Beckhoff EP5101-1002 Documentation

Documentation

EP5xxx

EtherCAT Box Modules for Angle and Position Measurement

2.3.0

2018-12-10

Version:

Date:

Table of contents

EP5xxx 3Version: 2.3.0

Table of contents

1 Foreword ....................................................................................................................................................7

1.1 Notes on the documentation..............................................................................................................7

1.2 Safety instructions .............................................................................................................................8

1.3 Documentation issue status ..............................................................................................................9

2 Product overview.....................................................................................................................................11

2.1 EtherCAT Box - Introduction............................................................................................................11

2.2 Module overview EP5xxx ................................................................................................................13

2.3 EP5001-0002...................................................................................................................................14

2.3.1 EP5001-0002 - Introduction............................................................................................. 14

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

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

2.4 EP51x1-x0xx ...................................................................................................................................16

2.4.1 EP5101-x0xx - Introduction ............................................................................................. 16

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

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

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

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

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

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

3 Mounting and connection.......................................................................................................................24

3.1 Mounting..........................................................................................................................................24

3.1.1 Dimensions ...................................................................................................................... 24

3.1.2 Fixing ............................................................................................................................... 25

3.1.3 Nut torque for connectors ................................................................................................ 26

3.1.4 Additional checks............................................................................................................. 27

3.2 EtherCAT.........................................................................................................................................28

3.2.1 EtherCAT connection....................................................................................................... 28

3.2.2 EtherCAT - Fieldbus LEDs .............................................................................................. 29

3.3 Power supply ...................................................................................................................................31

3.3.1 Power Connection ........................................................................................................... 31

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

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

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

3.4 Cabling ............................................................................................................................................37

3.5 Shielding..........................................................................................................................................39

3.6 UL Requirements.............................................................................................................................39

3.7 ATEX notes .....................................................................................................................................40

3.7.1 ATEX - Special conditions ............................................................................................... 40

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

3.7.3 ATEX Documentation ...................................................................................................... 42

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

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

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

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

Table of contents

EP5xxx4 Version: 2.3.0

4 Commissioning/Configuration ...............................................................................................................47

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

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

4.3 Configuration via TwinCAT..............................................................................................................57

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

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

4.5.1 Process data.................................................................................................................... 66

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

4.5.3 Features CoE................................................................................................................... 69

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

4.6.1 Process data.................................................................................................................... 71

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

4.6.3 Features CoE................................................................................................................... 82

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

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

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

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

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

.........................................................................................................................................................96

4.11.1 Restore object.................................................................................................................. 96

4.11.2 Configuration data ........................................................................................................... 97

4.11.3 Input data......................................................................................................................... 98

4.11.4 Output data ...................................................................................................................... 99

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

4.11.6 Standard objects.............................................................................................................. 99

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

4.12.1 Restore object................................................................................................................ 111

4.12.2 Configuration data ......................................................................................................... 112

4.12.3 Input data....................................................................................................................... 114

4.12.4 Output data .................................................................................................................... 115

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

4.12.6 Standard objects............................................................................................................ 115

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

4.13.1 Restore object................................................................................................................ 124

4.13.2 Configuration data ......................................................................................................... 125

4.13.3 Input data....................................................................................................................... 126

4.13.4 Output data .................................................................................................................... 127

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

4.13.6 Standard objects............................................................................................................ 127

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

4.14.1 Restore object................................................................................................................ 136

4.14.2 Configuration data ......................................................................................................... 137

4.14.3 Input data....................................................................................................................... 139

4.14.4 Output data .................................................................................................................... 140

4.14.5 Standard objects............................................................................................................ 140

4.15 Restoring the delivery state ...........................................................................................................149

Table of contents

EP5xxx 5Version: 2.3.0

5 Appendix ................................................................................................................................................150

5.1 General operating conditions.........................................................................................................150

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

5.3 Support and Service ......................................................................................................................152

Table of contents

EP5xxx6 Version: 2.3.0

Foreword

EP5xxx 7Version: 2.3.0

1 Foreword

1.1 Notes on the documentation

Intended audience

This description is only intended for the use of trained specialists in control and automation engineering who

are familiar with the applicable national standards.

It is essential that the documentation and the following notes and explanations are followed when installing

and commissioning these components.

It is the duty of the technical personnel to use the documentation published at the respective time of each

installation and commissioning.

The responsible staff must ensure that the application or use of the products described satisfy all the

requirements for safety, including all the relevant laws, regulations, guidelines and standards.

Disclaimer

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

development.

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

No claims for the modification of products that have already been supplied may be made on the basis of the

data, diagrams and descriptions in this documentation.

