Beckhoff EL7201-9014, EL7201-9015, EL7211-9014, EL7211-9015, EL7221-9014 Users manual
...
Documentation | EN
EL72x1-901x
Servo Motor Terminals with OCT and STO, 50 V DC
2020-09-24 | Version: 2.0
Table of contents
Table of contents
1 Foreword ....................................................................................................................................................7
1.1 Notes on the documentation..............................................................................................................7
1.2 Safety instructions .............................................................................................................................8
1.2.1 Delivery state ..................................................................................................................... 8
1.2.2 Operator's obligation to exercise diligence ........................................................................ 8
1.2.3 Description of instructions.................................................................................................. 9
1.3 Documentation issue status ............................................................................................................10
1.4 Version identification of EtherCAT devices .....................................................................................10
1.4.1 Beckhoff Identification Code (BIC)................................................................................... 15
2 Product overview.....................................................................................................................................17
2.1 Product overview Servomotor terminal with OCT and STO ............................................................17
2.2 Introduction......................................................................................................................................17
2.3 Technical data .................................................................................................................................20
2.4 Technology ......................................................................................................................................22
2.5 Start-up............................................................................................................................................24
3 Basics communication ...........................................................................................................................25
3.1 EtherCAT basics..............................................................................................................................25
3.2 EtherCAT cabling – wire-bound.......................................................................................................25
3.3 General notes for setting the watchdog...........................................................................................26
3.4 EtherCAT State Machine.................................................................................................................28
3.5 CoE Interface...................................................................................................................................30
3.6 Distributed Clock .............................................................................................................................35
4 Installation................................................................................................................................................36
4.1 Safety instructions ...........................................................................................................................36
4.2 Environmental conditions ................................................................................................................36
4.3 Transport / storage ..........................................................................................................................36
4.4 Control cabinet / terminal box..........................................................................................................36
4.5 Instructions for ESD protection........................................................................................................37
4.6 Installation on mounting rails ...........................................................................................................37
4.7 Installation position for operation with or without fan.......................................................................40
4.8 Positioning of passive Terminals .....................................................................................................43
4.9 Installation instructions for enhanced mechanical load capacity .....................................................44
4.10 Connection ......................................................................................................................................45
4.10.1 Connection system .......................................................................................................... 45
4.10.2 Wiring............................................................................................................................... 46
4.11 Example configuration for temperature measurement ....................................................................48
4.12 Shielding concept ............................................................................................................................48
4.13 UL notice - Compact Motion............................................................................................................50
4.14 Notes on current measurements using Hall sensors.......................................................................51
4.15 EL72x1-9014 - LEDs and connection..............................................................................................53
5 Commissioning........................................................................................................................................57
5.1 TwinCAT Quick Start .......................................................................................................................57
5.1.1 TwinCAT2 ....................................................................................................................... 60
EL72x1-901x 3Version: 2.0
Table of contents
5.1.2 TwinCAT 3 ....................................................................................................................... 70
5.2 TwinCAT Development Environment ..............................................................................................83
5.2.1 Installation of the TwinCAT real-time driver..................................................................... 84
5.2.2 Notes regarding ESI device description........................................................................... 89
5.2.3 TwinCAT ESI Updater ..................................................................................................... 93
5.2.4 Distinction between Online and Offline............................................................................ 93
5.2.5 OFFLINE configuration creation ...................................................................................... 94
5.2.6 ONLINE configuration creation ........................................................................................ 99
5.2.7 EtherCAT subscriber configuration................................................................................ 107
5.3 Start-up and parameter configuration............................................................................................116
5.3.1 Integration into the NC configuration ............................................................................. 116
5.3.2 Settings with the Drive Manager.................................................................................... 120
5.3.3 Settings in the CoE register ........................................................................................... 125
5.3.4 NC settings .................................................................................................................... 129
5.3.5 Application example....................................................................................................... 135
5.3.6 Commissioning without NC, status word/control word................................................... 140
5.3.7 Settings for the automatic configuration ........................................................................ 144
5.3.8 Configuring the limit switch ........................................................................................... 146
