Beckhoff EP5101-0002, EP5101-1002, EP5101-2011, EP5151-0002, EP5001-0002 Documentation

Documentation

EP5xxx

EtherCAT Box Modules for Angle and Position Measurement

2.3.0
2018-12-10

Version:
Date:

Table of contents

EP5xxx 3Version: 2.3.0

Table of contents

1 Foreword ....................................................................................................................................................7

1.1 Notes on the documentation..............................................................................................................7

1.2 Safety instructions .............................................................................................................................8

1.3 Documentation issue status ..............................................................................................................9

2 Product overview.....................................................................................................................................11

2.1 EtherCAT Box - Introduction............................................................................................................11

2.2 Module overview EP5xxx ................................................................................................................13

2.3 EP5001-0002...................................................................................................................................14

2.3.1 EP5001-0002 - Introduction............................................................................................. 14

2.3.2 EP5001-0002 - Technical data ........................................................................................ 15

2.3.3 EP5001-0002 - Process image........................................................................................ 15

2.4 EP51x1-x0xx ...................................................................................................................................16

2.4.1 EP5101-x0xx - Introduction ............................................................................................. 16

2.4.2 EP5151-000x - Introduction ............................................................................................. 18

2.4.3 EP51x1-x0xx - Technical data ......................................................................................... 19

2.4.4 EP5101-0002, EP5101-1002 - Process image................................................................ 20

2.4.5 EP5101-0011 - Process image........................................................................................ 21

2.4.6 EP5101-2011 - Process image........................................................................................ 22

2.4.7 EP5151-0002 - Process image........................................................................................ 23

3 Mounting and connection.......................................................................................................................24

3.1 Mounting..........................................................................................................................................24

3.1.1 Dimensions ...................................................................................................................... 24

3.1.2 Fixing ............................................................................................................................... 25

3.1.3 Nut torque for connectors ................................................................................................ 26

3.1.4 Additional checks............................................................................................................. 27

3.2 EtherCAT.........................................................................................................................................28

3.2.1 EtherCAT connection....................................................................................................... 28

3.2.2 EtherCAT - Fieldbus LEDs .............................................................................................. 29

3.3 Power supply ...................................................................................................................................31

3.3.1 Power Connection ........................................................................................................... 31

3.3.2 Status LEDs for power supply ......................................................................................... 34

3.3.3 Power cable conductor losses M8 ................................................................................... 35

3.3.4 Conductor losses 7/8"...................................................................................................... 36

3.4 Cabling ............................................................................................................................................37

3.5 Shielding..........................................................................................................................................39

3.6 UL Requirements.............................................................................................................................39

3.7 ATEX notes .....................................................................................................................................40

3.7.1 ATEX - Special conditions ............................................................................................... 40

3.7.2 BG2000-0000 - EtherCAT Box protection enclosure....................................................... 41

3.7.3 ATEX Documentation ...................................................................................................... 42

3.8 Signal connection and meaning of the LEDs...................................................................................43

3.8.1 EP5001-0002 - Signal connection ................................................................................... 43

3.8.2 EP5101-x0xx - Signal connection.................................................................................... 44

3.8.3 EP5151-0002 - Signal connection ................................................................................... 46

Table of contents

EP5xxx4 Version: 2.3.0

4 Commissioning/Configuration ...............................................................................................................47

4.1 TwinCAT configuration setup, manual.............................................................................................47

4.2 Configuration setup: TwinCAT - online scan ...................................................................................50

4.3 Configuration via TwinCAT..............................................................................................................57

4.4 EtherCAT slave process data settings (PDO) .................................................................................65

4.5 EP5001-0002 - Parameters and modes ..........................................................................................66

4.5.1 Process data.................................................................................................................... 66

4.5.2 DC (Distributed Clocks) ................................................................................................... 68

4.5.3 Features CoE................................................................................................................... 69

4.6 EP51x1-x0xx - Parameters and modes...........................................................................................71

4.6.1 Process data.................................................................................................................... 71

4.6.2 DC (Distributed Clocks) ................................................................................................... 81

4.6.3 Features CoE................................................................................................................... 82

4.7 EP5001 - Interface signal level........................................................................................................87

4.8 EP5101 - Interface signal level........................................................................................................88