Trademarks

Beckhoff

®

, TwinCAT

®

, EtherCAT

®

, EtherCATP

®

, SafetyoverEtherCAT

®

, TwinSAFE

®

, XFC

®

and XTS

®

are

registered trademarks of and licensed by Beckhoff Automation GmbH.

Other designations used in this publication may be trademarks whose use by third parties for their own

purposes could violate the rights of the owners.

Patent Pending

The EtherCAT Technology is covered, including but not limited to the following patent applications and

patents: EP1590927, EP1789857, DE102004044764, DE102007017835 with corresponding applications or

registrations in various other countries.

The TwinCAT Technology is covered, including but not limited to the following patent applications and

patents: EP0851348, US6167425 with corresponding applications or registrations in various other countries.

EtherCAT

®

is registered trademark and patented technology, licensed by Beckhoff Automation GmbH,

Germany.

Copyright

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

EP5xxx8 Version: 2.3.0

1.2 Safety instructions

Safety regulations

Please note the following safety instructions and explanations!

Product-specific safety instructions can be found on following pages or in the areas mounting, wiring,

commissioning etc.

Exclusion of liability

All the components are supplied in particular hardware and software configurations appropriate for the

application. Modifications to hardware or software configurations other than those described in the

documentation are not permitted, and nullify the liability of Beckhoff Automation GmbH & Co. KG.

Personnel qualification

This description is only intended for trained specialists in control, automation and drive engineering who are

familiar with the applicable national standards.

Description of instructions

In this documentation the following instructions are used.

These instructions must be read carefully and followed without fail!

DANGER

Serious risk of injury!

Failure to follow this safety instruction directly endangers the life and health of persons.

WARNING

Risk of injury!

Failure to follow this safety instruction endangers the life and health of persons.

CAUTION

Personal injuries!

Failure to follow this safety instruction can lead to injuries to persons.

NOTE

Damage to environment/equipment or data loss

Failure to follow this instruction can lead to environmental damage, equipment damage or data loss.

Tip or pointer

This symbol indicates information that contributes to better understanding.

Foreword

EP5xxx 9Version: 2.3.0

1.3 Documentation issue status

Version Modifications

2.3.0 • Note Shielding added

2.2.0 • Update chapter EP5001-0002 - Signal connection

2.1.0 • EP5101-2011 added

• Update chapter Mounting

• Update chapter Comissioninig/Configuration

• Structural update

2.0.0 • Migration

• EP5001-0002 added

• Renamed to EP5xxx

• Several chapters updated

1.6.0 • Pin assignment updated

• Status LEDs updated

• Chapter on Nut torque for connectors updated

• Accessories updated

1.5.0 • Power Connection updated

1.4.0 • Introduction expanded

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

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

• EP5151 signal level (interface signal level) added

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

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

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

• Information on basic function principles amended

• Parameters and modes amended

• EP5151-0002 process image added

• EP5101-0002 process image amended

• Notes on the documentation updated

• Support & service updated

• Safety instructions updated

• EtherCAT cables updated

• EtherCAT Box accessories updated

• Nut torques for connectors updated

• EtherCAT connection updated

• Mounting instructions updated

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

1.1.0 • Description of the power connection updated

• Notes on using EtherCAT Box modules (EPxxxx-xxxx) in potentially explosive

atmospheres (ATEX) added to documentation.

1.0.0 • First release

Firmware and hardware versions

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

documentation was written.

Foreword

EP5xxx10 Version: 2.3.0

The module features are continuously improved and developed further. Modules having earlier production

statuses cannot have the same properties as modules with the latest status. However, existing properties

are retained and are not changed, so that older modules can always be replaced with new ones.

The firmware and hardware version (delivery state) can be found in the batch number (D-number) printed on

the side of the EtherCATBox.

Syntax of the batch number (D-number)

D: WW YY FF HH

WW - week of production (calendar week)

YY - year of production

FF - firmware version

HH - hardware version

Example with D no. 29 10 02 01:

29 - week of production 29

10 - year of production 2010

02 - firmware version 02

01 - hardware version 01

Product overview

EP5xxx 11Version: 2.3.0

2 Product overview

2.1 EtherCAT Box - Introduction

The EtherCAT system has been extended with EtherCAT Box modules with protection class IP67. Through

the integrated EtherCAT interface the modules can be connected directly to an EtherCAT network without an

additional Coupler Box. The high-performance of EtherCAT is thus maintained into each module.

The extremely low dimensions of only 126x30x26.5 mm (hxw xd) are identical to those of the Fieldbus

Box extension modules. They are thus particularly suitable for use where space is at a premium. The small

mass of the EtherCAT modules facilitates applications with mobile I/O interface (e.g. on a robot arm). The

EtherCAT connection is established via screened M8connectors.

