Beckhoff EL9221-4030, EL9221-5090, EL9221-5000, EL9221-6040, EL9221-9080 Documentation
...
Documentation
EL922x
Electronic overcurrent protection terminals
Version:
Date:
1.0
2018-11-23
Table of contents
Table of contents
1 Product overview electronic overcurrent protection terminal ..............................................................5
2 Foreword ....................................................................................................................................................6
2.1 Notes on the documentation..............................................................................................................6
2.2 Safety instructions .............................................................................................................................7
2.3 Documentation issue status ..............................................................................................................8
2.4 Version identification of EtherCAT devices .......................................................................................9
3 Product overview.....................................................................................................................................13
3.1 Introduction......................................................................................................................................13
3.2 Technical data .................................................................................................................................16
4 Basic function principles........................................................................................................................20
5 Basics communication ...........................................................................................................................21
5.1 EtherCAT basics..............................................................................................................................21
5.2 EtherCAT cabling – wire-bound.......................................................................................................21
5.3 General notes for setting the watchdog...........................................................................................22
5.4 EtherCAT State Machine.................................................................................................................24
5.5 CoE Interface...................................................................................................................................26
6 Mounting and wiring................................................................................................................................31
6.1 Instructions for ESD protection........................................................................................................31
6.2 Installation on mounting rails ...........................................................................................................32
6.3 Connection ......................................................................................................................................35
6.3.1 Connection system .......................................................................................................... 35
6.3.2 Wiring............................................................................................................................... 36
6.4 Prescribed installation position ........................................................................................................38
6.5 Installation instructions for enhanced mechanical load capacity .....................................................39
6.6 Positioning of passive Terminals .....................................................................................................40
6.7 LEDs and pin assignment, programming with LED buttons ............................................................41
6.7.1 EL9221-xxxx .................................................................................................................... 41
6.7.2 EL9222-xxxx .................................................................................................................... 44
6.7.3 EL9227-xxxx .................................................................................................................... 48
6.7.4 Sample programming ...................................................................................................... 52
7 Commissioning........................................................................................................................................54
7.1 Quick start: Commissioning of the EL922x without EtherCAT ........................................................55
7.2 Commissioning and parameterization of the EL922x with EtherCAT..............................................58
7.3 TwinCAT Development Environment ..............................................................................................64
7.3.1 Installation of the TwinCAT real-time driver..................................................................... 64
7.3.2 Notes regarding ESI device description........................................................................... 70
7.3.3 TwinCAT ESI Updater ..................................................................................................... 74
7.3.4 Distinction between Online and Offline............................................................................ 74
7.3.5 OFFLINE configuration creation ...................................................................................... 75
7.3.6 ONLINE configuration creation ........................................................................................ 80
7.3.7 EtherCAT subscriber configuration.................................................................................. 88
7.4 General Notes - EtherCAT Slave Application..................................................................................97
7.5 Process data..................................................................................................................................106
EL922x 3Version: 1.0
Table of contents
7.5.1 EL9221-xxxx .................................................................................................................. 106
7.5.2 EL9222-xxxx .................................................................................................................. 108
7.5.3 EL9227-xxxx .................................................................................................................. 110
7.6 Object description and parameterization .......................................................................................114
7.6.1 EL9221-xxxx .................................................................................................................. 115
7.6.2 EL9222-xxxx .................................................................................................................. 123
7.6.3 EL9227-xxxx .................................................................................................................. 131
8 Diagnostics ............................................................................................................................................148
8.1 Diagnostics – basic principles of diag messages ..........................................................................148
8.2 Text ID’s EL922x ...........................................................................................................................151
9 Appendix ................................................................................................................................................152