4.9 EP5151 - Interface signal level........................................................................................................89

4.10 EP5001-0002 - Object description and parameterization................................................................90

4.11 EP5101-0002, EP5101-1002 - Object description and parameterization - normal operating mode

.........................................................................................................................................................96

4.11.1 Restore object.................................................................................................................. 96

4.11.2 Configuration data ........................................................................................................... 97

4.11.3 Input data......................................................................................................................... 98

4.11.4 Output data ...................................................................................................................... 99

4.11.5 Information / diagnostic data (channel specific)............................................................... 99

4.11.6 Standard objects.............................................................................................................. 99

4.12 EP5101-0011 - Object description and parameterization - normal operating mode......................111

4.12.1 Restore object................................................................................................................ 111

4.12.2 Configuration data ......................................................................................................... 112

4.12.3 Input data....................................................................................................................... 114

4.12.4 Output data .................................................................................................................... 115

4.12.5 Information / diagnostic data (channel specific)............................................................. 115

4.12.6 Standard objects............................................................................................................ 115

4.13 EP5101-2011 - Object description and parameterization - normal operating mode......................124

4.13.1 Restore object................................................................................................................ 124

4.13.2 Configuration data ......................................................................................................... 125

4.13.3 Input data....................................................................................................................... 126

4.13.4 Output data .................................................................................................................... 127

4.13.5 Information / diagnostic data (channel specific)............................................................. 127

4.13.6 Standard objects............................................................................................................ 127

4.14 EP5151-0002 - Object description and parameterization - normal operating mode......................136

4.14.1 Restore object................................................................................................................ 136

4.14.2 Configuration data ......................................................................................................... 137

4.14.3 Input data....................................................................................................................... 139

4.14.4 Output data .................................................................................................................... 140

4.14.5 Standard objects............................................................................................................ 140

4.15 Restoring the delivery state ...........................................................................................................149

Table of contents

EP5xxx 5Version: 2.3.0

5 Appendix ................................................................................................................................................150

5.1 General operating conditions.........................................................................................................150

5.2 EtherCAT Box- / EtherCATPBox - Accessories ..........................................................................151

5.3 Support and Service ......................................................................................................................152

Table of contents

EP5xxx6 Version: 2.3.0

Foreword

EP5xxx 7Version: 2.3.0

1 Foreword

1.1 Notes on the documentation

Intended audience

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

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

Disclaimer

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

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

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

Trademarks

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

Patent Pending

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

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

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

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.

Foreword

EP5xxx8 Version: 2.3.0

1.2 Safety instructions

Safety regulations

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

Exclusion of liability

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

Personnel qualification

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

Description of 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.

Foreword

EP5xxx 9Version: 2.3.0

1.3 Documentation issue status

Version Modifications

2.3.0 • Note Shielding added

2.2.0 • Update chapter EP5001-0002 - Signal connection

2.1.0 • EP5101-2011 added

• Update chapter Mounting

• Update chapter Comissioninig/Configuration

• Structural update

2.0.0 • Migration

• EP5001-0002 added

• Renamed to EP5xxx

• Several chapters updated

1.6.0 • Pin assignment updated

• Status LEDs updated

• Chapter on Nut torque for connectors updated

• Accessories updated

1.5.0 • Power Connection updated

1.4.0 • Introduction expanded

1.3.0 • EP5101-1002 and EP5151-0002 added to title page

• EP51x1 - EP5101-1002 and EP5151-0002 added to Introduction

• EP5151 signal level (interface signal level) added

• Status LEDs extended with EP5101-1002 and EP5151-0002

• Technical data extended with EP5101-1002 and EP5151-0002

• Encoder connection, M12, 8-pin extended with EP5151

• Information on basic function principles amended

• Parameters and modes amended

• EP5151-0002 process image added

• EP5101-0002 process image amended

• Notes on the documentation updated

• Support & service updated

• Safety instructions updated

• EtherCAT cables updated

• EtherCAT Box accessories updated

• Nut torques for connectors updated

• EtherCAT connection updated

• Mounting instructions updated

1.2.0 • Interface signal level amended (single-ended and differential signals)

1.1.0 • Description of the power connection updated

• Notes on using EtherCAT Box modules (EPxxxx-xxxx) in potentially explosive
atmospheres (ATEX) added to documentation.

