users are:
• 0x1000: This is where fixed identity information for the device is stored, including name, manufacturer,
serial number etc., plus information about the current and available process data configurations.
• 0x8000: This is where the operational and functional parameters for all channels are stored, such as
filter settings or output frequency.
Other important ranges are:
• 0x4000: here are the channel parameters for some EtherCAT devices. Historically, this was the first
parameter area before the 0x8000 area was introduced. EtherCAT devices that were previously
equipped with parameters in 0x4000 and changed to 0x8000 support both ranges for compatibility
reasons and mirror internally.
• 0x6000: Input PDOs (“input” from the perspective of the EtherCAT master)
• 0x7000: Output PDOs (“output” from the perspective of the EtherCAT master)
Availability
Not every EtherCAT device must have a CoE list. Simple I/O modules without dedicated processor
usually have no variable parameters and therefore no CoE list.
If a device has a CoE list, it is shown in the TwinCAT System Manager as a separate tab with a listing of the
elements:
EL72x1-001x 27Version: 2.7
Basics communication
Fig.12: “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
parameterized and enter a value in the “SetValue” dialog.
• from the control system/PLC via ADS, e.g. through blocks from the TcEtherCAT.lib library
This is recommended for modifications while the system is running or if no System Manager or
operating staff are available.
Data management
If slave CoE parameters are modified online, Beckhoff devices store any changes in a fail-safe
manner in the EEPROM, i.e. the modified CoE parameters are still available after a restart.
The situation may be different with other manufacturers.
An EEPROM is subject to a limited lifetime with respect to write operations. From typically 100,000
write operations onwards it can no longer be guaranteed that new (changed) data are reliably saved
or are still readable. This is irrelevant for normal commissioning. However, if CoE parameters are
continuously changed via ADS at machine runtime, it is quite possible for the lifetime limit to be
reached. Support for the NoCoeStorage function, which suppresses the saving of changed CoE values, depends on the firmware version.
Please refer to the technical data in this documentation as to whether this applies to the respective
device.
• If the function is supported: the function is activated by entering the code word 0x12345678 once
in CoE 0xF008 and remains active as long as the code word is not changed. After switching the
device on it is then inactive. Changed CoE values are not saved in the EEPROM and can thus
be changed any number of times.
• Function is not supported: continuous changing of CoE values is not permissible in view of the
lifetime limit.
EL72x1-001x28 Version: 2.7
Startup list
Changes in the local CoE list of the terminal are lost if the terminal is replaced. If a terminal is replaced with a new Beckhoff terminal, it will have the default settings. It is therefore advisable to link
all changes in the CoE list of an EtherCAT slave with the Startup list of the slave, which is processed whenever the EtherCAT fieldbus is started. In this way a replacement EtherCAT slave can
automatically be parameterized with the specifications of the user.
If EtherCAT slaves are used which are unable to store local CoE values permanently, the Startup
list must be used.
Recommended approach for manual modification of CoE parameters
• Make the required change in the System Manager
The values are stored locally in the EtherCAT slave
• If the value is to be stored permanently, enter it in the Startup list.
The order of the Startup entries is usually irrelevant.
Basics communication
Fig.13: Startup list in the TwinCAT System Manager
The Startup list may already contain values that were configured by the System Manager based on the ESI
specifications. Additional application-specific entries can be created.
Online/offline list
While working with the TwinCAT System Manager, a distinction has to be made whether the EtherCAT
device is “available”, i.e. switched on and linked via EtherCAT and therefore online, or whether a
configuration is created offline without connected slaves.
In both cases a CoE list as shown in Fig. “CoE online tab” is displayed. The connectivity is shown as offline/
online.
• If the slave is offline
◦ The offline list from the ESI file is displayed. In this case modifications are not meaningful or
possible.
◦ The configured status is shown under Identity.
◦ No firmware or hardware version is displayed, since these are features of the physical device.
◦ Offline is shown in red.
EL72x1-001x 29Version: 2.7
Basics communication
Fig.14: Offline list
• If the slave is online
◦ The actual current slave list is read. This may take several seconds, depending on the size and
cycle time.
◦ The actual identity is displayed
◦ The firmware and hardware version of the equipment according to the electronic information is
displayed
◦ Online is shown in green.
Fig.15: Online list
EL72x1-001x30 Version: 2.7
Basics communication
Channel-based order
The CoE list is available in EtherCAT devices that usually feature several functionally equivalent channels.
For example, a 4-channel analog 0...10V input terminal also has four logical channels and therefore four
identical sets of parameter data for the channels. In order to avoid having to list each channel in the
documentation, the placeholder “n” tends to be used for the individual channel numbers.
In the CoE system 16 indices, each with 255 subindices, are generally sufficient for representing all channel
parameters. The channel-based order is therefore arranged in 16
dec
/10
steps. The parameter range
hex
0x8000 exemplifies this:
• Channel 0: parameter range 0x8000:00 ... 0x800F:255
• Channel 1: parameter range 0x8010:00 ... 0x801F:255
• Channel 2: parameter range 0x8020:00 ... 0x802F:255
• ...
This is generally written as 0x80n0.
Detailed information on the CoE interface can be found in the EtherCAT system documentation on the
Beckhoff website.
EL72x1-001x 31Version: 2.7
Basics communication
4.6 Distributed Clock
The distributed clock represents a local clock in the EtherCAT slave controller (ESC) with the following
characteristics:
• Unit 1 ns
• Zero point 1.1.2000 00:00
• Size 64 bit (sufficient for the next 584 years; however, some EtherCAT slaves only offer 32-bit support,
i.e. the variable overflows after approx. 4.2 seconds)
• The EtherCAT master automatically synchronizes the local clock with the master clock in the EtherCAT
bus with a precision of < 100 ns.
For detailed information please refer to the EtherCAT system description.
EL72x1-001x32 Version: 2.7
Installation
5 Installation
5.1 Instructions for ESD protection
NOTE
Destruction of the devices by electrostatic discharge possible!
The devices contain components at risk from electrostatic discharge caused by improper handling.
• Please ensure you are electrostatically discharged and avoid touching the contacts of the device directly.
• Avoid contact with highly insulating materials (synthetic fibers, plastic film etc.).
• Surroundings (working place, packaging and personnel) should by grounded probably, when handling
with the devices.
• Each assembly must be terminated at the right hand end with an EL9011 or EL9012 bus end cap, to ensure the protection class and ESD protection.
Fig.16: Spring contacts of the Beckhoff I/O components
EL72x1-001x 33Version: 2.7
Installation
5.2 Installation on mounting rails
WARNING
Risk of electric shock and damage of device!
Bring the bus terminal system into a safe, powered down state before starting installation, disassembly or
wiring of the bus terminals!
Assembly
Fig.17: Attaching on mounting rail
The bus coupler and bus terminals are attached to commercially available 35mm mounting rails (DIN rails
according to EN60715) by applying slight pressure:
1. First attach the fieldbus coupler to the mounting rail.
2. The bus terminals are now attached on the right-hand side of the fieldbus coupler. Join the components with tongue and groove and push the terminals against the mounting rail, until the lock clicks
onto the mounting rail.
If the terminals are clipped onto the mounting rail first and then pushed together without tongue and
groove, the connection will not be operational! When correctly assembled, no significant gap should
be visible between the housings.
Fixing of mounting rails
The locking mechanism of the terminals and couplers extends to the profile of the mounting rail. At
the installation, the locking mechanism of the components must not come into conflict with the fixing
bolts of the mounting rail. To mount the mounting rails with a height of 7.5mm under the terminals
and couplers, you should use flat mounting connections (e.g. countersunk screws or blind rivets).
EL72x1-001x34 Version: 2.7
Disassembly
Fig.18: Disassembling of terminal
Each terminal is secured by a lock on the mounting rail, which must be released for disassembly:
Installation
1. Pull the terminal by its orange-colored lugs approximately 1cm away from the mounting rail. In doing
so for this terminal the mounting rail lock is released automatically and you can pull the terminal out of
the bus terminal block easily without excessive force.
2. Grasp the released terminal with thumb and index finger simultaneous at the upper and lower grooved
housing surfaces and pull the terminal out of the bus terminal block.
Connections within a bus terminal block
The electric connections between the Bus Coupler and the Bus Terminals are automatically realized by
joining the components:
• The six spring contacts of the K-Bus/E-Bus deal with the transfer of the data and the supply of the Bus
Terminal electronics.
• The power contacts deal with the supply for the field electronics and thus represent a supply rail within
the bus terminal block. The power contacts are supplied via terminals on the Bus Coupler (up to 24V)
or for higher voltages via power feed terminals.