9.1 EtherCAT AL Status Codes...........................................................................................................152
9.2 Firmware compatibility...................................................................................................................152
9.3 Firmware Update EL/ES/EM/EPxxxx ............................................................................................154
9.3.1 Device description ESI file/XML..................................................................................... 155
9.3.2 Firmware explanation .................................................................................................... 158
9.3.3 Updating controller firmware *.efw................................................................................. 159
9.3.4 FPGA firmware *.rbf....................................................................................................... 160
9.3.5 Simultaneous updating of several EtherCAT devices.................................................... 164
9.4 Restoring the delivery state ...........................................................................................................165
9.5 Support and Service ......................................................................................................................167
EL922x4 Version: 1.0
Product overview electronic overcurrent protection terminal
1 Product overview electronic overcurrent
protection terminal
EL9221-4030 Overcurrent protection terminal [}13], 1-channel, IN 3 A,
EL9221-5000 Overcurrent protection terminal [}13], 1-channel, IN adjustable up to 10 A,
EL9221-5090 Overcurrent protection terminal [}13], 1-channel, IN 10 A,
EL9221-6000 Overcurrent protection terminal [}13], 1-channel, IN adjustable up to 4 A,
EL9221-6040 Overcurrent protection terminal [}13], 1-channel, IN 4 A,
EL9221-9060 Overcurrent protection terminal [}13], 1-channel, IN 6 A,
EL9221-9080 Overcurrent protection terminal [}13], 1-channel, IN 8 A,
EL9222-4433 Overcurrent protection terminal [}14], 2-channel, IN 3 A/ 3 A,
EL9222-5500 Overcurrent protection terminal [}14], 2-channel, IN adjustable up to ∑10 A,
EL9222-6600 Overcurrent protection terminal [}14], 2-channel, IN adjustable up to 4 A,
EL9222-6644 Overcurrent protection terminal [}14], 2-channel, IN 4 A/ 4 A,
EL9222-9482 Overcurrent protection terminal [}14], 2-channel, IN 8 A/ 2 A,
EL9222-9664 Overcurrent protection terminal [}14], 2-channel, IN 6 A/ 4 A,
EL9227-4433 Overcurrent protection terminal [}14], 2-channel, IN 3 A/ 3 A, extended functionalities
EL9227-5500 Overcurrent protection terminal [}14], 2-channel, IN adjustable up to ∑10 A, extended
functionalities
EL9227-6600 Overcurrent protection terminal [}14], 2-channel, IN adjustable up to 4 A, extended
functionalities
EL9227-6644 Overcurrent protection terminal [}14], 2-channel, IN 4 A/ 4 A, extended functionalities
EL9227-9482 Overcurrent protection terminal [}14], 2-channel, IN 8 A/ 2 A, extended functionalities
EL9227-9664 Overcurrent protection terminal [}14], 2-channel, IN 6 A/ 4 A, extended functionalities
Specification of the type designation for Overcurrent Protection Terminals
Fig.1: Key type designation
EL922x 5Version: 1.0
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®, EtherCATP®, SafetyoverEtherCAT®, TwinSAFE®, XFC® and XTS® are
registered trademarks of and licensed by Beckhoff Automation GmbH.
Other designations used in this publication may be trademarks whose use by third parties for their own
purposes could violate the rights of the owners.
Patent Pending
The EtherCAT Technology is covered, including but not limited to the following patent applications and
patents: EP1590927, EP1789857, DE102004044764, DE102007017835 with corresponding applications or
registrations in various other countries.
The TwinCAT Technology is covered, including but not limited to the following patent applications and
patents: EP0851348, US6167425 with corresponding applications or registrations in various other countries.
EtherCAT® is registered trademark and patented technology, licensed by Beckhoff Automation GmbH,
Germany.
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.
EL922x6 Version: 1.0
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.
EL922x 7Version: 1.0
Foreword
2.3 Documentation issue status
Version Comment
1.0 - 1st public issue
- Complements, corrections
0.2 – 0.9.3 - Complements, corrections
0.1 - Provisional documentation for EL922x
EL922x8 Version: 1.0
Foreword
2.4 Version identification of EtherCAT devices
Designation
A Beckhoff EtherCAT device has a 14-digit designation, made up of
• family key
• type
• version
• revision
Example Family Type Version Revision
EL3314-0000-0016 EL terminal
(12 mm, nonpluggable connection
level)
ES3602-0010-0017 ES terminal
(12 mm, pluggable
connection level)
CU2008-0000-0000 CU device 2008 (8-port fast ethernet switch) 0000 (basic type) 0000
3314 (4-channel thermocouple
terminal)
3602 (2-channel voltage
measurement)
0000 (basic type) 0016
0010 (highprecision version)
0017
Notes
• The elements mentioned above result in the technical designation. EL3314-0000-0016 is used in the
example below.
• EL3314-0000 is the order identifier, in the case of “-0000” usually abbreviated to EL3314. “-0016” is the
EtherCAT revision.
• The order identifier is made up of
- family key (EL, EP, CU, ES, KL, CX, etc.)
- type (3314)
- version (-0000)
• The revision -0016 shows the technical progress, such as the extension of features with regard to the
EtherCAT communication, and is managed by Beckhoff.
In principle, a device with a higher revision can replace a device with a lower revision, unless specified
otherwise, e.g. in the documentation.
Associated and synonymous with each revision there is usually a description (ESI, EtherCAT Slave
Information) in the form of an XML file, which is available for download from the Beckhoff web site.
From 2014/01 the revision is shown on the outside of the IP20 terminals, see Fig. “EL5021 EL terminal,
standard IP20 IO device with batch number and revision ID (since 2014/01)”.
• The type, version and revision are read as decimal numbers, even if they are technically saved in
hexadecimal.
Identification number
Beckhoff EtherCAT devices from the different lines have different kinds of identification numbers:
Production lot/batch number/serial number/date code/D number
The serial number for Beckhoff IO devices is usually the 8-digit number printed on the device or on a sticker.
The serial number indicates the configuration in delivery state and therefore refers to a whole production
batch, without distinguishing the individual modules of a batch.
Structure of the serial number: KKYYFFHH
KK - week of production (CW, calendar week)
YY - year of production
FF - firmware version
HH - hardware version
EL922x 9Version: 1.0
Foreword
Example with
Ser. no.: 12063A02: 12 - production week 12 06 - production year 2006 3A - firmware version 3A 02 hardware version 02
Exceptions can occur in the IP67 area, where the following syntax can be used (see respective device
documentation):
Syntax: D ww yy x y z u
D - prefix designation
ww - calendar week
yy - year
x - firmware version of the bus PCB
y - hardware version of the bus PCB
z - firmware version of the I/O PCB
u - hardware version of the I/O PCB
Example: D.22081501 calendar week 22 of the year 2008 firmware version of bus PCB: 1 hardware version
of bus PCB: 5 firmware version of I/O PCB: 0 (no firmware necessary for this PCB) hardware version of I/O
PCB: 1
Unique serial number/ID, ID number
In addition, in some series each individual module has its own unique serial number.
