Beckhoff EK3100 Documentation

Documentation

EK3100

PROFIBUS Bus Coupler for EtherCAT Terminals

1.5

2020-04-23

Version:

Date:

Table of contents

EK3100 3Version: 1.5

Table of contents

1 Foreword ....................................................................................................................................................5

1.1 Notes on the documentation..............................................................................................................5

1.2 Safety instructions .............................................................................................................................6

1.3 Documentation issue status ..............................................................................................................7

2 Product overview.......................................................................................................................................8

2.1 EKxxxx - System overview ................................................................................................................8

2.2 EK3100 - Introduction........................................................................................................................9

2.3 Technical data - EK3100 .................................................................................................................10

2.4 Technical data - PROFIBUS............................................................................................................11

3 Mounting and wiring................................................................................................................................12

3.1 Instructions for ESD protection........................................................................................................12

3.2 Mounting..........................................................................................................................................12

3.2.1 Dimensions ...................................................................................................................... 12

3.2.2 Installation on mounting rails – Bus Coupler ................................................................... 13

3.3 Wiring...............................................................................................................................................16

3.3.1 Power supply ................................................................................................................... 16

3.3.2 PROFIBUS interface (X001)............................................................................................ 17

3.3.3 Cabling............................................................................................................................. 18

3.3.4 Topology .......................................................................................................................... 20

3.4 UL notice .........................................................................................................................................21

3.5 ATEX - Special conditions (standard temperature range) ...............................................................22

3.6 ATEX - Special conditions (extended temperature range) ..............................................................23

3.7 Continuative documentation about explosion protection .................................................................24

3.8 Version identification of EtherCAT devices .....................................................................................24

3.8.1 Beckhoff Identification Code (BIC)................................................................................... 28

4 Parameterization and Commissioning ..................................................................................................30

4.1 USB interface ..................................................................................................................................30

4.2 Address selection switch .................................................................................................................30

4.3 2-pin DIP switch...............................................................................................................................31

4.4 IP address (via USB interface) ........................................................................................................31

5 Configuration ...........................................................................................................................................32

5.1 EtherCAT configurations .................................................................................................................32

5.2 Beckhoff Device Manager ...............................................................................................................36

5.2.1 Installing the USB driver .................................................................................................. 36

5.2.2 Starting the Beckhoff Device Manager ............................................................................ 38

5.2.3 Setting the mappings for EtherCAT Terminals ................................................................ 39

5.2.4 Configuring EtherCAT Terminals .................................................................................... 41

5.2.5 Using Restore file ............................................................................................................ 42

5.3 Configuration in TwinCAT 3.............................................................................................................43

5.3.1 Adding the EK3100 Bus Coupler in TwinCAT ................................................................. 43

5.3.2 Using the CtrlStatus DWORD.......................................................................................... 44

5.3.3 Adding an EtherCAT Terminal......................................................................................... 45

5.3.4 Creating a virtual slave .................................................................................................... 46

Table of contents

EK31004 Version: 1.5

5.3.5 Packing digital signals ..................................................................................................... 48

5.4 Accessing COE data with DPV1 services .......................................................................................49

5.4.1 Activating the DPV1 service ............................................................................................ 49

5.4.2 Note the structure of the DPV1 telegram ........................................................................ 51

6 Error handling and diagnostics..............................................................................................................52

6.1 Diagnostic LEDs ..............................................................................................................................52

6.2 Power supply terminal LEDs in K-bus mode ...................................................................................52

6.3 Diagnostics via PROFIBUS .............................................................................................................53

6.3.1 Diagnostics for virtual slaves ........................................................................................... 53

6.3.2 Configuration of the diagnostic telegram ......................................................................... 54

7 Appendix ..................................................................................................................................................55

7.1 Update Bus Coupler image .............................................................................................................55

7.2 Support and Service ........................................................................................................................56

List of tables.............................................................................................................................................57

List of illustations....................................................................................................................................58

Foreword

EK3100 5Version: 1.5

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

The reproduction, distribution and utilization of this document as well as the communication of its contents to

others without express authorization are prohibited.

patent, utility model or design.