1.0.0 • First release

Firmware and hardware versions

This documentation refers to the firmware and hardware version that was applicable at the time the
documentation was written.

Foreword

EP5xxx10 Version: 2.3.0

The module features are continuously improved and developed further. Modules having earlier production
statuses cannot have the same properties as modules with the latest status. However, existing properties
are retained and are not changed, so that older modules can always be replaced with new ones.

The firmware and hardware version (delivery state) can be found in the batch number (D-number) printed on
the side of the EtherCATBox.

Syntax of the batch number (D-number)

D: WW YY FF HH

WW - week of production (calendar week)
YY - year of production
FF - firmware version
HH - hardware version

Example with D no. 29 10 02 01:

29 - week of production 29
10 - year of production 2010
02 - firmware version 02
01 - hardware version 01

Product overview

EP5xxx 11Version: 2.3.0

2 Product overview

2.1 EtherCAT Box - Introduction

The EtherCAT system has been extended with EtherCAT Box modules with protection class IP67. Through
the integrated EtherCAT interface the modules can be connected directly to an EtherCAT network without an
additional Coupler Box. The high-performance of EtherCAT is thus maintained into each module.

The extremely low dimensions of only 126x30x26.5 mm (hxw xd) are identical to those of the Fieldbus
Box extension modules. They are thus particularly suitable for use where space is at a premium. The small
mass of the EtherCAT modules facilitates applications with mobile I/O interface (e.g. on a robot arm). The
EtherCAT connection is established via screened M8connectors.

Fig.1: EtherCAT Box Modules within an EtherCAT network

The robust design of the EtherCAT Box modules enables them to be used directly at the machine. Control
cabinets and terminal boxes are now no longer required. The modules are fully sealed and therefore ideally
prepared for wet, dirty or dusty conditions.

Pre-assembled cables significantly simplify EtherCAT and signal wiring. Very few wiring errors are made, so
that commissioning is optimized. In addition to pre-assembled EtherCAT, power and sensor cables, field­configurable connectors and cables are available for maximum flexibility. Depending on the application, the
sensors and actuators are connected through M8 or M12connectors.

The EtherCAT modules cover the typical range of requirements for I/O signals with protection class IP67:

• digital inputs with different filters (3.0ms or 10μs)

• digital outputs with 0.5 or 2A output current

• analog inputs and outputs with 16bit resolution

• Thermocouple and RTD inputs

• Stepper motor modules

XFC (eXtreme Fast Control Technology) modules, including inputs with time stamp, are also available.

Product overview

EP5xxx12 Version: 2.3.0

Fig.2: EtherCAT Box with M8 connections for sensors/actuators

Fig.3: EtherCAT Box with M12 connections for sensors/actuators

Basic EtherCAT documentation

You will find a detailed description of the EtherCAT system in the Basic System Documentation for
EtherCAT, which is available for download from our website (www.beckhoff.com) under Downloads.

EtherCAT XML Device Description

You will find XML files (XML Device Description Files) for Beckhoff EtherCAT modules on our web­site (www.beckhoff.com) under Downloads, in the Configuration Files area.

Product overview

EP5xxx 13Version: 2.3.0

2.2 Module overview EP5xxx

SSI encoder interface

Module Connection encoder/sensor Number of chan-

nels

Sensor supply Comment

EP5001-0002 [}14]

M12, screw type 1 24V

DC

Distributed-Clocks

Incremental encoder interface with differential inputs

Module Connection encoder/sensor Number of chan-

nels

Sensor supply Comment

EP5101-0002 [}16]

M12, screw-type, 8-pin 1 +5VDC, 150mA (VCC) Distributed clocks,

4million increments/sec­ond

EP5101-1002 [}16]

1 24VDC, 500mA (VCC)

EP5101-0011 [}16]

D-Sub-socket, 15-pin 1 +5VDC, 150mA (VCC) Distributed clocks

4million increments/sec­ond
Latch, gate

EP5101-2011 [}16]

1 Distributed clocks

20million increments/sec­ond
Latch, gate

Incremental encoder interface with single-ended inputs

Module Connection encoder/sensor Number of chan-

nels

Sensor supply Comment

EP5151-0002 [}18]

M12, screw-type, 8-pin 1 24VDC, 0.5A Distributed clocks

4million increments/sec­ond
Latch, gate

Product overview

EP5xxx14 Version: 2.3.0

2.3 EP5001-0002

2.3.1 EP5001-0002 - Introduction

Fig.4: EP5001-0002

EP5001-0002 SSI encoder interface

The EP5001-0002 EtherCAT Box is an interface for direct connection of an SSI encoder with differential
inputs (RS422). The interface circuit generates a pulse for reading the encoder, and makes the incoming
data stream available to the controller as a data word in the process image. Various operating modes,
transmission frequencies and bit widths can be permanently stored in a control register. The encoder is
connected via an 8-pin M12 socket.