See also the further documentation in the area
• IP67: EtherCAT Box
• Safety: TwinSafe
• Terminals with factory calibration certificate and other measuring terminals
Examples of markings
Fig.2: EL5021 EL terminal, standard IP20 IO device with serial/ batch number and revision ID (since
2014/01)
EL922x10 Version: 1.0
Fig.3: EK1100 EtherCAT coupler, standard IP20 IO device with serial/ batch number
Foreword
Fig.4: CU2016 switch with serial/ batch number
Fig.5: EL3202-0020 with serial/ batch number 26131006 and unique ID-number 204418
EL922x 11Version: 1.0
Foreword
Fig.6: EP1258-00001 IP67 EtherCAT Box with batch number/ date code 22090101 and unique serial
number 158102
Fig.7: EP1908-0002 IP67 EtherCAT Safety Box with batch number/ date code 071201FF and unique serial
number 00346070
Fig.8: EL2904 IP20 safety terminal with batch number/ date code 50110302 and unique serial number
00331701
Fig.9: ELM3604-0002 terminal with unique ID number (QR code) 100001051 and serial/ batch number
44160201
EL922x12 Version: 1.0
Product overview
3 Product overview
3.1 Introduction
Electronic overcurrent protection terminal
EL9221-xxxx | Single-channel overcurrent protection terminal with standard functionalities
Fig.10: EL9221-5000
The EL9221-xxxx electronic overcurrent protection terminal is a 24 V DC EtherCAT Terminal with electronic
protection function. The single-channel EL9221-xxxx reliably switches off 24 V DC overcurrents. The nominal
current can be set in 1 A steps up to 10 A, either via TwinCAT or via a mechanical pushbutton on the
overcurrent protection terminal. In addition, there are further versions of the terminal with a fixed nominal
current. The protected output can be routed out via a terminal contact or directly to adjacent terminals
without wiring via the power contact.
The EL9221-xxxx has standard functionalities, i.e. the following setting options and process data are
available:
- Settings: Nominal current, LED button programming function
- Process data: Enabled, tripped, prewarning, cool-down lock, hardware protection
EL922x 13Version: 1.0
Product overview
EL9222-xxxx | Two-channel overcurrent protection terminal with standard functionalities
Fig.11: EL9222-5500
The EL9222-xxxx electronic overcurrent protection terminal is a 24 V DC EtherCAT Terminal with electronic
protection function. The 2-channel EL9222-xxxx reliably switches off 24 V DC overcurrents. The nominal
current can be set in 1 A steps up to ∑ 10 A, either via TwinCAT or via a mechanical pushbutton on the
overcurrent protection terminal. In addition, there are further versions of the terminal with a fixed nominal
current for each channel. The protected output 1 can be routed out via a terminal contact or directly to
adjacent terminals without wiring via the power contact.
The EL9222-xxxx has standard functionalities, i.e. the following setting options and process data are
available:
- Settings: Nominal current, LED button programming function
- Process data: Enabled, tripped, prewarning, cool-down lock, hardware protection
EL9227-xxxx | Two-channel overcurrent protection terminal with extended functionalities
Fig.12: EL9227-5500
The EL9227-xxxx electronic overcurrent protection terminal is a 24 V DC EtherCAT Terminal with electronic
protection function. The 2-channel EL9227-xxxx reliably switches off 24 V DC overcurrents. The nominal
current can be set in 1 A steps up to ∑ 10 A, either via TwinCAT or via a mechanical pushbutton on the
overcurrent protection terminal. In addition, there are further versions of the terminal with a fixed nominal
current for each channel. The protected output 1 can be routed out via a terminal contact or directly to
adjacent terminals without wiring via the power contact.
EL922x14 Version: 1.0
Product overview
The EL9227-xxxx has extended functionalities, i.e. it is additionally able to handle monitoring applications,
since numerous process data are available, e.g.:
enabled, tripped, short circuit, overload, overvoltage, undervoltage, current level warning, cool down lock,
hardware protection, switched off by pushbutton, DI, EtherCAT, load, instantaneous current, input voltage
and output voltage.
Furthermore, it can be used flexibly, since numerous settings are available individually, e.g.:
nominal current, characteristics, manual characteristics, prewarning, start behavior, input behavior,
overvoltage behavior, undervoltage level, reverse feed behavior, LED button programming function.
