How it Works
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EP6001-0002
Users manual
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Table of contents
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Beckhoff EP6001-0002 Users manual

Documentation | EN
EP6001-0002
1-channel serial interface (RS232 / RS422 / RS485)
2020-09-22 | Version: 1.1

Table of contents

Table of contents
1 Foreword ....................................................................................................................................................5
2 Product group: EtherCAT Box Modules..................................................................................................8
3 Product overview.......................................................................................................................................9
3.2 Technical data .................................................................................................................................10
3.3 Scope of supply ...............................................................................................................................11
3.4 Process image.................................................................................................................................12
3.4.1 Control word .................................................................................................................... 14
3.4.2 Status word...................................................................................................................... 14
3.5 Technology ......................................................................................................................................15
4 Mounting and connection.......................................................................................................................16
4.1 Mounting..........................................................................................................................................16
4.1.1 Dimensions ...................................................................................................................... 16
4.1.2 Fixing ............................................................................................................................... 17
4.1.3 Tightening torques for plug connectors ........................................................................... 17
4.2 Supply voltages ...............................................................................................................................18
4.2.1 Connectors ...................................................................................................................... 18
4.2.2 Status LEDs..................................................................................................................... 19
4.2.3 Conductor losses ............................................................................................................. 19
4.3 EtherCAT.........................................................................................................................................20
4.3.1 Connectors ...................................................................................................................... 20
4.3.2 Status LEDs..................................................................................................................... 21
4.3.3 Cables.............................................................................................................................. 21
4.4 RS232..............................................................................................................................................22
4.4.1 Connector ........................................................................................................................ 22
4.4.2 Status LEDs..................................................................................................................... 22
4.5 RS422..............................................................................................................................................23
4.5.1 Connectors ...................................................................................................................... 23
4.5.2 Status LEDs..................................................................................................................... 23
4.6 RS485..............................................................................................................................................24
4.6.1 Connector ........................................................................................................................ 24
4.6.2 Status LEDs..................................................................................................................... 24
4.7 Digital inputs/outputs .......................................................................................................................25
4.7.1 Connector ........................................................................................................................ 25
4.7.2 Status LEDs..................................................................................................................... 25
4.7.3 Examples of external connections ................................................................................... 26
4.8 UL Requirements.............................................................................................................................27
5 Commissioning/Configuration ...............................................................................................................28
5.1 Integration in TwinCAT ....................................................................................................................28
5.2 Serial interface.................................................................................................................................29
EP6001-0002 3Version: 1.1
Table of contents
5.2.1 Setting the interface type ................................................................................................. 29
5.2.2 Setting the interface parameters...................................................................................... 33
5.2.3 Communication by PLC program..................................................................................... 34
5.2.4 Communication via a virtual COM port ............................................................................ 36
5.3 Digital inputs/outputs .......................................................................................................................37
5.3.1 Activating process data.................................................................................................... 37
5.3.2 Assignment of connector pins to process data ................................................................ 37
5.4 CoE objects .....................................................................................................................................38
5.4.1 Directory .......................................................................................................................... 38
5.4.2 Object description and parameterization ......................................................................... 39
5.5 Restoring the delivery state .............................................................................................................53
5.6 Decommissioning ............................................................................................................................54
6 Appendix ..................................................................................................................................................55
6.1 General operating conditions...........................................................................................................55
6.2 Accessories .....................................................................................................................................56
6.3 Version identification of EtherCAT devices .....................................................................................57
6.3.1 Beckhoff Identification Code (BIC)................................................................................... 61
6.4 Support and Service ........................................................................................................................63
EP6001-00024 Version: 1.1
Foreword