Quick links

Installation [}24]

Configuration [}50]

UL requirements [}39] for UL-approved modules

ATEX - special conditions [}40] for ATEX-approved modules

Product overview

EP5xxx 15Version: 2.3.0

2.3.2 EP5001-0002 - Technical data

Technical data EP5001-0002

Fieldbus EtherCAT
Fieldbus connection 2 x M8 socket (green)
Number of channels 1
Channel connections

M12, screw type [}43]

Encoder connection Binary input: D+, D-, binary outputs: CI+, CI­Rated voltage 24VDC (-15%/+ 20%)
Signal type differential (RS422)
Distributed-Clocks yes
Data transfer rates Adjustable up to 1MHz, 250kHz preset
Serial input 24-bit width (adjustable)
Data direction Read
Power supply connection Power supply: 1 x M8 connector, 4-pin; downstream connection: 1 x M8

socket, 4-pin
Current consumption from UStyp. 130mA + sensor supply
Width in the process image 1 x 32-bit input, 8-bit status
Electrical isolation 500V
Special features Baud rate, coding and data length are adjustable
Weight app.165g
Operating/storage temperature 0…+55 °C / -25…+85 °C
Vibration/shock resistance conforms to EN60068-2-6/EN 60068-2-27
EMC immunity/emission conforms to EN61000-6-2/EN 61000-6-4
Protect. class / installation pos. IP65/66/67 (according to EN 60529)/variable
Approvals CE

2.3.3 EP5001-0002 - Process image

TwinCAT shows the data of the EP5001-0002 in a tree structure.

SSI Inputs

Status

• Data error SSI input error

• Frame error Wrong data frame

• Power failure An encoder-specific error has occurred.
Enabling through Enable Power failure bit
(index 0x8000:02)

• Sync error

EtherCAT error, see EtherCAT system doc-

umentation

• TxPDO State

See object description [}94]

• TxPDO Toggle

See object description [}94]

Counter value Current encoder counter value

Product overview

EP5xxx16 Version: 2.3.0

2.4 EP51x1-x0xx

2.4.1 EP5101-x0xx - Introduction

EP5101-x0xx | Incremental encoder interface with differential inputs

The EtherCAT Box EP5101-x0xx is an interface for direct connection of incremental encoders with
differential inputs (RS422). A 32/16-bit counter with quadrature decoder as well as a 32/16-bit latch for the
zero pulse can be read, set or activated. Incremental encoders with a fault message output can be
connected to the status input of the interface. A period measurement with a resolution of up to 100ns is
possible. The gate input allows the counter to be disabled; the latch input accepts the counter reading on the
rising edge. The EP5101-1002 has a 24VDC sensor supply.

Due to the optional interpolating micro-increment function, the EP5101 can supply even more precise axis
positions for dynamic axes. In addition to that it supports the synchronous reading of the encoder value
together with other input data in the EtherCAT system via high precision EtherCAT Distributed Clocks (DC).

Product overview

EP5xxx 17Version: 2.3.0

The encoder is connected via an 8-pin M12 socket (EP5101-0002 and EP5101-1002) or via a 15-pin D-sub
socket (EP5101-0011 and EP5101-2011). In the M12 version not all signals are available.

Quick links

Installation [}24]

Configuration [}50]

UL requirements [}39] for UL-approved modules

ATEX - special conditions [}40] for ATEX-approved modules

Product overview

EP5xxx18 Version: 2.3.0

2.4.2 EP5151-000x - Introduction

EP5151-0002 | Incremental encoder interface with single-ended inputs

The EP5151-0002 EtherCAT Box is an interface for direct connection of incremental encoders with 24 V DC
inputs. A 32/16-bit counter with quadrature decoder as well as a 32/16-bit latch for the zero pulse can be
read, set or activated. A period measurement with a resolution of up to 100 ns is possible.

