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
Mounting and wiring
6 Mounting and wiring
6.1 Instructions for ESD protection
NOTE
Destruction of the devices by electrostatic discharge possible!
The devices contain components at risk from electrostatic discharge caused by improper handling.
• Please ensure you are electrostatically discharged and avoid touching the contacts of the device directly.
• Avoid contact with highly insulating materials (synthetic fibers, plastic film etc.).
• Surroundings (working place, packaging and personnel) should by grounded probably, when handling
with the devices.
• Each assembly must be terminated at the right hand end with an EL9011 or EL9012 bus end cap, to ensure the protection class and ESD protection.
Fig.20: Spring contacts of the Beckhoff I/O components
Additional cover of the housing required!
The terminal housings are specified for use in the IO system.
If these are operated outside the Bus Terminal block (protection function is also provided without
EtherCAT), it must be ensured that the bus contacts and housing openings of the left-hand terminal
are additionally covered.
EL922x 31Version: 1.0
Mounting and wiring
6.2 Installation on mounting rails
WARNING
Risk of electric shock and damage of device!
Bring the bus terminal system into a safe, powered down state before starting installation, disassembly or
wiring of the bus terminals!
Assembly
Fig.21: Attaching on mounting rail
The bus coupler and bus terminals are attached to commercially available 35mm mounting rails (DIN rails
according to EN60715) by applying slight pressure:
1. First attach the fieldbus coupler to the mounting rail.
2. The bus terminals are now attached on the right-hand side of the fieldbus coupler. Join the components with tongue and groove and push the terminals against the mounting rail, until the lock clicks
onto the mounting rail.
If the terminals are clipped onto the mounting rail first and then pushed together without tongue and
groove, the connection will not be operational! When correctly assembled, no significant gap should
be visible between the housings.
Fixing of mounting rails
The locking mechanism of the terminals and couplers extends to the profile of the mounting rail. At
the installation, the locking mechanism of the components must not come into conflict with the fixing
bolts of the mounting rail. To mount the mounting rails with a height of 7.5mm under the terminals
and couplers, you should use flat mounting connections (e.g. countersunk screws or blind rivets).
EL922x32 Version: 1.0
Mounting and wiring
Disassembly
Fig.22: Disassembling of terminal
Each terminal is secured by a lock on the mounting rail, which must be released for disassembly:
1. Pull the terminal by its orange-colored lugs approximately 1cm away from the mounting rail. In doing
so for this terminal the mounting rail lock is released automatically and you can pull the terminal out of
the bus terminal block easily without excessive force.
2. Grasp the released terminal with thumb and index finger simultaneous at the upper and lower grooved
housing surfaces and pull the terminal out of the bus terminal block.
Connections within a bus terminal block
The electric connections between the Bus Coupler and the Bus Terminals are automatically realized by
joining the components:
• The six spring contacts of the K-Bus/E-Bus deal with the transfer of the data and the supply of the Bus
Terminal electronics.
• The power contacts deal with the supply for the field electronics and thus represent a supply rail within
the bus terminal block. The power contacts are supplied via terminals on the Bus Coupler (up to 24V)
or for higher voltages via power feed terminals.
Power Contacts
During the design of a bus terminal block, the pin assignment of the individual Bus Terminals must
be taken account of, since some types (e.g. analog Bus Terminals or digital 4-channel Bus Terminals) do not or not fully loop through the power contacts. Power Feed Terminals (KL91xx, KL92xx
or EL91xx, EL92xx) interrupt the power contacts and thus represent the start of a new supply rail.
PE power contact
The power contact labeled PE can be used as a protective earth. For safety reasons this contact mates first
when plugging together, and can ground short-circuit currents of up to 125A.
EL922x 33Version: 1.0
Mounting and wiring
Fig.23: Power contact on left side
NOTE
Possible damage of the device
Note that, for reasons of electromagnetic compatibility, the PE contacts are capacitatively coupled to the
mounting rail. This may lead to incorrect results during insulation testing or to damage on the terminal (e.g.
disruptive discharge to the PE line during insulation testing of a consumer with a nominal voltage of 230V).
For insulation testing, disconnect the PE supply line at the Bus Coupler or the Power Feed Terminal! In order to decouple further feed points for testing, these Power Feed Terminals can be released and pulled at
least 10mm from the group of terminals.
WARNING
Risk of electric shock!
The PE power contact must not be used for other potentials!
EL922x34 Version: 1.0
Mounting and wiring
6.3 Connection
6.3.1 Connection system
WARNING
Risk of electric shock and damage of device!
Bring the bus terminal system into a safe, powered down state before starting installation, disassembly or
wiring of the bus terminals!
Overview
The Bus Terminal system offers different connection options for optimum adaptation to the respective
application:
• The terminals of ELxxxx and KLxxxx series with standard wiring include electronics and connection
level in a single enclosure.
• The terminals of ESxxxx and KSxxxx series feature a pluggable connection level and enable steady
wiring while replacing.
• The High Density Terminals (HD Terminals) include electronics and connection level in a single
enclosure and have advanced packaging density.
Standard wiring (ELxxxx / KLxxxx)
Fig.24: Standard wiring
The terminals of ELxxxx and KLxxxx series have been tried and tested for years.
They feature integrated screwless spring force technology for fast and simple assembly.
Pluggable wiring (ESxxxx / KSxxxx)
Fig.25: Pluggable wiring
The terminals of ESxxxx and KSxxxx series feature a pluggable connection level.
The assembly and wiring procedure is the same as for the ELxxxx and KLxxxx series.
The pluggable connection level enables the complete wiring to be removed as a plug connector from the top
of the housing for servicing.
The lower section can be removed from the terminal block by pulling the unlocking tab.
Insert the new component and plug in the connector with the wiring. This reduces the installation time and
eliminates the risk of wires being mixed up.
The familiar dimensions of the terminal only had to be changed slightly. The new connector adds about 3
mm. The maximum height of the terminal remains unchanged.
EL922x 35Version: 1.0
Mounting and wiring
A tab for strain relief of the cable simplifies assembly in many applications and prevents tangling of individual
connection wires when the connector is removed.
Conductor cross sections between 0.08mm2 and 2.5mm2 can continue to be used with the proven spring
force technology.
The overview and nomenclature of the product names for ESxxxx and KSxxxx series has been retained as
known from ELxxxx and KLxxxx series.
High Density Terminals (HD Terminals)
Fig.26: High Density Terminals
The Bus Terminals from these series with 16 terminal points are distinguished by a particularly compact
design, as the packaging density is twice as large as that of the standard 12mm Bus Terminals. Massive
conductors and conductors with a wire end sleeve can be inserted directly into the spring loaded terminal
point without tools.
Wiring HD Terminals
The High Density (HD) Terminals of the ELx8xx and KLx8xx series doesn't support pluggable
wiring.
Ultrasonically "bonded" (ultrasonically welded) conductors
Ultrasonically “bonded" conductors
It is also possible to connect the Standard and High Density Terminals with ultrasonically
"bonded" (ultrasonically welded) conductors. In this case, please note the tables concerning the
wire-size width below!
6.3.2 Wiring
WARNING
Risk of electric shock and damage of device!
Bring the bus terminal system into a safe, powered down state before starting installation, disassembly or
wiring of the Bus Terminals!
EL922x36 Version: 1.0
Mounting and wiring
Terminals for standard wiring ELxxxx/KLxxxx and for pluggable wiring ESxxxx/KSxxxx
Fig.27: Connecting a cable on a terminal point
Up to eight terminal points enable the connection of solid or finely stranded cables to the Bus Terminal. The
terminal points are implemented in spring force technology. Connect the cables as follows:
1. Open a terminal point by pushing a screwdriver straight against the stop into the square opening
above the terminal point. Do not turn the screwdriver or move it alternately (don't toggle).
2. The wire can now be inserted into the round terminal opening without any force.
3. The terminal point closes automatically when the pressure is released, holding the wire securely and
permanently.
See the following table for the suitable wire size width.
Terminal housing ELxxxx, KLxxxx ESxxxx, KSxxxx
Wire size width (single core wires) 0.08 ... 2.5mm
Wire size width (fine-wire conductors) 0.08 ... 2.5mm
Wire size width (conductors with a wire end sleeve) 0.14 ... 1.5mm
2
2
2
0.08 ... 2.5mm
0,08 ... 2.5mm
0.14 ... 1.5mm
2
2
2
Wire stripping length 8 ... 9mm 9 ... 10mm
High Density Terminals (HD Terminals [}36]) with 16 terminal points
The conductors of the HD Terminals are connected without tools for single-wire conductors using the direct
plug-in technique, i.e. after stripping the wire is simply plugged into the terminal point. The cables are
released, as usual, using the contact release with the aid of a screwdriver. See the following table for the
suitable wire size width.
Terminal housing High Density Housing
Wire size width (single core wires) 0.08 ... 1.5mm
Wire size width (fine-wire conductors) 0.25 ... 1.5mm
Wire size width (conductors with a wire end sleeve) 0.14 ... 0.75mm
Wire size width (ultrasonically “bonded" conductors) only 1.5mm
2
2
2
2
Wire stripping length 8 ... 9mm
EL922x 37Version: 1.0
Mounting and wiring
6.3.2.1 Wire cross-section of the load circuit
NOTE
Adapting the wire cross-section to the load circuit
The user must ensure that the wire cross-section of the respective load circuit is adapted accordingly!
6.4 Prescribed installation position
NOTE
Constraints regarding installation position and operating temperature range
When installing the terminals ensure that an adequate spacing is maintained between other components
above and below the terminal in order to guarantee adequate ventilation!
Prescribed installation position
The prescribed installation position requires the mounting rail to be installed horizontally and the connection
surfaces of the EL/KL terminals to face forward (see Fig. Recommended distances for standard installation
position).
The terminals are ventilated from below, which enables optimum cooling of the electronics through
convection. "From below" is relative to the acceleration of gravity.
Fig.28: Recommended minimum distances for standard installation position
Compliance with the distances shown in Fig. Recommended distances for standard installation position is
strongly recommended.
EL922x38 Version: 1.0
Mounting and wiring
6.5 Installation instructions for enhanced mechanical load capacity
WARNING
Risk of injury through electric shock and damage to the device!
Bring the Bus Terminal system into a safe, de-energized state before starting mounting, disassembly or
wiring of the Bus Terminals!
Additional checks
The terminals have undergone the following additional tests:
Verification Explanation
Vibration 10 frequency runs in 3 axes
6 Hz < f < 60 Hz displacement 0.35 mm, constant amplitude
60.1Hz<f<500Hz acceleration 5g, constant amplitude
Shocks 1000 shocks in each direction, in 3 axes
25 g, 6 ms
Additional installation instructions
For terminals with enhanced mechanical load capacity, the following additional installation instructions apply:
• The enhanced mechanical load capacity is valid for all permissible installation positions
• Use a mounting rail according to EN 60715 TH35-15
• Fix the terminal segment on both sides of the mounting rail with a mechanical fixture, e.g. an earth
terminal or reinforced end clamp
• The maximum total extension of the terminal segment (without coupler) is:
64 terminals (12 mm mounting with) or 32 terminals (24 mm mounting with)
• Avoid deformation, twisting, crushing and bending of the mounting rail during edging and installation of
the rail
• The mounting points of the mounting rail must be set at 5 cm intervals
• Use countersunk head screws to fasten the mounting rail
• The free length between the strain relief and the wire connection should be kept as short as possible. A
distance of approx. 10 cm should be maintained to the cable duct.
EL922x 39Version: 1.0
Mounting and wiring
6.6 Positioning of passive Terminals
Hint for positioning of passive terminals in the bus terminal block
EtherCAT Terminals (ELxxxx / ESxxxx), which do not take an active part in data transfer within the
bus terminal block are so called passive terminals. The passive terminals have no current consumption out of the E-Bus.
To ensure an optimal data transfer, you must not directly string together more than 2 passive terminals!