5.3.9 Homing .......................................................................................................................... 147
5.3.10 Touch Probe .................................................................................................................. 150
5.4 Operation modes ...........................................................................................................................153
5.4.1 Overview........................................................................................................................ 153
5.4.2 CSV ............................................................................................................................... 153
5.4.3 CST................................................................................................................................ 157
5.4.4 CSTCA........................................................................................................................... 160
5.4.5 CSP ............................................................................................................................... 164
5.5 Profile MDP 742 or DS 402 ...........................................................................................................168
5.6 MDP742 process data ...................................................................................................................168
5.7 DS402 process data ......................................................................................................................172
6 Integrated safety....................................................................................................................................177
6.1 Safety regulations..........................................................................................................................177
6.2 Description of product and function ...............................................................................................177
6.2.1 Intended use .................................................................................................................. 177
6.2.2 Dimensions .................................................................................................................... 178
6.2.3 TwinSAFE reaction times .............................................................................................. 179
6.2.4 Application example for STO function (Cat. 3, PL d) ..................................................... 181
6.3 Maintenance ..................................................................................................................................187
6.4 Service life .....................................................................................................................................187
7 Object description and parameterization............................................................................................189
7.1 EL72x1-9014 (MDP742)................................................................................................................189
7.1.1 Restore object................................................................................................................ 189
7.1.2 Configuration data ......................................................................................................... 189
7.1.3 Configuration data (vendor-specific).............................................................................. 196
7.1.4 Command object............................................................................................................ 196
7.1.5 Input data....................................................................................................................... 196
EL72x1-901x4 Version: 2.0
Table of contents
7.1.6 Output data .................................................................................................................... 198
7.1.7 Information / diagnosis data .......................................................................................... 200
7.1.8 Standard objects............................................................................................................ 203
7.2 EL72x1-9014 (DS402)...................................................................................................................212
7.2.1 Configuration data ......................................................................................................... 213
7.2.2 Configuration data (vendor-specific).............................................................................. 218
7.2.3 Command object ........................................................................................................... 218
7.2.4 Input/output data............................................................................................................ 219
7.2.5 Information / diagnosis data .......................................................................................... 224
7.2.6 Standard objects............................................................................................................ 227
8 Error correction .....................................................................................................................................234
8.1 Diagnostics – basic principles of diag messages ..........................................................................234
9 Appendix ................................................................................................................................................244
9.1 EtherCAT AL Status Codes...........................................................................................................244
9.2 Firmware compatibility...................................................................................................................244
9.3 Firmware Update EL/ES/EM/ELM/EPxxxx ....................................................................................245
9.3.1 Device description ESI file/XML..................................................................................... 246
9.3.2 Firmware explanation .................................................................................................... 249
9.3.3 Updating controller firmware *.efw................................................................................. 250
9.3.4 FPGA firmware *.rbf....................................................................................................... 252
9.3.5 Simultaneous updating of several EtherCAT devices.................................................... 256
9.4 Restoring the delivery state ...........................................................................................................257
9.5 Certificates.....................................................................................................................................258
9.6 Support and Service ......................................................................................................................259
EL72x1-901x 5Version: 2.0
Table of contents
EL72x1-901x6 Version: 2.0
Foreword
1 Foreword
1.1 Notes on the documentation
Intended audience
This description is only intended for the use of trained specialists in control and automation engineering who
are familiar with the applicable national standards.
It is essential that the following notes and explanations are followed when installing and commissioning
these components.
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.
Origin of the document
This original documentation is written in German. All other languages are derived from the German original.
Currentness
Please check whether you are using the current and valid version of this document. The current version can
be downloaded from the Beckhoff homepage at http://www.beckhoff.com/english/download/twinsafe.htm.
In case of doubt, please contact Technical Support [}259].
Product features
Only the product features specified in the current user documentation are valid. Further information given on
the product pages of the Beckhoff homepage, in emails or in other publications is not authoritative.
Disclaimer
The documentation has been prepared with care. The products described are subject to cyclical revision. For
that reason the documentation is not in every case checked for consistency with performance data,
standards or other characteristics. 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.
EL72x1-901x 7Version: 2.0
Foreword
EtherCAT® and Safety over EtherCAT® are registered trademarks and patented technologies, 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.
Delivery conditions
In addition, the general delivery conditions of the company Beckhoff Automation GmbH & Co. KG apply.