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

The robust design of the EtherCAT Box modules enables them to be used directly at the machine. Control

cabinets and terminal boxes are now no longer required. The modules are fully sealed and therefore ideally

prepared for wet, dirty or dusty conditions.

Pre-assembled cables significantly simplify EtherCAT and signal wiring. Very few wiring errors are made, so

that commissioning is optimized. In addition to pre-assembled EtherCAT, power and sensor cables, field-

configurable connectors and cables are available for maximum flexibility. Depending on the application, the

sensors and actuators are connected through M8 or M12connectors.

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

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

• digital outputs with 0.5 or 2A output current

• analog inputs and outputs with 16bit resolution

• Thermocouple and RTD inputs

• Stepper motor modules

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

Product overview

EP5xxx12 Version: 2.3.0

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

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

Basic EtherCAT documentation

You will find a detailed description of the EtherCAT system in the Basic System Documentation for

EtherCAT, which is available for download from our website (www.beckhoff.com) under Downloads.

EtherCAT XML Device Description

You will find XML files (XML Device Description Files) for Beckhoff EtherCAT modules on our web-

site (www.beckhoff.com) under Downloads, in the Configuration Files area.

Product overview

EP5xxx 13Version: 2.3.0

2.2 Module overview EP5xxx

SSI encoder interface

Module Connection encoder/sensor Number of chan-

nels

Sensor supply Comment

EP5001-0002 [}14]

M12, screw type 1 24V

DC

Distributed-Clocks

Incremental encoder interface with differential inputs

Module Connection encoder/sensor Number of chan-

nels

Sensor supply Comment

EP5101-0002 [}16]

M12, screw-type, 8-pin 1 +5V

DC

, 150mA (VCC) Distributed clocks,

4million increments/sec-

ond

EP5101-1002 [}16]

1 24V

DC

, 500mA (VCC)

EP5101-0011 [}16]

D-Sub-socket, 15-pin 1 +5V

DC

, 150mA (VCC) Distributed clocks

4million increments/sec-

ond

Latch, gate

EP5101-2011 [}16]

1 Distributed clocks

20million increments/sec-

ond

Latch, gate

Incremental encoder interface with single-ended inputs

Module Connection encoder/sensor Number of chan-

nels

Sensor supply Comment

EP5151-0002 [}18]

M12, screw-type, 8-pin 1 24V

DC

, 0.5A Distributed clocks

4million increments/sec-

ond

Latch, gate

Product overview

EP5xxx14 Version: 2.3.0

2.3 EP5001-0002

2.3.1 EP5001-0002 - Introduction

Fig.4: EP5001-0002

EP5001-0002 SSI encoder interface

The EP5001-0002 EtherCAT Box is an interface for direct connection of an SSI encoder with differential

inputs (RS422). The interface circuit generates a pulse for reading the encoder, and makes the incoming

data stream available to the controller as a data word in the process image. Various operating modes,

transmission frequencies and bit widths can be permanently stored in a control register. The encoder is

connected via an 8-pin M12 socket.

Quick links

Installation [}24]

Configuration [}50]

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

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

Product overview

EP5xxx 15Version: 2.3.0

2.3.2 EP5001-0002 - Technical data

Technical data EP5001-0002

Fieldbus EtherCAT

Fieldbus connection 2 x M8 socket (green)

Number of channels 1

Channel connections

M12, screw type [}43]

Encoder connection Binary input: D+, D-, binary outputs: CI+, CI-

Rated voltage 24V

DC

(-15%/+ 20%)

Signal type differential (RS422)

Distributed-Clocks yes

Data transfer rates Adjustable up to 1MHz, 250kHz preset

Serial input 24-bit width (adjustable)

Data direction Read

Power supply connection Power supply: 1 x M8 connector, 4-pin; downstream connection: 1 x M8

socket, 4-pin

Current consumption from U

S

typ. 130mA + sensor supply

Width in the process image 1 x 32-bit input, 8-bit status

Electrical isolation 500V

Special features Baud rate, coding and data length are adjustable

Weight app.165g

Operating/storage temperature 0…+55 °C / -25…+85 °C

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

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

Protect. class / installation pos. IP65/66/67 (according to EN 60529)/variable

Approvals CE

2.3.3 EP5001-0002 - Process image

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

SSI Inputs

Status

• Data error SSI input error

• Frame error Wrong data frame

• Power failure An encoder-specific error has occurred.