Power Contacts
During the design of a bus terminal block, the pin assignment of the individual Bus Terminals must
be taken account of, since some types (e.g. analog Bus Terminals or digital 4-channel Bus Terminals) do not or not fully loop through the power contacts. Power Feed Terminals (KL91xx, KL92xx
or EL91xx, EL92xx) interrupt the power contacts and thus represent the start of a new supply rail.
PE power contact
The power contact labeled PE can be used as a protective earth. For safety reasons this contact mates first
when plugging together, and can ground short-circuit currents of up to 125A.
EL72x1-001x 35Version: 2.7
Installation
Fig.19: Power contact on left side
NOTE
Possible damage of the device
Note that, for reasons of electromagnetic compatibility, the PE contacts are capacitatively coupled to the
mounting rail. This may lead to incorrect results during insulation testing or to damage on the terminal (e.g.
disruptive discharge to the PE line during insulation testing of a consumer with a nominal voltage of 230V).
For insulation testing, disconnect the PE supply line at the Bus Coupler or the Power Feed Terminal! In order to decouple further feed points for testing, these Power Feed Terminals can be released and pulled at
least 10mm from the group of terminals.
WARNING
Risk of electric shock!
The PE power contact must not be used for other potentials!
EL72x1-001x36 Version: 2.7
Installation
5.3 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
60.1Hz<f<500Hz acceleration 5g, constant amplitude
Shocks 1000 shocks in each direction, in 3 axes
25 g, 6 ms
Additional installation instructions
For terminals with enhanced mechanical load capacity, the following additional installation instructions apply:
• The enhanced mechanical load capacity is valid for all permissible installation positions
• Use a mounting rail according to EN 60715 TH35-15
• Fix the terminal segment on both sides of the mounting rail with a mechanical fixture, e.g. an earth
terminal or reinforced end clamp
• The maximum total extension of the terminal segment (without coupler) is:
64 terminals (12mm mounting with) or 32 terminals (24mm 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. 10cm should be maintained to the cable duct.
EL72x1-001x 37Version: 2.7
Installation
5.4 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.20: 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.
Pluggable wiring
Fig.21: 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.
EL72x1-001x38 Version: 2.7
Installation
Conductor cross sections between 0.08mm2 and 2.5mm2 can continue to be used with the proven spring
force technology.
The overview and nomenclature of the product names for KSxxxx and ESxxxx series has been retained as
known from KLxxxx and ELxxxx series.
High Density Terminals (HD Terminals)
Fig.22: 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 12mm Bus Terminals. Massive
conductors and conductors with a wire end sleeve can be inserted directly into the spring loaded terminal
point without tools.
Wiring HD Terminals
The High Density Terminals of the KLx8xx and ELx8xx series doesn't support steady wiring.
Ultrasonically "bonded" (ultrasonically welded) conductors
Ultrasonically “bonded” conductors
It is also possible to connect the Standard and High Density terminals with ultrasonically
“bonded” (ultrasonically welded) conductors. In this case, please note the tables concerning the
wire-size width [}40] below!
EL72x1-001x 39Version: 2.7
Installation
Wiring
Terminals for standard wiring ELxxxx/KLxxxx and for pluggable wiring ESxxxx/KSxxxx
Fig.23: 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 ... 2,5mm
2
0.08 ... 2.5mm
2
Wire stripping length 8 ... 9mm 9 ... 10mm
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 ... 0.75mm
Wire size width (single core wires) 0.08 ... 1.5mm
Wire size width (fine-wire conductors) 0.25 ... 1.5mm
Wire size width (ultrasonically “bonded" conductors)
only 1.5mm2 (see notice [}39]!)
2
2
2
Wire stripping length 8 ... 9mm
EL72x1-001x40 Version: 2.7
Shielding
Installation
Shielding
Analog sensors and actors should always be connected with shielded, twisted paired wires.
EL72x1-001x 41Version: 2.7
Installation
5.5 Positioning of passive Terminals
Hint for positioning of passive terminals in the bus terminal block
EtherCAT Terminals (ELxxxx / ESxxxx), which do not take an active part in data transfer within the
bus terminal block are so called passive terminals. The passive terminals have no current consumption out of the E-Bus.
To ensure an optimal data transfer, you must not directly string together more than two passive terminals!
Examples for positioning of passive terminals (highlighted)
Fig.24: Correct positioning
Fig.25: Incorrect positioning
EL72x1-001x42 Version: 2.7
Installation
5.6 Installation position for operation with or without fan
NOTE
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 for operation without fan
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 of installation position for
operating without fan“).
The terminals are ventilated from below, which enables optimum cooling of the electronics through
convection.
Fig.26: Recommended distances of installation position for operating without fan
Compliance with the distances shown in Fig. “Recommended distances of installation position for operating
without fan” is recommended.
For further information regarding the operation without fan refer to the Technical Data of the terminal.
Standard installation position for operation with fan
The standard installation position for operation with fan 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
installation position for operation with fan).
The terminals are ventilated fan supported (e.g. with fan cartridge ZB8610) from below.
EL72x1-001x 43Version: 2.7
Installation
Fig.27: Recommended distances for installation position for operation with fan
Other installation positions
Due to the enforced effect of the fan on the ventilation of the terminals, other installation positions (see Fig.
“Other installation positions, example 1 + 2“) may be permitted where appropriate.
See corresponding notes in the Technical Data of the terminal.
Fig.28: Other installation positions, example 1
EL72x1-001x44 Version: 2.7
Fig.29: Other installation positions, example 2
Installation
EL72x1-001x 45Version: 2.7
Installation
5.7 Shielding concept
Together with the shield busbar, the prefabricated cables from Beckhoff Automation offer optimum protection
against electromagnetic interference.
It is highly recommended to apply the shield as close as possible to the terminal, in order to minimize
operational disturbances.
Connection of the motor cable to the shield busbar
Fasten the shield busbar supports 1 to the DIN rail 2. The mounting rail 2 must be in contact with the metallic
rear wall of the control cabinet over a wide area. Install the shield busbar 3 as shown below.
As an alternative, a shield busbar clamp 3a can be screwed directly to the metallic rear wall of the control
cabinet (fig. “shield busbar clamp”)
Fig.30: Shield busbar
EL72x1-001x46 Version: 2.7
Installation
Fig.31: Shield busbar clamp
Connect the cores 4 of the motor cable 5, then attach the copper-sheathed end 6 of the motor cable 5 with
the shield clamp 7 to the shield busbar 3 or shield busbar clamp 3a. Tighten the screw 8 to the stop.
Fasten the PE clamp 9 to the shield busbar 3 or shield busbar clamp 3a. Clamp the PE core 10 of the motor
cable 5 under the PE clamp 9.
Fig.32: Shield connection
EL72x1-001x 47Version: 2.7
Installation
Connection of the feedback cable to the motor
Twisting of the feedback cable cores
The feedback cable cores should be twisted, in order to avoid operational disturbances.
When screwing the feedback plug to the motor, the shield of the feedback cable is connected via the metallic
plug fastener.
On the terminal side the shield can also be connected. Connect the cores of the feedback cable and attach
the copper-sheathed end of the feedback cable to the shield busbar 3 or shield busbar clamp 3a with the
shield clamp 7. The motor cable and the feedback cable can be connected to the shield clamp 7 with the
screw 8.
EL72x1-001x48 Version: 2.7
Installation
5.8 Notes on current measurements using Hall sensors
The device described in this documentation features one or several integrated Hall sensor for the purpose of
current measurements.
During this process, the Hall sensor monitors the magnetic field generated by a current flowing through a
conductor.
In order to prevent compromising the measurement we recommend screening exterior magnetic fields from
the device, or to keep such fields at an adequate distance.
Fig.33: Note
Background
A current-carrying conductor generates a magnetic field around it according to
B = µ0 * I / (2π * d)
with
B [Tesla] magnetic field
µ0 = 4*π*10-7 [H/m] (assumption: no magnetic shielding)
I [A] current
d [m] distance to conductor
Interference from external magnetic fields
The magnetic field strength should not exceed a permitted level all around the device.
In practice this equates to a recommended minimum distance between a conductor and the device
surface as follows:
- Current 10 A: 12mm
- Current 20 A: 25mm
- Current 40 A: 50 mm
Unless specified otherwise in the device documentation, stringing together modules (e.g. terminal
blocks based on a 12 mm grid) of same type (e.g. EL2212-0000) is permitted.
EL72x1-001x 49Version: 2.7
Installation
5.9 LEDs and connection
EL7201-001x
Fig.34: EL7201-001x - LEDs
LEDs
LED Color Meaning
RUN green This LED indicates the terminal's operating state:
off State of the EtherCAT State Machine: INIT=initialization of the terminal
flashing
rapidly
flashing State of the EtherCAT State Machine: PREOP = function for mailbox communication and
single flash State of the EtherCAT State Machine: SAFEOP = verification of the Sync Manager chan-
on State of the EtherCAT State Machine: OP = normal operating state; mailbox and process
Drive OK green on Driver stage ready for operation
Limit orange on
Read OCT green flashing The electronic type plate is being read
off The reading of the electronic type plate has been completed
Warning orange flashing Error while reading the type plate
on
Enable green on
Error red on
+24 V via power
contacts
DC link supply green on Voltage for the DC link supply is present.
green on 24 V voltage supply for the terminal is present.