All EL9227 terminals are equipped with protection against reverse polarity and reverse feed
Quick links
Also see about this
2 Technical data [}16]
2 Mounting and wiring [}31]
2 Object description and parameterization [}114]
EL922x 15Version: 1.0
Product overview
3.2 Technical data
Technical data EL9221-5000 EL9221-6000 EL9221-4030 EL9221-6040 EL9221-9060 EL9221-9080 EL9221-5090
Nominal voltage 24VDC (-15 %/+20 %)
Nominal current max. 10 A,
Nominal current steps 1, 2, 3, 4, 5,
Input current max. 10A (Input current = forwarding current + current of the own terminal)
Number of outputs 1
Output 1 Terminal contact and power contact
Power contacts (right) +24 V DC protected; 0V DC
Number of digital inputs 1 (24V DC falling edge -15% + 20%); same 0 V reference as input voltage
Prewarning output load Fixed 90%, 5% hysteresis
Tripping behavior
Restart time ≥ 10 seconds*
Internal fuse (faile-safe element)
Internal max. power dissipation limitation
Max. current limitation typically 25 A
Switch-on delay typical 15ms
Overcurrent protection operation without E-bus
Switch-on capacitance typically 20,000 µF**
Overvoltage shutdown > 32 V DC
Parallel connection of several outputs
E-Bus current consumption typ. 80mA
Electrical connection to
mounting rail
Measuring error typ. ± 100 mA @23°C+- 20°C @24 V
Electrical isolation 500 V (E-bus/signal voltage)
Dimensions (WxHxD) approx. 15mm x 100mm x 70mm (width aligned: 12mm)
Weight approx. 60g
Permissible ambient temperature range during operation
Permissible ambient temperature range during storage
Permissible relative air humidity
Mounting [}32]
Vibration / shock resistance conforms to EN60068-2-6 / EN60068-2-27
EMC immunity/emission conforms to EN61000-6-2 / EN61000-6-4
Installation position
Protection class IP20
Approvals CE
adjustable
6, 7, 8, 9, 10
A
see tables showing tripping times [}19]
15 A (F) 6 A (T) 4 A (T) 6 A (T) 10 A (F) 10 A (F) 15 A (F)
typically 400
W for 20 ms
for 20 ms
Yes
not permissible
Yes
0°C ... + 55°C
-25°C ... + 85°C
95%, no condensation
on 35mm mounting rail according to EN 60715
see note [}38]!
max. 4 A, adjustable
1, 2, 3, 4 A
typically 160
W for 50 ms
typically 10 A
for 50 ms
3 A, fixed 4 A, fixed 6 A, fixed 8 A, fixed 10 A, fixed
typically 160
W for 50 ms
typically 10 A
for 50 ms
typically 160
W for 50 ms
typically 10 A
for 50 ms
typically 266
W for 30 ms
typically 16 A
for 30 ms
typically 266
W for 30 ms
typically 16 A
for 30 ms
typically 400
W for 20 ms
typically 25 A
for 20 ms
*) for further explanations see note in chapter Commissioning [}54]
**) depending on: installed power supply, line resistance, load current, component tolerances, selected current range
EL922x16 Version: 1.0
Product overview
Technical data EL9222-5500 EL9222-6600 EL9222-4433 EL9222-6644 EL9222-9664 EL9222-9482
Nominal voltage 24VDC (-15 %/+20 %)
Nominal current Max. Ʃ10 A
Nominal current steps 1, 2, 3, 4, 5, 6,
Input current max. 10A (Input current = forwarding current + current of the own terminal)
Number of outputs 2
Output 1 Terminal contact and power contact
Power contacts (right) +24 V DC protected; 0V DC
Number of digital inputs 2 (24V DC falling edge -15% + 20%); same 0 V reference as input voltage
Prewarning output load Fixed 90%, 5% hysteresis
Tripping behavior
Restart time ≥ 10 seconds*
Internal fuse (faile-safe element)
(channel1/channel2)
Internal max. power dissipation limitation (channel1/
channel2)
Max. current limitation
(channel1/channel2)
Switch-on delay typical 15ms
Overcurrent protection operation without E-bus
Switch-on capacitance typically 20,000 µF**
Overvoltage shutdown > 32 V DC
Parallel connection of several outputs
E-Bus current consumption typ. 80mA
Electrical connection to
mounting rail
Measuring error typ. ± 100 mA @23°C+- 20°C @24 V
Electrical isolation 500 V (E-bus/signal voltage)
Dimensions (WxHxD) approx. 15mm x 100mm x 70mm (width aligned: 12mm)
Weight approx. 60g
Permissible ambient temperature range during operation
Permissible ambient temperature range during storage
Permissible relative air humidity
Mounting [}32]
Vibration / shock resistance conforms to EN60068-2-6 / EN60068-2-27
EMC immunity/emission conforms to EN61000-6-2 / EN61000-6-4
Installation position
Protection class IP20
Approvals CE
ajustable
7, 8, 9, 10 A
see tables showing tripping times [}19]
15 A (F) /
15 A (F)
typically 400 W
for 20 ms /
typically 400 W
for 20 ms
typically 25 A for
20 ms /
typically 25 A for
20 ms
Yes
not permissible
Yes
0°C ... + 55°C
-25°C ... + 85°C
95%, no condensation
on 35mm mounting rail according to EN60715
see note [}38]!