Examples for positioning of passive terminals (highlighted)
Fig.29: Correct positioning
Fig.30: Incorrect positioning
EL922x40 Version: 1.0
Mounting and wiring
6.7 LEDs and pin assignment, programming with LED buttons
6.7.1 EL9221-xxxx
LEDs and connection
Fig.31: EL9221-5000, assignment and designation of connections and LEDs
Meaning of the connections
Terminal point Description
Name No.
Digital input 1 1 Digital input for switching output 1
24 V power supply 2 +24 V DC input voltage (internally connected to terminal point 6)
0 V power supply 3 0 V DC input voltage (internally connected to terminal point 7 and power contact 0 V)
4 Not used
Protected output 1 5 Protected + 24 V DC (internally connected to positive power contact)
Protected output 1
via power contact
24 V power supply 6 +24 V DC input voltage (internally connected to terminal point 2)
0 V power supply 7 0 V DC input voltage (internally connected to terminal point 3 and power contact 0 V)
8 Not used
(negative edge; 0 V reference as supply)
Protected + 24 V DC (internally connected to output 1)
EL922x 41Version: 1.0
Mounting and wiring
Meaning of the LEDs and button LED EL9221-xxxx
LED Color Meaning
Button LED 1 This button LED 1 indicates the status of output 1
Green off Output1 switched off
on Output1 switched on
flashing Programming mode active:
flickering Switch-off process not yet completed,
Orange on Output 1 switched on + prewarning threshold reached
Flash (after pressing)
flashing Reverse current active
Red on Output 1 triggered
flashing Output 1 triggered and cooling phase active
Run LED Run LED indicates the EtherCAT operating state of the terminal
Green off
flashing State of the EtherCAT State Machine: PREOP = function for mailbox communication and
Single
flash
on State of the EtherCAT State Machine: OP = normal operating state; mailbox and process
flickering
Ready LED Ready LED indicates the status for overcurrent protection / programming mode / query mode
Green on 24 V DC supply voltage present and initialization completed, overcurrent protection active,
Orange on Programming mode / query mode active
Red on Missing 24 V DC supply voltage or initialization error
flashing Loading the factory settings
flickering Wiring error or cable break (e.g. wrong ground reference)
Permissible nominal current value for output 1 can be read with flashing code (1x flashing
= 1 A; 2x flashing = 2 A, etc.).
wiring error: voltage detected at switched-off output ( with Ready LED green)
Output 1 disabled (nominal current value is set to "OFF")
or
Query mode or programming mode active (additionally orange Ready LED is on):
Nominal current value cannot be changed because disabled or fixed variant; set nominal
current value for output 1 can be read with flashing code (1x flashing = 1 A; 2x flashing = 2
A; etc.)
State of the EtherCAT State Machine [}94]: INIT=initialization of the terminal
different default settings set
State of the EtherCAT State Machine: SAFEOP = verification of the Sync Manager [}96]
channels and the distributed clocks.
The outputs remain in safe state.
data communication is possible
State of the EtherCAT State Machine: BOOTSTRAP=function for terminal firmware up-
dates [}154]
operation mode active
The EL9221-xxxx has an illuminated push-button!
The illuminated push-button allows operation of the overcurrent protection terminal such as switching on and off and resetting the output. It is also used for programming and querying the nominal
current. There are 3 modes: operation mode, programming mode and query mode.
With the EL9221-xxxx, only push-button LED 1 has a function, since it is a 1-channel version.
Overview of the 3 operation modes:
Operation mode
The operation mode is active as soon as the overcurrent protection terminal is supplied with supply voltage,
the initialization has been successfully completed and no other mode is active. This is effectively the normal
mode of operation.
Programming mode
The programming mode is available for the adjustable overcurrent protection terminals. To enter this mode,
press and hold the button in operation mode for more than 3 seconds.
Query mode
The query mode exists for the fixed overcurrent protection terminals, which are not adjustable. If
programming is disabled for the adjustable overcurrent protection terminals, only the query mode is
available. No changes can be made in query mode, i.e. it is only intended for querying the nominal current
value. To enter this mode, press and hold the button in operation mode for more than 3 seconds.
EL922x42 Version: 1.0
Mounting and wiring
For operation in the respective modes, please refer to the table LED buttons Operation / Programming.
Button LED Operation / Programming
LED State Meaning
Operation in operation mode
Button LED 1 Press briefly Switching output 1 on and off or resetting it
Long press (>3s) Activating the programming or query mode
Operation in programming mode
Button LED 1 Press briefly Set nominal current value for output 1, press 1x = 1A, press 2x = 2A etc. up to
Long press (>3s) Saving the nominal current value and leaving the programming mode
No operation for 45 seconds After 45 seconds, the programming mode is automatically exited without saving
Operation in query mode
Button LED 1 Press briefly No function
Long press (>3s) Exiting the query mode
No operation for 45 seconds After 45 seconds, the settings query mode is automatically exited again
press 10x = 10A, press more than 11x = OFF
For variants up to 4A, press more than 5x = OFF applies
the settings.
Sample programming
Further sample programming can be found in chapter "Sample programming [}52]".
Behavior of the outputs when the settings are changed
If settings are changed during operation (outputs are switched on), the outputs remain switched on.
This has the advantage that the system can remain in operation and a change can be made "online".
EL922x 43Version: 1.0
Mounting and wiring
6.7.2 EL9222-xxxx
LEDs and connection
Fig.32: EL9222-5500, assignment and designation of connections and LEDs
Meaning of the connections
Terminal point Description
Name No.
Digital input 1 1 Digital input for switching output 1
24 V power supply 2 +24 V DC input voltage (internally connected to terminal point 6)
0 V power supply 3 0 V DC input voltage (internally connected to terminal point 7 and power contact 0 V)
Digital input 2 4 Digital input for switching output 2
Protected output 1 5 Protected + 24 V DC (internally connected to positive power contact)
Protected output 1
via power contact
24 V power supply 6 +24 V DC input voltage (internally connected to terminal point 2)
0 V power supply 7 0 V DC input voltage (internally connected to terminal point 3 and power contact 0 V)
Protected output 2 8 Protected + 24 V DC,
(negative edge; 0 V reference as supply)
(negative edge; 0 V reference as supply)
Protected + 24 V DC (internally connected to output 1)
EL922x44 Version: 1.0
Meaning of the EL9222-xxxx LEDs and button LEDs
LED Color Meaning
Button
LED 1
Run LED Run LED indicates the EtherCAT operating state of the terminal
Ready
LED
Button
LED 2
Button LED 1 indicates the status of output 1.
Green off Output1 switched off
on Output1 switched on
flashing Programming mode active:
flickering Switch-off process not yet completed,
Orange on Output 1 switched on + prewarning threshold reached
Flash (after
pressing)
flashing Reverse current active
Red on Output 1 triggered
flashing Output 1 triggered and cooling phase active
Green off
flashing State of the EtherCAT State Machine: PREOP = function for mailbox communication and dif-
Single flash
on State of the EtherCAT State Machine: OP = normal operating state; mailbox and process
flickering
Ready LED indicates the status for overcurrent protection / programming mode / query mode
Green on 24 V DC supply voltage present and initialization completed, overcurrent protection active,
Orange on Programming mode / query mode active
Red on Missing 24 V DC supply voltage or initialization error
flashing Loading the factory settings
flickering Wiring error or cable break (e.g. wrong ground reference)
Button LED 2 indicates the status of output 2.
Green off Output2 switched off
on Output2 switched on
flashing Programming mode active:
flickering Switch-off process not yet completed,
Orange on Output 2 switched on + prewarning threshold reached
Flash (after
pressing)
flashing Reverse current active
Red on Output 2 triggered
flashing Output 2 triggered and cooling phase active
Permissible nominal current value for output 1 can be read with flashing code (1x flashing =
1 A; 2x flashing = 2 A, etc.).
wiring error: voltage detected at switched-off output ( with Ready LED green)
Output 1 disabled (nominal current value is set to "OFF")
or
Query mode or programming mode active (additionally orange Ready LED is on):
Nominal current value cannot be changed because disabled or fixed variant; set nominal current value for output 1 can be read with flashing code (1x flashing = 1 A; 2x flashing = 2 A;
etc.)
or
Programming mode active (additionally Ready LED orange on):
Sum current of both outputs exceeded, impermissible nominal current value for output 1 can
be read with flashing code (1x flashing = 1 A; 2x flashing = 2 A, etc.)
State of the EtherCAT State Machine [}94]: INIT=initialization of the terminal
ferent default settings set
State of the EtherCAT State Machine: SAFEOP = verification of the Sync Manager [}96]
channels and the distributed clocks.
The outputs remain in safe state.
data communication is possible
State of the EtherCAT State Machine: BOOTSTRAP=function for terminal firmware updates
[}154]
operation mode active
Permissible nominal current value for output 2 can be read with flashing code (1x flashing =
1 A; 2x flashing = 2 A, etc.).
wiring error: voltage detected at switched-off output ( with Ready LED green)
Output 2 disabled (nominal current value is set to "OFF")
or
Query mode or programming mode active (additionally orange Ready LED is on):
Nominal current value cannot be changed because disabled or fixed variant; set nominal current value for output 2 can be read with flashing code (1x flashing = 1 A; 2x flashing = 2 A;
etc.).
or
Programming mode active (additionally Ready LED orange on):
Sum current of both outputs exceeded, impermissible nominal current value for output 2 can
be read with flashing code (1x flashing = 1 A; 2x flashing = 2 A, etc.)
Mounting and wiring
EL922x 45Version: 1.0
Mounting and wiring
The EL9222-xxxx has illuminated push-buttons!
The illuminated push-buttons allow the overcurrent protection terminal to be operated, e.g. switching on and off and resetting the respective output. They are also used for programming and querying the nominal current. There are 3 modes: operation mode, programming mode and query mode.
There is a common programming mode in which the two outputs can be set simultaneously, as they
are interdependent for the terminal with sum current limitation.
Overview of the 3 operation modes:
Operation mode
The operation mode is active as soon as the overcurrent protection terminal is supplied with supply voltage,
the initialization has been successfully completed and no other mode is active. This is effectively the normal
mode of operation.
Programming mode
The programming mode is available for the adjustable overcurrent protection terminals. To enter this mode,
press and hold one of the two buttons in operation mode for > 3 seconds. In programming mode, both
outputs can be set simultaneously.
Query mode
The query mode exists for the fixed overcurrent protection terminals, which are not adjustable. If
programming is disabled for the adjustable overcurrent protection terminals, only the query mode is
available. No changes can be made in query mode, i.e. it is only intended for querying the nominal current
value. To enter this mode, press and hold one of the two buttons in operation mode for > 3 seconds.
For operation in the respective modes, please refer to the table LED buttons Operation / Programming.
Button LED Operation / Programming
LED State Meaning
Operation in operation mode
Button LED 1 Press briefly Switching output 1 on and off or resetting it
Long press (>3s) Activating the programming or query mode
Button LED 2 Press briefly Switching output 2 on and off or resetting it
Long press (>3s) Activating the programming or query mode
Operation in programming mode
Button LED 1 Press briefly Set nominal current value for output 1, press 1x = 1A, press 2x = 2A etc. up to
Long press (>3s) Saving the nominal current value and leaving the programming mode
Button LED 2 Press briefly Set nominal current value for output 2, press 1x = 1A, press 2x = 2A etc. up to
Long press (>3s) Saving the nominal current value and leaving the programming mode
Press button LEDs 1 and 2 simultaneously for > 5 s Resetting to factory settings
No operation for 45 seconds After 45 seconds, the programming mode is automatically exited without saving
Operation in query mode
Button LED 1 Press briefly No function
Long press (>3s) Exiting the query mode
Button LED 2 Press briefly No function
Long press (>3s) Exiting the query mode
No operation for 45 seconds After 45 seconds, the settings query mode is automatically exited again
press 10x = 10A, press more than 11x = OFF
For variants up to 4A, press more than 5x = OFF applies
press 10x = 10A, press more than 11x = OFF
For variants up to 4A, press more than 5x = OFF applies
the settings.