1.2 Safety instructions
1.2.1 Delivery state
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.
1.2.2 Operator's obligation to exercise diligence
The operator must ensure that
• the TwinSAFE products are only used as intended (see chapter Product description);
• the TwinSAFE products are only operated in sound condition and in working order.
• the TwinSAFE products are operated only by suitably qualified and authorized personnel.
• the personnel is instructed regularly about relevant occupational safety and environmental protection
aspects, and is familiar with the operating instructions and in particular the safety instructions contained
herein.
• the operating instructions are in good condition and complete, and always available for reference at the
location where the TwinSAFE products are used.
• none of the safety and warning notes attached to the TwinSAFE products are removed, and all notes
remain legible.
EL72x1-901x8 Version: 2.0
1.2.3 Description of instructions
In these operating instructions 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 the environment/equipment or data loss
Failure to follow this instruction can lead to environmental damage, equipment damage or data loss.
Foreword
Tip or pointer
This symbol indicates information that contributes to better understanding.
EL72x1-901x 9Version: 2.0
Foreword
1.3 Documentation issue status
Version Comment
2.0 • Update chapter “Introduction”
• Update chapter “Technical data”
• Update chapter “Technology”
• Update chapter “LEDs and connection”
• Update revision status
• Update structure
1.9 • Note for fuse protection of the supply voltage added
• Update revision status
• Update structure
1.8 • Update chapter “Object description”
• Update structure
1.7 • Update chapter “Introduction”
• Update structure
1.6 • EL7221-901x added
1.5 • Addenda chapter “UL notice – Compact motion”
• Update revision status
• Update structure
1.4 • Update chapter “Object description and parameterization”
• Update revision status
• Update structure
1.3 • Update revision status
• Update structure
1.2 • Update chapter “Technical Data”
• Update structure
1.1 • Commissioning: chapter Quickstart added
• TwinCAT Development Environment: TwinCAT 3 added
1.0 • First published (only German)
0.1 - 0.5 • Preliminary versions (for internal use only)
1.4 Version identification of EtherCAT devices
Designation
A Beckhoff EtherCAT device has a 14-digit designation, made up of
• family key
• type
• version
• revision
EL72x1-901x10 Version: 2.0
Foreword
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
Identification number
Beckhoff EtherCAT devices from the different lines have different kinds of identification numbers:
Production lot/batch number/serial number/date code/D number
The serial number for Beckhoff IO devices is usually the 8-digit number printed on the device or on a sticker.
The serial number indicates the configuration in delivery state and therefore refers to a whole production
batch, without distinguishing the individual modules of a batch.
Structure of the serial number: KKYYFFHH
KK - week of production (CW, calendar week)
YY - year of production
FF - firmware version
HH - hardware version
Example with
Ser. no.: 12063A02: 12 - production week 12 06 - production year 2006 3A - firmware version 3A 02 hardware version 02
Exceptions can occur in the IP67 area, where the following syntax can be used (see respective device
documentation):
Syntax: D ww yy x y z u
D - prefix designation
ww - calendar week
yy - year
x - firmware version of the bus PCB
EL72x1-901x 11Version: 2.0
Foreword
y - hardware version of the bus PCB
z - firmware version of the I/O PCB
u - hardware version of the I/O PCB
Example: D.22081501 calendar week 22 of the year 2008 firmware version of bus PCB: 1 hardware version
of bus PCB: 5 firmware version of I/O PCB: 0 (no firmware necessary for this PCB) hardware version of I/O
PCB: 1
Unique serial number/ID, ID number
In addition, in some series each individual module has its own unique serial number.