max. 4 A, adjustable
1, 2, 3, 4 A
6 A (T) /
6 A (T)
typically 160 W
for 50 ms / typically 160 W for
50 ms
typically 10 A for
50 ms /
typically 10 A for
50 ms
3 A / 3 A,
fixed
4 A (T) /
4 A (T)
typically 160 W
for 50 ms / typically 160 W for
50 ms
typically 10 A for
50 ms /
typically 10 A for
50 ms
4 A / 4 A,
fixed
6 A (T) /
6 A (T)
typically 160 W
for 50 ms / typically 160 W for
50 ms
typically 10 A for
50 ms /
typically 10 A for
50 ms
6 A / 4 A,
fixed
10 A (F) /
6 A (T)
typically 266 W
for 30 ms /
typically 160 W
for 50 ms
typically 16 A for
30 ms /
typically 10 A for
50 ms
8 A / 2 A,
fixed
10 A (F) /
4 A (T)
typically 266 W
for 30 ms /
typically 160 W
for 50 ms
typically 16 A for
30 ms /
typically 10 A for
50 ms
*) for further explanations see note in chapter Commissioning [}54]
**) depending on: installed power supply, line resistance, load current, component tolerances, selected current range
EL922x 17Version: 1.0
Product overview
Technical data EL9227-5500 EL9227-6600 EL9227-4433 EL9227-6644 EL9227-9664 EL9227-9482
Nominal voltage 24VDC (-15 %/+20 %)
Nominal current Max. Ʃ10 A, ad-
justable
Nominal current steps 1, 2, 3, 4, 5, 6, 7,
8, 9, 10 A
Input current max. 10A (Input current = forwarding current + current of the own terminal)
Number of outputs 2
Output 1 Terminal contact and power contact
Power contacts (right) +24V DC protected; 0V DC
Number of digital inputs 2 (24V DC falling edge -15% + 20%); same 0 V reference as input voltage
Prewarning output load Adjustable between 50% and 100%, 5% hysteresis
Tripping behavior
see tables showing tripping times [}19]
Restart time ≥ 10 seconds (temperature-dependent)*
Internal fuse (faile-safe element) (channel1/channel2)
Internal max. power dissipation limitation (channel1/
channel2)
15 A (F) / 15 A
(F)
typically 400 W
for 20 ms /
typically 400 W
for 20 ms
Max. current limitation
(channel1/channel2)
typically 25 A for
20 ms / typically
25 A for 20 ms
Switch-on delay typical 15ms
Overcurrent protection op-
Yes
eration without E-bus
Switch-on capacitance typically 20,000 µF**
Undervoltage prewarning Adjustable between 17 and 24 V DC
Overvoltage shutdown > 32 V DC
Reverse polarity switch-off Yes
Reverse feed shutdown U
Parallel connection of sev-
+ 1 V > U
Out
Switch-off times adjustable in 3 steps (fast: after 10 ms, standard: after 100 ms, slow: after 1000 ms)
not permissible
eral outputs
E-Bus current consumption typ. 80mA
Electrical connection to
Yes
mounting rail
Measuring error typ. ± 75 mA @23°C+- 20°C @24 V
typ. ± 150 mV @23°C+- 20°C @24 V
Electrical isolation 500 V (E-bus/signal voltage)
Dimensions (WxHxD) approx. 15mm x 100mm x 70mm (width aligned: 12mm)
Weight approx. 60g
Permissible ambient tem-
0°C ... + 55°C
perature range during operation
Permissible ambient tem-
-25°C ... + 85°C
perature range during storage
Permissible relative air hu-
95%, no condensation
midity
Mounting [}32]
on 35mm mounting rail according to EN60715
Vibration / shock resistance conforms to EN60068-2-6 / EN60068-2-27
EMC immunity/emission conforms to EN61000-6-2 / EN61000-6-4
Installation position
see note [}38]!
Protection class IP20
Approvals CE
Max. 4 A, ad-
3 A / 3 A, fixed 4 A / 4 A, fixed 6 A / 4 A, fixed 8 A / 2 A, fixed
justable
1, 2, 3, 4 A
6 A (T) / 6 A (T) 4 A (T) / 4 A (T) 6 A (T) / 6 A (T) 10 A (F) / 6 A (T) 10 A (F) / 4 A (T)
typically 160 W
for 50 ms / typically 160 W for
50 ms
typically 10 A for
50 ms / typically
10 A for 50 ms
In
typically 160 W
for 50 ms / typically 160 W for
50 ms
typically 10 A for
50 ms / typically
10 A for 50 ms
typically 160 W
for 50 ms / typically 160 W for
50 ms
typically 10 A for
50 ms / typically
10 A for 50 ms
typically 266 W
for 30 ms /
typically 160 W
for 50 ms
typically 16 A for
30 ms / typically
10 A for 50 ms
typically 266 W
for 30 ms /
typically 160 W
for 50 ms
typically 16 A for
30 ms / typically
10 A for 50 ms
*) for further explanations see note in chapter Commissioning [}54]
**) depending on: installed power supply, line resistance, load current, component tolerances, selected current range
EL922x18 Version: 1.0
Product overview
Table1: Typical tripping times for: EL9221-5000*; EL9221-5090*; EL9222-5500*; EL9227-5500
X * I
N
Current fast standard slow
t / in ms
1.1 7,000 10,000 15,000
1.2 7,000 10,000 15,000
1.3 3,500 5,000 7,500
1.4 3,500 5,000 7,500
1.5 700 1,000 1,500
1.6 700 1,000 1,500
1.7 700 1,000 1,500
1.8 70 100 150
1.9 70 100 150
≥ 2 Max. typ. 25A 1 8 12
*) only “standard” for these variants
Table2: Typical tripping times for: EL9221-9060*; EL9221-9080*; EL9222-9664 (channel 1)*; EL9222-9482
(channel 1)*; EL9227-9664 (channel 1), EL9227-9482 (channel 1)
X * I
N
Current fast standard slow
t / in ms
1.1 7,000 10,000 15,000
1.2 7,000 10,000 15,000
1.3 3,500 5,000 7,500
1.4 3,500 5,000 7,500
1.5 700 1,000 1,500
1.6 700 1,000 1,500
1.7 700 1,000 1,500
1.8 70 100 150