1 Foreword

1.1 Notes on the documentation

Intended audience
This description is only intended for the use of trained specialists in control and automation engineering who are familiar with the applicable national standards. It is essential that the 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G®, EtherCATG10®, EtherCATP®, SafetyoverEtherCAT®, TwinSAFE®, XFC®, XTS® and XPlanar® are registered trademarks of and licensed by Beckhoff Automation GmbH. Other designations used in this publication may be trademarks whose use by third parties for their own purposes could violate the rights of the owners.
Patent Pending
The EtherCAT Technology is covered, including but not limited to the following patent applications and patents: EP1590927, EP1789857, EP1456722, EP2137893, DE102015105702 with corresponding applications or registrations in various other countries.
EtherCAT® is registered trademark and patented technology, licensed by Beckhoff Automation GmbH, Germany.
Copyright
© Beckhoff Automation GmbH & Co. KG, Germany. The reproduction, distribution and utilization of this document as well as the communication of its contents to others without express authorization are prohibited. Offenders will be held liable for the payment of damages. All rights reserved in the event of the grant of a patent, utility model or design.
EP6001-0002 5Version: 1.1
Foreword

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.
EP6001-00026 Version: 1.1
Foreword

1.3 Documentation issue status

Version Comment
1.1 • Front page updated
1.0 • First release, adapted from the documentation EP600x V2.1.0
Firmware and hardware versions
This documentation refers to the firmware and hardware version that was applicable at the time the documentation was written.
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
Further information on this topic: Version identification of EtherCAT devices [}57].
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
EP6001-0002 7Version: 1.1
Product group: EtherCAT Box Modules
Power
EtherCAT
...
...

2 Product group: EtherCAT Box Modules

EtherCAT Box modules are I/O modules for industrial controllers.
They comply with protection class IP67 and are intended for use outside the control cabinet in wet, dirty or dusty industrial environments.
EtherCAT Box modules communicate with the controller via the EtherCAT fieldbus. They each have two connections for EtherCAT communication and for the power supply:
• Feed
• Downstream connection
This enables the cabling of EtherCAT Box modules in a line structure:
Fig.1: EtherCAT Box modules: Example of cabling in a line structure
EP6001-00028 Version: 1.1

3 Product overview

3.1 Introduction

Product overview
Fig.2: EP6001-0002
EP6001-0002 | 1-channel serial interface, RS232, RS422/RS485
The EP6001-0002 serial interface module allows the connection of devices with an RS232 or RS422/RS485 interface. The module transmits the data in a fully transparent manner to the higher-level automation device. The active serial communication channel functions independently of the higher-level bus system in full duplex mode at up to 115,200 baud, while a 864 byte receive buffer and a 128 byte send buffer are available. The 1-channel version has an increased end device power supply of up to 1 A, the connector assignment depends on the selected interface. The two integrated digital inputs/outputs allow the connection of additional sensors/actuators in order, for example, to trigger the reading process of the barcode reader or, depending on the result, to initiate an action. In conjunction with the TwinCAT Virtual Serial COM Driver the EP6001-0002 can be used as a normal Windows COM interface.
EP6001-0002 9Version: 1.1
Product overview

3.2 Technical data

All values are typical values over the entire temperature range, unless stated otherwise.
Technical data EP6001-0002
Fieldbus
Fieldbus EtherCAT Connection 2x M8 socket, 4-pin, green Electrical isolation 500V (fieldbus/ IO)
Supply voltages
Connection Input: 1 x M8 plug, 4-pin, black
Downstream connection: 1 x M8 socket, 4-pin, black Control voltage U Nominal voltage 24VDC (-15%/ +20%) Sum current max. 4A Consumers • Module electronics: 130mA
Peripheral voltage U Nominal voltage 24VDC (-15%/ +20%) Sum current max. 4A Current consumption from U
Serial interface
Number of channels 1 Interface type Parameterizable:
Connection RS232: 1x M12 socket
End device supply voltage
Cable length RS232: max. 15m
Data transfer rate Parameterizable:
Data format Parameterizable:
Bit distortion <3% Receive buffer 846Byte Transmit buffer 128Byte
S
1)
• Remote communication station (e.g. barcode scanner)
• Loads at digital outputs
P
1)
P
None. UP is only forwarded.
• RS232
• RS422
• RS485
RS422: 2x M12 socket
RS485: 1x M12 socket
2)
5VDC from the control voltage U
S
max. 1A, short-circuit proof
RS422/RS485: max. 1,000m
300 .. 115,200baud (bit/s)
8N1, 7E1, 7O1, 8N1, 8E1, 8O1, 7E2, 7O2, 8N2, 8E2, 8O2
1)
This value corresponds to the current carrying capacity of the connections for the supply voltages.
2)
Supply voltage available at the connections of the serial interface.
EP6001-000210 Version: 1.1
Product overview
Technical data EP6001-0002
Digital inputs/outputs
Number 2 Connection 1x M12 socket I/O supply voltage
3)
24VDC from the control voltage U
S
max. 0.5A, short-circuit proof Input specification Characteristics Type 3 according to EN 61131-2, compatible with type 1 Input filter 10µs Signal voltage “0” -3.. +5V Signal voltage "1" +11.. +30V Input current 3mA at 24V
DC
DC
DC
Output specification Load type ohmic, inductive, lamp load Nominal voltage 24 VDC (-15%/+20%) from the control voltage U
S
Output current max. 0.5A per channel, short-circuit proof
Environmental conditions
Ambient temperature during operation
Ambient temperature
-25 .. +60°C
-25 .. +55°C according to cURus
-40.. +85°C
during storage 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
Mechanics
Weight approx. 165g Installation position variable
Approvals and conformity
Approvals
CE, cURus [}27]
3)
Supply voltage available at the connections of the digital inputs/outputs.