State of the EtherCAT State Machine: BOOTSTRAP = function for firmware updates
[}205] of the terminal
different standard-settings set
nels and the distributed clocks.
Outputs remain in safe state
data communication is possible
The LED is linked with bit 11 of the status word (MDP742 [}157] / DS402 [}179]) (internal
limit active)
Limit reached (e.g. torque or speed limit)
The LED is linked with bit 7 of the status word (MDP742 [}157] / DS402 [}179]) (warning)
The “Warning” threshold value is exceeded.
I²T model
Temperature (80°C) exceeded
Voltage
The LED is linked with the bits 1 and 2 of status word (MDP742 [}157] / DS402 [}179]) (if
"Switched on" or "Operation enabled")
Driver stage enabled
The LED is linked with bit 3 of the status word (MDP742 [}157] / DS402 [}179]) (fault)
The “Error” threshold value is exceeded.
Overcurrent
Voltage not available
Resolver not connected
Max. temperature (100°C) exceeded
NOTE
Fuse protection of the supply voltage
The electrical protection of the load voltage must be selected in such a way that the maximum flowing current is limited to 3 times the rated current (max. 1 second)!
EL72x1-001x50 Version: 2.7
Connection
Installation
Fig.35: EL7201-0010 - Connection
Terminal point Name Comment
1 OCT + Positive input of the absolute feedback
2 Input 1 Digital input 1
3 +24V Power contact +24V
4 U Motor phase U
5 W Motor phase W
6 Brake + Motor brake +
7 48V DC link supply + (8...48 V)
8
9 OCT - Negative input of the absolute feedback
10 Input 2 Digital input 2
11 0V Power contact 0 V
12 V Motor phase V
13 n.c. not connected
14 Brake GND Motor brake 0V
15 0V DC link 0V supply
16
EL72x1-001x 51Version: 2.7
Installation
EL7211-001x
Fig.36: EL7211-001x - LEDs
LEDs
LED Color Meaning
RUN green This LED indicates the terminal's operating state:
off State of the EtherCAT State Machine: INIT=initialization of the terminal
flashing
rapidly
flashing State of the EtherCAT State Machine: PREOP = function for mailbox communication and
single flash State of the EtherCAT State Machine: SAFEOP = verification of the Sync Manager chan-
on State of the EtherCAT State Machine: OP = normal operating state; mailbox and process
Drive OK green on Driver stage ready for operation
Limit orange on
Read OCT green flashing The electronic type plate is being read
off The reading of the electronic type plate has been completed
Warning orange flashing Error while reading the type plate
on
Enable green on
Error red on
+24 V via power
contacts
DC link supply green on Voltage for the DC link supply is present.
green on 24 V voltage supply for the terminal is present.
State of the EtherCAT State Machine: BOOTSTRAP = function for firmware updates
[}205] of the terminal
different standard-settings set
nels and the distributed clocks.
Outputs remain in safe state
data communication is possible
The LED is linked with bit 11 of the status word (MDP742 [}157] / DS402 [}179]) (internal
limit active)
Limit reached (e.g. torque or speed limit)
The LED is linked with bit 7 of the status word (MDP742 [}157] / DS402 [}179]) (warning)
The “Warning” threshold value is exceeded.
I²T model
Temperature (80°C) exceeded
Voltage
The LED is linked with the bits 1 and 2 of status word (MDP742 [}157] / DS402 [}179]) (if
"Switched on" or "Operation enabled")
Driver stage enabled
The LED is linked with bit 3 of the status word (MDP742 [}157] / DS402 [}179]) (fault)
The “Error” threshold value is exceeded.
Overcurrent
Voltage not available
Resolver not connected
Max. temperature (100°C) exceeded
NOTE
Fuse protection of the supply voltage
The electrical protection of the load voltage must be selected in such a way that the maximum flowing current is limited to 3 times the rated current (max. 1 second)!
EL72x1-001x52 Version: 2.7
Connection
Installation
Fig.37: EL7211-001x - Connection
Terminal point Name Comment
1 OCT + Positive input of the absolute feedback
2 Input 1 Digital input 1
3 +24 V Power contact +24 V
4 U Motor phase U
5 W Motor phase W
6 Brake + Motor brake +
7 48V DC link supply + (8...48 V)
8
9 OCT - Negative input of the absolute feedback
10 Input 2 Digital input 2
11 0V Power contact 0 V
12 V Motor phase V
13 n.c. not connected
14 Brake GND Motor brake 0V
15 0V DC link 0V supply
16
1' - 16' n.c.
EL72x1-001x 53Version: 2.7
Installation
5.10 UL notice - Compact Motion
Application
Beckhoff EtherCAT modules are intended for use with Beckhoff’s UL Listed EtherCAT System only.
Examination
For cULus examination, the Beckhoff I/O System has only been investigated for risk of fire
and electrical shock (in accordance with UL508 and CSAC22.2 No.142).
For devices with Ethernet connectors
Not for connection to telecommunication circuits.
Notes on motion devices
• Motor overtemperature
Motor overtemperature sensing is not provided by the drive.
• Application for compact motion devices
The modules are intended for use only within Beckhoff’s Programmable Controller system Listed in File E172151.
• Galvanic isolation from the supply
The modules are intended for operation within circuits not connected directly to the supply mains (galvanically isolated from the supply, i.e. on transformer secondary).
• Requirement for environmental conditions
For use in Pollution Degree 2 Environment only.
Basic principles
UL certification according to UL508. Devices with this kind of certification are marked by this sign:
Application
If terminals certified with restrictions are used, then the current consumption at 24VDC must be limited
accordingly by means of supply
• from an isolated source protected by a fuse of max. 4A (according to UL248) or
• from a voltage supply complying with NECclass2.
A voltage source complying with NECclass2 may not be connected in series or parallel with another
NECclass2compliant voltage supply!
These requirements apply to the supply of all EtherCAT bus couplers, power adaptor terminals, Bus
Terminals and their power contacts.
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Commissioning
6 Commissioning
6.1 TwinCAT Development Environment
The Software for automation TwinCAT (The Windows Control and Automation Technology) will be
distinguished into:
• TwinCAT2: System Manager (Configuration) & PLC Control (Programming)
• TwinCAT3: Enhancement of TwinCAT2 (Programming and Configuration takes place via a common
Development Environment)
Details:
• TwinCAT2:
◦ Connects I/O devices to tasks in a variable-oriented manner
◦ Connects tasks to tasks in a variable-oriented manner
◦ Supports units at the bit level
◦ Supports synchronous or asynchronous relationships
◦ Exchange of consistent data areas and process images
◦ Datalink on NT - Programs by open Microsoft Standards (OLE, OCX, ActiveX, DCOM+, etc.)
◦ Integration of IEC 61131-3-Software-SPS, Software- NC and Software-CNC within Windows
NT/2000/XP/Vista, Windows 7, NT/XP Embedded, CE
◦ Interconnection to all common fieldbusses
◦ More…
Additional features:
• TwinCAT3 (eXtended Automation):
◦ Visual-Studio®-Integration
◦ Choice of the programming language
◦ Supports object orientated extension of IEC 61131-3
◦ Usage of C/C++ as programming language for real time applications
◦ Connection to MATLAB®/Simulink®
◦ Open interface for expandability
◦ Flexible run-time environment
◦ Active support of Multi-Core- und 64-Bit-Operatingsystem
◦ Automatic code generation and project creation with the TwinCAT Automation Interface
◦ More…
Within the following sections commissioning of the TwinCAT Development Environment on a PC System for
the control and also the basically functions of unique control elements will be explained.
Please see further information to TwinCAT2 and TwinCAT3 at http://infosys.beckhoff.com.
6.1.1 Installation of the TwinCAT real-time driver
In order to assign real-time capability to a standard Ethernet port of an IPC controller, the Beckhoff real-time
driver has to be installed on this port under Windows.
This can be done in several ways. One option is described here.
In the System Manager call up the TwinCAT overview of the local network interfaces via Options → Show
Real Time Ethernet Compatible Devices.
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Commissioning
Fig.38: System Manager “Options” (TwinCAT2)
This have to be called up by the Menü “TwinCAT” within the TwinCAT3 environment:
Fig.39: Call up under VS Shell (TwinCAT3)
The following dialog appears:
Fig.40: Overview of network interfaces
Interfaces listed under “Compatible devices” can be assigned a driver via the “Install” button. A driver should
only be installed on compatible devices.