Sample programming
Further sample programming can be found in chapter "Sample programming [}52]".
EL922x46 Version: 1.0
Mounting and wiring
Behavior of the outputs when the settings are changed
If settings are changed during operation (outputs are switched on), the outputs remain switched on.
This has the advantage that the system can remain in operation and a change can be made "online".
The EL9222-5500 has a sum current limitation of 10A.
The 10A can be split between the two channels. If one channel is set to 10A, the other channel
must be set to OFF! If the sum current is exceeded, button LED 1 and button LED 2 flash red.
The flashing code shows how the channels have been set, and at least one channel must be
changed.
When the value falls below the maximum sum current again, button LED 1 and button LED 2 flash
green or are off. Only now can the programming mode be saved and exited.
EL922x 47Version: 1.0
Mounting and wiring
6.7.3 EL9227-xxxx
LEDs and connection
Fig.33: EL9227-5500, assignment and designation of connections and LEDs
Meaning of the connections
Terminal point Description
Name No.
Digital input 1 1 Digital input for switching output 1
24 V power supply 2 +24 V DC input voltage (internally connected to terminal point 6)
0 V power supply 3 0 V DC input voltage (internally connected to terminal point 7 and power contact 0 V)
Digital input 2 4 Digital input for switching output 2
Protected output 1 5 Protected + 24 V DC (internally connected to positive power contact)
Protected output 1
via power contact
24 V power supply 6 +24 V DC input voltage (internally connected to terminal point 2)
0 V power supply 7 0 V DC input voltage (internally connected to terminal point 3 and power contact 0 V)
Protected output 2 8 Protected + 24 V DC,
(negative edge; 0 V reference as supply)
(negative edge; 0 V reference as supply)
Protected + 24 V DC (internally connected to output 1)
EL922x48 Version: 1.0
Meaning of the EL9227-xxxx LEDs and button LEDs
LED Color Meaning
Button
LED 1
Run
LED
Status
LED 1
Ready
LED
Status
LED 2
Button
LED 2
Button LED 1 indicates the status of output 1.
Green off Output1 switched off
on Output1 switched on
flashing Programming mode active; permissible nominal current value for output 1 can be read with
flickering Switch-off process not yet completed ( with green Ready LED ),
Orange on Output 1 switched on + prewarning threshold reached
Flash (after
pressing)
flashing Query mode or programming mode active (additionally orange Ready LED is on):
Red on Output 1 triggered
flashing Programming mode active (additionally Ready LED orange on):
Run LED indicates the EtherCAT operating state of the terminal
Green off
flashing State of the EtherCAT State Machine: PREOP = function for mailbox communication and dif-
Single flash
on State of the EtherCAT State Machine: OP = normal operating state; mailbox and process data
flickering
Status LED 1 shows additional information for output 1
Orange on Output 1 has detected undervoltage or overvoltage
Red flashing Cooling phase output 1 active
Ready LED indicates the status for overcurrent protection / programming mode / query mode
Green on 24 V DC supply voltage present and initialization completed, overcurrent protection active, op-
Orange on Programming mode / query mode active
Red on Missing 24 V DC supply voltage, initialization error or wiring error
flashing Loading the factory settings
flickering Wiring error or cable break (e.g. wrong ground reference)
Status LED 2 shows additional information for output 2
Orange on Output 2 has detected undervoltage or overvoltage
Red flashing Cooling phase output 2 active
Button LED 2 indicates the status of output 2.
Green off Output2 switched off
on Output2 switched on
flashing Programming mode active; permissible nominal current value for output 2 can be read with
flickering Switch-off process not yet completed ( with green Ready LED ),
Orange on Output 2 switched on + prewarning threshold reached
Flash (after
pressing)
flashing Query mode or programming mode active (additionally orange Ready LED is on):
Red on Output 2 triggered
flashing Programming mode active (additionally Ready LED orange on):
flashing code (1x flashing = 1 A; 2x flashing = 2 A, etc.).
wiring error: voltage detected at switched-off output ( with red Ready LED )
Output 1 disabled (nominal current value is set to "OFF")
Nominal current value cannot be changed because disabled or fixed variant; set nominal current value for output 1 can be read with flashing code (1x flashing = 1 A; 2x flashing = 2 A;
etc.)
Sum current of both outputs exceeded, impermissible nominal current value for output 1 can
be read with flashing code (1x flashing = 1 A; 2x flashing = 2 A, etc.)
State of the EtherCAT State Machine [}94]: INIT=initialization of the terminal
ferent default settings set
State of the EtherCAT State Machine: SAFEOP = verification of the Sync Manager [}96]
channels and the distributed clocks.
The outputs remain in safe state.
communication is possible
State of the EtherCAT State Machine: BOOTSTRAP=function for terminal firmware updates
[}154]
eration mode active
(together with Button LED flickering green; e.g. supply at output)
flashing code (1x flashing = 1 A; 2x flashing = 2 A, etc.).
wiring error: voltage detected at switched-off output ( with red Ready LED )
Output 2 disabled (nominal current value is set to "OFF")
Nominal current value cannot be changed because disabled or fixed variant; set nominal current value for output 2 can be read with flashing code (1x flashing = 1 A; 2x flashing = 2 A;
etc.)
Sum current of both outputs exceeded, impermissible nominal current value for output 2 can
be read with flashing code (1x flashing = 1 A; 2x flashing = 2 A, etc.)
Mounting and wiring
EL922x 49Version: 1.0
Mounting and wiring
The EL9227-xxxx has illuminated push-buttons!
The illuminated push-buttons allow the overcurrent protection terminal to be operated, e.g. switching on and off and resetting the respective output. They are also used for programming and querying the nominal current. There are 3 modes: operation mode, programming mode and query mode.
There is a common programming mode in which the two outputs can be set simultaneously, as they
are interdependent for the terminal with sum current limitation.
Overview of the 3 operation modes:
Operation mode
The operation mode is active as soon as the overcurrent protection terminal is supplied with supply voltage,
the initialization has been successfully completed and no other mode is active. This is effectively the normal
mode of operation.
Programming mode
The programming mode is available for the adjustable overcurrent protection terminals. To enter this mode,
press and hold one of the two buttons in operation mode for > 3 seconds. In programming mode, both
outputs can be set simultaneously.
Query mode
The query mode exists for the fixed overcurrent protection terminals, which are not adjustable. If
programming is disabled for the adjustable overcurrent protection terminals, only the query mode is
available. No changes can be made in query mode, i.e. it is only intended for querying the nominal current
value. To enter this mode, press and hold one of the two buttons in operation mode for > 3 seconds.
For operation in the respective modes, please refer to the table LED buttons Operation / Programming.
Button LED Operation / Programming
LED State Meaning
Operation in operation mode
Button LED 1 Press briefly Switching output 1 on and off or resetting it
Long press (>3s) Activating the programming or query mode
Button LED 2 Press briefly Switching output 2 on and off or resetting it
Long press (>3s) Activating the programming or query mode
Operation in programming mode
Button LED 1 Press briefly Set nominal current value of output 1, press 1x = 1A, press 2x = 2A etc. up to
Long press (>3s) Saving the nominal current value and leaving the programming mode
Button LED 2 Press briefly Set nominal current value of output 2, press 1x = 1A, press 2x = 2A etc. up to
Long press (>3s) Saving the nominal current value and leaving the programming mode
Press button LEDs 1 and 2 simultaneously for > 5s Resetting to factory settings
No operation for 45 seconds After 45 seconds, the programming mode is automatically exited without saving
Operation in query mode
Button LED 1 Press briefly No function
Long press (>3s) Exiting the query mode
Button LED 2 Press briefly No function
Long press (>3s) Exiting the query mode
No operation for 45 seconds After 45 seconds, the settings query mode is automatically exited again
press 10x = 10A, press more than 11x= OFF
For variants up to 4A, press more than 5x = OFF applies
press 10x = 10A, press more than 11x= OFF
For variants up to 4A, press more than 5x = OFF applies
the settings.
Sample programming
Further sample programming can be found in chapter "Sample programming [}52]".
EL922x50 Version: 1.0
Mounting and wiring
Behavior of the outputs when the settings are changed
If settings are changed during operation (outputs are switched on), the outputs remain switched on.
This has the advantage that the system can remain in operation and a change can be made "online".
The EL9227-5500 has a sum current limitation of 10A.
The 10A can be split between the two channels. If one channel is set to 10A, the other channel
must be set to OFF! If the sum current is exceeded, button LED 1 and button LED 2 flash red.
The flashing code shows how the channels have been set, and at least one channel must be
changed.
When the value falls below the maximum sum current again, button LED 1 and button LED 2 flash
green or are off. Only now can the programming mode be saved and exited.
EL922x 51Version: 1.0
Mounting and wiring
6.7.4 Sample programming
The EL922x devices have illuminated push-buttons!
The illuminated push-buttons allow the overcurrent protection terminal to be operated, e.g. switching on and off and resetting the respective output. They are also used for programming and querying the nominal current. There are 3 modes: operation mode, programming mode and query mode.
There is a common programming mode in which the two outputs can be set simultaneously, as they
are interdependent for the terminal with sum current limitation.
1. Press button LED 1 or button LED 2 for >3 seconds to enter the programming mode.
2. The Ready LED lights orange and indicates that they are in programming mode.
3. The green flashing code of button LED 1 indicates the nominal current still set for channel 1, button LED 2
indicates the nominal current still set for channel 2. Flashing once means 1 A, flashing twice 2 A, flashing
three times 3 A, etc… Non-flashing indicates OFF.
4. The programming mode is exited automatically if no entries have been made after 45 seconds, in which
case the settings made previously are not saved. In other words, the previously saved settings are retained.
5. The nominal currents are changed by entering the absolute current values.
I.e. 1 x press button LED 1 or 2 = 1 A, 2 x press = 2 A, 3 x press = 3 A, …, 10 x press = 10 A, press more
than 11x press = OFF!
For variants up to 4A, press more than 5x press = OFF!
6. Press button LED 1 or button LED 2 for >3 seconds to save the new settings, exit programming mode and
the new values are active.
Behavior of the outputs when the settings are changed
If settings are changed during operation (outputs are switched on), the outputs remain switched on.
This has the advantage that the system can remain in operation and a change can be made "online".
Sample programming 1
Operation Display Meaning
Press button LED 1 for >3 seconds Activate programming mode
Ready LED lights up orange
Button LED 1 flashes 6x green
Button LED 2 flashes 2x green
Press button LED1 8x Output 1 is set to 8 A
Ready LED lights up orange
Button LED 1 flashes 8x green
Button LED 2 flashes 2x green
Press button LED 1 for >3 seconds Save the new settings and exit programming
Programming mode is active
Output 1 is set to 6 A
Output 2 is set to 2 A
Programming mode is active
Output 1 is set to 8 A
Output 2 is set to 2 A
mode
EL922x52 Version: 1.0
Mounting and wiring
Sample programming 2
Operation Display Meaning
Press button LED 1 for >3 seconds Activate programming mode
Ready LED lights up orange
Button LED 1 flashes 6x green
Button LED 2 flashes 4x green
Press button LED 1 7x Output 1 is set to 7 A
Ready LED lights up orange
Button LED 1 flashes 7x red
Button LED 2 flashes 4x red
Press button LED2 3x Output 2 is set to 3 A
Ready LED lights up orange
Button LED 1 flashes 7x green
Button LED 2 flashes 3x green
Press button LED 1 for >3 seconds Save the new settings and exit programming
Programming mode is active
Output 1 is set to 6 A
Output 2 is set to 4 A
Programming mode is active
Output 1 is set to 7 A
Output 2 is set to 4 A
Sum current of 10 A exceeded!