See also the further documentation in the area
• IP67: EtherCAT Box
• Safety: TwinSafe
• Terminals with factory calibration certificate and other measuring terminals
Examples of markings
Fig.1: EL5021 EL terminal, standard IP20 IO device with serial/ batch number and revision ID (since
2014/01)
Fig.2: EK1100 EtherCAT coupler, standard IP20 IO device with serial/ batch number
EL72x1-901x12 Version: 2.0
Fig.3: CU2016 switch with serial/ batch number
Foreword
Fig.4: EL3202-0020 with serial/ batch number 26131006 and unique ID-number 204418
Fig.5: EP1258-00001 IP67 EtherCAT Box with batch number/ date code 22090101 and unique serial
number 158102
Fig.6: EP1908-0002 IP67 EtherCAT Safety Box with batch number/ date code 071201FF and unique serial
number 00346070
EL72x1-901x 13Version: 2.0
Foreword
Fig.7: EL2904 IP20 safety terminal with batch number/ date code 50110302 and unique serial number
00331701
Fig.8: ELM3604-0002 terminal with unique ID number (QR code) 100001051 and serial/ batch number
44160201
EL72x1-901x14 Version: 2.0
Foreword
1.4.1 Beckhoff Identification Code (BIC)
The Beckhoff Identification Code (BIC) is increasingly being applied to Beckhoff products to uniquely identify
the product. The BIC is represented as a Data Matrix Code (DMC, code scheme ECC200), the content is
based on the ANSI standard MH10.8.2-2016.
Fig.9: 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:
EL72x1-901x 15Version: 2.0
Foreword
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
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.
EL72x1-901x16 Version: 2.0
Product overview
2 Product overview
2.1 Product overview Servomotor terminal with OCT and STO
EL7201-9014 [}17] servo motor terminal with OCT and STO, 48 VDC, 2.8 A
EL7201-9015 [}17] servo motor terminal with OCT and STO, 48 VDC, 2.8 A
EL7211-9014 [}17] servo motor terminal with OCT and STO, 48 VDC, 4.5 A
EL7211-9015 [}17] servo motor terminal with OCT and STO, 48 VDC, 4.5 A
EL7221-9014 [}17] servo motor terminal with OCT and STO, 48 VDC, 7…8 A
EL7221-9015 [}17] servo motor terminal with OCT and STO, 48 VDC, 7…8 A
2.2 Introduction
, MDP742 profile
rms
, DS402 profile
rms
, MDP742 profile
rms
, DS402 profile
rms
, MDP742 profile
rms
, DS402 profile
rms
Fig.10: EL7201-901x
EL72x1-901x 17Version: 2.0
Product overview
Fig.11: EL7211-901x, EL7221-901x
Quick links
Connection instructions
Chapter "Mounting and wiring",
- LEDs and pin assignment [}53]
- Shielding concept [}48]
- Notes on current measurement via Hall sensor [}51]
Configuration instructions
Chapter "Commissioning",
- Configuration of the main parameters [}116]
Chapter "Configuration with the TwinCAT System Manager",
- Object description and parameterization [}189]
Application example
Chapter "Commissioning",
- Application example [}135]
Servo motor terminals with OCT and STO input
The servo-motor EtherCAT terminals EL7201-901x (48VDC, 2.8A
EL7221-901x (48VDC, 7…8A
) with integrated absolute value interface, offer high servo performance in a
rms
), EL7211-901x (48VDC, 4.5A
rms
rms
) and
very compact design. The EL72x1-901x were 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.
EL72x1-901x18 Version: 2.0
Product overview
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 EL72x1-901x provides an STO input with which the motor connected to the terminal can be switched
torque-free. This STO input is connected to a safe output of an EL2904.
Performance Level d, Category 3 according to DIN EN ISO 13849-1:2015 is attained for the SFO safety
function of the EL72x1-901x together with an EL2904.
Recommended TwinCAT version
In order to be able to utilize the full power of the EL72x1-901x, we recommend using the
EL72x1-901x with TwinCAT 2.11 R3 or higher!
Mandatory hardware
The EL72x1-901x must be operated with a real-time capable computer and distributed clocks!
Approved motors
The EL72x1-901x may be operated only with the following Beckhoff motors.
- AM8111-xF1x, AM8112-xF1x, AM8113-xF1x, AM8121-xF1x, AM8122-xF1x, AM8131-xF1x,
AM8132-xJ1x, AM8133-xJ1x, AM8141-xJ1x
- AM8111-xF2x, AM8112-xF2x, AM8113-xF2x, AM8121-xF2x, AM8122-xF2x, AM8131-xF2x,
AM8132-xJ2x, AM8133-xJ2x, AM8141-xJ2x
Operation of the EL7221-901x with fan cartridge ZB8610
Due to the increased thermal load, the EL7221-091x must only be operated in conjunction with the
fan cartridge ZB8610 in order to avoid malfunctions.