Due to the optional interpolating micro-increment function, the EP5151-0002 can supply even more precise
axis positions for dynamic axes. In addition to that it supports the synchronous reading of the encoder value
together with other input data in the EtherCAT system via high precision EtherCAT Distributed Clocks (DC).
The encoder is connected via an 8-pin M12 socket.

Quick links

Installation [}24]

Configuration [}50]

UL requirements [}39] for UL-approved modules

ATEX - special conditions [}40] for ATEX-approved modules

Product overview

EP5xxx 19Version: 2.3.0

2.4.3 EP51x1-x0xx - Technical data

Technical data EP5101-0002 EP5101-1002 EP5101-0011 EP5101-2011 EP5151-0002

Fieldbus EtherCAT

Fieldbus connection 2 x M8 socket (green)

Number of encoder inputs 1

Encoder connection

A, , B, , C,

(RS485 differential inputs)

also single-ended connection (5V
±20%) possible

A, , B, , C,

(RS485 differential inputs)

also single-ended connection (5V
±20%) possible,

Latch, Gate

A, B,C, (24VDC),

Latch, Gate

Encoder connection

M12 socket, 8-pin [}44] D-Sub-socket, 15-pin [}44] M12 socket, 8-pin

[}46]

Encoder supply +5VDC, 150mA +24V

DC

+5VDC, 150mA +24V

DC

Counter 32bit or 16bit, binary

Limit frequency 4 million increments/s (with four-fold evaluation) 20 million incre-

ments/s (with
four-fold evalua­tion)

4 million incre­ments/s (with four­fold evaluation)

Quadrature decoder Four-fold evaluation

Zero-pulse latch Bit16

Commands read, set, enable

Distributed Clocks yes

Supply of the module electronics from the control voltage U

S

Current consumption of the module elec­tronics

typically 130mA + load

Power supply connection Power supply: 1 x M8 plug, 4-pole

Onward connection: 1 x M8 socket, 4-pole

Process image Inputs: 32bit data, 8bit status

Outputs: 16bit data, 8bit control

Electrical isolation Control voltage/fieldbus: 500V

Permissible ambient temperature during
operation

-25°C...+60°C

0°C ... +55°C (conforms to ATEX, see special conditions [}40])

0 °C ... +55 °C (according to cULus, see UL requirements [}39])

Permissible ambient temperature during
storage

-40°C ... +85°C

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

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

Protection class IP65, IP66, IP67 (conforms to EN 60529)

Installation position variable

Approvals

CE, cULus [}39], ATEX [}40] CE, cULus [}39] CE, cULus [}39],

ATEX [}40]

Product overview

EP5xxx20 Version: 2.3.0

2.4.4 EP5101-0002, EP5101-1002 - Process image

TwinCAT shows the data of the EP5101-0002 and EP5101-1002 in a tree structure, using the EP5101-0002
as an example.

ENC Status Compact Input data of the encoder interface

Status

• Latch C valid New data are available in the process data Latch value.
Reset via Enable latch C

• Set Counter done Acknowledgement for setting the Set counter

• Counter

underflow

The counter is lower than the lowest counter value that
can be displayed

• Counter overflow The counter is higher than the highest counter value that
can be displayed

• Open circuit One of the channels (A, B or C) has an open circuit
(configurable for each channel via CoE)

• Extrapolation stall Micro-increment value invalid (when micro-increment
evaluation is enabled -> index 0x8000:0A)

• Status of Input A,

B,C

Status of inputs A, B and C

• Sync error

EtherCAT error, see EtherCAT system documentation

• TxPDO State

See object description [}98]

• TxPDO Toggle

See object description [}98]

Counter value Current encoder counter value

Latch value Counter value of the encoder with rising edge at the

latch input

ENC Control Compact Output data of the encoder interface.

Control

• Enable latch C Input C is activated. When an edge is encountered, the

Counter value is stored in Latch value.

• Set counter When a positive edge is encountered, the Set counter
value is transferred to the Counter value

Set Counter value Preselection value for Counter value

Product overview

EP5xxx 21Version: 2.3.0

2.4.5 EP5101-0011 - Process image

TwinCAT shows the data of the EP5101-0011 in a tree structure.

