Beckhoff EL72 1-901 Series User manual

Documentation

EL72x1-901x

Servo Motor Terminals with OCT and STO, 50 V DC

1.9

2020-02-18

Version:

Date:

Table of contents

EL72x1-901x 3Version: 1.9

Table of contents

1 Foreword ....................................................................................................................................................7

1.1 Notes on the documentation..............................................................................................................7

1.2 Safety instructions .............................................................................................................................8

1.2.1 Delivery state ..................................................................................................................... 8

1.2.2 Operator's obligation to exercise diligence ........................................................................ 8

1.2.3 Description of instructions.................................................................................................. 9

1.3 Documentation issue status ............................................................................................................10

1.4 Version identification of EtherCAT devices .....................................................................................10

1.4.1 Beckhoff Identification Code (BIC)................................................................................... 15

2 Product overview.....................................................................................................................................17

2.1 Product overview Servomotor terminal with OCT and STO ............................................................17

2.2 Introduction......................................................................................................................................17

2.3 Technical data .................................................................................................................................20

2.4 Technology ......................................................................................................................................22

2.5 Start-up............................................................................................................................................24

3 Basics communication ...........................................................................................................................25

3.1 EtherCAT basics..............................................................................................................................25

3.2 EtherCAT cabling – wire-bound.......................................................................................................25

3.3 General notes for setting the watchdog...........................................................................................26

3.4 EtherCAT State Machine.................................................................................................................28

3.5 CoE Interface...................................................................................................................................30

3.6 Distributed Clock .............................................................................................................................35

4 Installation................................................................................................................................................36

4.1 Safety instructions ...........................................................................................................................36

4.2 Environmental conditions ................................................................................................................36

4.3 Transport / storage ..........................................................................................................................36

4.4 Control cabinet / terminal box..........................................................................................................36

4.5 Instructions for ESD protection........................................................................................................37

4.6 Installation on mounting rails ...........................................................................................................37

4.7 Installation position for operation with or without fan.......................................................................40

4.8 Positioning of passive Terminals .....................................................................................................43

4.9 Installation instructions for enhanced mechanical load capacity .....................................................44

4.10 Connection ......................................................................................................................................45

4.10.1 Connection system .......................................................................................................... 45

4.10.2 Wiring............................................................................................................................... 46

4.11 Example configuration for temperature measurement ....................................................................48

4.12 Shielding concept ............................................................................................................................48

4.13 UL notice - Compact Motion ............................................................................................................50

4.14 Notes on current measurements using Hall sensors.......................................................................51

4.15 EL72x1-9014 - LEDs and connection..............................................................................................53

5 Commissioning........................................................................................................................................57

5.1 TwinCAT Quick Start .......................................................................................................................57

5.1.1 TwinCAT2 ....................................................................................................................... 60

Table of contents

EL72x1-901x4 Version: 1.9

5.1.2 TwinCAT 3 ....................................................................................................................... 70

5.2 TwinCAT Development Environment ..............................................................................................82

5.2.1 Installation of the TwinCAT real-time driver..................................................................... 82

5.2.2 Notes regarding ESI device description........................................................................... 88

5.2.3 TwinCAT ESI Updater ..................................................................................................... 92

5.2.4 Distinction between Online and Offline............................................................................ 92

5.2.5 OFFLINE configuration creation ...................................................................................... 93

5.2.6 ONLINE configuration creation ........................................................................................ 98

5.2.7 EtherCAT subscriber configuration................................................................................ 106

5.3 Start-up and parameter configuration............................................................................................115

5.3.1 Integration into the NC configuration ............................................................................. 115

5.3.2 Settings with the Drive Manager.................................................................................... 119

5.3.3 Settings in the CoE register ........................................................................................... 124

5.3.4 NC settings .................................................................................................................... 128

5.3.5 Application example....................................................................................................... 134

5.3.6 Commissioning without NC, status word/control word................................................... 139

5.3.7 Settings for the automatic configuration ........................................................................ 143

5.3.8 Configuring the limit switch ........................................................................................... 145

5.3.9 Homing .......................................................................................................................... 146

5.3.10 Touch Probe .................................................................................................................. 149

5.4 Operation modes ...........................................................................................................................152