3.3 Scope of supply

Make sure that the following components are included in the scope of delivery:
• 1x EtherCAT Box EP6001-0002
• 2x protective cap for EtherCAT socket, M8, green (pre-assembled)
• 1x protective cap for supply voltage input, M8, transparent (pre-assembled)
• 1x protective cap for supply voltage output, M8, black (pre-assembled)
• 10x labels, blank (1 strip of 10)
Pre-assembled protective caps do not ensure IP67 protection
Protective caps are pre-assembled at the factory to protect connectors during transport. They may not be tight enough to ensure IP67 protection.
Ensure that the protective caps are correctly seated to ensure IP67 protection.
EP6001-0002 11Version: 1.1
Product overview

3.4 Process image

COM Inputs
Status
Status word for receive data.
Data In [n]
The input variables "Data In 0" .. "Data In 22" each contain one byte of receive data (USINT).
"Data In 0" contains the first-received byte.
EP6001-000212 Version: 1.1
COM outputs
Product overview
Ctrl
Control word for transmit data.
Data Out [n]
The output variables "Data Out 0" .. "Data Out 22" can each be filled with one byte of send data.
The content of "Data Out 0" is transmitted first.
EP6001-0002 13Version: 1.1
Product overview

3.4.1 Control word

Bit 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0
Name OL7 OL6 OL5 OL4 OL3 OL2 OL1 OL0 - - - - SC IR RA TR
Bit no. Name Description
15.. 8 OL7…OL0
(OutLength)
7..4 reserved
3 SC
(SendContinuous)
2 IR
(InitRequest)
1 RA
(ReceiveAccepted)
0 TR
(TransmitRequest)
1
dec…22dec
rise Continuous sending of data from the FIFO.
1
bin
0
bin
toggle The controller acknowledges receipt of data by changing the state of this bit. Only
toggle Via a change of state of this bit the controller notifies the box that the DataOut bytes
The number of output bytes available for the transmission from the controller to the box.
The send buffer is filled (up to 128 bytes) by the controller. The buffer content is sent with rising edge of bit SC. Once the data has been transferred, this is acknowledged by the box to the controller by setting the SW.2 bit. SW.2 is cancelled with CW.3.
The controller requests the box to initialize. The send and receive functions are blocked, the FIFO pointers are reset, and the interface is initialized with the values of the responsible objects (baud rate 4073, data frame 4074, feature bits 4075). The execution of the initialization is acknowledged by the box with the SW.2 (IA) bit.
The controller once again requests the box to prepare for serial data exchange.
then can new data be transferred from the box to the controller.
contain the number of bytes indicated via the OL bits. The box acknowledges receipt of the data in the status byte by changing the state of the SW.0 (TA) bit. Only then can new data be transferred from the controller to the box.