EL72x1-901x 19Version: 2.0
Product overview
2.3 Technical data
EL72x1-901x20 Version: 2.0
Product overview
Technical data EL7201-901x EL7211-901x EL7221-901x
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 5.7A
Rated power
Motor holding brake output voltage 24V (+ 6 %, - 10 %)
Max. motor holding brake output cur-
rent
Load type permanently excited synchronous motors, inductive
PWM switching frequency 16kHz
Current controller frequency double PWM switching frequency
Velocity controller frequency 16 kHz
Diagnostic LED Status, warning, errors and limits
Power loss typ. 1.6W
Current consumption via E-bus typ. 120 mA
Current consumption from the 24 V typ. 55 mA + holding brake
Supports NoCoeStorage [}30] function
Reverse voltage protection 24 V power supply yes, through the body diode of the overvoltage protection device
Fuse protection
(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 during operation
Permissible ambient temperature
range during storage
Permissible relative humidity 95%, no condensation
Dimensions (W x H x D) approx. 15 mm x 100 mm x 70
Mounting [}37]
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. 1 STO input
DC
2.8A
(without fan cartridge
rms
ZB8610)
4.5A
(with fan cartridge
rms
ZB8610)
for 1 second 2.8A
rms
(without fan cartridge ZB8610)
9A
for 1 second 2.8A
rms
4.5A
rms
7A
up to 55°C (with fan car-
rms
tridge ZB8610)
8A
up to 45°C (with fan car-
rms
tridge ZB8610)
9A
rms
for 1 second
rms
16A
for 1 second (with fan
rms
cartridge ZB8610)
rms
(with fan cartridge ZB8610)
170 W (without fan cartridge
ZB8610)
276 W (with fan cartridge
ZB8610)
276 W
428 W up to 55°C (with fan
cartridge ZB8610)
490 W up to 45°C (with fan
cartridge ZB8610)
max. 0.5 A
(series AM81xx)
Yes
50 V power supply yes, through the body diode of the overvoltage protection device
24 V power supply 10 A
50 V power supply 10 A
configuration via TwinCAT System Manager
0°C ... + 55°C
-25°C ... + 85°C
approx. 27 mm x 100 mm x 70
mm (width aligned: 12 mm)
mm (width aligned: 24 mm)
on 35 mm mounting rail conforms to EN 60715
see also installation instructions [}44] 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 [}40]!
cULus [}50]
TÜV-Süd [}258]
EL72x1-901x 21Version: 2.0
Product overview
2.4 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.12: 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.
EL72x1-901x22 Version: 2.0
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.
EL72x1-901x 23Version: 2.0
Product overview
Fig.13: Limitation to the rated motor current
2.5 Start-up
For commissioning:
• mount the EL72x1-901x as described in the chapter Installation [}36].
• configure the EL72x1-901x in TwinCAT as described in the chapter Commissioning [}57].
EL72x1-901x24 Version: 2.0
Basics communication
3 Basics communication
3.1 EtherCAT basics
Please refer to the EtherCAT System Documentation for the EtherCAT fieldbus basics.
3.2 EtherCAT cabling – wire-bound
The cable length between two EtherCAT devices must not exceed 100 m. This results from the FastEthernet
technology, which, above all for reasons of signal attenuation over the length of the cable, allows a maximum
link length of 5 + 90 + 5 m if cables with appropriate properties are used. See also the Design
recommendations for the infrastructure for EtherCAT/Ethernet.
Cables and connectors
For connecting EtherCAT devices only Ethernet connections (cables + plugs) that meet the requirements of
at least category 5 (CAt5) according to EN 50173 or ISO/IEC 11801 should be used. EtherCAT uses 4 wires
for signal transfer.
EtherCAT uses RJ45 plug connectors, for example. The pin assignment is compatible with the Ethernet
standard (ISO/IEC 8802-3).
Pin Color of conductor Signal Description
1 yellow TD + Transmission Data +
2 orange TD - Transmission Data 3 white RD + Receiver Data +
6 blue RD - Receiver Data -
Due to automatic cable detection (auto-crossing) symmetric (1:1) or cross-over cables can be used between
EtherCAT devices from Beckhoff.