5.4.1 Overview........................................................................................................................ 152

5.4.2 CSV ............................................................................................................................... 152

5.4.3 CST................................................................................................................................ 156

5.4.4 CSTCA........................................................................................................................... 159

5.4.5 CSP ............................................................................................................................... 163

5.5 Profile MDP 742 or DS 402 ...........................................................................................................167

5.6 MDP742 process data ...................................................................................................................167

5.7 DS402 process data ......................................................................................................................171

6 Integrated safety....................................................................................................................................176

6.1 Safety regulations..........................................................................................................................176

6.2 Description of product and function ...............................................................................................176

6.2.1 Intended use .................................................................................................................. 176

6.2.2 Dimensions .................................................................................................................... 177

6.2.3 TwinSAFE reaction times .............................................................................................. 178

6.2.4 Application example for STO function (Cat. 3, PL d) ..................................................... 180

6.3 Maintenance ..................................................................................................................................186

6.4 Service life .....................................................................................................................................186

7 Object description and parameterization............................................................................................188

7.1 EL72x1-9014 (MDP742)................................................................................................................188

7.1.1 Restore object................................................................................................................ 188

7.1.2 Configuration data ......................................................................................................... 188

7.1.3 Configuration data (vendor-specific).............................................................................. 195

7.1.4 Command object............................................................................................................ 195

7.1.5 Input data....................................................................................................................... 195

Table of contents

EL72x1-901x 5Version: 1.9

7.1.6 Output data .................................................................................................................... 197

7.1.7 Information / diagnosis data .......................................................................................... 199

7.1.8 Standard objects............................................................................................................ 202

7.2 EL72x1-9014 (DS402)...................................................................................................................211

7.2.1 Configuration data ......................................................................................................... 212

7.2.2 Configuration data (vendor-specific).............................................................................. 217

7.2.3 Command object ........................................................................................................... 217

7.2.4 Input/output data............................................................................................................ 218

7.2.5 Information / diagnosis data .......................................................................................... 223

7.2.6 Standard objects............................................................................................................ 226

8 Error correction .....................................................................................................................................233

8.1 Diagnostics – basic principles of diag messages ..........................................................................233

9 Appendix ................................................................................................................................................243

9.1 EtherCAT AL Status Codes...........................................................................................................243

9.2 Firmware compatibility...................................................................................................................243

9.3 Firmware Update EL/ES/EM/ELM/EPxxxx ....................................................................................244

9.3.1 Device description ESI file/XML..................................................................................... 245

9.3.2 Firmware explanation .................................................................................................... 248

9.3.3 Updating controller firmware *.efw................................................................................. 249

9.3.4 FPGA firmware *.rbf....................................................................................................... 250

9.3.5 Simultaneous updating of several EtherCAT devices.................................................... 254

9.4 Restoring the delivery state ...........................................................................................................255

9.5 Certificates.....................................................................................................................................256

9.6 Support and Service ......................................................................................................................257

Table of contents

EL72x1-901x6 Version: 1.9

Foreword

EL72x1-901x 7Version: 1.9

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 following notes and explanations are followed when installing and commissioning

these components.

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.

Origin of the document

This original documentation is written in German. All other languages are derived from the German original.

Currentness

Please check whether you are using the current and valid version of this document. The current version can

be downloaded from the Beckhoff homepage at http://www.beckhoff.com/english/download/twinsafe.htm.

In case of doubt, please contact Technical Support [}257].

Product features

Only the product features specified in the current user documentation are valid. Further information given on

the product pages of the Beckhoff homepage, in emails or in other publications is not authoritative.

Disclaimer

The documentation has been prepared with care. The products described are subject to cyclical revision. For

that reason the documentation is not in every case checked for consistency with performance data,

standards or other characteristics. 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.

Foreword

EL72x1-901x8 Version: 1.9

EtherCAT

®

and Safety over EtherCAT

®

are registered trademarks and patented technologies, 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.

Delivery conditions

In addition, the general delivery conditions of the company Beckhoff Automation GmbH & Co. KG apply.

1.2 Safety instructions

1.2.1 Delivery state

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.

1.2.2 Operator's obligation to exercise diligence

The operator must ensure that

• the TwinSAFE products are only used as intended (see chapter Product description);

• the TwinSAFE products are only operated in sound condition and in working order.