Foreword

EK31006 Version: 1.5

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

EK3100 7Version: 1.5

1.3 Documentation issue status

Version Modifications

1.5 • Update chapter “Technical data”

1.4 • Update chapter “Configuration”

1.3 • Update chapter UL notice

1.2 • Update chapter “Update Bus Coupler image”

1.1 • Minor corrections & addenda

1.0 • First version and publication

Product overview

EK31008 Version: 1.5

2 Product overview

2.1 EKxxxx - System overview

Fig.1: EtherCAT Terminals at an EKxxxx series Bus Coupler

The Bus Couplers from the EKxxxx series allow EtherCAT Terminals to be operated on conventional fieldbus

systems. The ultra-fast, high-performance EtherCAT Terminals with their large range of signal types are thus

also available for other fieldbus and Industrial Ethernet systems.

The EKxxxx Bus Couplers are fieldbus slaves and contain an EtherCAT master for the EtherCAT terminals.

They convert the telegrams from the higher-level fieldbus systems into the E-bus signal representation. A

station consists of an EKxxxx and a number of EtherCAT Terminals.

The EKxxxx is integrated in exactly the same way as the Bus Couplers from the BKxxxx series via the

corresponding fieldbus system configuration tools and the associated configuration files, such as GSD, ESD

or GSDML.

EtherCAT makes a very flexible topology configuration possible. Thanks to the Ethernet physics, long

distances can also be bridged without the bus speed being affected. When changing to the field level –

without a control cabinet – the EtherCAT Box modules (EPxxxx) in protection class IP65 can also be

connected to the EK9xxx.

Bus Couplers for various fieldbus systems

The variants from the EKxxxx series differ from one another by the interface for the higher-level fieldbus

system.

An overview of the various Beckhoff Bus Couplers covering the most important fieldbus systems can be

found on the Beckhoff Website.

Embedded PCs with fieldbus interface and decentralized control

The TwinCAT-programmable variant is the CX80xx Embedded PC series.

The variants from the CX80xx series differ from one another by the interface for the higher-level fieldbus

system and the possibility to program it.

An overview of the various Beckhoff Embedded PCs covering the most important fieldbus systems can be

found on the Beckhoff Website.

Product overview

EK3100 9Version: 1.5

2.2 EK3100 - Introduction

Fig.2: EK3100 product overview.

The EK3100 Bus Coupler connects PROFIBUS networks with the EtherCAT Terminals (ELxxxx) and

EtherCAT Box modules (EPxxxx) and converts the telegrams from PROFIBUS to E-bus signal

representation.

One station consists of an EK3100 and any number of EtherCAT Terminals. A 9-pin D-sub connector is used

for connecting the coupler to PROFIBUS. In EtherCAT, the PROFIBUS coupler has at its disposal a lower-

level, powerful and ultra-fast I/O system with a large selection of terminals. The coupler supports the

PROFIBUS profile and therefore fits seamlessly into PROFIBUS networks.

Configuration

The EK3100 is configured via HTML pages provided by the Bus Coupler (Beckhoff device manager) or via

the PROFIBUS DPV1 services.

Product overview

EK310010 Version: 1.5

2.3 Technical data - EK3100

Technical data EK3100

Bus interface 1 x D-sub socket, 9-pin with shielding

Protocol PROFIBUS DP

Data transfer rates up to max. 12 Mbaud (automatic recognition)

Interfaces 1 x USB (behind the front flap)

Web interface yes

Power supply 24 V DC (-15 %/+20 %)

Power contacts 24 V DC max./10 A max.

Electrical isolation 500 V (power contact/supply voltage)

Max. power loss 3W

I/O connection E-bus (EtherCAT Terminals)

Power supply for I/O terminals max. 2A

I/O terminals E-bus (EL, ES, EP), standard digital signals, standard analog signals. All

compatible EtherCAT devices are listed in the GSD file.

No gateway EC terminals, no EC terminals with XFC or DC function.

