Pilz PSSnet GW1 MOD-EtherCAT User Manual
PSSnet GW1 MOD-EtherCAT
Gateways
Operating Manual-1002692-EN-02
Preface
This document is a translation of the original document.
All rights to this documentation are reserved by Pilz GmbH & Co. KG. Copies may be made
for internal purposes. Suggestions and comments for improving this documentation will be
gratefully received.
Pilz®, PIT®, PMI®, PNOZ®, Primo®, PSEN®, PSS®, PVIS®, SafetyBUS p®, SafetyEYE®,
SafetyNET p®, the spirit of safety® are registered and protected trademarks of Pilz GmbH
& Co. KG in some countries.
SD means Secure Digital
Content
Section 1 Introduction 5
1.1 Validity of documentation 5
1.2 Retaining the documentation 5
1.3 Definition of symbols 5
Section 2 Overview 6
2.1 Module features 6
2.2 Unit view 7
2.2.1 Front 7
2.2.2 Top 8
2.2.3 Right-hand side 8
2.2.4 Bottom 9
Section 3 Safety 10
3.1 Intended use 10
3.1.1 Electromagnetic compatibility 10
3.1.1.1 Connecting the earth cables 11
3.1.1.2 Cable routing 12
3.1.1.3 Equipotential bonding 12
3.1.1.4 Shielding 13
3.1.1.5 Lighting in the control cabinet 13
3.1.1.6 Testing the EMC-compliance of an installation 13
3.2 Safety regulations 14
3.2.1 Use of qualified personnel 14
3.2.2 Warranty and liability 15
3.2.3 Disposal 15
3.3 Safety during installation 15
Section 4 Function description 16
4.1 Operation 16
4.1.1 Block diagram 16
4.2 Modbus/TCP 17
4.2.1 Modbus/TCP data ranges (Server connections) 17
4.2.2 Data transfer limits 17
4.2.3 Function codes (Client connections) 18
4.3 EtherCAT 19
4.4 Translation tables 20
4.4.1 Payload 20
4.4.2 Diagnostic data 20
4.5 Interfaces 23
Section 5 Installation 24
5.1 General installation guidelines 24
5.1.1 Dimensions 25
5.2 Mounting distances 26
5.3 Supply voltage 26
5.4 Install Gateway 27
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Content
Section 6 Commissioning 28
6.1 General wiring guidelines 28
6.2 Wiring the units 28
6.2.1 Cable requirements 28
6.2.2 Terminals 29
6.3 Terminal configuration 29
6.4 Interfaces 29
6.4.1 RJ45 interface 29
6.4.1.1 RJ45 connection cable 30
6.5 Address setting 30
6.5.1 IP address setting 30
Section 7 Operation 32
7.1 Display elements 32
7.1.1 Display elements for device diagnostics 32
7.2 Web server 33
7.2.1 Password management 33
7.2.2 Call web server 34
7.3 Exchange Gateway 34
Section 8 Technical Details 35
Section 9 Order reference 38
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Introduction
1
1.1
1.2
1.3
Introduction
Validity of documentation
This documentation is valid for the product PSSnet GW1 MOD-EtherCAT. It is valid until
new documentation is published.
This operating manual explains the function and operation, describes the installation and
provides guidelines on how to connect the product.
Retaining the documentation
This documentation is intended for instruction and should be retained for future reference.
Definition of symbols
Information that is particularly important is identified as follows:
DANGER!
This warning must be heeded! It warns of a hazardous situation that poses
an immediate threat of serious injury and death and indicates preventive
measures that can be taken.
WARNING!
This warning must be heeded! It warns of a hazardous situation that could
lead to serious injury and death and indicates preventive measures that can
be taken.
ATTENTION!
This refers to a hazard that can lead to a less serious or minor injury plus
material damage, and also provides information on preventive measures
that can be taken.
CAUTION!
This describes a situation in which the product or devices could be damaged and also provides information on preventive measures that can be taken. It also highlights areas within the text that are of particular importance.
Information
This gives advice on applications and provides information on special features.