Programming mode is active
Output 1 is set to 7 A
Output 2 is set to 3 A
Sum current of 10 A adhered to!
mode
Sample programming 3
Operation Display Meaning
Press button LED 2 for >3 seconds Activate programming mode
Ready LED lights up orange
Button LED 1 flashes 6x green
Button LED 2 flashes 4x green
Press button LED 1 7x Output 1 is set to 7 A
Ready LED lights up orange
Button LED 1 flashes 7x red
Button LED 2 flashes 4x red
Press button LED 2 11x Output 2 is set to Off
Ready LED lights up orange
Button LED 1 flashes 7x green
Button LED 2 is NOT lit
Press button LED 1 for >3 seconds Save the new settings and exit programming
Programming mode is active
Output 1 is set to 6 A
Output 2 is set to 4 A
Programming mode is active
Output 1 is set to 7 A
Output 2 is set to 4 A
Sum current of 10 A exceeded!
Programming mode is active
Output 1 is set to 7 A
Output 2 is off
Sum current of 10 A adhered to!
mode
The EL9227-5500 / EL9222-5500 devices have a sum current limitation of 10A
The 10A can be split between the two channels. If one channel is set to 10A, the other channel
must be set to OFF! If the sum current is exceeded, button LED 1 and button LED 2 flash red.
The flashing code shows how the channels have been set, and at least one channel must be
changed.
When the value falls below the maximum sum current again, button LED 1 and button LED 2 flash
green or are off. Only now can the programming mode be saved and exited.
EL922x 53Version: 1.0
Commissioning
7 Commissioning
The EL922x is an EtherCAT Terminal with electronic overcurrent protection function. The overcurrent
protection function is available at all times, i.e. as soon as the input voltage has been applied, the
overcurrent protection function is active (after a successful initialization run), regardless of whether EtherCAT
is present or not. The EL922x can therefore also be operated in stand-alone mode, without EtherCAT. This
function enables applications where Industrial PCs, Embedded PCs or couplers with 24 V DC can be
supplied and protected, which then start EtherCAT later.
Commissioning for the first time
Before the first start-up, please check the wiring [}55] and make sure that it has been carried out
correctly.
After the outputs have been switched on for the first time, they may trigger immediately and the
push-button LED may light up red. Check the set rated current.
Ensure that the power supply is high enough to ensure a safe voltage supply even in the event of a
fault. Power supplies that are dimensioned too small may not only result in a voltage dip in the
event of a fault, but may also lead to frequent or unintentional switching on and off. This could also
lead to the destruction of the electronics.
Check the process data [}106] (hardware protection) and the Diag messages [}151] for warnings
that could indicate a wiring error. Also check the Ready LED and the Button LEDs for flickering. The
terminal must not be operated in such a condition as this could destroy the electronics.
When commissioning for the first time without changing the parameters, the terminals are set to the factory
settings.
Table4: Factory settings
EL9221- EL9222 EL9227
-5000 -6000 -5500 -6600 -5500 -6600
Nominal Current 4 A / 4 A 2 A / 2 A 4 A / 4 A 2 A / 2 A 4 A / 4 A 2 A / 2 A
Channel Status Off Off Off
Characteristic standard standard standard
Current-Level Warning 90% 90% 90%
Fuse Init State Last State Last State Last State
Input Functions
(DI&Switch)
Overvoltage Behaviour Tripping, auto-reset Tripping, auto-reset Tripping, auto-reset
Undervoltage level Not available Not available 17 V
Reverse Current Filter standard standard standard
Switch Programming
Control
Switch On Channel Delay Not available Not available Disable
Dig Safe State Active FALSE FALSE FALSE
Dig Safe State Value FALSE FALSE FALSE
Reset, On/Off Reset, On/Off Reset, On/Off
Enable Enable Enable
Lock settings with password protection
It is possible to use object 0xF009 [}122] (password protection, data type UINT32) to protect user
parameter data from accidental access. The password protection prevents accidental overwriting of
the parameters, for example. The protection is enabled with password 0x12345678 and remains active until it is disabled with the password 0x11223344. Object 0xF009 also indicates whether password protection is enabled or disabled. Protection is enabled if the object has the value "1" and dis-
abled if the value of the object is "0". If protection is enabled, write access to objects 0x80n0 [}115]
and 0x80n1 [}115] is not possible, and the parameters are retained. This also applies if the factory
settings of the terminal are to be restored via object 0x1011 [}115] or via the LED buttons on the
device. When the terminal is reset, e.g. by de-energizing it, the protection remains enabled. The
password protection is noted in the terminal until it is disabled.
EL922x54 Version: 1.0
Commissioning
NOTE
Permanent reset, Permanent switch-on/switch-off
A permanently applied reset process and continuous switching on and off of the supply voltage is not permitted. This could lead to destruction of the electronics.
NOTE
Restart delay
EL9221 / EL9222
If another tripping event takes place within 15 seconds after a 10-second restart lock has elapsed, the cooling time is extended by an additional 10 seconds. If another tripping event takes place within 15 seconds
after the 20-second restart lock has elapsed, the restart lock is extended by another 10 seconds. This
process is continued as required, but only up to the maximum restart time of 60 seconds. If another tripping
event does not take place within 15 seconds after a tripping event, the cooling time remains at 10 seconds.
EL9227
The restart time depends on the internal temperature of the terminal. If the temperature rises, the restart
time can be increased accordingly.
CAUTION
Danger for persons, the environment or devices!
Note that changing output values can have a direct effect on your automation application. Special precautions must therefore be taken in the plant or machine to prevent automatic restarting of plant components
(see Machinery Directive 2006/42/EC and EN60204-1)!
Only modify these output values if you are certain that the state of your equipment permits it, and that there
will be no risk to people or to the machine!
In the event of a fault (short circuit/overload), the load circuit is electronically switched off by the overcurrent
protection terminal.
7.1 Quick start: Commissioning of the EL922x without EtherCAT
To commission the EL922x quickly without EtherCAT, proceed as follows
1. Mounting
Mount the EL922x as described in the chapter Mounting and wiring [}31]
2. Terminal wiring
Power supply
Connect the 24 V DC power supply to the respective terminal contacts. Supply 24 V DC to terminal
contacts 2 or 6 and 0 V to terminal contacts 3 or 7. The maximum permissible input current, in case of
forwarding the input voltage, can be found in the technical data.
(Input current = forwarding current + current of the own terminal)
Protected outputs
Connect output 1 to terminal point 5 and/or use the power contact. Output 2 is tapped via terminal
point 8 (no further power contact is available here)
Digital inputs
Connect the digital inputs (for switching and resetting the outputs) to terminal point 1 for switching output 1 and terminal point 4 for switching output 2.
A negative edge of 24 V DC is required (same 0 V reference as input voltage).
EL922x 55Version: 1.0
Commissioning
Fig.34: Exemplary wiring of an EL9221-5000 and EL9227-5500
Fig.35: Exemplary wiring of an input voltage of the EL9221-5000 to another terminal.
3. Nominal current setting
Use button LED 1 or button LED 2 to set the desired nominal current.
Programming sequence:
Press one of the LED buttons for ≥3 seconds. Press button LED 1 as many times as you require the
EL922x56 Version: 1.0
Commissioning
nominal current for output 1. Press once = 1 A, press twice = 2 A, ...., press 10 times = 10 A, press …
≥11 times = OFF; (in the 4 A variant, press ≥5 times = Off). For output 2, use button LED 2. Press one
of the LED buttons for ≥3 seconds to save your entries. See also chapter LEDs and connection, pro-
gramming with LED buttons [}41].
4. Commissioning
The EL922x is ready for operation when the green Ready LED lights up after successful nominal current setting and initialization.
Checking of the process data (hardware protection) and the Diag messages
Check the process data [}106] (hardware protection) and the Diag messages [}151] for warnings
that could indicate a wiring error. Also check the Ready LED and the Button LEDs for flickering. The
terminal must not be operated in such a condition as this could destroy the electronics.
EL922x 57Version: 1.0
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7.2 Commissioning and parameterization of the EL922x with EtherCAT
To commission the EL922x with EtherCAT, proceed as follows:
1. Mounting
Mount the EL922x as described in the chapter Mounting and wiring [}31]
2. Terminal wiring
Power supply
Connect the 24 V DC power supply to the respective terminal contacts. Supply 24 V DC to terminal
contacts 2 or 6 and 0 V to terminal contacts 3 or 7. The maximum permissible input current, in case of
forwarding the input voltage, can be found in the technical data.
(Input current = forwarding current + current of the own terminal)
Protected output
Connect output 1 to terminal point 5 and/or use the power contact. Output 2 is tapped via terminal
point 8 (no further power contact is available here)
Digital inputs
Connect the digital inputs (for switching and resetting the outputs) to terminal point 1 for switching output 1 and terminal point 4 for switching output 2. A negative edge of 24 V DC is required.
Fig.36: Exemplary wiring of an EL9221-5000 and EL9227-5500
EL922x58 Version: 1.0
Commissioning
Fig.37: Exemplary wiring of an input voltage of the EL9221-5000 to another terminal.
3. Configuration
Create a configuration in the TwinCAT System Manager by manually inserting the terminal or scan-
ning it online. Please refer to the TwinCAT installation chapter [}64].
EtherCAT XML Device Description
If the XML description of the EL922x is not available in your system you can download the latest
XML file from the download area of the Beckhoff website and install it according to the installation
instructions.
4. Commissioning
Observe the notes on operation and configuration using the LED buttons [}41], as described in chapter Mounting and wiring [}41].
Checking of the process data (hardware protection) and the Diag messages
Check the process data [}106] (hardware protection) and the Diag messages [}151] for warnings
that could indicate a wiring error. Also check the Ready LED and the Button LEDs for flickering. The
terminal must not be operated in such a condition as this could destroy the electronics.
There are two options for setting the respective parameters, either via CoE or via the "Settings" tab.
Settings via CoE
The respective parameters should be set as usual in index 8000. Settings for channel 1 index 8000:0,
manual characteristic curve for channel 1 index 8001:0 (EL9227), settings for channel 2 index 8010:0,
manual characteristic curve for channel 2 index 8011:0 (EL9227).
EL922x 59Version: 1.0
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Fig.38: CoE-8000-Settings – EL9227
Fig.39: CoE-8000-Settings - EL9222
DIG Safe State Active (index 0x80n0:01) / DIG Safe State Value (index 0x80n1:01)
The setting in “DIG Safe State Active” (index 0x80n0:01) defines whether the outputs should assume a safe
state in the case of a bus error. The safe state of the output in the case of a bus error is defined with “DIG
Safe State Value” (index 0x80n1:01).
1. “DIG Safe State Active“ = TRUE and
◦ “DIG Safe State Value“ = TRUE: the output is switched on.
2. “DIG Safe State Active“ = TRUE and
◦ “DIG Safe State Value“ = FALSE: the output is switched off
3. “DIG Safe State Active“ = FALSE
◦ The state of the output is retained. Entries in “DIG Safe State Value” (index 0x80n1:01) have no
effect.
Tabular example:
EL922x60 Version: 1.0
Commissioning
DIG Safe State Active
Index 0x80n0:01
TRUE TRUE FALSE TRUE
TRUE FALSE FALSE FALSE
FALSE FALSE / TRUE FALSE FALSE
DIG Safe State Value
Index 0x80n1:01
Output before bus error
TRUE TRUE
TRUE FALSE
TRUE TRUE
Output bus error occurs
DIG Safe State
By default, the EL922x have the DIG Safe State Active set to "FALSE".
This means that no action is executed when switching to the safe state (e.g. watchdog) and the outputs remain in the last state.
Please note that the terminals also perform the protection function and remain operable without
EtherCAT. Therefore, if the outputs are in the safe state, they can still be switched via the LED buttons and the digital inputs!
Settings via the "Settings" tab
In a more compact display, the settings can also be entered via the "Settings" tab. Proceed as follows:
• Activate the Settings input mask in the upper left corner under "Enable Settings" and confirm the
message box with OK. The input masks of the most common parameters are enabled.
• Select the desired channel.
• Set the desired parameters via the preselect fields (preselect xxx). The corresponding display field
(active xxx) can be found under each preselect field. The value that is currently active in the terminal is
displayed there. Use the "Apply Online" button to write modified parameters to the terminal.