A Windows warning regarding the unsigned driver can be ignored.
Alternatively an EtherCAT-device can be inserted first of all as described in chapter Offline configuration
creation, section “Creating the EtherCAT device” [}66] in order to view the compatible ethernet ports via its
EtherCAT properties (tab “Adapter”, button “Compatible Devices…”):
EL72x1-001x56 Version: 2.7
Commissioning
Fig.41: EtherCAT device properties(TwinCAT2): click on “Compatible Devices…” of tab “Adapte””
TwinCAT 3: the properties of the EtherCAT device can be opened by double click on “Device .. (EtherCAT)”
within the Solution Explorer under “I/O”:
After the installation the driver appears activated in the Windows overview for the network interface
(Windows Start → System Properties → Network)
Fig.42: Windows properties of the network interface
A correct setting of the driver could be:
EL72x1-001x 57Version: 2.7
Commissioning
Fig.43: Exemplary correct driver setting for the Ethernet port
Other possible settings have to be avoided:
EL72x1-001x58 Version: 2.7
Commissioning
Fig.44: Incorrect driver settings for the Ethernet port
EL72x1-001x 59Version: 2.7
Commissioning
IP address of the port used
IP address/DHCP
In most cases an Ethernet port that is configured as an EtherCAT device will not transport general
IP packets. For this reason and in cases where an EL6601 or similar devices are used it is useful to
specify a fixed IP address for this port via the “Internet Protocol TCP/IP” driver setting and to disable
DHCP. In this way the delay associated with the DHCP client for the Ethernet port assigning itself a
default IP address in the absence of a DHCP server is avoided. A suitable address space is
192.168.x.x, for example.
Fig.45: TCP/IP setting for the Ethernet port
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Commissioning
6.1.2 Notes regarding ESI device description
Installation of the latest ESI device description
The TwinCAT EtherCAT master/System Manager needs the device description files for the devices to be
used in order to generate the configuration in online or offline mode. The device descriptions are contained
in the so-called ESI files (EtherCAT Slave Information) in XML format. These files can be requested from the
respective manufacturer and are made available for download. An *.xml file may contain several device
descriptions.
The ESI files for Beckhoff EtherCAT devices are available on the Beckhoff website.
The ESI files should be stored in the TwinCAT installation directory.
Default settings:
• TwinCAT2: C:\TwinCAT\IO\EtherCAT
• TwinCAT3: C:\TwinCAT\3.1\Config\Io\EtherCAT
The files are read (once) when a new System Manager window is opened, if they have changed since the
last time the System Manager window was opened.
A TwinCAT installation includes the set of Beckhoff ESI files that was current at the time when the TwinCAT
build was created.
For TwinCAT2.11/TwinCAT3 and higher, the ESI directory can be updated from the System Manager, if the
programming PC is connected to the Internet; by
• TwinCAT2: Option → “Update EtherCAT Device Descriptions”
• TwinCAT3: TwinCAT → EtherCAT Devices → “Update Device Descriptions (via ETG Website)…”
The TwinCAT ESI Updater [}65] is available for this purpose.
ESI
The *.xml files are associated with *.xsd files, which describe the structure of the ESI XML files. To
update the ESI device descriptions, both file types should therefore be updated.
Device differentiation
EtherCAT devices/slaves are distinguished by four properties, which determine the full device identifier. For
example, the device identifier EL2521-0025-1018 consists of:
• family key “EL”
• name “2521”
• type “0025”
• and revision “1018”
Fig.46: Identifier structure
The order identifier consisting of name + type (here: EL2521-0010) describes the device function. The
revision indicates the technical progress and is managed by Beckhoff. In principle, a device with a higher
revision can replace a device with a lower revision, unless specified otherwise, e.g. in the documentation.
Each revision has its own ESI description. See further notes.
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Commissioning
Online description
If the EtherCAT configuration is created online through scanning of real devices (see section Online setup)
and no ESI descriptions are available for a slave (specified by name and revision) that was found, the
System Manager asks whether the description stored in the device should be used. In any case, the System
Manager needs this information for setting up the cyclic and acyclic communication with the slave correctly.
Fig.47: OnlineDescription information window (TwinCAT2)
In TwinCAT3 a similar window appears, which also offers the Web update:
Fig.48: Information window OnlineDescription (TwinCAT3)
If possible, the Yes is to be rejected and the required ESI is to be requested from the device manufacturer.
After installation of the XML/XSD file the configuration process should be repeated.
NOTE
Changing the “usual” configuration through a scan
ü If a scan discovers a device that is not yet known to TwinCAT, distinction has to be made between two
cases. Taking the example here of the EL2521-0000 in the revision 1019
a) no ESI is present for the EL2521-0000 device at all, either for the revision 1019 or for an older revision.
The ESI must then be requested from the manufacturer (in this case Beckhoff).
b) an ESI is present for the EL2521-0000 device, but only in an older revision, e.g. 1018 or 1017.
In this case an in-house check should first be performed to determine whether the spare parts stock allows the integration of the increased revision into the configuration at all. A new/higher revision usually
also brings along new features. If these are not to be used, work can continue without reservations with
the previous revision 1018 in the configuration. This is also stated by the Beckhoff compatibility rule.
Refer in particular to the chapter “General notes on the use of Beckhoff EtherCAT IO components” and for
manual configuration to the chapter “Offline configuration creation [}66]”.
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.
EL72x1-001x62 Version: 2.7
Commissioning
Fig.49: File OnlineDescription.xml created by the System Manager
Is a slave desired to be added manually to the configuration at a later stage, online created slaves are
indicated by a prepended symbol “>” in the selection list (see Figure Indication of an online recorded ESI of
EL2521 as an example).
Fig.50: Indication of an online recorded ESI of EL2521 as an example
If such ESI files are used and the manufacturer's files become available later, the file OnlineDescription.xml
should be deleted as follows:
• close all System Manager windows
• restart TwinCAT in Config mode
• delete “OnlineDescription0000...xml”
• restart TwinCAT System Manager
This file should not be visible after this procedure, if necessary press <F5> to update
OnlineDescription for TwinCAT3.x
In addition to the file described above “OnlineDescription0000...xml”, a so called EtherCAT cache
with new discovered devices is created by TwinCAT3.x, e.g. under Windows 7:
(Please note the language settings of the OS!)
You have to delete this file, too.
Faulty ESI file
If an ESI file is faulty and the System Manager is unable to read it, the System Manager brings up an
information window.
Fig.51: Information window for faulty ESI file (left: TwinCAT2; right: TwinCAT3)
EL72x1-001x 63Version: 2.7
Commissioning
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
EL72x1-001x64 Version: 2.7
Commissioning
6.1.3 TwinCAT ESI Updater
For TwinCAT2.11 and higher, the System Manager can search for current Beckhoff ESI files automatically, if
an online connection is available:
Fig.52: Using the ESI Updater (>= TwinCAT2.11)
The call up takes place under:
“Options” → “Update EtherCAT Device Descriptions”
Selection under TwinCAT3:
Fig.53: Using the ESI Updater (TwinCAT3)
The ESI Updater (TwinCAT3) is a convenient option for automatic downloading of ESI data provided by
EtherCAT manufacturers via the Internet into the TwinCAT directory (ESI = EtherCAT slave information).
TwinCAT accesses the central ESI ULR directory list stored at ETG; the entries can then be viewed in the
Updater dialog, although they cannot be changed there.
The call up takes place under:
“TwinCAT” → “EtherCAT Devices” → “Update Device Description (via ETG Website)…”.
6.1.4 Distinction between Online and Offline
The distinction between online and offline refers to the presence of the actual I/O environment (drives,
terminals, EJ-modules). If the configuration is to be prepared in advance of the system configuration as a
programming system, e.g. on a laptop, this is only possible in “Offline configuration” mode. In this case all
components have to be entered manually in the configuration, e.g. based on the electrical design.
If the designed control system is already connected to the EtherCAT system and all components are
energised and the infrastructure is ready for operation, the TwinCAT configuration can simply be generated
through “scanning” from the runtime system. This is referred to as online configuration.
In any case, during each startup the EtherCAT master checks whether the slaves it finds match the
configuration. This test can be parameterised in the extended slave settings. Refer to note “Installation of
the latest ESI-XML device description” [}61].
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
EL72x1-001x 65Version: 2.7
Commissioning
• the devices/modules be connected to the power supply and ready for communication
• TwinCAT must be in CONFIG mode on the target system.
The online scan process consists of:
• detecting the EtherCAT device [}71] (Ethernet port at the IPC)
• detecting the connected EtherCAT devices [}72]. This step can be carried out independent of the
preceding step
• troubleshooting [}75]
The scan with existing configuration [}76] can also be carried out for comparison.