1.9 70 100 150
≥ 2 Max. typ. 16A 1 8 12
*) only “standard” for these variants
Table3: Typical tripping times for: EL9221-4030*; EL9221-6000*; EL9221-6040*; EL9222-4433*;
EL9222-6600*; EL9222-6644*; EL9227-4433; EL9227-6600; EL9227-6644; EL9222-9664 (channel 2)*;
EL9227-9664 (channel 2); EL9227-9482 (channel 2); EL9222-9482 (channel 2)*
X * I
N
Current fast standard slow
t / in ms
1.1 7,000 10,000 15,000
1.2 7,000 10,000 15,000
1.3 3,500 5,000 7,500
1.4 3,500 5,000 7,500
1.5 700 1,000 1,500
1.6 700 1,000 1,500
1.7 700 1,000 1,500
1.8 70 100 150
1.9 70 100 150
≥ 2 Max. typ. 10A 1 8 12
*) only “standard” for these variants
EL922x 19Version: 1.0
Basic function principles
4 Basic function principles
The functional principle of the electronic overcurrent protection terminals is based on measurement and
evaluation of the current flow. Depending on the result of the evaluation, the corresponding action is then
executed. One possible action is shutdown.
There are several shutdown options: once according to typical tripping times (characteristic curve), according
to hardware parameters or after exceeding the limit load integral..
Shutdown based on characteristic curve
Shutdown based on the characteristic curve can take place if the outputs were previously switched on
successfully. How long the respective overcurrent may flow until the shutdown is triggered depends on the
tripping times specified in the characteristic curve. Typical tripping times can be found under Technical data
[}19].
Shutdown based on hardware parameters
The electronic overcurrent protection terminals EL9221, EL9222 and EL9227 have an internal current and
power limitation based on hardware parameters. The shut-down according to hardware parameters (power
limitation / current limitation) occurs when the outputs are already overloaded when switched on and could
not be switched on. If, for example, an existing short-circuit is switched on. However, the hardware shutdown also takes effect in characteristic curve operation if the power limit and/or current limit are exceeded. If
one of them is exceeded, the switch-off takes place after a fixed time.
The specification of the power dissipation limitation refers to the internal power dissipation in the terminal.
The value of the power dissipation limitation is fixed, whereas the current flow depends on the voltage drop
in the terminal. For example, if a 0 Ohm short circuit was present, the 24 V DC would drop completely in the
terminal. A power limitation of 400 W would result in a current of approx. 16.67 A until shutdown. Depending
on the voltage distribution, the current increases, but only to a maximum limiting value. The respective
limitation values can be found under Technical data [}16].
The power loss limitation including current limitation is always active. This means that this function is always
available regardless of whether the outputs could already be switched on or not.
Shutdown after exceeding the limit load integral
The tripping time can vary if, for example, the limit load integral is exceeded.
Example: In pulsed operation, an overcurrent occurs several times in succession. Shortly before the switchoff, the overcurrent remains off, and then returns after a short time. As a result, the limit load integral has
built up and finally a switch-off occurs.
Shutdown during the switch-on process
Electrical loads can be switched on in two different ways. Once directly via the output at the overcurrent
protection terminal or via other switching products. When the load is switched on via the channel at the
terminal, the power dissipation and current limitation values are decisive for a possible switch-off at the
switch-on time. When a load is switched on via additional switching terminals (output of the overcurrent
protection terminal is already switched on), the data of the characteristic curve are decisive.
EL922x20 Version: 1.0
Basics communication
5 Basics communication
5.1 EtherCAT basics
Please refer to the EtherCAT System Documentation for the EtherCAT fieldbus basics.
5.2 EtherCAT cabling – wire-bound
The cable length between two EtherCAT devices must not exceed 100 m. This results from the FastEthernet
technology, which, above all for reasons of signal attenuation over the length of the cable, allows a maximum
link length of 5 + 90 + 5 m if cables with appropriate properties are used. See also the Design
recommendations for the infrastructure for EtherCAT/Ethernet.
Cables and connectors
For connecting EtherCAT devices only Ethernet connections (cables + plugs) that meet the requirements of
at least category 5 (CAt5) according to EN 50173 or ISO/IEC 11801 should be used. EtherCAT uses 4 wires
for signal transfer.
EtherCAT uses RJ45 plug connectors, for example. The pin assignment is compatible with the Ethernet
standard (ISO/IEC 8802-3).