Number of EtherCAT devices max. 255

Dimensions (W x H x L) 65mm x 100mm x 73mm

Operating/storage temperature

horizontal mounting position

-25°C … +60°C/-40°C … +85°C

Operating/storage temperature

other mounting position

0…+55 °C/-25…+85 °C

Relative humidity 95% no condensation

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. IP 20/variable

Approvals CE,

cULus

ATEX [}22]

Product overview

EK3100 11Version: 1.5

2.4 Technical data - PROFIBUS

Technical data PROFIBUS (EK3100)

Number of I/O modules depending on controller

Number of I/O points depending on controller

Data transfer medium shielded copper cable, 2 x 0.25 mm²

Cable length 1200m 1000m 400m 200m 100m

Data transfer rate 9.6/19.2/93.75

kbaud

187.5 kbaud 500 kbaud 1500 kbaud 3 /6 /12

Mbaud

Topology Line topology

Fieldbus PROFIBUS DP

Bus interface 1 x D sub-socket, 9-pin

Extendable process image Up to 3 virtual slaves in addition

max. process image 4 slaves x (240 bytes in / 240 bytes out)

Protocol

PROFIBUS DP slave Yes

PROFIBUS-DP (virtual slave) 4 (3 virtual PROFIBUS nodes)

Functions/Services

PROFIBUS DP

DPV1 class 1 Yes

Diagnostics/Status/Alarm

RUN LED Yes, green/red

BF LED Yes, green/red

DIA LED Yes, green/red

Mounting and wiring

EK310012 Version: 1.5

3 Mounting and wiring

3.1 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 en-

sure the protection class and ESD protection.

Fig.3: Spring contacts of the Beckhoff I/O components

3.2 Mounting

3.2.1 Dimensions

The following illustrations show the dimensions of the Bus Couplers.

Drawings in DWF and STEP format can be found in the Download section of the Beckhoff website.

Mounting and wiring

EK3100 13Version: 1.5

Fig.4: Dimensions, based on EK9300 as an example.

3.2.2 Installation on mounting rails – Bus Coupler

Snapping onto the mounting rail

The Bus Coupler can simply be snapped onto the mounting rail. To this end position the block on the

mounting rail and push it slightly until it engages on the right-hand side. This is indicated by a distinct click.

Use a screwdriver to push up the lock on the left-hand side, thereby turning it and causing it to engage

audibly.

Fig.5: Snapping onto the mounting rail, based on the EK9300 as an example.

NOTE

Avoid damage!

Do not force the module or apply excessive pressure!

Installation positions

The installation position of the Bus Coupler is arbitrary.

Mounting and wiring

EK310014 Version: 1.5

NOTE

Installation position of EtherCAT terminals

Observe the installation position of the EtherCAT terminals used – not all of them have an arbitrary installa-

tion position. Pay attention to the respective EtherCAT infrastructure components and installation instruc-

tions.

Fig.6: Recommended distances for standard installation position, based on the EK9300 as an example.

NOTE

Comply with the permitted installation position and minimum distances!

We recommend the installation in the horizontal position for optimum ventilation. Furthermore, it is not nec-

essary with this installation position to check whether there are terminals present that may only be installed

horizontally.

Other installation positions are allowed, but not recommended.

Mounting and wiring

EK3100 15Version: 1.5

Fig.7: Other installation positions, based on the EK9300 as an example.

Mounting and wiring

EK310016 Version: 1.5

3.3 Wiring

3.3.1 Power supply

Supply of Bus Couplers and Bus Terminals (Us)

The Bus Coupler requires a supply voltage of 24V

DC

(-15 %/+20 %) for operation.

The connection is made via the two upper terminal points labelled 24V and 0V. This power input supplies

the Bus Coupler electronics and, via the E-Bus, the electronics of the EtherCAT Terminals. It is electrically

isolated from the peripheral supply (Up) of the power contacts.

In order to guarantee the operation of the Bus Coupler and the terminal segment in all cases, the power

supply unit must supply 2A at 24V.

Fig.8: Bus Coupler power supply, based on the EK9300 as an example.

Power contacts supply (Up)

The three power contacts (spring contacts) are located on the right-hand lateral surface of the Bus Coupler.