6.1.5 OFFLINE configuration creation
Creating the EtherCAT device
Create an EtherCAT device in an empty System Manager window.
Fig.54: Append EtherCAT device (left: TwinCAT2; right: TwinCAT3)
Select type “EtherCAT” for an EtherCAT I/O application with EtherCAT slaves. For the present publisher/
subscriber service in combination with an EL6601/EL6614 terminal select “EtherCAT Automation Protocol
via EL6601”.
Fig.55: Selecting the EtherCAT connection (TwinCAT2.11, TwinCAT3)
Then assign a real Ethernet port to this virtual device in the runtime system.
Fig.56: Selecting the Ethernet port
EL72x1-001x66 Version: 2.7
Commissioning
This query may appear automatically when the EtherCAT device is created, or the assignment can be set/
modified later in the properties dialog; see Fig. “EtherCAT device properties (TwinCAT2)”.
Fig.57: EtherCAT device properties (TwinCAT2)
TwinCAT 3: the properties of the EtherCAT device can be opened by double click on “Device .. (EtherCAT)”
within the Solution Explorer under “I/O”:
Selecting the Ethernet port
Ethernet ports can only be selected for EtherCAT devices for which the TwinCAT real-time driver is
installed. This has to be done separately for each port. Please refer to the respective installation
page [}55].
Defining EtherCAT slaves
Further devices can be appended by right-clicking on a device in the configuration tree.
Fig.58: Appending EtherCAT devices (left: TwinCAT2; right: TwinCAT3)
The dialog for selecting a new device opens. Only devices for which ESI files are available are displayed.
Only devices are offered for selection that can be appended to the previously selected device. Therefore the
physical layer available for this port is also displayed (Fig. “Selection dialog for new EtherCAT device”, A). In
the case of cable-based Fast-Ethernet physical layer with PHY transfer, then also only cable-based devices
are available, as shown in Fig. “Selection dialog for new EtherCAT device”. If the preceding device has
several free ports (e.g. EK1122 or EK1100), the required port can be selected on the right-hand side (A).
Overview of physical layer
• “Ethernet”: cable-based 100BASE-TX: EK couplers, EP boxes, devices with RJ45/M8/M12 connector
EL72x1-001x 67Version: 2.7
Commissioning
• “E-Bus”: LVDS “terminal bus”, “EJ-module”: EL/ES terminals, various modular modules
The search field facilitates finding specific devices (since TwinCAT2.11 or TwinCAT3).
Fig.59: Selection dialog for new EtherCAT device
By default only the name/device type is used as selection criterion. For selecting a specific revision of the
device the revision can be displayed as “Extended Information”.
Fig.60: Display of device revision
In many cases several device revisions were created for historic or functional reasons, e.g. through
technological advancement. For simplification purposes (see Fig. “Selection dialog for new EtherCAT
device”) only the last (i.e. highest) revision and therefore the latest state of production is displayed in the
selection dialog for Beckhoff devices. To show all device revisions available in the system as ESI
descriptions tick the “Show Hidden Devices” check box, see Fig. “Display of previous revisions”.
EL72x1-001x68 Version: 2.7
Fig.61: Display of previous revisions
Device selection based on revision, compatibility
The ESI description also defines the process image, the communication type between master and
slave/device and the device functions, if applicable. The physical device (firmware, if available) has
to support the communication queries/settings of the master. This is backward compatible, i.e.
newer devices (higher revision) should be supported if the EtherCAT master addresses them as an
older revision. The following compatibility rule of thumb is to be assumed for Beckhoff EtherCAT
Terminals/ Boxes/ EJ-modules:
device revision in the system >= device revision in the configuration
This also enables subsequent replacement of devices without changing the configuration (different
specifications are possible for drives).
Commissioning
Example
If an EL2521-0025-1018 is specified in the configuration, an EL2521-0025-1018 or higher (-1019, -1020) can
be used in practice.
Fig.62: Name/revision of the terminal
If current ESI descriptions are available in the TwinCAT system, the last revision offered in the selection
dialog matches the Beckhoff state of production. It is recommended to use the last device revision when
creating a new configuration, if current Beckhoff devices are used in the real application. Older revisions
should only be used if older devices from stock are to be used in the application.
In this case the process image of the device is shown in the configuration tree and can be parameterized as
follows: linking with the task, CoE/DC settings, plug-in definition, startup settings, ...
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Commissioning
Fig.63: EtherCAT terminal in the TwinCAT tree (left: TwinCAT2; right: TwinCAT3)
EL72x1-001x70 Version: 2.7
Commissioning
6.1.6 ONLINE configuration creation
Detecting/scanning of the EtherCAT device
The online device search can be used if the TwinCAT system is in CONFIG mode. This can be indicated by
a symbol right below in the information bar:
• on TwinCAT2 by a blue display “Config Mode” within the System Manager window: .
• on TwinCAT3 within the user interface of the development environment by a symbol .
TwinCAT can be set into this mode:
• TwinCAT2: by selection of in the Menubar or by “Actions” → “Set/Reset TwinCATtoConfig
Mode…”
• TwinCAT3: by selection of in the Menubar or by “TwinCAT” → “RestartTwinCAT(ConfigMode)”
Online scanning in Config mode
The online search is not available in RUN mode (production operation). Note the differentiation between TwinCAT programming system and TwinCAT target system.
The TwinCAT2 icon ( ) or TwinCAT3 icon ( ) within the Windows-Taskbar always shows the
TwinCAT mode of the local IPC. Compared to that, the System Manager window of TwinCAT2 or the user
interface of TwinCAT3 indicates the state of the target system.
Fig.64: Differentiation local/target system (left: TwinCAT2; right: TwinCAT3)
Right-clicking on “I/O Devices” in the configuration tree opens the search dialog.
Fig.65: Scan Devices (left: TwinCAT2; right: TwinCAT3)
This scan mode attempts to find not only EtherCAT devices (or Ethernet ports that are usable as such), but
also NOVRAM, fieldbus cards, SMB etc. However, not all devices can be found automatically.
Fig.66: Note for automatic device scan (left: TwinCAT2; right: TwinCAT3)
EL72x1-001x 71Version: 2.7
Commissioning
Ethernet ports with installed TwinCAT real-time driver are shown as “RT Ethernet” devices. An EtherCAT
frame is sent to these ports for testing purposes. If the scan agent detects from the response that an
EtherCAT slave is connected, the port is immediately shown as an “EtherCAT Device” .
Fig.67: Detected Ethernet devices
Via respective checkboxes devices can be selected (as illustrated in Fig. “Detected Ethernet devices” e.g.
Device 3 and Device 4 were chosen). After confirmation with “OK” a device scan is suggested for all selected
devices, see Fig.: “Scan query after automatic creation of an EtherCAT device”.
Selecting the Ethernet port
Ethernet ports can only be selected for EtherCAT devices for which the TwinCAT real-time driver is
installed. This has to be done separately for each port. Please refer to the respective installation
page [}55].
Detecting/Scanning the EtherCAT devices
Online scan functionality
During a scan the master queries the identity information of the EtherCAT slaves from the slave
EEPROM. The name and revision are used for determining the type. The respective devices are located in the stored ESI data and integrated in the configuration tree in the default state defined
there.
Fig.68: Example default state
NOTE
Slave scanning in practice in series machine production
The scanning function should be used with care. It is a practical and fast tool for creating an initial configuration as a basis for commissioning. In series machine production or reproduction of the plant, however, the
function should no longer be used for the creation of the configuration, but if necessary for comparison
[}76] with the defined initial configuration.Background: since Beckhoff occasionally increases the revision
version of the delivered products for product maintenance reasons, a configuration can be created by such
a scan which (with an identical machine construction) is identical according to the device list; however, the
respective device revision may differ from the initial configuration.
Example:
Company A builds the prototype of a machine B, which is to be produced in series later on. To do this the
prototype is built, a scan of the IO devices is performed in TwinCAT and the initial configuration “B.tsm” is
created. The EL2521-0025 EtherCAT terminal with the revision 1018 is located somewhere. It is thus built
into the TwinCAT configuration in this way:
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Commissioning
Fig.69: Installing EthetCAT terminal with revision -1018
Likewise, during the prototype test phase, the functions and properties of this terminal are tested by the
programmers/commissioning engineers and used if necessary, i.e. addressed from the PLC “B.pro” or the
NC. (the same applies correspondingly to the TwinCAT3 solution files).
The prototype development is now completed and series production of machine B starts, for which Beckhoff
continues to supply the EL2521-0025-0018. If the commissioning engineers of the series machine production
department always carry out a scan, a B configuration with the identical contents results again for each
machine. Likewise, A might create spare parts stores worldwide for the coming series-produced machines
with EL2521-0025-1018 terminals.