Pin Color of conductor Signal Description
1 yellow TD + Transmission Data +
2 orange TD - Transmission Data -
3 white RD + Receiver Data +
6 blue RD - Receiver Data -
Due to automatic cable detection (auto-crossing) symmetric (1:1) or cross-over cables can be used between
EtherCAT devices from Beckhoff.
Recommended cables
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.
EL922x 21Version: 1.0
Basics communication
Fig.13: System manager current calculation
NOTE
Malfunction possible!
The same ground potential must be used for the E-Bus supply of all EtherCAT terminals in a terminal block!
5.3 General notes for setting the watchdog
ELxxxx terminals are equipped with a safety feature (watchdog) that switches off the outputs after a
specifiable time e.g. in the event of an interruption of the process data traffic, depending on the device and
settings, e.g. in OFF state.
The EtherCAT slave controller (ESC) in the EL2xxx terminals features 2 watchdogs:
• SM watchdog (default: 100 ms)
• PDI watchdog (default: 100 ms)
SM watchdog (SyncManager Watchdog)
The SyncManager watchdog is reset after each successful EtherCAT process data communication with the
terminal. If no EtherCAT process data communication takes place with the terminal for longer than the set
and activated SM watchdog time, e.g. in the event of a line interruption, the watchdog is triggered and the
outputs are set to FALSE. The OP state of the terminal is unaffected. The watchdog is only reset after a
successful EtherCAT process data access. Set the monitoring time as described below.
The SyncManager watchdog monitors correct and timely process data communication with the ESC from the
EtherCAT side.
PDI watchdog (Process Data Watchdog)
If no PDI communication with the EtherCAT slave controller (ESC) takes place for longer than the set and
activated PDI watchdog time, this watchdog is triggered.
PDI (Process Data Interface) is the internal interface between the ESC and local processors in the EtherCAT
slave, for example. The PDI watchdog can be used to monitor this communication for failure.
The PDI watchdog monitors correct and timely process data communication with the ESC from the
application side.
The settings of the SM- and PDI-watchdog must be done for each slave separately in the TwinCAT System
Manager.
EL922x22 Version: 1.0
Basics communication
Fig.14: EtherCAT tab -> Advanced Settings -> Behavior -> Watchdog
Notes:
• the multiplier is valid for both watchdogs.
• each watchdog has its own timer setting, the outcome of this in summary with the multiplier is a
resulting time.
• Important: the multiplier/timer setting is only loaded into the slave at the start up, if the checkbox is
activated.
If the checkbox is not activated, nothing is downloaded and the ESC settings remain unchanged.
Multiplier
Multiplier
Both watchdogs receive their pulses from the local terminal cycle, divided by the watchdog multiplier:
1/25 MHz * (watchdog multiplier + 2) = 100 µs (for default setting of 2498 for the multiplier)
The standard setting of 1000 for the SM watchdog corresponds to a release time of 100 ms.
The value in multiplier + 2 corresponds to the number of basic 40 ns ticks representing a watchdog tick.
The multiplier can be modified in order to adjust the watchdog time over a larger range.
EL922x 23Version: 1.0
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 100 ms. The setting range is 0..65535. Together with a multiplier with a range
of 1..65535 this covers a watchdog period between 0..~170 seconds.
Calculation
Multiplier = 2498 → watchdog base time = 1 / 25MHz * (2498 + 2) = 0.0001seconds = 100µs
SM watchdog = 10000 → 10000 * 100µs = 1second watchdog monitoring time
CAUTION
Undefined state possible!
The function for switching off of the SM watchdog via SM watchdog = 0 is only implemented in terminals
from version -0016. In previous versions this operating mode should not be used.
CAUTION
Damage of devices and undefined state possible!
If the SM watchdog is activated and a value of 0 is entered the watchdog switches off completely. This is
the deactivation of the watchdog! Set outputs are NOT set in a safe state, if the communication is interrupted.
5.4 EtherCAT State Machine
The state of the EtherCAT slave is controlled via the EtherCAT State Machine (ESM). Depending upon the
state, different functions are accessible or executable in the EtherCAT slave. Specific commands must be
sent by the EtherCAT master to the device in each state, particularly during the bootup of the slave.
A distinction is made between the following states:
• Init
• Pre-Operational
• Safe-Operational and
• Operational
• Boot
The regular state of each EtherCAT slave after bootup is the OP state.
EL922x24 Version: 1.0
Fig.15: 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 [}22] 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.
EL922x 25Version: 1.0
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.
5.5 CoE Interface
General description
The CoE interface (CANopen over EtherCAT) is used for parameter management of EtherCAT devices.
EtherCAT slaves or the EtherCAT master manage fixed (read only) or variable parameters which they
require for operation, diagnostics or commissioning.
CoE parameters are arranged in a table hierarchy. In principle, the user has read access via the fieldbus.
The EtherCAT master (TwinCAT System Manager) can access the local CoE lists of the slaves via
EtherCAT in read or write mode, depending on the attributes.
Different CoE parameter types are possible, including string (text), integer numbers, Boolean values or larger
byte fields. They can be used to describe a wide range of features. Examples of such parameters include
manufacturer ID, serial number, process data settings, device name, calibration values for analog
measurement or passwords.