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Overview
2
2.1
Overview
Module features
The PSSnet GW1 MOD-EtherCAT
} operates as a protocol converter between Modbus/TCP and EtherCAT,
} can be used to exchange data between products that support Modbus/TCP or Ether-
CAT . For example, this may be a control system from the automation system
PSS 4000 from Pilz on one side and a third-party product on the other. The third party
product must support EtherCAT .
Features of the PSSnet GW1 MOD-EtherCAT:
} Can be used with Pilz products that support Modbus/TCP:
– Control systems from the automation system PSS 4000 (e.g. PSSu H)
– Compact/modular 3rd generation PSS-range programmable safety systems (e.g.
PSS SB 3006-3 ETH-2, PSS(1) SB CPU3 ETH-2)
– Operator terminals PMI with Modbus/TCP interface (e.g. PMI 5)
– Motion control systems (e.g. PMCprimo Drive3, PMCprimo DriveP, PMCprimo 16+)
} 1 x RJ45 socket for connection to Modbus/TCP,
} Can manage up to 8 Modbus/TCP connections
} Can operate as a Modbus/TCP connection Server,
} Web server for managing and configuring the Gateway,
} Supports CANopen over EtherCAT,
} Operates as a Slave in the EtherCAT network,
} Transmission rate 10 MBit/s (10BaseT) and 100 MBit/s (100BaseTX),
} 2 x RJ45 socket for connection to EtherCAT,
} supports autonegotiating,
} LEDs for displaying the communication status and errors,
} input/output data
– up to 512 Bytes acyclical data (SDO),
– in total (RxPDO and TxPDO) max. 512 Bytes,
– additionally it is possible to transfer data between the control systems,
} supply voltage
– 20 ms buffer in case of supply interruptions,
– plug-in connection terminals (either spring-loaded terminal or screw terminal).
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Overview
2.2
2.2.1
Unit view
Front
22,5 (0,88“)
Front view
: LEDs for displaying the communication status and faults
: EtherCAT interfaces X1 and X2 (RJ45)
: MAC address
: Barcode with the item number, serial number and version of the Gateway
: 2D code with the MAC address
is registered trademark and patented technology, licensed by Beckhoff
Automation GmbH, Germany
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Overview
2.2.2
Top
Top
: Modbus/TCP interface (RJ45)
: DIP switch for IP address
OFFON
128
IP-ADDRESS
64
32
16
8
4
2
1
2.2.3
Right-hand side
1
2
4
8
16
110,4 (4,35“)
32
64
128
IP-Address
96 (3,78“)
Right-hand side
: QR code with a link to the Pilz homepage with further information on the Gateway
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Overview
2.2.4
Bottom
Bottom
: Supply voltage connection
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Safety
3
3.1
Safety
Intended use
The product serves as a protocol converter between Modbus/TCP and EtherCAT. It can be
used with various Pilz products as well as third-party products, provided they support the
documented properties and requirements.
} Modbus/TCP
The Gateway can be used with products that operate as connection Client during data
exchange. The product must support at least one of the documented function codes .
} EtherCAT
The Gateway can be used as a passive subscriber (Slave) in a EtherCAT network. The
basic functions of communication via EtherCAT correspond to the System Description
published by the EtherCAT User Group.
The Gateway may not be used for safety-related functions.
Intended use includes making the electrical installation EMC-compliant. The product is designed for use in an industrial environment. It is not suitable for use in a domestic environment, as this can lead to interference.
The following is deemed improper use in particular:
} Any component, technical or electrical modification to the product
} Use of the product outside the areas described in this manual
} Use of the product outside the technical details (see chapter entitled "Technical De-
tails")
3.1.1
Electromagnetic compatibility
To ensure electromagnetic compatibility the correct procedures must be carried out during
installation.
A device is electromagnetically compatible if:
} It functions without error in a given electromagnetic environment
} It does not adversely affect its own environment.
Electromagnetic interference can reach the devices through:
} Fields
} Power supplies
} Earth cabling
} Bus connections
} Interfaces
} Input and output cables
The interference can be transferred from the producer (source) to the receiver (interference
sink) via the coupling routes.