3.4.2 Status word

Bit 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0
Name IL7 IL6 IL5 IL4 IL3 IL2 IL1 IL0 - OVERRUN
ERR
Key
Bit no. Name Description
15...8 IL7... IL0
(InLength)
7 reserved
6 OVERRUN ERR 0 .. 1 An overrun error has occurred. The data concerned is not loaded to the receive
5 FRAMING ERR 0 .. 1 A framing error has occurred. The data concerned is not loaded to the receive FIFO
4 PARITY ERR 0 .. 1 A parity error has occurred. The data concerned is not loaded to the receive FIFO of
3 BUF_F 1 The number of bytes in the receive buffer exceeds the value of parameter 8010:1A
2 IA
(InitAccepted)
1 RR
(ReceiveRequest)
0 TA
(TransmitAccepted)
1
.. 22
dec
1 The initialization has been executed by the box.
0 The box is ready again for serial data exchange.
toggle Via a change of state of this bit the box notifies the controller that the DataIn bytes
toggle The box acknowledges the receipt of data by changing the state of this bit. Only then
The number of input bytes available for the transmission from the box to the con-
dec
troller.
FIFO of the box and is lost.
of the box and is lost.
the box and is lost.
"Rx buffer full notification" (factory setting: 864bytes).
contain the number of bytes indicated via the IL bits. The controller has to acknowl­edge receipt of the data in the control byte via a change of state of bit CW.1 (RA). Only then can new data be transferred from the box to the controller.
can new data be transferred from the controller to the box.
FRAMING ERR
PARITY ERR
BUF_F IA RR TA
EP6001-000214 Version: 1.1

3.5 Technology

Product overview
Fig.3: Level of RS232, RS422, RS485 interfaces
Data transfer rate
The process image contains 22bytes of user data. It is possible to transmit or receive these 22bytes every second PLC cycle at the most:
• The data is transferred from the box to the controller in the first PLC cycle.
• In the second PLC cycle, the controller must acknowledge that it has accepted the data.
Therefore, if the cycle time is 10ms, 50times 22bytes can be transmitted per second.
If the data format is set to 8N1, each transmitted byte is made up of a start bit, eight data bits and a stop bit. This is equivalent to 10bits per byte of user data.
With the above-mentioned settings, a continuous data transfer rate of:
• 50[1/s] x 22[bytes] x 10[bits] = 11000 baud (bit/s)
can be achieved.
The next lower standard data transfer rate is 9600baud. Accordingly, continuous transfer at a maximum baud rate of9600 can be secured with a cycle time of 10ms.
If only low quantities of data are transmitted or received sporadically (e.g.barcode scanner), the data transfer rate can also be set higher, or the cycle time can be enlarged.
If the controller cannot fetch the data quickly enough from the box, they are buffered in the box's receive buffer. All further data are lost if the receive buffer is full.
A buffer is also available for the send data. With a baud rate of 300 and a data format of 8N1, the box can only transmit 30bytespersecond. However, if more than 30bytecome inpersecond, the send buffer is written to first in this case also. Once this is full, all further data will be lost.
EP6001-0002 15Version: 1.1
Mounting and connection
119
126
23
30
26.5
13.5
Ø 3.5

4 Mounting and connection

4.1 Mounting

4.1.1 Dimensions

Fig.4: Dimensions
All dimensions are given in millimeters.
Housing features
Housing material PA6 (polyamide) Sealing compound polyurethane Mounting two fastening holes Ø 3.5 mm for M3 Metal parts brass, nickel-plated Contacts CuZn, gold-plated Power feed through max. 4A Installation position variable Protection class IP65, IP66, IP67 (conforms to EN 60529) when screwed together Dimensions (H x W x D) approx. 126 x 30 x 26.5 mm (without connectors)
EP6001-000216 Version: 1.1
Mounting and connection

4.1.2 Fixing

NOTE
Dirt during assembly
Dirty connectors can lead to malfunctions. Protection class IP67 can only be guaranteed if all cables and connectors are connected.
• Protect the plug connectors against dirt during the assembly.
Mount the module with two M3 screws on the fastening holes in the corners of the module. The fastening holes have no thread.