• For terminals with extended functionalities (EL9227), the mode of operation can also be changed here.
See also chapter Process data [}106].
EL922x 61Version: 1.0
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Fig.40: Settings with standard parameters – EL9227
To be able to set advanced parameters, enable the advanced settings at the top right, and further input
masks will open (fuse init state, input functions, overvoltage behavior, undervoltage, reverse current filter,
channel delay and manual characteristic). The active characteristic area is not an input mask (value field
highlighted in gray). Only the values of the active characteristic curve are displayed there.
Manual characteristic curve
The maximum values for a manual characteristic curve are the values of the slow characteristic
curve.
EL922x62 Version: 1.0
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Fig.41: Settings with advanced-parameters
• Import/Export
The settings can be imported or exported via this button.
• Product Details
Here you can find information such as a product image with connection instructions.
• Default Values
Pressing this button loads the default values into the preselect windows. These must still be confirmed
with Apply Online.
EL922x 63Version: 1.0
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7.3 TwinCAT Development Environment
The Software for automation TwinCAT (The Windows Control and Automation Technology) will be
distinguished into:
• TwinCAT2: System Manager (Configuration) & PLC Control (Programming)
• TwinCAT3: Enhancement of TwinCAT2 (Programming and Configuration takes place via a common
Development Environment)
Details:
• TwinCAT2:
◦ Connects I/O devices to tasks in a variable-oriented manner
◦ Connects tasks to tasks in a variable-oriented manner
◦ Supports units at the bit level
◦ Supports synchronous or asynchronous relationships
◦ Exchange of consistent data areas and process images
◦ Datalink on NT - Programs by open Microsoft Standards (OLE, OCX, ActiveX, DCOM+, etc.)
◦ Integration of IEC 61131-3-Software-SPS, Software- NC and Software-CNC within Windows
NT/2000/XP/Vista, Windows 7, NT/XP Embedded, CE
◦ Interconnection to all common fieldbusses
◦ More…
Additional features:
• TwinCAT3 (eXtended Automation):
◦ Visual-Studio®-Integration
◦ Choice of the programming language
◦ Supports object orientated extension of IEC 61131-3
◦ Usage of C/C++ as programming language for real time applications
◦ Connection to MATLAB®/Simulink®
◦ Open interface for expandability
◦ Flexible run-time environment
◦ Active support of Multi-Core- und 64-Bit-Operatingsystem
◦ Automatic code generation and project creation with the TwinCAT Automation Interface
◦ More…
Within the following sections commissioning of the TwinCAT Development Environment on a PC System for
the control and also the basically functions of unique control elements will be explained.
Please see further information to TwinCAT2 and TwinCAT3 at http://infosys.beckhoff.com.
7.3.1 Installation of the TwinCAT real-time driver
In order to assign real-time capability to a standard Ethernet port of an IPC controller, the Beckhoff real-time
driver has to be installed on this port under Windows.
This can be done in several ways. One option is described here.
In the System Manager call up the TwinCAT overview of the local network interfaces via Options → Show
Real Time Ethernet Compatible Devices.
EL922x64 Version: 1.0
Fig.42: System Manager “Options” (TwinCAT2)
This have to be called up by the Menü “TwinCAT” within the TwinCAT3 environment:
Commissioning
Fig.43: Call up under VS Shell (TwinCAT3)
The following dialog appears:
Fig.44: Overview of network interfaces
Interfaces listed under “Compatible devices” can be assigned a driver via the “Install” button. A driver should
only be installed on compatible devices.
A Windows warning regarding the unsigned driver can be ignored.
Alternatively an EtherCAT-device can be inserted first of all as described in chapter Offline configuration
creation, section “Creating the EtherCAT device” [}75] in order to view the compatible ethernet ports via its
EtherCAT properties (tab „Adapter“, button „Compatible Devices…“):
EL922x 65Version: 1.0
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Fig.45: EtherCAT device properties(TwinCAT2): click on „Compatible Devices…“ of tab “Adapter”
TwinCAT 3: the properties of the EtherCAT device can be opened by double click on “Device .. (EtherCAT)”
within the Solution Explorer under “I/O”:
After the installation the driver appears activated in the Windows overview for the network interface
(Windows Start → System Properties → Network)
Fig.46: Windows properties of the network interface
A correct setting of the driver could be:
EL922x66 Version: 1.0
Fig.47: Exemplary correct driver setting for the Ethernet port
Other possible settings have to be avoided:
Commissioning
EL922x 67Version: 1.0
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Fig.48: Incorrect driver settings for the Ethernet port
EL922x68 Version: 1.0
IP address of the port used
IP address/DHCP
In most cases an Ethernet port that is configured as an EtherCAT device will not transport general
IP packets. For this reason and in cases where an EL6601 or similar devices are used it is useful to
specify a fixed IP address for this port via the “Internet Protocol TCP/IP” driver setting and to disable
DHCP. In this way the delay associated with the DHCP client for the Ethernet port assigning itself a
default IP address in the absence of a DHCP server is avoided. A suitable address space is
192.168.x.x, for example.
Commissioning
Fig.49: TCP/IP setting for the Ethernet port
EL922x 69Version: 1.0
Commissioning
7.3.2 Notes regarding ESI device description
Installation of the latest ESI device description
The TwinCAT EtherCAT master/System Manager needs the device description files for the devices to be
used in order to generate the configuration in online or offline mode. The device descriptions are contained
in the so-called ESI files (EtherCAT Slave Information) in XML format. These files can be requested from the
respective manufacturer and are made available for download. An *.xml file may contain several device
descriptions.
The ESI files for Beckhoff EtherCAT devices are available on the Beckhoff website.
The ESI files should be stored in the TwinCAT installation directory.
Default settings:
• TwinCAT2: C:\TwinCAT\IO\EtherCAT
• TwinCAT3: C:\TwinCAT\3.1\Config\Io\EtherCAT
The files are read (once) when a new System Manager window is opened, if they have changed since the
last time the System Manager window was opened.
A TwinCAT installation includes the set of Beckhoff ESI files that was current at the time when the TwinCAT
build was created.
For TwinCAT2.11/TwinCAT3 and higher, the ESI directory can be updated from the System Manager, if the
programming PC is connected to the Internet; by
• TwinCAT2: Option → “Update EtherCAT Device Descriptions”
• TwinCAT3: TwinCAT → EtherCAT Devices → “Update Device Descriptions (via ETG Website)…”
The TwinCAT ESI Updater [}74] is available for this purpose.
ESI
The *.xml files are associated with *.xsd files, which describe the structure of the ESI XML files. To
update the ESI device descriptions, both file types should therefore be updated.
Device differentiation
EtherCAT devices/slaves are distinguished by four properties, which determine the full device identifier. For
example, the device identifier EL2521-0025-1018 consists of:
• family key “EL”
• name “2521”
• type “0025”
• and revision “1018”
Fig.50: Identifier structure
The order identifier consisting of name + type (here: EL2521-0010) describes the device function. The
revision indicates the technical progress and is managed by Beckhoff. In principle, a device with a higher
revision can replace a device with a lower revision, unless specified otherwise, e.g. in the documentation.
Each revision has its own ESI description. See further notes [}9].
EL922x70 Version: 1.0
Commissioning
Online description
If the EtherCAT configuration is created online through scanning of real devices (see section Online setup)
and no ESI descriptions are available for a slave (specified by name and revision) that was found, the
System Manager asks whether the description stored in the device should be used. In any case, the System
Manager needs this information for setting up the cyclic and acyclic communication with the slave correctly.
Fig.51: OnlineDescription information window (TwinCAT2)
In TwinCAT3 a similar window appears, which also offers the Web update:
Fig.52: Information window OnlineDescription (TwinCAT3)
If possible, the Yes is to be rejected and the required ESI is to be requested from the device manufacturer.
After installation of the XML/XSD file the configuration process should be repeated.
NOTE
Changing the ‘usual’ configuration through a scan
ü If a scan discovers a device that is not yet known to TwinCAT, distinction has to be made between two
cases. Taking the example here of the EL2521-0000 in the revision 1019
a) no ESI is present for the EL2521-0000 device at all, either for the revision 1019 or for an older revision.
The ESI must then be requested from the manufacturer (in this case Beckhoff).
b) an ESI is present for the EL2521-0000 device, but only in an older revision, e.g. 1018 or 1017.
In this case an in-house check should first be performed to determine whether the spare parts stock allows the integration of the increased revision into the configuration at all. A new/higher revision usually
also brings along new features. If these are not to be used, work can continue without reservations with
the previous revision 1018 in the configuration. This is also stated by the Beckhoff compatibility rule.
Refer in particular to the chapter ‘General notes on the use of Beckhoff EtherCAT IO components’ and for
manual configuration to the chapter ‘Offline configuration creation’ [}75].
If the OnlineDescription is used regardless, the System Manager reads a copy of the device description from
the EEPROM in the EtherCAT slave. In complex slaves the size of the EEPROM may not be sufficient for the
complete ESI, in which case the ESI would be incomplete in the configurator. Therefore it’s recommended
using an offline ESI file with priority in such a case.
The System Manager creates for online recorded device descriptions a new file
“OnlineDescription0000...xml” in its ESI directory, which contains all ESI descriptions that were read online.
EL922x 71Version: 1.0
Commissioning
Fig.53: File OnlineDescription.xml created by the System Manager
Is a slave desired to be added manually to the configuration at a later stage, online created slaves are
indicated by a prepended symbol “>” in the selection list (see Figure “Indication of an online recorded ESI of
EL2521 as an example”).
Fig.54: Indication of an online recorded ESI of EL2521 as an example
If such ESI files are used and the manufacturer's files become available later, the file OnlineDescription.xml
should be deleted as follows:
• close all System Manager windows
• restart TwinCAT in Config mode
• delete "OnlineDescription0000...xml"
• restart TwinCAT System Manager
This file should not be visible after this procedure, if necessary press <F5> to update
OnlineDescription for TwinCAT3.x
In addition to the file described above "OnlineDescription0000...xml" , a so called EtherCAT cache
with new discovered devices is created by TwinCAT3.x, e.g. under Windows 7:
(Please note the language settings of the OS!)
You have to delete this file, too.
Faulty ESI file
If an ESI file is faulty and the System Manager is unable to read it, the System Manager brings up an
information window.
Fig.55: Information window for faulty ESI file (left: TwinCAT2; right: TwinCAT3)
EL922x72 Version: 1.0
Reasons may include:
• Structure of the *.xml does not correspond to the associated *.xsd file → check your schematics
• Contents cannot be translated into a device description → contact the file manufacturer
Commissioning
EL922x 73Version: 1.0
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7.3.3 TwinCAT ESI Updater
For TwinCAT2.11 and higher, the System Manager can search for current Beckhoff ESI files automatically, if
an online connection is available:
Fig.56: Using the ESI Updater (>= TwinCAT2.11)
The call up takes place under:
“Options” → "Update EtherCAT Device Descriptions"
Selection under TwinCAT3:
Fig.57: Using the ESI Updater (TwinCAT3)
The ESI Updater (TwinCAT3) is a convenient option for automatic downloading of ESI data provided by
EtherCAT manufacturers via the Internet into the TwinCAT directory (ESI = EtherCAT slave information).
TwinCAT accesses the central ESI ULR directory list stored at ETG; the entries can then be viewed in the
Updater dialog, although they cannot be changed there.
The call up takes place under:
“TwinCAT“ → „EtherCAT Devices“ → “Update Device Description (via ETG Website)…“.
7.3.4 Distinction between Online and Offline
The distinction between online and offline refers to the presence of the actual I/O environment (drives,
terminals, EJ-modules). If the configuration is to be prepared in advance of the system configuration as a
programming system, e.g. on a laptop, this is only possible in “Offline configuration” mode. In this case all
components have to be entered manually in the configuration, e.g. based on the electrical design.