• the TwinSAFE products are operated only by suitably qualified and authorized personnel.

• the personnel is instructed regularly about relevant occupational safety and environmental protection

aspects, and is familiar with the operating instructions and in particular the safety instructions contained

herein.

• the operating instructions are in good condition and complete, and always available for reference at the

location where the TwinSAFE products are used.

• none of the safety and warning notes attached to the TwinSAFE products are removed, and all notes

remain legible.

Foreword

EL72x1-901x 9Version: 1.9

1.2.3 Description of instructions

In these operating instructions 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 the 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

EL72x1-901x10 Version: 1.9

1.3 Documentation issue status

Version Comment

1.9 • Note for fuse protection of the supply voltage added

• Update revision status

• Update structure

1.8 • Update chapter “Object description”

• Update structure

1.7 • Update chapter “Introduction”

• Update structure

1.6 • EL7221-901x added

1.5 • Addenda chapter “UL notice – Compact motion”

• Update revision status

• Update structure

1.4 • Update chapter “Object description and parameterization”

• Update revision status

• Update structure

1.3 • Update revision status

• Update structure

1.2 • Update chapter “Technical Data”

• Update structure

1.1 • Commissioning: chapter Quickstart added

• TwinCAT Development Environment: TwinCAT 3 added

1.0 • First published (only German)

0.1 - 0.5 • Preliminary versions (for internal use only)

1.4 Version identification of EtherCAT devices

Designation

A Beckhoff EtherCAT device has a 14-digit designation, made up of

• family key

• type

• version

• revision

Example Family Type Version Revision

EL3314-0000-0016 EL terminal

(12 mm, non-

pluggable connection

level)

3314 (4-channel thermocouple

terminal)

0000 (basic type) 0016

ES3602-0010-0017 ES terminal

(12 mm, pluggable

connection level)

3602 (2-channel voltage

measurement)

0010 (high-

precision version)

0017

CU2008-0000-0000 CU device 2008 (8-port fast ethernet switch) 0000 (basic type) 0000

Notes

• The elements mentioned above result in the technical designation. EL3314-0000-0016 is used in the

example below.

Foreword

EL72x1-901x 11Version: 1.9

• EL3314-0000 is the order identifier, in the case of “-0000” usually abbreviated to EL3314. “-0016” is the

EtherCAT revision.

• The order identifier is made up of

- family key (EL, EP, CU, ES, KL, CX, etc.)

- type (3314)

- version (-0000)

• The revision -0016 shows the technical progress, such as the extension of features with regard to the

EtherCAT communication, and is managed by Beckhoff.

In principle, a device with a higher revision can replace a device with a lower revision, unless specified

otherwise, e.g. in the documentation.

Associated and synonymous with each revision there is usually a description (ESI, EtherCAT Slave

Information) in the form of an XML file, which is available for download from the Beckhoff web site.

From 2014/01 the revision is shown on the outside of the IP20 terminals, see Fig. “EL5021 EL terminal,

standard IP20 IO device with batch number and revision ID (since 2014/01)”.

• The type, version and revision are read as decimal numbers, even if they are technically saved in

hexadecimal.

Identification number

Beckhoff EtherCAT devices from the different lines have different kinds of identification numbers:

Production lot/batch number/serial number/date code/D number

The serial number for Beckhoff IO devices is usually the 8-digit number printed on the device or on a sticker.

The serial number indicates the configuration in delivery state and therefore refers to a whole production

batch, without distinguishing the individual modules of a batch.

Structure of the serial number: KKYYFFHH

KK - week of production (CW, calendar week)

YY - year of production

FF - firmware version

HH - hardware version

Example with

Ser. no.: 12063A02: 12 - production week 12 06 - production year 2006 3A - firmware version 3A 02 -

hardware version 02

Exceptions can occur in the IP67 area, where the following syntax can be used (see respective device

documentation):

Syntax: D ww yy x y z u

D - prefix designation

ww - calendar week

yy - year

x - firmware version of the bus PCB

y - hardware version of the bus PCB

z - firmware version of the I/O PCB

u - hardware version of the I/O PCB

Example: D.22081501 calendar week 22 of the year 2008 firmware version of bus PCB: 1 hardware version

of bus PCB: 5 firmware version of I/O PCB: 0 (no firmware necessary for this PCB) hardware version of I/O

PCB: 1

Unique serial number/ID, ID number

In addition, in some series each individual module has its own unique serial number.