Recommended cables
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.
EL72x1-901x 25Version: 2.0
Basics communication
Fig.14: System manager current calculation
NOTE
Malfunction possible!
The same ground potential must be used for the E-Bus supply of all EtherCAT terminals in a terminal block!
3.3 General notes for setting the watchdog
ELxxxx terminals are equipped with a safety feature (watchdog) that switches off the outputs after a
specifiable time e.g. in the event of an interruption of the process data traffic, depending on the device and
settings, e.g. in OFF state.
The EtherCAT slave controller (ESC) in the EL2xxx terminals features two watchdogs:
• SM watchdog (default: 100 ms)
• PDI watchdog (default: 100 ms)
SM watchdog (SyncManager Watchdog)
The SyncManager watchdog is reset after each successful EtherCAT process data communication with the
terminal. If no EtherCAT process data communication takes place with the terminal for longer than the set
and activated SM watchdog time, e.g. in the event of a line interruption, the watchdog is triggered and the
outputs are set to FALSE. The OP state of the terminal is unaffected. The watchdog is only reset after a
successful EtherCAT process data access. Set the monitoring time as described below.
The SyncManager watchdog monitors correct and timely process data communication with the ESC from the
EtherCAT side.
PDI watchdog (Process Data Watchdog)
If no PDI communication with the EtherCAT slave controller (ESC) takes place for longer than the set and
activated PDI watchdog time, this watchdog is triggered.
PDI (Process Data Interface) is the internal interface between the ESC and local processors in the EtherCAT
slave, for example. The PDI watchdog can be used to monitor this communication for failure.
The PDI watchdog monitors correct and timely process data communication with the ESC from the
application side.
The settings of the SM- and PDI-watchdog must be done for each slave separately in the TwinCAT System
Manager.
EL72x1-901x26 Version: 2.0
Basics communication
Fig.15: 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.
EL72x1-901x 27Version: 2.0
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.
3.4 EtherCAT State Machine
The state of the EtherCAT slave is controlled via the EtherCAT State Machine (ESM). Depending upon the
state, different functions are accessible or executable in the EtherCAT slave. Specific commands must be
sent by the EtherCAT master to the device in each state, particularly during the bootup of the slave.
A distinction is made between the following states:
• Init
• Pre-Operational
• Safe-Operational and
• Operational
• Boot
The regular state of each EtherCAT slave after bootup is the OP state.
EL72x1-901x28 Version: 2.0
Fig.16: States of the EtherCAT State Machine
Basics communication
Init
After switch-on the EtherCAT slave in the Init state. No mailbox or process data communication is possible.
The EtherCAT master initializes sync manager channels 0 and 1 for mailbox communication.
Pre-Operational (Pre-Op)
During the transition between Init and Pre-Op the EtherCAT slave checks whether the mailbox was initialized
correctly.
In Pre-Op state mailbox communication is possible, but not process data communication. The EtherCAT
master initializes the sync manager channels for process data (from sync manager channel 2), the FMMU
channels and, if the slave supports configurable mapping, PDO mapping or the sync manager PDO
assignment. In this state the settings for the process data transfer and perhaps terminal-specific parameters
that may differ from the default settings are also transferred.
Safe-Operational (Safe-Op)
During transition between Pre-Op and Safe-Op the EtherCAT slave checks whether the sync manager
channels for process data communication and, if required, the distributed clocks settings are correct. Before
it acknowledges the change of state, the EtherCAT slave copies current input data into the associated DPRAM areas of the EtherCAT slave controller (ECSC).
In Safe-Op state mailbox and process data communication is possible, although the slave keeps its outputs
in a safe state, while the input data are updated cyclically.
Outputs in SAFEOP state
The default set watchdog [}26] 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.
EL72x1-901x 29Version: 2.0
Basics communication
Boot
In the Boot state the slave firmware can be updated. The Boot state can only be reached via the Init state.
In the Boot state mailbox communication via the file access over EtherCAT (FoE) protocol is possible, but no
other mailbox communication and no process data communication.
3.5 CoE Interface
General description
The CoE interface (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:
EL72x1-901x30 Version: 2.0
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