The order is specified in 2 levels via hexadecimal numbering: (main)index, followed by subindex. The value
ranges are
• Index: 0x0000 …0xFFFF (0...65535
• SubIndex: 0x00…0xFF (0...255
dez
)
dez
)
A parameter localized in this way is normally written as 0x8010:07, with preceding "x" to identify the
hexadecimal numerical range and a colon between index and subindex.
The relevant ranges for EtherCAT fieldbus users are:
• 0x1000: This is where fixed identity information for the device is stored, including name, manufacturer,
serial number etc., plus information about the current and available process data configurations.
• 0x8000: This is where the operational and functional parameters for all channels are stored, such as
filter settings or output frequency.
Other important ranges are:
• 0x4000: In some EtherCAT devices the channel parameters are stored here (as an alternative to the
0x8000 range).
• 0x6000: Input PDOs ("input" from the perspective of the EtherCAT master)
• 0x7000: Output PDOs ("output" from the perspective of the EtherCAT master)
Availability
Not every EtherCAT device must have a CoE list. Simple I/O modules without dedicated processor
usually have no variable parameters and therefore no CoE list.
If a device has a CoE list, it is shown in the TwinCAT System Manager as a separate tab with a listing of the
elements:
EL922x26 Version: 1.0
Basics communication
Fig.16: "CoE Online " tab
The figure above shows the CoE objects available in device "EL2502", ranging from 0x1000 to 0x1600. The
subindices for 0x1018 are expanded.
Data management and function "NoCoeStorage"
Some parameters, particularly the setting parameters of the slave, are configurable and writeable. This can
be done in write or read mode
• via the System Manager (Fig. "CoE Online " tab) by clicking
This is useful for commissioning of the system/slaves. Click on the row of the index to be
parameterised and enter a value in the "SetValue" dialog.
• from the control system/PLC via ADS, e.g. through blocks from the TcEtherCAT.lib library
This is recommended for modifications while the system is running or if no System Manager or
operating staff are available.
Data management
If slave CoE parameters are modified online, Beckhoff devices store any changes in a fail-safe
manner in the EEPROM, i.e. the modified CoE parameters are still available after a restart.
The situation may be different with other manufacturers.
An EEPROM is subject to a limited lifetime with respect to write operations. From typically 100,000
write operations onwards it can no longer be guaranteed that new (changed) data are reliably saved
or are still readable. This is irrelevant for normal commissioning. However, if CoE parameters are
continuously changed via ADS at machine runtime, it is quite possible for the lifetime limit to be
reached. Support for the NoCoeStorage function, which suppresses the saving of changed CoE values, depends on the firmware version.
Please refer to the technical data in this documentation as to whether this applies to the respective
device.
• If the function is supported: the function is activated by entering the code word 0x12345678 once
in CoE 0xF008 and remains active as long as the code word is not changed. After switching the
device on it is then inactive. Changed CoE values are not saved in the EEPROM and can thus
be changed any number of times.
• Function is not supported: continuous changing of CoE values is not permissible in view of the
lifetime limit.
EL922x 27Version: 1.0
Basics communication
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.
Fig.17: Startup list in the TwinCAT System Manager
The Startup list may already contain values that were configured by the System Manager based on the ESI
specifications. Additional application-specific entries can be created.
Online/offline list
While working with the TwinCAT System Manager, a distinction has to be made whether the EtherCAT
device is "available", i.e. switched on and linked via EtherCAT and therefore online, or whether a
configuration is created offline without connected slaves.
In both cases a CoE list as shown in Fig. “’CoE online’ tab” is displayed. The connectivity is shown as offline/
online.
• If the slave is offline
◦ The offline list from the ESI file is displayed. In this case modifications are not meaningful or
possible.
◦ The configured status is shown under Identity.
◦ No firmware or hardware version is displayed, since these are features of the physical device.
◦ Offline is shown in red.
EL922x28 Version: 1.0
Basics communication
Fig.18: Offline list
• If the slave is online
◦ The actual current slave list is read. This may take several seconds, depending on the size and
cycle time.
◦ The actual identity is displayed
◦ The firmware and hardware version of the equipment according to the electronic information is
displayed
◦ Online is shown in green.
Fig.19: Online list
EL922x 29Version: 1.0
Basics communication
Channel-based order
The CoE list is available in EtherCAT devices that usually feature several functionally equivalent channels.
For example, a 4-channel analog 0..10 V input terminal also has 4 logical channels and therefore 4 identical
sets of parameter data for the channels. In order to avoid having to list each channel in the documentation,
the placeholder "n" tends to be used for the individual channel numbers.
In the CoE system 16 indices, each with 255 subindices, are generally sufficient for representing all channel
parameters. The channel-based order is therefore arranged in 16
dec
/10
steps. The parameter range
hex
0x8000 exemplifies this:
• Channel 0: parameter range 0x8000:00 ... 0x800F:255
• Channel 1: parameter range 0x8010:00 ... 0x801F:255
• Channel 2: parameter range 0x8020:00 ... 0x802F:255
• ...
This is generally written as 0x80n0.
Detailed information on the CoE interface can be found in the EtherCAT system documentation on the
Beckhoff website.
EL922x30 Version: 1.0
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