After some time Beckhoff extends the EL2521-0025 by a new feature C. Therefore the FW is changed,
outwardly recognizable by a higher FW version and a new revision -1019. Nevertheless the new device
naturally supports functions and interfaces of the predecessor version(s); an adaptation of “B.tsm” or even
“B.pro” is therefore unnecessary. The series-produced machines can continue to be built with “B.tsm” and
“B.pro”; it makes sense to perform a comparative scan [}76] against the initial configuration “B.tsm” in order
to check the built machine.
However, if the series machine production department now doesn’t use “B.tsm”, but instead carries out a
scan to create the productive configuration, the revision -1019 is automatically detected and built into the
configuration:
Fig.70: Detection of EtherCAT terminal with revision -1019
This is usually not noticed by the commissioning engineers. TwinCAT cannot signal anything either, since
virtually a new configuration is created. According to the compatibility rule, however, this means that no
EL2521-0025-1018 should be built into this machine as a spare part (even if this nevertheless works in the
vast majority of cases).
In addition, it could be the case that, due to the development accompanying production in company A, the
new feature C of the EL2521-0025-1019 (for example, an improved analog filter or an additional process
data for the diagnosis) is discovered and used without in-house consultation. The previous stock of spare
part devices are then no longer to be used for the new configuration “B2.tsm” created in this way. Þ if series
machine production is established, the scan should only be performed for informative purposes for
comparison with a defined initial configuration. Changes are to be made with care!
If an EtherCAT device was created in the configuration (manually or through a scan), the I/O field can be
scanned for devices/slaves.
Fig.71: Scan query after automatic creation of an EtherCAT device (left: TwinCAT2; right: TwinCAT3)
EL72x1-001x 73Version: 2.7
Commissioning
Fig.72: Manual triggering of a device scan on a specified EtherCAT device (left: TwinCAT2; right:
TwinCAT3)
In the System Manager (TwinCAT2) or the User Interface (TwinCAT3) the scan process can be monitored
via the progress bar at the bottom in the status bar.
Fig.73: Scan progressexemplary by TwinCAT2
The configuration is established and can then be switched to online state (OPERATIONAL).
Fig.74: Config/FreeRun query (left: TwinCAT2; right: TwinCAT3)
In Config/FreeRun mode the System Manager display alternates between blue and red, and the EtherCAT
device continues to operate with the idling cycle time of 4ms (default setting), even without active task (NC,
PLC).
Fig.75: Displaying of “Free Run” and “Config Mode” toggling right below in the status bar
Fig.76: TwinCAT can also be switched to this state by using a button (left: TwinCAT2; right: TwinCAT3)
The EtherCAT system should then be in a functional cyclic state, as shown in Fig. Online display example.
EL72x1-001x74 Version: 2.7
Commissioning
Fig.77: Online display example
Please note:
• all slaves should be in OP state
• the EtherCAT master should be in “Actual State” OP
• “frames/sec” should match the cycle time taking into account the sent number of frames
• no excessive “LostFrames” or CRC errors should occur
The configuration is now complete. It can be modified as described under manual procedure [}66].
Troubleshooting
Various effects may occur during scanning.
• An unknown device is detected, i.e. an EtherCAT slave for which no ESI XML description is available.
In this case the System Manager offers to read any ESI that may be stored in the device. This case is
described in the chapter “Notes regarding ESI device description”.
• Device are not detected properly
Possible reasons include:
◦ faulty data links, resulting in data loss during the scan
◦ slave has invalid device description
The connections and devices should be checked in a targeted manner, e.g. via the emergency
scan.
Then re-run the scan.
Fig.78: Faulty identification
In the System Manager such devices may be set up as EK0000 or unknown devices. Operation is not
possible or meaningful.
EL72x1-001x 75Version: 2.7
Commissioning
Scan over existing Configuration
NOTE
Change of the configuration after comparison
With this scan (TwinCAT2.11 or 3.1) only the device properties vendor (manufacturer), device name and
revision are compared at present! A “ChangeTo” or “Copy” should only be carried out with care, taking into
consideration the Beckhoff IO compatibility rule (see above). The device configuration is then replaced by
the revision found; this can affect the supported process data and functions.
If a scan is initiated for an existing configuration, the actual I/O environment may match the configuration
exactly or it may differ. This enables the configuration to be compared.
Fig.79: Identical configuration (left: TwinCAT2; right: TwinCAT3)
If differences are detected, they are shown in the correction dialog, so that the user can modify the
configuration as required.
Fig.80: Correction dialog
It is advisable to tick the “Extended Information” check box to reveal differences in the revision.
EL72x1-001x76 Version: 2.7
Commissioning
Color Explanation
green This EtherCAT slave matches the entry on the other side. Both type and revision match.
blue This EtherCAT slave is present on the other side, but in a different revision. This other revision can
have other default values for the process data as well as other/additional functions.
If the found revision is higher than the configured revision, the slave may be used provided
compatibility issues are taken into account.
If the found revision is lower than the configured revision, it is likely that the slave cannot be used.
The found device may not support all functions that the master expects based on the higher
revision number.
light
blue
red • This EtherCAT slave is not present on the other side.
This EtherCAT slave is ignored (“Ignore” button)
• It is present, but in a different revision, which also differs in its properties from the one specified.
The compatibility principle then also applies here: if the found revision is higher than the
configured revision, use is possible provided compatibility issues are taken into account, since
the successor devices should support the functions of the predecessor devices.
If the found revision is lower than the configured revision, it is likely that the slave cannot be
used. The found device may not support all functions that the master expects based on the
higher revision number.
Device selection based on revision, compatibility
The ESI description also defines the process image, the communication type between master and
slave/device and the device functions, if applicable. The physical device (firmware, if available) has
to support the communication queries/settings of the master. This is backward compatible, i.e.
newer devices (higher revision) should be supported if the EtherCAT master addresses them as an
older revision. The following compatibility rule of thumb is to be assumed for Beckhoff EtherCAT
Terminals/ Boxes/ EJ-modules:
device revision in the system >= device revision in the configuration
This also enables subsequent replacement of devices without changing the configuration (different
specifications are possible for drives).
Example
If an EL2521-0025-1018 is specified in the configuration, an EL2521-0025-1018 or higher (-1019, -1020) can
be used in practice.
Fig.81: Name/revision of the terminal
If current ESI descriptions are available in the TwinCAT system, the last revision offered in the selection
dialog matches the Beckhoff state of production. It is recommended to use the last device revision when
creating a new configuration, if current Beckhoff devices are used in the real application. Older revisions
should only be used if older devices from stock are to be used in the application.
In this case the process image of the device is shown in the configuration tree and can be parameterized as
follows: linking with the task, CoE/DC settings, plug-in definition, startup settings, ...
EL72x1-001x 77Version: 2.7
Commissioning
Fig.82: 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 Type
TwinCAT offers a function Change to Compatible Type… for the exchange of a device whilst retaining the
links in the task.
Fig.83: Dialog “Change to Compatible Type…” (left: TwinCAT2; right: TwinCAT3)
This function is preferably to be used on AX5000 devices.
Change to Alternative Type
The TwinCAT System Manager offers a function for the exchange of a device: Change to Alternative Type
Fig.84: TwinCAT2 Dialog Change to Alternative Type
EL72x1-001x78 Version: 2.7
Commissioning
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).
6.1.7 EtherCAT subscriber configuration
In the left-hand window of the TwinCAT2 System Manager or the Solution Explorer of the TwinCAT3
Development Environment respectively, click on the element of the terminal within the tree you wish to
configure (in the example: EL3751 Terminal 3).
Fig.85: Branch element as terminal EL3751
In the right-hand window of the TwinCAT System Manager (TwinCAT2) or the Development Environment
(TwinCAT3), various tabs are now available for configuring the terminal. And yet the dimension of
complexity of a subscriber determines which tabs are provided. Thus as illustrated in the example above the
terminal EL3751 provides many setup options and also a respective number of tabs are available. On the
contrary by the terminal EL1004 for example the tabs “General”, “EtherCAT”, “Process Data” and “Online“
are available only. Several terminals, as for instance the EL6695 provide special functions by a tab with its
own terminal name, so “EL6695” in this case. A specific tab “Settings” by terminals with a wide range of
setup options will be provided also (e.g. EL3751).
“General” tab
Fig.86: “General” tab
Name Name of the EtherCAT device
Id Number of the EtherCAT device
Type EtherCAT device type
Comment Here you can add a comment (e.g. regarding the system).
Disabled Here you can deactivate the EtherCAT device.
Create symbols Access to this EtherCAT slave via ADS is only available if this control box is
activated.