See also the further documentation in the area

• IP67: EtherCAT Box

• Safety: TwinSafe

Foreword

EL72x1-901x12 Version: 1.9

• Terminals with factory calibration certificate and other measuring terminals

Examples of markings

Fig.1: EL5021 EL terminal, standard IP20 IO device with serial/ batch number and revision ID (since

2014/01)

Fig.2: EK1100 EtherCAT coupler, standard IP20 IO device with serial/ batch number

Fig.3: CU2016 switch with serial/ batch number

Foreword

EL72x1-901x 13Version: 1.9

Fig.4: EL3202-0020 with serial/ batch number 26131006 and unique ID-number 204418

Fig.5: EP1258-00001 IP67 EtherCAT Box with batch number/ date code 22090101 and unique serial

number 158102

Fig.6: EP1908-0002 IP67 EtherCAT Safety Box with batch number/ date code 071201FF and unique serial

number 00346070

Fig.7: EL2904 IP20 safety terminal with batch number/ date code 50110302 and unique serial number

00331701

Foreword

EL72x1-901x14 Version: 1.9

Fig.8: ELM3604-0002 terminal with unique ID number (QR code) 100001051 and serial/ batch number

44160201

Foreword

EL72x1-901x 15Version: 1.9

1.4.1 Beckhoff Identification Code (BIC)

The Beckhoff Identification Code (BIC) is increasingly being applied to Beckhoff products to uniquely identify

the product. The BIC is represented as a Data Matrix Code (DMC, code scheme ECC200), the content is

based on the ANSI standard MH10.8.2-2016.

Fig.9: BIC as data matrix code (DMC, code scheme ECC200)

The BIC will be introduced step by step across all product groups.

Depending on the product, it can be found in the following places:

• on the packaging unit

• directly on the product (if space suffices)

• on the packaging unit and the product

The BIC is machine-readable and contains information that can also be used by the customer for handling

and product management.

Each piece of information can be uniquely identified using the so-called data identifier

(ANSIMH10.8.2-2016). The data identifier is followed by a character string. Both together have a maximum

length according to the table below. If the information is shorter, spaces are added to it. The data under

positions 1 to 4 are always available.

The following information is contained:

Foreword

EL72x1-901x16 Version: 1.9

Item

no.

Type of

information

Explanation Data

identifier

Number of digits

incl. data identifier

Example

1 Beckhoff order

number

Beckhoff order number 1P 8 1P072222

2 Beckhoff Traceability

Number (BTN)

Unique serial number,

see note below

S 12 SBTNk4p562d7

3 Article description Beckhoff article

description, e.g.

EL1008

1K 32 1KEL1809

4 Quantity Quantity in packaging

unit, e.g. 1, 10, etc.

Q 6 Q1

5 Batch number Optional: Year and week

of production

2P 14 2P401503180016

6 ID/serial number Optional: Present-day

serial number system,

e.g. with safety products

51S 12 51S678294104

7 Variant number Optional: Product variant

number on the basis of

standard products

30P 32 30PF971, 2*K183

...

Further types of information and data identifiers are used by Beckhoff and serve internal processes.

Structure of the BIC

Example of composite information from item 1 to 4 and 6. The data identifiers are marked in red for better

display:

BTN

An important component of the BIC is the Beckhoff Traceability Number (BTN, item no.2). The BTN is a

unique serial number consisting of eight characters that will replace all other serial number systems at

Beckhoff in the long term (e.g. batch designations on IO components, previous serial number range for

safety products, etc.). The BTN will also be introduced step by step, so it may happen that the BTN is not yet

coded in the BIC.

NOTE

This information has been carefully prepared. However, the procedure described is constantly being further

developed. We reserve the right to revise and change procedures and documentation at any time and with-

out prior notice. No claims for changes can be made from the information, illustrations and descriptions in

this information.