If the designed control system is already connected to the EtherCAT system and all components are
energised and the infrastructure is ready for operation, the TwinCAT configuration can simply be generated
through “scanning” from the runtime system. This is referred to as online configuration.
In any case, during each startup the EtherCAT master checks whether the slaves it finds match the
configuration. This test can be parameterised in the extended slave settings. Refer to note “Installation of
the latest ESI-XML device description” [}70].
For preparation of a configuration:
• the real EtherCAT hardware (devices, couplers, drives) must be present and installed
• the devices/modules must be connected via EtherCAT cables or in the terminal/ module strand in the
same way as they are intended to be used later
EL922x74 Version: 1.0
Commissioning
• the devices/modules be connected to the power supply and ready for communication
• TwinCAT must be in CONFIG mode on the target system.
The online scan process consists of:
• detecting the EtherCAT device [}80] (Ethernet port at the IPC)
• detecting the connected EtherCAT devices [}81]. This step can be carried out independent of the
preceding step
• troubleshooting [}84]
The scan with existing configuration [}85] can also be carried out for comparison.
7.3.5 OFFLINE configuration creation
Creating the EtherCAT device
Create an EtherCAT device in an empty System Manager window.
Fig.58: Append EtherCAT device (left: TwinCAT2; right: TwinCAT3)
Select type ‘EtherCAT’ for an EtherCAT I/O application with EtherCAT slaves. For the present publisher/
subscriber service in combination with an EL6601/EL6614 terminal select “EtherCAT Automation Protocol
via EL6601”.
Fig.59: Selecting the EtherCAT connection (TwinCAT2.11, TwinCAT3)
Then assign a real Ethernet port to this virtual device in the runtime system.
Fig.60: Selecting the Ethernet port
EL922x 75Version: 1.0
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This query may appear automatically when the EtherCAT device is created, or the assignment can be set/
modified later in the properties dialog; see Fig. “EtherCAT device properties (TwinCAT2)”.
Fig.61: EtherCAT device properties (TwinCAT2)
TwinCAT 3: the properties of the EtherCAT device can be opened by double click on “Device .. (EtherCAT)”
within the Solution Explorer under “I/O”:
Selecting the Ethernet port
Ethernet ports can only be selected for EtherCAT devices for which the TwinCAT real-time driver is
installed. This has to be done separately for each port. Please refer to the respective installation
page [}64].
Defining EtherCAT slaves
Further devices can be appended by right-clicking on a device in the configuration tree.
Fig.62: Appending EtherCAT devices (left: TwinCAT2; right: TwinCAT3)
The dialog for selecting a new device opens. Only devices for which ESI files are available are displayed.
Only devices are offered for selection that can be appended to the previously selected device. Therefore the
physical layer available for this port is also displayed (Fig. “Selection dialog for new EtherCAT device”, A). In
the case of cable-based Fast-Ethernet physical layer with PHY transfer, then also only cable-based devices
are available, as shown in Fig. “Selection dialog for new EtherCAT device”. If the preceding device has
several free ports (e.g. EK1122 or EK1100), the required port can be selected on the right-hand side (A).
Overview of physical layer
• “Ethernet”: cable-based 100BASE-TX: EK couplers, EP boxes, devices with RJ45/M8/M12 connector
EL922x76 Version: 1.0
• “E-Bus”: LVDS “terminal bus”, “EJ-module”: EL/ES terminals, various modular modules
The search field facilitates finding specific devices (since TwinCAT2.11 or TwinCAT3).
Commissioning
Fig.63: Selection dialog for new EtherCAT device
By default only the name/device type is used as selection criterion. For selecting a specific revision of the
device the revision can be displayed as “Extended Information”.
Fig.64: Display of device revision
In many cases several device revisions were created for historic or functional reasons, e.g. through
technological advancement. For simplification purposes (see Fig. “Selection dialog for new EtherCAT
device”) only the last (i.e. highest) revision and therefore the latest state of production is displayed in the
selection dialog for Beckhoff devices. To show all device revisions available in the system as ESI
descriptions tick the “Show Hidden Devices” check box, see Fig. “Display of previous revisions”.
EL922x 77Version: 1.0
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Fig.65: Display of previous revisions
Device selection based on revision, compatibility
The ESI description also defines the process image, the communication type between master and
slave/device and the device functions, if applicable. The physical device (firmware, if available) has
to support the communication queries/settings of the master. This is backward compatible, i.e.
newer devices (higher revision) should be supported if the EtherCAT master addresses them as an
older revision. The following compatibility rule of thumb is to be assumed for Beckhoff EtherCAT
Terminals/ Boxes/ EJ-modules:
device revision in the system >= device revision in the configuration
This also enables subsequent replacement of devices without changing the configuration (different
specifications are possible for drives).
Example:
If an EL2521-0025-1018 is specified in the configuration, an EL2521-0025-1018 or higher (-1019, -1020) can
be used in practice.
Fig.66: Name/revision of the terminal
If current ESI descriptions are available in the TwinCAT system, the last revision offered in the selection
dialog matches the Beckhoff state of production. It is recommended to use the last device revision when
creating a new configuration, if current Beckhoff devices are used in the real application. Older revisions
should only be used if older devices from stock are to be used in the application.
In this case the process image of the device is shown in the configuration tree and can be parameterised as
follows: linking with the task, CoE/DC settings, plug-in definition, startup settings, ...
EL922x78 Version: 1.0
Commissioning
Fig.67: EtherCAT terminal in the TwinCAT tree (left: TwinCAT2; right: TwinCAT3)
EL922x 79Version: 1.0
Commissioning
7.3.6 ONLINE configuration creation
Detecting/scanning of the EtherCAT device
The online device search can be used if the TwinCAT system is in CONFIG mode. This can be indicated by
a symbol right below in the information bar:
• on TwinCAT2 by a blue display “Config Mode” within the System Manager window: .
• on TwinCAT3 within the user interface of the development environment by a symbol .
TwinCAT can be set into this mode:
• TwinCAT2: by selection of in the Menubar or by “Actions” → “Set/Reset TwinCATtoConfig
Mode…”
• TwinCAT3: by selection of in the Menubar or by „TwinCAT“ → “RestartTwinCAT(ConfigMode)“
Online scanning in Config mode
The online search is not available in RUN mode (production operation). Note the differentiation between TwinCAT programming system and TwinCAT target system.
The TwinCAT2 icon ( ) or TwinCAT3 icon ( ) within the Windows-Taskbar always shows the
TwinCAT mode of the local IPC. Compared to that, the System Manager window of TwinCAT2 or the user
interface of TwinCAT3 indicates the state of the target system.
Fig.68: Differentiation local/target system (left: TwinCAT2; right: TwinCAT3)
Right-clicking on “I/O Devices” in the configuration tree opens the search dialog.
Fig.69: Scan Devices (left: TwinCAT2; right: TwinCAT3)
This scan mode attempts to find not only EtherCAT devices (or Ethernet ports that are usable as such), but
also NOVRAM, fieldbus cards, SMB etc. However, not all devices can be found automatically.
Fig.70: Note for automatic device scan (left: TwinCAT2; right: TwinCAT3)
EL922x80 Version: 1.0
Commissioning
Ethernet ports with installed TwinCAT real-time driver are shown as “RT Ethernet” devices. An EtherCAT
frame is sent to these ports for testing purposes. If the scan agent detects from the response that an
EtherCAT slave is connected, the port is immediately shown as an “EtherCAT Device” .
Fig.71: Detected Ethernet devices
Via respective checkboxes devices can be selected (as illustrated in Fig. “Detected Ethernet devices” e.g.
Device 3 and Device 4 were chosen). After confirmation with “OK” a device scan is suggested for all selected
devices, see Fig.: “Scan query after automatic creation of an EtherCAT device”.
Selecting the Ethernet port
Ethernet ports can only be selected for EtherCAT devices for which the TwinCAT real-time driver is
installed. This has to be done separately for each port. Please refer to the respective installation
page [}64].
Detecting/Scanning the EtherCAT devices
Online scan functionality
During a scan the master queries the identity information of the EtherCAT slaves from the slave
EEPROM. The name and revision are used for determining the type. The respective devices are located in the stored ESI data and integrated in the configuration tree in the default state defined
there.
Fig.72: Example default state
NOTE
Slave scanning in practice in series machine production
The scanning function should be used with care. It is a practical and fast tool for creating an initial configuration as a basis for commissioning. In series machine production or reproduction of the plant, however, the
function should no longer be used for the creation of the configuration, but if necessary for comparison
[}85] with the defined initial configuration.Background: since Beckhoff occasionally increases the revision
version of the delivered products for product maintenance reasons, a configuration can be created by such
a scan which (with an identical machine construction) is identical according to the device list; however, the
respective device revision may differ from the initial configuration.
Example:
Company A builds the prototype of a machine B, which is to be produced in series later on. To do this the
prototype is built, a scan of the IO devices is performed in TwinCAT and the initial configuration ‘B.tsm’ is
created. The EL2521-0025 EtherCAT terminal with the revision 1018 is located somewhere. It is thus built
into the TwinCAT configuration in this way:
EL922x 81Version: 1.0
Commissioning
Fig.73: Installing EthetCAT terminal with revision -1018
Likewise, during the prototype test phase, the functions and properties of this terminal are tested by the
programmers/commissioning engineers and used if necessary, i.e. addressed from the PLC ‘B.pro’ or the
NC. (the same applies correspondingly to the TwinCAT3 solution files).
The prototype development is now completed and series production of machine B starts, for which Beckhoff
continues to supply the EL2521-0025-0018. If the commissioning engineers of the series machine production
department always carry out a scan, a B configuration with the identical contents results again for each
machine. Likewise, A might create spare parts stores worldwide for the coming series-produced machines
with EL2521-0025-1018 terminals.
After some time Beckhoff extends the EL2521-0025 by a new feature C. Therefore the FW is changed,
outwardly recognizable by a higher FW version and a new revision -1019. Nevertheless the new device
naturally supports functions and interfaces of the predecessor version(s); an adaptation of ‘B.tsm’ or even
‘B.pro’ is therefore unnecessary. The series-produced machines can continue to be built with ‘B.tsm’ and
‘B.pro’; it makes sense to perform a comparative scan [}85] against the initial configuration ‘B.tsm’ in order
to check the built machine.
However, if the series machine production department now doesn’t use ‘B.tsm’, but instead carries out a
scan to create the productive configuration, the revision -1019 is automatically detected and built into the
configuration:
Fig.74: Detection of EtherCAT terminal with revision -1019
This is usually not noticed by the commissioning engineers. TwinCAT cannot signal anything either, since
virtually a new configuration is created. According to the compatibility rule, however, this means that no
EL2521-0025-1018 should be built into this machine as a spare part (even if this nevertheless works in the
vast majority of cases).
In addition, it could be the case that, due to the development accompanying production in company A, the
new feature C of the EL2521-0025-1019 (for example, an improved analog filter or an additional process
data for the diagnosis) is discovered and used without in-house consultation. The previous stock of spare
part devices are then no longer to be used for the new configuration ‘B2.tsm’ created in this way.Þ if series
machine production is established, the scan should only be performed for informative purposes for
comparison with a defined initial configuration. Changes are to be made with care!
If an EtherCAT device was created in the configuration (manually or through a scan), the I/O field can be
scanned for devices/slaves.
Fig.75: Scan query after automatic creation of an EtherCAT device (left: TwinCAT2; right: TwinCAT3)
EL922x82 Version: 1.0
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Fig.76: Manual triggering of a device scan on a specified EtherCAT device (left: TwinCAT2; right:
TwinCAT3)
In the System Manager (TwinCAT2) or the User Interface (TwinCAT3) the scan process can be monitored
via the progress bar at the bottom in the status bar.
Fig.77: Scan progressexemplary by TwinCAT2
The configuration is established and can then be switched to online state (OPERATIONAL).