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Commissioning
“EtherCAT” tab
Fig.87: “EtherCAT” tab
Type EtherCAT device type
Product/Revision Product and revision number of the EtherCAT device
Auto Inc Addr. Auto increment address of the EtherCAT device. The auto increment address can
be used for addressing each EtherCAT device in the communication ring through
its physical position. Auto increment addressing is used during the start-up phase
when the EtherCAT master allocates addresses to the EtherCAT devices. With
auto increment addressing the first EtherCAT slave in the ring has the address
0000
. For each further slave the address is decremented by 1 (FFFF
hex
, FFFE
hex
etc.).
EtherCAT Addr. Fixed address of an EtherCAT slave. This address is allocated by the EtherCAT
master during the start-up phase. Tick the control box to the left of the input field in
order to modify the default value.
Previous Port Name and port of the EtherCAT device to which this device is connected. If it is
possible to connect this device with another one without changing the order of the
EtherCAT devices in the communication ring, then this combination field is
activated and the EtherCAT device to which this device is to be connected can be
selected.
Advanced Settings This button opens the dialogs for advanced settings.
hex
The link at the bottom of the tab points to the product page for this EtherCAT device on the web.
“Process Data” tab
Indicates the configuration of the process data. The input and output data of the EtherCAT slave are
represented as CANopen process data objects (Process Data Objects, PDOs). The user can select a PDO
via PDO assignment and modify the content of the individual PDO via this dialog, if the EtherCAT slave
supports this function.
EL72x1-001x80 Version: 2.7
Fig.88: “Process Data” tab
Commissioning
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”).
EL72x1-001x 81Version: 2.7
Commissioning
Fig.89: Configuring the process data
Manual modification of the process data
According to the ESI description, a PDO can be identified as “fixed” with the flag “F” in the PDO
overview (Fig. Configuring the process data, J). The configuration of such PDOs cannot be
changed, even if TwinCAT offers the associated dialog (“Edit”). In particular, CoE content cannot be
displayed as cyclic process data. This generally also applies in cases where a device supports
download of the PDO configuration, “G”. In case of incorrect configuration the EtherCAT slave usually refuses to start and change to OP state. The System Manager displays an “invalid SM cfg” logger message: This error message (“invalid SM IN cfg” or “invalid SM OUT cfg”) also indicates the
reason for the failed start.
A detailed description [}87] 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.
EL72x1-001x82 Version: 2.7
Fig.90: “Startup” tab
Column Description
Transition Transition to which the request is sent. This can either be
• the transition from pre-operational to safe-operational (PS), or
• the transition from safe-operational to operational (SO).
If the transition is enclosed in “<>” (e.g. <PS>), the mailbox request is fixed and cannot be
modified or deleted by the user.
Protocol Type of mailbox protocol
Index Index of the object
Data Date on which this object is to be downloaded.
Comment Description of the request to be sent to the mailbox
Commissioning
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.
EL72x1-001x 83Version: 2.7
Commissioning
Fig.91: “CoE - Online” tab
Object list display
Column Description
Index Index and sub-index of the object
Name Name of the object
Flags RW The object can be read, and data can be written to the object (read/write)
RO The object can be read, but no data can be written to the object (read only)
P An additional P identifies the object as a process data object.
Value Value of the object
Update List The Update list button updates all objects in the displayed list
Auto Update If this check box is selected, the content of the objects is updated automatically.
Advanced The Advanced button opens the Advanced Settings dialog. Here you can specify which
objects are displayed in the list.
EL72x1-001x84 Version: 2.7
Commissioning
Fig.92: Dialog “Advanced settings”
Online - via SDO Information If this option button is selected, the list of the objects included in the object
list of the slave is uploaded from the slave via SDO information. The list
below can be used to specify which object types are to be uploaded.
Offline - via EDS File If this option button is selected, the list of the objects included in the object
list is read from an EDS file provided by the user.
“Online” tab
Fig.93: “Online” tab
EL72x1-001x 85Version: 2.7
Commissioning
State Machine
Init This button attempts to set the EtherCAT device to the Init state.
Pre-Op This button attempts to set the EtherCAT device to the pre-operational state.
Op This button attempts to set the EtherCAT device to the operational state.
Bootstrap This button attempts to set the EtherCAT device to the Bootstrap state.
Safe-Op This button attempts to set the EtherCAT device to the safe-operational state.
Clear Error This button attempts to delete the fault display. If an EtherCAT slave fails during
change of state it sets an error flag.
Example: An EtherCAT slave is in PREOP state (pre-operational). The master now
requests the SAFEOP state (safe-operational). If the slave fails during change of
state it sets the error flag. The current state is now displayed as ERR PREOP.
When the Clear Error button is pressed the error flag is cleared, and the current
state is displayed as PREOP again.
Current State Indicates the current state of the EtherCAT device.
Requested State Indicates the state requested for the EtherCAT device.
DLL Status
Indicates the DLL status (data link layer status) of the individual ports of the EtherCAT slave. The DLL status
can have four different states:
Status Description
No Carrier / Open No carrier signal is available at the port, but the port is open.
No Carrier / Closed No carrier signal is available at the port, and the port is closed.
Carrier / Open A carrier signal is available at the port, and the port is open.
Carrier / Closed A carrier signal is available at the port, but the port is closed.
File Access over EtherCAT
Download With this button a file can be written to the EtherCAT device.
Upload With this button a file can be read from the EtherCAT device.
“DC” tab (Distributed Clocks)
Fig.94: “DC” tab (Distributed Clocks)
Operation Mode Options (optional):
• FreeRun
• SM-Synchron
• DC-Synchron (Input based)
• DC-Synchron
Advanced Settings… Advanced settings for readjustment of the real time determinant TwinCAT-clock
Detailed information to Distributed Clocks is specified on http://infosys.beckhoff.com:
Fieldbus Components → EtherCAT Terminals → EtherCAT System documentation → EtherCAT basics →
Distributed Clocks
EL72x1-001x86 Version: 2.7
6.1.7.1 Download revision
Download revision in Start-up list
Several terminals / modules generate the entry from object 0xF081:01 in the Start-up list automatically (see fig. “Download revision in Start-up list“).
The object 0xF081:01 (Download revision) describes the revision of the terminal / module, e.g.
0x0018000A for EL7201-0010-0024, and is necessary to ensure compatibility.
Please note, that you must not delete this entry from the Start-up list!
Fig.95: Download revision in Start-up list
Commissioning
6.1.7.2 Detailed description of Process Data tab
Sync Manager
Lists the configuration of the Sync Manager (SM).
If the EtherCAT device has a mailbox, SM0 is used for the mailbox output (MbxOut) and SM1 for the mailbox
input (MbxIn).
SM2 is used for the output process data (outputs) and SM3 (inputs) for the input process data.
If an input is selected, the corresponding PDO assignment is displayed in the PDO Assignment list below.
PDO Assignment
PDO assignment of the selected Sync Manager. All PDOs defined for this Sync Manager type are listed
here:
• If the output Sync Manager (outputs) is selected in the Sync Manager list, all RxPDOs are displayed.
• If the input Sync Manager (inputs) is selected in the Sync Manager list, all TxPDOs are displayed.
The selected entries are the PDOs involved in the process data transfer. In the tree diagram of the System
Manager these PDOs are displayed as variables of the EtherCAT device. The name of the variable is
identical to the Name parameter of the PDO, as displayed in the PDO list. If an entry in the PDO assignment
list is deactivated (not selected and greyed out), this indicates that the input is excluded from the PDO
assignment. In order to be able to select a greyed out PDO, the currently selected PDO has to be deselected
first.
Activation of PDO assignment
ü If you have changed the PDO assignment, in order to activate the new PDO assignment,
a) the EtherCAT slave has to run through the PS status transition cycle (from pre-operational to
safe-operational) once (see Online tab [}85]),
b) and the System Manager has to reload the EtherCAT slaves
( button for TwinCAT2 or button for TwinCAT3)
EL72x1-001x 87Version: 2.7
Commissioning
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 [}82] 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.
6.2 Start-up and parameter configuration
6.2.1 Integration into the NC configuration
(Master: TwinCAT 2.11 R3)
Installation of the latest XML device description
Please ensure that you have installed the corresponding latest XML device description in TwinCAT.
This can be downloaded from the Beckhoff Website and installed according to the installation in-
structions.
Integration into the NC can be accomplished as follows:
• The terminal must already have been added manually under I/O devices or have been scanned in by
the system (see section "Configuration set-up in TwinCAT [}55]").
EL72x1-001x88 Version: 2.7
Commissioning
Adding an axis automatically
• Once the terminals have been scanned successfully, TwinCAT detects the new axes automatically.
The user is asked whether the detected axes should be added
automatically (see Fig. Axis detected). If this is confirmed, all axes are automatically liked to the NC.
Fig.96: Axis detected
• Several parameters have to be set before the motor can be started up. The values can be found in
section "Configuration of the main parameters [}97]".