ENC Status Compact

Status

• Latch C valid New data are available in the process data Latch
value. Reset via Enable latch C

• Latch extern

valid

New data are available in the process data Latch
value. Reset through Enable latch extern on posi­tive/negative edge

• Set Counter

done

Acknowledgement for setting the Set counter

• Counter

underflow

The counter is lower than the lowest counter
value that can be displayed

• Counter

overflow

The counter is higher than the highest counter
value that can be displayed

• Status of

input status

Status of the error signal (typically from the en­coder)

• Open circuit One of the channels (A, B or C) has an open cir­cuit (configurable for each channel via CoE)

• Extrapolation

stall

Micro-increment value invalid (when micro-incre­ment evaluation is enabled -> index 0x8000:0A)

• Status of

Input A, B,C

Status of inputs A, B and C

• Status of

input gate

Status of the gate input

• Status of

extern latch

Status of the latch input

• Sync error

EtherCAT error, see EtherCAT system documen-

tation

• TxPDO State

See object description [}98]

• TxPDO

Toggle

See object description [}98]

Counter value Current encoder counter value

Latch value Counter value of the encoder with rising edge at

the latch input

ENC Control Compact Output data of the encoder interface.

Control

• Enable latchCInput C is activated. When an edge is encoun­tered, the Counter value is stored in Latch value.

• Enable latch

extern on
positive edge

External latch input is enabled. When a positive
edge is encountered, the Counter value is stored
in Latch value.

• Set counter When a positive edge is encountered, the Set
counter value is transferred to the Counter value

• Enable latch

extern on
negative edge

External latch input is enabled. When a negative
edge is encountered, the Counter value is stored
in Latch value.

Set Counter value Preselection value for Counter value

Product overview

EP5xxx22 Version: 2.3.0

2.4.6 EP5101-2011 - Process image

TwinCAT shows the data of the EP5101-2011 in a tree structure.

ENC Status Compact

Status

• Latch C valid New data are available in the process data Latch
value. Reset via Enable latch C

• Latch extern

valid

New data are available in the process data Latch
value. Reset through Enable latch extern on posi­tive/negative edge

• Set Counter

done

Acknowledgement for setting the Set counter

• Status of

input status

Status of the error signal (typically from the en­coder)

• Open circuit One of the channels (A, B or C) has an open cir­cuit (configurable for each channel via CoE)

• Status of

Input A, B,C

Status of inputs A, B and C

• Status of

input gate

Status of the gate input

• Status of

extern latch

Status of the latch input

• Sync error

EtherCAT error, see EtherCAT system documen-

tation

• TxPDO State

See object description [}126]

• TxPDO

Toggle

See object description [}126]

Counter value Current encoder counter value

Latch value Counter value of the encoder with rising edge at

the latch input

ENC Control Compact Output data of the encoder interface.

Control

• Enable latchCInput C is activated. When an edge is encoun­tered, the Counter value is stored in Latch value.

• Enable latch

extern on
positive edge

External latch input is enabled. When a positive
edge is encountered, the Counter value is stored
in Latch value.

• Set counter When a positive edge is encountered, the Set
counter value is transferred to the Counter value

• Enable latch

extern on
negative edge

External latch input is enabled. When a negative
edge is encountered, the Counter value is stored
in Latch value.

Set Counter value Preselection value for Counter value

Product overview

EP5xxx 23Version: 2.3.0

2.4.7 EP5151-0002 - Process image

ENC Status Compact

Status

• Latch C valid New data are available in the process data

Latch value. Reset via Enable latch C

• Latch extern valid New data are available in the process data

Latch value. Reset through Enable latch extern
on positive/negative edge

• Set Counter done Acknowledgement for setting the Set counter

• Counter underflow The counter is lower than the lowest counter
value that can be displayed

• Counter overflow The counter is higher than the highest counter
value that can be displayed

• Status of input

status

Status of the error signal (typically from the en­coder)

• Open circuit One of the channels (A, B or C) has an open
circuit (configurable for each channel via CoE)

• Extrapolation stall Micro-increment value invalid (when micro-in­crement evaluation is enabled -> index
0x8000:0A)

• Status of Input A,

B,C

Status of inputs A, B and C

• Status of input gate Status of the gate input

• Status of extern

latch

Status of the latch input

• Sync error

EtherCAT error, see EtherCAT system docu-

mentation

• TxPDO State

See object description [}139]

• TxPDO Toggle

See object description [}139]

Counter value Current encoder counter value

Latch value Counter value of the encoder with rising edge at

the latch input

ENC Control Compact Output data of the encoder interface.