Product overview

EL72x1-901x 17Version: 1.9

2 Product overview

2.1 Product overview Servomotor terminal with OCT and

STO

EL7201-9014 [}17] servo motor terminal with OCT and STO, 50 V

DC

, 2.8 A

rms

, MDP742 profile

EL7201-9015 [}17] servo motor terminal with OCT and STO, 50 V

DC

, 2.8 A

rms

, DS402 profile

EL7211-9014 [}17] servo motor terminal with OCT and STO, 50 V

DC

, 4.5 A

rms

, MDP742 profile

EL7211-9015 [}17] servo motor terminal with OCT and STO, 50 V

DC

, 4.5 A

rms

, DS402 profile

EL7221-9014 [}17] servo motor terminal with OCT and STO, 50 V

DC

, 7…8 A

rms

, MDP742 profile

EL7221-9015 [}17] servo motor terminal with OCT and STO, 50 V

DC

, 7…8 A

rms

, DS402 profile

2.2 Introduction

Fig.10: EL7201-901x

Product overview

EL72x1-901x18 Version: 1.9

Fig.11: EL7211-901x, EL7221-901x

Quick links

Connection instructions

Chapter "Mounting and wiring",

- LEDs and pin assignment [}53]

- Shielding concept [}48]

- Notes on current measurement via Hall sensor [}51]

Configuration instructions

Chapter "Commissioning",

- Configuration of the main parameters [}115]

Chapter "Configuration with the TwinCAT System Manager",

- Object description and parameterization [}188]

Application example

Chapter "Commissioning",

- Application example [}134]

Servo motor terminals with OCT and STO input

The servo-motor EtherCAT terminals EL7201-901x (50V

DC

, 2.8A

rms

), EL7211-901x (50V

DC

, 4.5A

rms

) and

EL7221-901x (50V

DC

, 7…8A

rms

) with integrated absolute value interface, offer high servo performance in a

very compact design. The EL72x1-901x were designed for the motor types of the AM81xx series from

Beckhoff Automation.

The fast control technology, based on field-orientated current and PI speed control, supports fast and highly

dynamic positioning tasks. The monitoring of numerous parameters, such as overvoltage and undervoltage,

overcurrent, terminal temperature or motor load via the calculation of a I²T model, offers maximum

operational reliability.

Product overview

EL72x1-901x 19Version: 1.9

EtherCAT, as a high-performance system communication, and CAN-over-EtherCAT (CoE), as the

application layer, enable ideal interfacing with PC-based control technology.

The latest power semiconductors guarantee minimum power loss and enable feedback into the DC link when

braking.

The LEDs indicate status, warning and error messages as well as possibly active limitations.

With the One Cable Technology (OCT) the encoder cable is omitted by transmitting the signals of the

encoder digitally via the existing motor cable. The option to read the electronic type plates of suitable motors

from the AM81xx series enables a plug-and-play solution for maximum convenience during commissioning.

The EL72x1-901x provides an STO input with which the motor connected to the terminal can be switched

torque-free. This STO input is connected to a safe output of an EL2904.

Performance Level d, Category 3 according to DIN EN ISO 13849-1:2015 is attained for the SFO safety

function of the EL72x1-901x together with an EL2904.

Recommended TwinCAT version

In order to be able to utilize the full power of the EL72x1-901x, we recommend using the

EL72x1-901x with TwinCAT 2.11 R3 or higher!

Mandatory hardware

The EL72x1-901x must be operated with a real-time capable computer and distributed clocks!

Approved motors

The EL72x1-901x may be operated only with the following Beckhoff motors.

- AM8111-xF1x, AM8112-xF1x, AM8113-xF1x, AM8121-xF1x, AM8122-xF1x, AM8131-xF1x,

AM8132-xJ1x, AM8133-xJ1x, AM8141-xJ1x

- AM8111-xF2x, AM8112-xF2x, AM8113-xF2x, AM8121-xF2x, AM8122-xF2x, AM8131-xF2x,

AM8132-xJ2x, AM8133-xJ2x, AM8141-xJ2x

Operation of the EL7221-901x with fan cartridge ZB8610

Due to the increased thermal load, the EL7221-091x must only be operated in conjunction with the

fan cartridge ZB8610 in order to avoid malfunctions.

Product overview

EL72x1-901x20 Version: 1.9

2.3 Technical data

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