The spring contacts are hidden in slots so that they can not be accidentally touched. When a Bus Terminal is

added, its blade contacts are connected to the spring contacts of the Bus Coupler. The tongue and groove

guides on the top and bottom of the Bus Terminal Controllers and of the Bus Terminals guarantees that the

power contacts mate securely.

The lower six terminal points labelled +, - and PE are for supplying power to the peripheral supply (Up).

These terminal points are connected in pairs to a power contact. This power input allows voltages of up to 24

V and is electrically isolated from the Bus Coupler supply voltage (Us).

The connection of these terminal points in pairs enables the supply to be forwarded. The current load of the

power contacts may not permanently exceed 10 A. The current carrying capacity between two terminal

points is identical to the current carrying capacity of the connecting wires.

The spring-loaded terminal points are designed for wires with cross-sections from 0.08mm² to 2.5mm².

Mounting and wiring

EK3100 17Version: 1.5

LED

If the power supply unit is connected correctly and the power supply is switched on, the two upper LEDs in

the terminal prism are green. The left-hand LED (Us) indicates the supply for the Bus Coupler electronics.

The right-hand LED (Up) indicates the supply for the power contacts. The other LEDs indicate the state of

the E-bus. The detailed meanings of the LED displays are described in the chapter LED displays.

PE power contacts

NOTE

Power contact PE

The PE power contact must not be used for other potentials.

3.3.2 PROFIBUS interface (X001)

PROFIBUS, 9-pin D-sub

Pin 6 transfers 5V

DC,

pin 5 transfers GND for the active termination resistor. These must never be used for

other functions, as this can lead to destruction of the device.

Pins 3 and 8 transfer the PROFIBUS signals. These must never be swapped over, as this will prevent

communication.

Fig.9: PROFIBUS, Pin assignment D-Sub

The Profibus bus line is connected via a 9-pin D sub with the following pin assignment:

Pin Assignment

1 Shielding

2 not used

3 RxD/TxD-P

4 not used

5 GND

6 +5 V

DC

7 not used

8 RxD/TxD-N

9 not used

cable colors

PROFIBUS line D sub

B red Pin 3

A green Pin 8

Mounting and wiring

EK310018 Version: 1.5

3.3.3 Cabling

Physical aspects of the data transmission are defined in the PROFIBUS standard (see PROFIBUS layer 1:

Physical Layer).

The types of area where a fieldbus system can be used is largely determined by the choice of the

transmission medium and the physical bus interface. In addition to the requirements for transmission

security, the expense and work involved in acquiring and installing the bus cable is of crucial significance.

The PROFIBUS standard therefore allows for a variety of implementations of the transmission technology

while retaining a uniform bus protocol.

Cable-based transmission:

This version, which accords with the American EIA RS-485 standard, was specified as a basic version for

applications in production engineering, building management and drive technology. A twisted copper cable

with one pair of conductors is used. Depending on the intended application area (EMC aspects should be

considered) the shielding may be omitted.

Two types of conductor are available, with differing maximum conductor lengths (see the RS485 table).

RS-485 transmission according to the PROFIBUS standard

Network topology Linear bus, active bus terminator at both ends, stubs

are possible.

Medium Shielded twisted cable, shielding may be omitted,

depending upon the environmental conditions (EMC).

Number of stations 32 stations in each segment with no repeater. Can be

extended to 125 stations with repeater

Max. bus length without repeater 100 m at 12 Mbit/s

200 m at 1500 Kbit/s, up to 1.2 km at 93.75 kbit/s

Max. bus length with repeater Repeaters can increase the bus length up to 10km.

The number of repeaters possible is at least 3, and,

depending on the manufacturer, may be up to 10.