Enabling through Enable Power failure bit

(index 0x8000:02)

• Sync error

EtherCAT error, see EtherCAT system doc-

umentation

• TxPDO State

See object description [}94]

• TxPDO Toggle

See object description [}94]

Counter value Current encoder counter value

Product overview

EP5xxx16 Version: 2.3.0

2.4 EP51x1-x0xx

2.4.1 EP5101-x0xx - Introduction

EP5101-x0xx | Incremental encoder interface with differential inputs

The EtherCAT Box EP5101-x0xx is an interface for direct connection of incremental encoders with

differential inputs (RS422). A 32/16-bit counter with quadrature decoder as well as a 32/16-bit latch for the

zero pulse can be read, set or activated. Incremental encoders with a fault message output can be

connected to the status input of the interface. A period measurement with a resolution of up to 100ns is

possible. The gate input allows the counter to be disabled; the latch input accepts the counter reading on the

rising edge. The EP5101-1002 has a 24V

DC

sensor supply.

Due to the optional interpolating micro-increment function, the EP5101 can supply even more precise axis

positions for dynamic axes. In addition to that it supports the synchronous reading of the encoder value

together with other input data in the EtherCAT system via high precision EtherCAT Distributed Clocks (DC).

Product overview

EP5xxx 17Version: 2.3.0

The encoder is connected via an 8-pin M12 socket (EP5101-0002 and EP5101-1002) or via a 15-pin D-sub

socket (EP5101-0011 and EP5101-2011). In the M12 version not all signals are available.

Quick links

Installation [}24]

Configuration [}50]

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

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

Product overview

EP5xxx18 Version: 2.3.0

2.4.2 EP5151-000x - Introduction

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

The EP5151-0002 EtherCAT Box is an interface for direct connection of incremental encoders with 24 V DC

inputs. A 32/16-bit counter with quadrature decoder as well as a 32/16-bit latch for the zero pulse can be

read, set or activated. A period measurement with a resolution of up to 100 ns is possible.

Due to the optional interpolating micro-increment function, the EP5151-0002 can supply even more precise

axis positions for dynamic axes. In addition to that it supports the synchronous reading of the encoder value

together with other input data in the EtherCAT system via high precision EtherCAT Distributed Clocks (DC).

The encoder is connected via an 8-pin M12 socket.

Quick links

Installation [}24]

Configuration [}50]

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

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

Product overview

EP5xxx 19Version: 2.3.0

2.4.3 EP51x1-x0xx - Technical data

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

Fieldbus EtherCAT

Fieldbus connection 2 x M8 socket (green)

Number of encoder inputs 1

Encoder connection

A, , B, , C,

(RS485 differential inputs)

also single-ended connection (5V

±20%) possible

A, , B, , C,

(RS485 differential inputs)

also single-ended connection (5V

±20%) possible,

Latch, Gate

A, B,C, (24V

DC

),

Latch, Gate

Encoder connection

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

[}46]

Encoder supply +5V

DC

, 150mA +24V

DC

+5V

DC

, 150mA +24V

DC

Counter 32bit or 16bit, binary

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

ments/s (with

four-fold evalua-

tion)

4 million incre-

ments/s (with four-

fold evaluation)

Quadrature decoder Four-fold evaluation

Zero-pulse latch Bit16

Commands read, set, enable

Distributed Clocks yes

Supply of the module electronics from the control voltage U

S

Current consumption of the module elec-

tronics

typically 130mA + load

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

Onward connection: 1 x M8 socket, 4-pole

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

Outputs: 16bit data, 8bit control

Electrical isolation Control voltage/fieldbus: 500V

Permissible ambient temperature during

operation

-25°C...+60°C

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

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

Permissible ambient temperature during

storage

-40°C ... +85°C

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

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

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

Installation position variable

Approvals

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

ATEX [}40]

Product overview

EP5xxx20 Version: 2.3.0

2.4.4 EP5101-0002, EP5101-1002 - Process image

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

as an example.

ENC Status Compact Input data of the encoder interface

Status

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

Reset via Enable latch C

• Set Counter done Acknowledgement for setting the Set counter

• Counter

underflow

The counter is lower than the lowest counter value that

can be displayed

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

can be displayed

• Open circuit One of the channels (A, B or C) has an open circuit

(configurable for each channel via CoE)

• Extrapolation stall Micro-increment value invalid (when micro-increment

evaluation is enabled -> index 0x8000:0A)

• Status of Input A,

B,C

Status of inputs A, B and C

• Sync error

EtherCAT error, see EtherCAT system documentation

• TxPDO State

See object description [}98]

• TxPDO Toggle

See object description [}98]

Counter value Current encoder counter value

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

latch input

ENC Control Compact Output data of the encoder interface.

Control

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

Counter value is stored in Latch value.

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

value is transferred to the Counter value

Set Counter value Preselection value for Counter value

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