Control

• Enable latch C Input C is activated. When an edge is encoun­tered, the Counter value is stored in Latch
value.

• Enable latch extern

on positive edge

External latch input is enabled. When a positive
edge is encountered, the Counter value is
stored in Latch value.

• Set counter When a positive edge is encountered, the Set

counter value is transferred to the Counter
value

• Enable latch extern

on negative edge

External latch input is enabled. When a nega­tive edge is encountered, the Counter value is
stored in Latch value.

Set Counter value Preselection value for Counter value

Mounting and connection

EP5xxx24 Version: 2.3.0

3 Mounting and connection

3.1 Mounting

3.1.1 Dimensions

Fig.5: Dimensions of the EtherCAT Box Modules

All dimensions are given in millimeters.

Housing properties

EtherCAT Box lean body wide bodies

Housing material PA6 (polyamide)
Casting compound Polyurethane
Mounting two fastening holes Ø3mm for M3 two fastening holes Ø3mm for M3

two fastening holes Ø4.5mm for M4
Metal parts Brass, nickel-plated
Contacts CuZn, gold-plated
Power feed through max. 4A (M8)

max. 16A (7/8“)

max. 15.5A (B17 5G 1.5mm2)
Installation position variable
Protection class IP65, IP66, IP67 (conforms to EN 60529) when screwed together
Dimensions

(HxWxD)

app. 126 x 30 x 26.5mm app. 126 x 60 x 26,5mm

app. 150 x 60 x 26.5mm (without 7/8", B17)

Mounting and connection

EP5xxx 25Version: 2.3.0

3.1.2 Fixing

Note or pointer

While mounting the modules, protect all connectors, especially the IP-Link, against contamination!
Only with connected cables or plugs the protection class IP67 is guaranteed! Unused connectors
have to be protected with the right plugs! See for plug sets in the catalogue.

Modules with narrow housing are mounted with two M3 bolts.
Modules with wide housing are mounted with two M3 bolts to the fixing holes located at the corners or
mounted with two M4 bolts to the fixing holes located centrally.

The bolts must be longer than 15 mm. The fixing holes of the modules are not threaded.

When assembling, remember that the fieldbus connectors increases the overall height. See chapter
accessories.

Mounting Rail ZS5300-0001

The mounting rail ZS5300-0001 (500 mm x 129 mm) allows the time saving assembly of modules.

The rail is made of stainless steel, 1.5 mm thick, with already pre-made M3 threads for the modules. The rail
has got 5.3 mm slots to mount it via M5 screws to the machine.

Fig.6: Mounting Rail ZS5300-000

The mounting rail is 500 mm long, that way 15 narrow modules can be mounted with a distance of 2 mm
between two modules. The rail can be cut to length for the application.

Mounting Rail ZS5300-0011

The mounting rail ZS5300-0011 (500 mm x 129 mm) has in addition to the M3 treads also pre-made M4
treads to fix 60 mm wide modules via their middle holes.

Up to 14 narrow or 7 wide modules may be mixed mounted.

Mounting and connection

EP5xxx26 Version: 2.3.0

3.1.3 Nut torque for connectors

M8 connectors

It is recommended to pull the M8 connectors tight with a nut torque of 0.4 Nm. When using the torque control
screwdriver ZB8800 is also a max. torque of 0.5Nm permissible.

Fig.7: EtherCAT Box with M8 connectors

M12 connectors

It is recommended to pull the M12 connectors tight with a nut torque of 0.6 Nm.

Fig.8: EtherCAT Box with M8 and M12 connectors

Mounting and connection

EP5xxx 27Version: 2.3.0

7/8" plug connectors

We recommend fastening the 7/8" plug connectors with a torque of 1.5Nm.