Data transfer rate (adjustable in steps) 9.6kbit/s; 19.2kbit/s; 93.75kbit/s; 187.5kbit/s;

500kbit/s; 1500kbit/s; 12Mbit/s

Connector 9-pin D sub connector for IP20

M12 round connector for IP65/67

Cable-related faults

Note the special requirements on the data cable for bit rates greater than 1.5 Mbit/s. The correct cable is a

basic requirement for correct operation of the bus system. If a simple 1.5 Mbit/s cable is used, reflections

and excessive attenuation can lead to some surprising phenomena. It is possible, for instance, for a

connected PROFIBUS station not to achieve a connection, but for it to be included again when the

neighboring station is disconnected. Or there may be transmission errors when a specific bit pattern is

transmitted. The result of this can be that when the equipment is not operating, PROFIBUS works without

faults, but that there are apparently random bus errors after start-up. Reducing the bit rate (<93.75kbit/s)

corrects this faulty behavior.

If reducing the bit rate does not correct the error, then in many cases this can indicate a wiring fault. The two

data lines may be crossed over at one or more connectors, or the termination resistors may not be active, or

they may be active at the wrong locations.

Preassembled cable from BECKHOFF

Installation is made a great deal more straightforward if preassembled cables from BECKHOFF are

used! Wiring faults are avoided, and commissioning is more rapidly completed. The BECKHOFF

range includes fieldbus cables, power supply cables, sensor cables and accessories such as termi-

nation resistors and T-pieces. Connectors and cables for field assembly are nevertheless also avail-

able.

The following diagram shows the cabling between two stations, as well as the D sub connection assignment:

Mounting and wiring

EK3100 19Version: 1.5

Fig.10: PROFIBUS cabling

Termination resistors

In systems with more than two stations all devices are wired in parallel. It is essential that the bus

cables are terminated with resistances at the conductor ends in order to avoid reflections and asso-

ciated transmission problems.

Distances

The bus line is specified in EN 50170. This yields the following lengths for a bus segment.

Bit rate in

kbits/sec

9.6 19.2 93.75 187.5 500 1500 12000

Cable

length in m

1200 1200 1200 1000 400 200 100

Stubs up to 1500 kbit/s <6.6 m; at 12 Mbit/s stub segments should not be used.

Bus segments

A bus segment consists of at most 32 devices. 125 devices are permitted in a PROFIBUS network.

Repeaters are required to refresh the signal in order to achieve this number. Each repeater is counted as

one device.

IP-Link is the subsidiary bus system for Fieldbus Boxes, whose topology is a ring structure. There is an IP-

Link master in the coupler modules (IP230x-Bxxx or IP230x-Cxxx) to which up to 120 extension modules

(IExxxx) may be connected. The distance between two modules may not exceed 5m. When planning and

installing the modules, remember that because of the ring structure the IP-Link master must be connected

again to the last module.

Installation guidelines

When assembling the modules and laying the cables, observe the technical guidelines provided by the

PROFIBUS User Organization (PROFIBUS Nutzerorganization e.V.) for PROFIBUS DP/FMS (see:

www.profibus.de).

Check the PROFIBUS cable

A PROFIBUS cable (or a cable segment when using repeaters) can be checked with a few simple resistance

measurements. The cable should meanwhile be removed from all stations:

1. Resistance between A and B at the start of the line: approx. 110 Ohm

2. Resistance between A and B at the end of the line: approx. 110 Ohm

3. Resistance between A at the start and A at the end of the line: approx. 0 Ohm

4. Resistance between B at the start and B at the end of the line: approx. 0 Ohm

5. Resistance between shield at the start and shield at the end of the line: approx. 0 Ohm

Mounting and wiring

EK310020 Version: 1.5

If these measurements are successful, the cable is okay. If, in spite of this, bus malfunctions still occur, this

is usually a result of EMC interference. Observe the installation notes from the PROFIBUS User

Organization (www.profibus.com).

3.3.4 Topology

• A bus segment may consist of a maximum of 32 devices (including the repeaters).

• The maximum cable length of a segment depends on the data transfer rate in use and on the quality of

the bus cables being used.

• No more than 9 repeaters may be installed between two devices.

• Stubs are to be avoided, and are not permitted above 1.5 Mbaud.

• The maximum number of devices is 125

• Interrupting the supply voltages from cable ends by switching off the repeater/slave, or by pulling out

the plug, is not permitted.

Fig.11: PROFIBUS topology with the EK3100 Bus Coupler.

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Beckhoff EK3100 Documentation

Beckhoff EK3100 Documentation

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