Fig.78: Config/FreeRun query (left: TwinCAT2; right: TwinCAT3)
In Config/FreeRun mode the System Manager display alternates between blue and red, and the EtherCAT
device continues to operate with the idling cycle time of 4 ms (default setting), even without active task (NC,
PLC).
Fig.79: Displaying of “Free Run” and “Config Mode” toggling right below in the status bar
Fig.80: TwinCAT can also be switched to this state by using a button (left: TwinCAT2; right: TwinCAT3)
The EtherCAT system should then be in a functional cyclic state, as shown in Fig. “Online display example”.
EL922x 83Version: 1.0
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Fig.81: Online display example
Please note:
• all slaves should be in OP state
• the EtherCAT master should be in “Actual State” OP
• “frames/sec” should match the cycle time taking into account the sent number of frames
• no excessive “LostFrames” or CRC errors should occur
The configuration is now complete. It can be modified as described under manual procedure [}75].
Troubleshooting
Various effects may occur during scanning.
• An unknown device is detected, i.e. an EtherCAT slave for which no ESI XML description is available.
In this case the System Manager offers to read any ESI that may be stored in the device. This case is
described in the chapter "Notes regarding ESI device description".
• Device are not detected properly
Possible reasons include:
- faulty data links, resulting in data loss during the scan
- slave has invalid device description
The connections and devices should be checked in a targeted manner, e.g. via the emergency scan.
Then re-run the scan.
Fig.82: Faulty identification
In the System Manager such devices may be set up as EK0000 or unknown devices. Operation is not
possible or meaningful.
EL922x84 Version: 1.0
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Scan over existing Configuration
NOTE
Change of the configuration after comparison
With this scan (TwinCAT2.11 or 3.1) only the device properties vendor (manufacturer), device name and
revision are compared at present! A ‘ChangeTo’ or ‘Copy’ should only be carried out with care, taking into
consideration the Beckhoff IO compatibility rule (see above). The device configuration is then replaced by
the revision found; this can affect the supported process data and functions.
If a scan is initiated for an existing configuration, the actual I/O environment may match the configuration
exactly or it may differ. This enables the configuration to be compared.
Fig.83: Identical configuration (left: TwinCAT2; right: TwinCAT3)
If differences are detected, they are shown in the correction dialog, so that the user can modify the
configuration as required.
Fig.84: Correction dialog
It is advisable to tick the “Extended Information” check box to reveal differences in the revision.
EL922x 85Version: 1.0
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Colour Explanation
green This EtherCAT slave matches the entry on the other side. Both type and revision match.
blue This EtherCAT slave is present on the other side, but in a different revision. This other
revision can have other default values for the process data as well as other/additional
functions.
If the found revision is higher than the configured revision, the slave may be used provided
compatibility issues are taken into account.
If the found revision is lower than the configured revision, it is likely that the slave cannot be
used. The found device may not support all functions that the master expects based on the
higher revision number.
light blue This EtherCAT slave is ignored (“Ignore” button)
red • This EtherCAT slave is not present on the other side.
• It is present, but in a different revision, which also differs in its properties from the one
specified.
The compatibility principle then also applies here: if the found revision is higher than the
configured revision, use is possible provided compatibility issues are taken into account,
since the successor devices should support the functions of the predecessor devices.
If the found revision is lower than the configured revision, it is likely that the slave cannot
be used. The found device may not support all functions that the master expects based on
the higher revision number.
Device selection based on revision, compatibility
The ESI description also defines the process image, the communication type between master and
slave/device and the device functions, if applicable. The physical device (firmware, if available) has
to support the communication queries/settings of the master. This is backward compatible, i.e.
newer devices (higher revision) should be supported if the EtherCAT master addresses them as an
older revision. The following compatibility rule of thumb is to be assumed for Beckhoff EtherCAT
Terminals/ Boxes/ EJ-modules:
device revision in the system >= device revision in the configuration
This also enables subsequent replacement of devices without changing the configuration (different
specifications are possible for drives).
Example:
If an EL2521-0025-1018 is specified in the configuration, an EL2521-0025-1018 or higher (-1019, -1020) can
be used in practice.
Fig.85: Name/revision of the terminal
If current ESI descriptions are available in the TwinCAT system, the last revision offered in the selection
dialog matches the Beckhoff state of production. It is recommended to use the last device revision when
creating a new configuration, if current Beckhoff devices are used in the real application. Older revisions
should only be used if older devices from stock are to be used in the application.
In this case the process image of the device is shown in the configuration tree and can be parameterised as
follows: linking with the task, CoE/DC settings, plug-in definition, startup settings, ...
EL922x86 Version: 1.0
Fig.86: Correction dialog with modifications
Commissioning
Once all modifications have been saved or accepted, click “OK” to transfer them to the real *.tsm
configuration.
Change to Compatible Type
TwinCAT offers a function “Change to Compatible Type…” for the exchange of a device whilst retaining the
links in the task.
Fig.87: Dialog “Change to Compatible Type…” (left: TwinCAT2; right: TwinCAT3)
This function is preferably to be used on AX5000 devices.
Change to Alternative Type
The TwinCAT System Manager offers a function for the exchange of a device: Change to Alternative Type
Fig.88: TwinCAT2 Dialog Change to Alternative Type
EL922x 87Version: 1.0
Commissioning
If called, the System Manager searches in the procured device ESI (in this example: EL1202-0000) for
details of compatible devices contained there. The configuration is changed and the ESI-EEPROM is
overwritten at the same time – therefore this process is possible only in the online state (ConfigMode).
7.3.7 EtherCAT subscriber configuration
In the left-hand window of the TwinCAT2 System Manager or the Solution Explorer of the TwinCAT3
Development Environment respectively, click on the element of the terminal within the tree you wish to
configure (in the example: EL3751 Terminal 3).
Fig.89: Branch element as terminal EL3751
In the right-hand window of the TwinCAT System manager (TwinCAT2) or the Development Environment
(TwinCAT3), various tabs are now available for configuring the terminal. And yet the dimension of
complexity of a subscriber determines which tabs are provided. Thus as illustrated in the example above the
terminal EL3751 provides many setup options and also a respective number of tabs are available. On the
contrary by the terminal EL1004 for example the tabs "General", "EtherCAT", "Process Data" and “Online“
are available only. Several terminals, as for instance the EL6695 provide special functions by a tab with its
own terminal name, so “EL6695” in this case. A specific tab “Settings” by terminals with a wide range of
setup options will be provided also (e.g. EL3751).
„General“ tab
Fig.90: “General” tab
Name Name of the EtherCAT device
Id Number of the EtherCAT device
Type EtherCAT device type
Comment Here you can add a comment (e.g. regarding the
system).
Disabled Here you can deactivate the EtherCAT device.
Create symbols Access to this EtherCAT slave via ADS is only
available if this control box is activated.
EL922x88 Version: 1.0
Commissioning
„EtherCAT“ tab
Fig.91: „EtherCAT“ tab
Type EtherCAT device type
Product/Revision Product and revision number of the EtherCAT device
Auto Inc Addr. Auto increment address of the EtherCAT device. The
auto increment address can be used for addressing
each EtherCAT device in the communication ring
through its physical position. Auto increment
addressing is used during the start-up phase when
the EtherCAT master allocates addresses to the
EtherCAT devices. With auto increment addressing
the first EtherCAT slave in the ring has the address
0000
decremented by 1 (FFFF
. For each further slave the address is
hex
, FFFE
hex
hex
etc.).
EtherCAT Addr. Fixed address of an EtherCAT slave. This address is
allocated by the EtherCAT master during the start-up
phase. Tick the control box to the left of the input field
in order to modify the default value.
Previous Port Name and port of the EtherCAT device to which this
device is connected. If it is possible to connect this
device with another one without changing the order of
the EtherCAT devices in the communication ring,
then this combination field is activated and the
EtherCAT device to which this device is to be
connected can be selected.
Advanced Settings This button opens the dialogs for advanced settings.
The link at the bottom of the tab points to the product page for this EtherCAT device on the web.
“Process Data” tab
Indicates the configuration of the process data. The input and output data of the EtherCAT slave are
represented as CANopen process data objects (Process Data Objects, PDOs). The user can select a PDO
via PDO assignment and modify the content of the individual PDO via this dialog, if the EtherCAT slave
supports this function.
EL922x 89Version: 1.0
Commissioning
Fig.92: “Process Data” tab
The process data (PDOs) transferred by an EtherCAT slave during each cycle are user data which the
application expects to be updated cyclically or which are sent to the slave. To this end the EtherCAT master
(Beckhoff TwinCAT) parameterizes each EtherCAT slave during the start-up phase to define which process
data (size in bits/bytes, source location, transmission type) it wants to transfer to or from this slave. Incorrect
configuration can prevent successful start-up of the slave.
For Beckhoff EtherCAT EL, ES, EM, EJ and EP slaves the following applies in general:
• The input/output process data supported by the device are defined by the manufacturer in the ESI/XML
description. The TwinCAT EtherCAT Master uses the ESI description to configure the slave correctly.
• The process data can be modified in the system manager. See the device documentation.
Examples of modifications include: mask out a channel, displaying additional cyclic information, 16-bit
display instead of 8-bit data size, etc.
• In so-called “intelligent” EtherCAT devices the process data information is also stored in the CoE
directory. Any changes in the CoE directory that lead to different PDO settings prevent successful
startup of the slave. It is not advisable to deviate from the designated process data, because the
device firmware (if available) is adapted to these PDO combinations.
If the device documentation allows modification of process data, proceed as follows (see Figure “Configuring
the process data”).
• A: select the device to configure
• B: in the “Process Data” tab select Input or Output under SyncManager (C)
• D: the PDOs can be selected or deselected
• H: the new process data are visible as linkable variables in the system manager
The new process data are active once the configuration has been activated and TwinCAT has been
restarted (or the EtherCAT master has been restarted)
• E: if a slave supports this, Input and Output PDO can be modified simultaneously by selecting a socalled PDO record (“predefined PDO settings”).
EL922x90 Version: 1.0
Commissioning
Fig.93: Configuring the process data
Manual modification of the process data
According to the ESI description, a PDO can be identified as “fixed” with the flag “F” in the PDO
overview (Fig. “Configuring the process data”, J). The configuration of such PDOs cannot be
changed, even if TwinCAT offers the associated dialog (“Edit”). In particular, CoE content cannot be
displayed as cyclic process data. This generally also applies in cases where a device supports
download of the PDO configuration, “G”. In case of incorrect configuration the EtherCAT slave usually refuses to start and change to OP state. The System Manager displays an “invalid SM cfg” logger message: This error message (“invalid SM IN cfg” or “invalid SM OUT cfg”) also indicates the
reason for the failed start.
A detailed description [}96] can be found at the end of this section.
„Startup“ tab
The Startup tab is displayed if the EtherCAT slave has a mailbox and supports the CANopen over EtherCAT
(CoE) or Servo drive over EtherCAT protocol. This tab indicates which download requests are sent to the
mailbox during startup. It is also possible to add new mailbox requests to the list display. The download
requests are sent to the slave in the same order as they are shown in the list.
EL922x 91Version: 1.0
Commissioning
Fig.94: „Startup“ tab
Column Description
Transition Transition to which the request is sent. This can either be
• the transition from pre-operational to safe-operational (PS), or
• the transition from safe-operational to operational (SO).
If the transition is enclosed in "<>" (e.g. <PS>), the mailbox request is fixed and cannot be
modified or deleted by the user.
Protocol Type of mailbox protocol
Index Index of the object
Data Date on which this object is to be downloaded.
Comment Description of the request to be sent to the mailbox
Move Up This button moves the selected request up by one
position in the list.
Move Down This button moves the selected request down by one
position in the list.
New This button adds a new mailbox download request to
be sent during startup.
Delete This button deletes the selected entry.
Edit This button edits an existing request.
“CoE – Online” tab
The additional CoE - Online tab is displayed if the EtherCAT slave supports the CANopen over EtherCAT
(CoE) protocol. This dialog lists the content of the object list of the slave (SDO upload) and enables the user
to modify the content of an object from this list. Details for the objects of the individual EtherCAT devices can
be found in the device-specific object descriptions.