Please set these parameters before continuing with the motor commissioning procedure.
Adding an axis manually
• First add a new task. Right-click on NC configuration and select "Append Task..." (see Fig. Adding a
new task).
• Rename the task if required and confirm with OK.
EL72x1-001x 89Version: 2.7
Commissioning
Fig.97: Adding a new task
• Right-click on Axes, then add a new axis (see Fig. Adding a new axis).
Fig.98: Adding a new axis
• Select Continuous Axis type and confirm with OK (see Fig. Selecting and confirming the axis type).
Fig.99: Selecting and confirming the axis type
• Left-click your axis to select it. Under the Settings tab select "Link To..." (see Fig. Linking the axis with
the terminal).
EL72x1-001x90 Version: 2.7
Fig.100: Linking the axis with the terminal
• Select the required terminal (CANopen DS402, EtherCAT CoE) and confirm with OK.
Commissioning
Fig.101: Selecting the right terminal
• All main links between the NC configuration and the terminal are set automatically (see Fig. Automatic
linking of all main variables)
EL72x1-001x 91Version: 2.7
Commissioning
Fig.102: Automatic linking of all main variables
• Several parameters have to be set before the motor can be started up. The values can be found in
sections "CoE settings [}97]" and "NC settings".
Please set these parameters before continuing with the motor commissioning procedure.
6.2.2 Settings with the Drive Manager
(Master TwinCAT 2.11 R3)
The data given here serve as an example for a servomotor type AM8131-0F20-0000 from Beckhoff
Automation. For other motors the values may vary, depending on the application.
Using the Drive Manager from revision -0019
The Drive Manager is only supported from revision -0019 [}204] of the EL72x1-xxxx. If you use an
older version, the settings have to be made manually. See chapters "CoE settings [}97]" and "NC
settings"
Table of contents
• Start-up with the Drive Manager [}93]
• Setting further parameters with the Drive Manager [}96]
- Integral velocity controller component Tn [}96]
- Proportional velocity controller component Kp [}97]
The TwinCAT Drive Manager is available for download in the AX5000 download package.
The TwinCAT Drive Manager for parameterizing an EL72x1-xxxx servo terminal is integrated in the System
Manager, so that no separate configuration tool is required. Once a servo terminal has been detected or
entered, the TwinCAT Drive Manager is available in the Configuration tab.
The following instructions are intended to enable you to start up the servo terminal relatively quickly. More
detailed information on the Drive Manager can be found in the corresponding documentation "AX5000
Introduction in the TCDrivemanager"
EL72x1-001x92 Version: 2.7
Commissioning
Start-up with the Drive Manager
• The terminal must already have been added manually under I/O devices or have been scanned in by
the system (see section "Configuration set-up in TwinCAT [}66]")
• The terminal must already be integrated in the NC (see section "Integration in the NC configuration
[}88]")
• Select the Configuration tab for the EL72x1-xxxx.
• Select the connected voltage under Power Management.
Fig.103: Selecting the connected voltage
• You can subsequently scan or select the connected motor under Motor and Feedback. If you decide to
use automatic scanning, click on Scan motor and feedback. The electronic type plate of the AM81xxx2xx motor will then be read automatically. To do this it is necessary for automatic scanning of the
motor to be activated in the terminal (Index 0x8008 [}150], MDP or Index 0x2018 [}178], DS402)
EL72x1-001x 93Version: 2.7
Commissioning
Fig.104: Automatic scanning of the connected motor
• If you decide to manually input the connected motor, please click on Select Motor.
Fig.105: Selecting the connected motor
• Select the suitable motor in the selection window and confirm with Ok.
EL72x1-001x94 Version: 2.7
Commissioning
Fig.106: List of available motors
• Confirm the next dialog box with OK. All required parameters are automatically entered in the NC, and
the scaling factor is calculated. If this is not confirmed, these settings have to be entered manually. See
section "NC settings".
Fig.107: Confirmation of the automatic NC settings parameters
• The scaling can be determined under Scalings and NC Parameters. A motor revolution is defined as
360° as an example. All required parameters are adjusted automatically. The setting only becomes
active once the configuration is activated.
EL72x1-001x 95Version: 2.7
Commissioning
Fig.108: Adapting the scaling
All main parameters for the commissioning the motor are now set. The motor can now be commissioned with
the NC, for example. A brief description can be found in section "Commissioning the motor with the NC
[}123]". Or the NC can be addressed from the PLC. A small https://infosys.beckhoff.com/content/1033/
el72x1-001x/Resources/zip/1859339787.zip is included in the documentation.
Some parameters can be adjusted manually for your particular application.
Setting further parameters with the Drive Manager
The values specified here are exemplary, although in most cases they have led to excellent results.
Depending on the application, other values may yield better results.
These values can be changed during operation. Click on Download to apply the values.
Integral velocity controller component Tn
• Reduce the value, until the motor starts to oscillate slightly. Then increase the value by 10%.
EL72x1-001x96 Version: 2.7
Fig.109: Adapting Tn
Commissioning
Proportional velocity controller component Kp
• Increase the value, until the motor starts to oscillate slightly. Then reduce the value by 80%.
Fig.110: Adapting Kp
6.2.3 Settings in the CoE register
(Master TwinCAT 2.11 R3)
The data given here serve as an example for a servomotor type AM8131-0F20-0001 from Beckhoff
Automation. For other motors the values may vary, depending on the application.
EL72x1-001x 97Version: 2.7
Commissioning
Table of contents
• Inserting the motor XML file [}98]
- Adaptation of current and voltage [}100]
• Setting further parameters [}100]
- Single turn bits / Multi turn bits [}100]
- Torque limitation [}100]
- Integral velocity controller component Tn [}100]
- Proportional velocity controller component Kp [}100]
Inserting the motor XML file
Downloading the EL72x1-xxxx motor XML files
The motor XML files are available for download from the Beckhoff website.
To facilitate commissioning of the EL72x1-xxxx servo terminal, motor XML files are provided for the
servomotors that are supported by the EL72x1-xxxx. The XML files can be read in the System Manager.
All CoE parameters and DS402 parameters are then set as required.
• To read the motor XML file select the EL72x1-xxxx and open the Startup tab. Right-click in the empty
field and select Import from XML...(see Fig. Importing the motor XML file).
Fig.111: Importing the motor XML file
• Select the motor XML file that matches the connected motor (see Fig. Selecting the correct motor XML
file)
EL72x1-001x98 Version: 2.7
Commissioning
Fig.112: Selecting the correct motor XML file
• All required parameters are then set, and the motor can be put into operation (see Fig. CoE
parameters of the motor XML file).
Fig.113: CoE parameters of the motor XML file
Startup list
Any further application-specific settings should also be implemented in the Startup list. Otherwise
the modified settings will be overwritten next time the terminal starts up.
EL72x1-001x 99Version: 2.7
Commissioning
Adaptation of current and voltage
NOTE
The motor may overheat!
In order to prevent overheating of the connected motor, it is important to adjust the voltage of the servo terminal to the actually connected voltage.
This requires the index 0x8010:19 [}151] (0x2002:19 [}173], DS402 profile) "Nominal DC Link Voltage" of
the connected voltage to be set accordingly
Setting further parameters
Single-turn Bits (MDP742: Index 0x8000:12 [}149] / DS402: Index 0x2010:12 [}177]) / Multi-turn Bits
(MDP742: Index 0x8000:13 [}149] / DS402: Index 0x2010:13 [}177])
Here the user can specify how many single-turn and multi-turn bits the terminal should display. A total of 32
bits are available. These 32 bits can be subdivided as required.
The standard setting is 20 single-turn bits and 12 multi-turn bits.
Singleturn bits: number of bits relating to the resolution of one rotor rotation.
Multiturn bits: after a rotor rotation the multi-turn bits are incremented by one.
The motor may overheat!
If the number of single-turn bits is changed, the scaling factor in the NC has to be adjusted
Fig.114: Multi-turn / single-turn bits:
Torque limitation (MDP742: Index 0x7010:0B [}159] / DS402: Index 0x6072:0 [}181])
Limits the current / torque to this value. The value is specified in 1000th of the rated current.
Integral velocity controller component Tn (MDP742: Index 0x8010:14 [}151] / DS402: Index
0x2002:14 [}173])
The values specified here are exemplary, although in most cases they have led to excellent results.
Depending on the application, other values may yield better results.
• Reduce the value, until the motor starts to oscillate slightly. Then increase the value by 10%.
Proportional velocity controller component Kp (MDP742: Index 0x8010:15 [}151] / DS402: Index
0x2002:15 [}173])
The values specified here are exemplary, although in most cases they have led to excellent results.
Depending on the application, other values may yield better results.
EL72x1-001x100 Version: 2.7
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