Fig.9: 7/8" plug connectors

Torque socket wrenches

Fig.10: ZB8801 torque socket wrench

Ensure the right torque

Use the torque socket wrenches available by Beckhoff to pull the connectors tight (ZB8800,
ZB8801-0000)!

3.1.4 Additional checks

The boxes have undergone the following additional tests:

Verification Explanation

Vibration 10 frequency runs in 3 axes

5Hz < f < 60Hz displacement 0.35mm, constant amplitude

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

Shocks 1000 shocks in each direction, in 3 axes

35g, 11ms

Mounting and connection

EP5xxx28 Version: 2.3.0

3.2 EtherCAT

3.2.1 EtherCAT connection

For the incoming and ongoing EtherCAT connection,

• the EtherCAT Box (EPxxxx) has two M8 sockets, marked in green

• the Coupler Box (FBB-x110) has two M12 sockets

Fig.11: EtherCAT Box: M8, 30mm housing

Fig.12: EtherCAT Box: M860mm housing (example: EP9214)

Fig.13: Coupler Box: M12

Assignment

There are various different standards for the assignment and colors of connectors and cables for Ethernet/
EtherCAT.

Mounting and connection

EP5xxx 29Version: 2.3.0

Ethernet/EtherCAT Plug connector Cable Standard

Signal Description M8 M12 RJ45

1

ZB9010, ZB9020,
ZB9030, ZB9032,
ZK1090-6292,
ZK1090-3xxx-xxxx

ZB9031 and old ver­sions
of ZB9030, ZB9032,
ZK1090-3xxx-xxxx

TIA-568B

Tx + Transmit Data+ Pin 1 Pin 1 Pin 1 yellow

2

orange/white

3

white/orange

Tx - Transmit Data- Pin 4 Pin 3 Pin 2 orange

2

orange

3

orange

Rx + Receive Data+ Pin 2 Pin 2 Pin 3 white

2

blue/white

3

white/green

Rx - Receive Data- Pin 3 Pin 4 Pin 6 blue

2

blue

3

green

Shield Shield Housing Shroud Screen Screen Screen

1

) colored markings according to EN 61918 in the four-pin RJ45 connector ZS1090-0003

2

) wire colors according to EN 61918

3

) wire colors

Assimilation of color coding for cable ZB9030, ZB9032 and ZK1090-3xxxx-xxxx (with
M8 connectors)

For unification the prevalent cables ZB9030, ZB9032 and ZK1090-3xxx-xxxx this means the pre as­sembled cables with M8 connectors were changed to the colors of EN61918 (yellow, orange, white,
blue).So different color coding exists. But the electrical properties are absolutely identical.

EtherCAT connector

The following connectors can be supplied for use in Beckhoff EtherCAT systems.

Name Connector Comment

ZS1090-0003 RJ45 four-pole, IP20, field-configurable
ZS1090-0004 M12, male four-pin, IP67, for field assembly
ZS1090-0005 RJ45 eight-pole, IP20, field-configurable, suitable for gigabit Ethernet
ZS1090-0006 M8 plug connector four-pole, IP67, field-configurable, for cable type ZB903x
ZS1090-0007 M8 socket four-pole, IP67, field-configurable, for cable type ZB903x
ZS1090-1006 M8 plug connector four-pole, IP67, field-configurable up to OD=6.5mm
ZS1090-1007 M8 socket four-pole, IP67, field-configurable up to OD=6.5mm

3.2.2 EtherCAT - Fieldbus LEDs

Fig.14: EtherCAT-LEDs

Mounting and connection

EP5xxx30 Version: 2.3.0

LED display

LED Display Meaning

IN L/A off no connection to the preceding EtherCAT module

Lit LINK: connection to the preceding EtherCAT module
flashing ACT: Communication with the preceding EtherCAT module

OUT L/A off no connection to the following EtherCAT module

Lit LINK: connection to the following EtherCAT module
flashing ACT: Communication with the following EtherCAT module

Run off Status of the EtherCAT module is Init

flashes quickly Status of the EtherCAT module is pre-operational
flashes slowly Status of the EtherCAT module is safe-operational
Lit Status of the EtherCAT module is operational

EtherCAT statuses

The various statuses in which an EtherCAT module may be found are described in the Basic Sys­tem Documentation for EtherCAT, which is available for download from our website (www.beck-
hoff.com) under Downloads.