Interference reaches the interference sink (e.g. the control system devices) in various ways:
} DC coupling:
DC coupling occurs if the source and sink of interference have common cable connec-
tions. The common cable presents complex resistances, inducing potential differences.
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Safety
Typical sources of interference are switches/relays, running motors or varying potentials
for other systems on the same power supply.
} Capacitive (electrical) coupling:
A different potential between the source and interference sink (e.g. two cables) creates
an electrical field. Coupling is proportional to the rate of voltage change.
Typical sources of interference are contactors, static discharge, parallel signal cables.
} Inductive (magnetic) coupling:
A live cable produces a magnetic field which also surrounds adjacent cables. Interfer-
ence voltage is induced. Coupling is proportional to the rate of current change.
Typical sources of interference are mains cables running in parallel, live cables, high
frequency cables, inductors, transformers, motors.
} Electromagnetic coupling:
A cable can emit a signal as a radio wave. This wave is then picked up by another ca-
ble.
Typical sources of interference are transmitters such as radios, sparks from spark
plugs, welding equipment, etc.
3.1.1.1
CAUTION!
Powerful HF transmitters should only be operated at a distance of more
than 0.6 m.
} Static discharge:
Static discharge occurs where there are very high differences in potential between two
points. If the two points are brought closer together or if the potential difference is increased, discharges can occur in the air gaps.
Typical sources of interference are people who are statically charged from a synthetic
carpet, for example.
Connecting the earth cables
Please note:
} A conductor cross section of at least 2.5 mm
2
should be used for the connection to the
central earth bar. Connections should be kept as short as possible.
} Connections to the earth bar should always be in star form.
} Connect together the 0V connections on all the 24 V power supplies and earth the 0 V
mains at a single point, or ensure that measures are in place to monitor for earth faults.
Earthed supply voltages offer the best noise immunity.
} The connection of the 0 V supply to the central earth bar or earth fault monitor must be
in accordance with relevant national regulations (such as EN 60204-1, NFPA 79:17-7,
NEC: Article 250).
} Connections should be protected from corrosion.
} Flexible earthing straps should be used on moving earth parts (e.g. machine parts,
gates). Ensure these earthing straps are as short and wide as possible.
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Safety
3.1.1.2
Cable routing
It is possible to differentiate between cables according to their function. The
following groups exist:
}
Group 1: Data and supply lines for DC voltages below 60 V and AC voltages below 25 V
} Group 2: Data and supply lines for DC voltages from 60 V to 400 V and AC voltages
from 25 V to 400 V.
} Group 3: Supply lines above 400 V
Cabling inside buildings:
} The cable groups listed above should be laid separately.
} Cables of the same group can be laid within the same cable duct.
} Cables from group 1 and group 2 should be laid in separate groups or in cable ducts
which are at least 10 cm apart.
} Cables from group 1 and group 3 should be laid in separate groups or in cable ducts
which are at least 50 cm apart.
} Data and signal lines should be laid as close as possible to an earthed surface.
Cabling to open air systems:
} As far as possible use metal conduits. These should be electrically connected and
earthed.
} Ensure there is sufficient protection against lightning by using metal conduits earthed at
both ends, or concrete cable ducts with reinforcements connected across the joints.
3.1.1.3
Equipotential bonding
Potential differences can occur if the devices are connected to different earth or ground
connections. Even cable shields that are connected at either end and have different earth
connections can cause potential differences. In order to avoid interference, equipotential
bonding cables must be installed.
In doing so you must ensure the following:
} Select a low impedance equipotential bonding cable.
} Select the following as standard values for the cross section of the equipotential bond-
ing cables:
– 16 mm
– 25 mm
2
for equipotential bonding cable up to 200 m in length
2
for equipotential bonding cable over 200 m in length
} If the control system devices are connected with shielded signal cables which are
earthed at either end, the impedance is calculated as follows:
– Impedance equipotential bonding cable = 10 % of shield impedance.
} Use copper or galvanised steel equipotential bonding cable.
} Connect equipotential bonding cables to the earth bar over as wide a surface area as
possible.
} As short a distance as possible should be kept between the equipotential bonding cable
and signal cable.
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