EL922x92 Version: 1.0
Commissioning
Fig.95: “CoE – Online” tab
Object list display
Column Description
Index Index and sub-index of the object
Name Name of the object
Flags RW The object can be read, and data can be written to the object (read/write)
RO The object can be read, but no data can be written to the object (read only)
P An additional P identifies the object as a process data object.
Value Value of the object
Update List The Update list button updates all objects in the displayed list
Auto Update If this check box is selected, the content of the objects is updated automatically.
Advanced The Advanced button opens the Advanced Settings dialog. Here you can specify
which objects are displayed in the list.
EL922x 93Version: 1.0
Commissioning
Fig.96: Dialog “Advanced settings”
Online - via SDO Information If this option button is selected, the list of the objects included in the object
list of the slave is uploaded from the slave via SDO information. The list
below can be used to specify which object types are to be uploaded.
Offline - via EDS File If this option button is selected, the list of the objects included in the object
list is read from an EDS file provided by the user.
„Online“ tab
Fig.97: „Online“ tab
EL922x94 Version: 1.0
Commissioning
State Machine
Init This button attempts to set the EtherCAT device to the Init state.
Pre-Op This button attempts to set the EtherCAT device to the pre-operational state.
Op This button attempts to set the EtherCAT device to the operational state.
Bootstrap This button attempts to set the EtherCAT device to the Bootstrap state.
Safe-Op This button attempts to set the EtherCAT device to the safe-operational state.
Clear Error This button attempts to delete the fault display. If an EtherCAT slave fails during
change of state it sets an error flag.
Example: An EtherCAT slave is in PREOP state (pre-operational). The master now
requests the SAFEOP state (safe-operational). If the slave fails during change of state
it sets the error flag. The current state is now displayed as ERR PREOP. When the
Clear Error button is pressed the error flag is cleared, and the current state is
displayed as PREOP again.
Current State Indicates the current state of the EtherCAT device.
Requested State Indicates the state requested for the EtherCAT device.
DLL Status
Indicates the DLL status (data link layer status) of the individual ports of the EtherCAT slave. The DLL status
can have four different states:
Status Description
No Carrier / Open No carrier signal is available at the port, but the port is open.
No Carrier / Closed No carrier signal is available at the port, and the port is closed.
Carrier / Open A carrier signal is available at the port, and the port is open.
Carrier / Closed A carrier signal is available at the port, but the port is closed.
File Access over EtherCAT
Download With this button a file can be written to the EtherCAT device.
Upload With this button a file can be read from the EtherCAT device.
"DC" tab (Distributed Clocks)
Fig.98: "DC" tab (Distributed Clocks)
Operation Mode Options (optional):
• FreeRun
• SM-Synchron
• DC-Synchron (Input based)
• DC-Synchron
Advanced Settings… Advanced settings for readjustment of the real time determinant TwinCAT-
clock
Detailed information to Distributed Clocks are specified on http://infosys.beckhoff.com:
Fieldbus Components → EtherCAT Terminals → EtherCAT System documentation → EtherCAT basics →
Distributed Clocks
EL922x 95Version: 1.0
Commissioning
7.3.7.1 Download revision
Download revision in Start-up list
Several terminals / modules generate the entry from object 0xF081:01 in the Start-up list automatically (see fig. “Download revision in Start-up list“).
The object 0xF081:01 (Download revision) describes the revision of the terminal / module, e.g.
0x0018000A for EL7201-0010-0024, and is necessary to ensure compatibility.
Please note, that you must not delete this entry from the Start-up list!
Fig.99: Download revision in Start-up list
7.3.7.2 Detailed description of Process Data tab
Sync Manager
Lists the configuration of the Sync Manager (SM).
If the EtherCAT device has a mailbox, SM0 is used for the mailbox output (MbxOut) and SM1 for the mailbox
input (MbxIn).
SM2 is used for the output process data (outputs) and SM3 (inputs) for the input process data.
If an input is selected, the corresponding PDO assignment is displayed in the PDO Assignment list below.
PDO Assignment
PDO assignment of the selected Sync Manager. All PDOs defined for this Sync Manager type are listed
here:
• If the output Sync Manager (outputs) is selected in the Sync Manager list, all RxPDOs are displayed.
• If the input Sync Manager (inputs) is selected in the Sync Manager list, all TxPDOs are displayed.
The selected entries are the PDOs involved in the process data transfer. In the tree diagram of the System
Manager these PDOs are displayed as variables of the EtherCAT device. The name of the variable is
identical to the Name parameter of the PDO, as displayed in the PDO list. If an entry in the PDO assignment
list is deactivated (not selected and greyed out), this indicates that the input is excluded from the PDO
assignment. In order to be able to select a greyed out PDO, the currently selected PDO has to be deselected
first.
Activation of PDO assignment
ü If you have changed the PDO assignment, in order to activate the new PDO assignment,
a) the EtherCAT slave has to run through the PS status transition cycle (from pre-operational to
safe-operational) once (see Online tab [}94]),
b) and the System Manager has to reload the EtherCAT slaves
( button for TwinCAT2 or button for TwinCAT3)
EL922x96 Version: 1.0
Commissioning
PDO list
List of all PDOs supported by this EtherCAT device. The content of the selected PDOs is displayed in the
PDO Content list. The PDO configuration can be modified by double-clicking on an entry.
Column Description
Index PDO index.
Size Size of the PDO in bytes.
Name Name of the PDO.
If this PDO is assigned to a Sync Manager, it appears as a variable of the slave with this
parameter as the name.
Flags F Fixed content: The content of this PDO is fixed and cannot be changed by the
System Manager.
M Mandatory PDO. This PDO is mandatory and must therefore be assigned to a
Sync Manager! Consequently, this PDO cannot be deleted from the PDO
Assignment list
SM Sync Manager to which this PDO is assigned. If this entry is empty, this PDO does not take
part in the process data traffic.
SU Sync unit to which this PDO is assigned.
PDO Content
Indicates the content of the PDO. If flag F (fixed content) of the PDO is not set the content can be modified.
Download
If the device is intelligent and has a mailbox, the configuration of the PDO and the PDO assignments can be
downloaded to the device. This is an optional feature that is not supported by all EtherCAT slaves.
PDO Assignment
If this check box is selected, the PDO assignment that is configured in the PDO Assignment list is
downloaded to the device on startup. The required commands to be sent to the device can be viewed in the
Startup [}91] tab.
PDO Configuration
If this check box is selected, the configuration of the respective PDOs (as shown in the PDO list and the
PDO Content display) is downloaded to the EtherCAT slave.
7.4 General Notes - EtherCAT Slave Application
This summary briefly deals with a number of aspects of EtherCAT Slave operation under TwinCAT. More
detailed information on this may be found in the corresponding sections of, for instance, the EtherCAT
System Documentation.
Diagnosis in real time: WorkingCounter, EtherCAT State and Status
Generally speaking an EtherCAT Slave provides a variety of diagnostic information that can be used by the
controlling task.
This diagnostic information relates to differing levels of communication. It therefore has a variety of sources,
and is also updated at various times.
Any application that relies on I/O data from a fieldbus being correct and up to date must make diagnostic
access to the corresponding underlying layers. EtherCAT and the TwinCAT System Manager offer
comprehensive diagnostic elements of this kind. Those diagnostic elements that are helpful to the controlling
task for diagnosis that is accurate for the current cycle when in operation (not during commissioning) are
discussed below.
EL922x 97Version: 1.0
Commissioning
Fig.100: Selection of the diagnostic information of an EtherCAT Slave
In general, an EtherCAT Slave offers
• communication diagnosis typical for a slave (diagnosis of successful participation in the exchange of
process data, and correct operating mode)
This diagnosis is the same for all slaves.
as well as
• function diagnosis typical for a channel (device-dependent)
See the corresponding device documentation
The colors in Fig. “Selection of the diagnostic information of an EtherCAT Slave” also correspond to the
variable colors in the System Manager, see Fig. “Basic EtherCAT Slave Diagnosis in the PLC”.
Colour Meaning
yellow Input variables from the Slave to the EtherCAT Master, updated in every cycle
red Output variables from the Slave to the EtherCAT Master, updated in every cycle
green Information variables for the EtherCAT Master that are updated acyclically. This means that
it is possible that in any particular cycle they do not represent the latest possible status. It is
therefore useful to read such variables through ADS.
Fig. “Basic EtherCAT Slave Diagnosis in the PLC” shows an example of an implementation of basic
EtherCAT Slave Diagnosis. A Beckhoff EL3102 (2-channel analogue input terminal) is used here, as it offers
both the communication diagnosis typical of a slave and the functional diagnosis that is specific to a channel.
Structures are created as input variables in the PLC, each corresponding to the process image.
EL922x98 Version: 1.0
Commissioning
Fig.101: Basic EtherCAT Slave Diagnosis in the PLC
The following aspects are covered here:
EL922x 99Version: 1.0
Commissioning
Code Function Implementation Application/evaluation
A The EtherCAT Master's diagnostic infor-
mation
updated acyclically (yellow) or provided
acyclically (green).
B In the example chosen (EL3102) the
EL3102 comprises two analogue input
channels that transmit a single function
status for the most recent cycle.
C For every EtherCAT Slave that has cyclic
process data, the Master displays, using
what is known as a WorkingCounter,
whether the slave is participating successfully and without error in the cyclic exchange of process data. This important, elementary information is therefore provided
for the most recent cycle in the System
Manager
1. at the EtherCAT Slave, and, with
identical contents
2. as a collective variable at the
EtherCAT Master (see Point A)
for linking.
D Diagnostic information of the EtherCAT
Master which, while it is represented at the
slave for linking, is actually determined by
the Master for the Slave concerned and
represented there. This information cannot
be characterized as real-time, because it
• is only rarely/never changed,
except when the system starts up
• is itself determined acyclically (e.g.
EtherCAT Status)
Status
• the bit significations may be
found in the device
documentation
• other devices may supply
more information, or none
that is typical of a slave
WcState (Working Counter)
0: valid real-time communication in
the last cycle
1: invalid real-time communication
This may possibly have effects on
the process data of other Slaves
that are located in the same SyncUnit
State
current Status (INIT..OP) of the
Slave. The Slave must be in OP
(=8) when operating normally.
AdsAddr
The ADS address is useful for
communicating from the PLC/task
via ADS with the EtherCAT Slave,
e.g. for reading/writing to the CoE.
The AMS-NetID of a slave corresponds to the AMS-NetID of the
EtherCAT Master; communication
with the individual Slave is possible
via the port (= EtherCAT address).
At least the DevState is to be evaluated for
the most recent cycle in the PLC.
The EtherCAT Master's diagnostic information offers many more possibilities than are
treated in the EtherCAT System Documentation. A few keywords:
• CoE in the Master for communication
with/through the Slaves
• Functions from TcEtherCAT.lib
• Perform an OnlineScan
In order for the higher-level PLC task (or corresponding control applications) to be able to
rely on correct data, the function status must
be evaluated there. Such information is
therefore provided with the process data for
the most recent cycle.
In order for the higher-level PLC task (or corresponding control applications) to be able to
rely on correct data, the communication status of the EtherCAT Slave must be evaluated
there. Such information is therefore provided
with the process data for the most recent cycle.
Information variables for the EtherCAT Master that are updated acyclically. This means
that it is possible that in any particular cycle
they do not represent the latest possible status. It is therefore possible to read such variables through ADS.
NOTE
Diagnostic information
It is strongly recommended that the diagnostic information made available is evaluated so that the application can react accordingly.
CoE Parameter Directory
The CoE parameter directory (CanOpen-over-EtherCAT) is used to manage the set values for the slave
concerned. Changes may, in some circumstances, have to be made here when commissioning a relatively
complex EtherCAT Slave. It can be accessed through the TwinCAT System Manager, see Fig. “EL3102,
CoE directory”:
EL922x100 Version: 1.0
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