4.1.3 Tightening torques for plug connectors

Screw connectors tight with a torque wrench. (e.g. ZB8801 from Beckhoff)
Connector diameter Tightening torque
M8 0.4Nm M12 0.6Nm
EP6001-0002 17Version: 1.1
Mounting and connection
Plug
Input
Socket
Forwarding
3 1
24
3 1
24

4.2 Supply voltages

The EtherCAT Box is supplied with two supply voltages. The supply voltages are electrically isolated in the EtherCAT Box.
• Control voltage U
• Peripheral voltage U
S
P
Redirection of the supply voltages
The IN and OUT power connections are bridged in the module (not IP204x-Bxxx and IE204x). The supply voltages US and UP can thus easily be transferred from EtherCATBox to EtherCATBox.
NOTE
Pay attention to the maximum permissible current!
Pay attention also for the redirection of the supply voltages US and UP, the maximum permissible current for M8 connectors of 4A must not be exceeded!

4.2.1 Connectors

NOTE
Risk of confusion: supply voltages and EtherCAT
Defect possible through incorrect insertion.
• Observe the color coding of the connectors: black: Supply voltages green: EtherCAT
Fig.5: Connectors for supply voltages
Fig.6: M8 connector
Contact Function Description Core color
1 U 2 U 3 GND 4 GND
1)
The core colors apply to cables of the type: Beckhoff ZK2020-3xxx-xxxx
S
P
S
P
Control voltage Brown Peripheral voltage White GND to U GND to U
S
P
Blue Black
1)
EP6001-000218 Version: 1.1
Mounting and connection
Vert. Faktor: 0,45 cm / V
5 10 15 20
2
4
6
8
10
250
0
12
30
Vert. Faktor: 0,45 cm / V
Voltage drop (V)
Cable length (m)
35
0,25 mm²
0,34 mm²
0,5 mm² 0,75 mm²
I = 2 A
Vert. Faktor: 0,45 cm / V
5 10 15 20
2
4
6
8
10
250
0
12
30
Vert. Faktor: 0,45 cm / V
Voltage drop (V)
Cable length (m)
35
0,25 mm²
0,34 mm²
0,5 mm²
0,75 mm²
I = 4 A

4.2.2 Status LEDs

Fig.7: Status LEDs for the supply voltages
LED Display Meaning
US (control voltage) off Supply voltage US is not present
green illuminated Supply voltage US is present
UP (peripheral voltage) off Supply voltage UP is not present
green illuminated Supply voltage UP is present

4.2.3 Conductor losses

Take into account the voltage drop on the supply line when planning a system. Avoid the voltage drop being so high that the supply voltage at the box lies below the minimum nominal voltage.
Variations in the voltage of the power supply unit must also be taken into account.
Voltage drop on the supply line
EP6001-0002 19Version: 1.1
Mounting and connection
3 1
24

4.3 EtherCAT

4.3.1 Connectors

NOTE
Risk of confusion: supply voltages and EtherCAT
Defect possible through incorrect insertion.
• Observe the color coding of the connectors: black: Supply voltages green: EtherCAT
EtherCAT Box Modules have two green M8 sockets for the incoming and downstream EtherCAT connections.
Fig.8: EtherCAT connectors
Connection
Fig.9: M8 socket
EtherCAT M8
Signal Contact ZB9010, ZB9020, ZB9030, ZB9032,
Tx + 1 yellow
Tx - 4 orange
Rx + 2 white
Rx - 3 blue
Shield Housing Shield Shield Shield
1)
Core colors according to EN61918
connector
Core colors
ZK1090-6292, ZK1090-3xxx-xxxx
1)
1)
1)
1)
ZB9031 and old versions of ZB9030, ZB9032, ZK1090-3xxx­xxxx
orange/white white/orange
orange orange
blue/white white/green
blue green
TIA-568B
Adaptation of core colors for cables ZB9030, ZB9032 and ZK1090-3xxxx-xxxx
For standardization, the core colors of the ZB9030, ZB9032 and ZK1090-3xxx-xxxx cables have been changed to the EN61918 core colors: yellow, orange, white, blue. So there are different color codes in circulation. The electrical properties of the cables have been retained when the core colors were changed.
EP6001-000220 Version: 1.1
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