cable and

connector

LED diagnosis

version EtherCAT in practice

identification

state machine

sync manager

FMMU

mailbox Michael Jost

protocols
Beckhoff

working
counter

10/02/2009 EtherCAT in practice 1

 Cable

cable and Requirements:

connector
Category 5 / class D cable

LED diagnosis EtherCAT uses 4 poles

version symmetrical assignment 1:1 (no cross-cable
identification is needed)

state machine max. length 100m

sync manager

FMMU Pin Pin Wire color Wire color Signal Description

M12 RJ45 (EIA/TIA-T568B) (Industrial Ethernet cable)

mailbox
1 1 white-orange yellow TD+ Transmission Data +

protocols 3 2 orange orange TD- Transmission Data -

working 2 3 white-green white RD+ Receiver Data +
counter
4 6 green blue RD- Receiver Data -

* ZB90x0, Industrial Ethernet cable

10/02/2009 EtherCAT in practice 2
 Cable

cable and Standard patch cable (min. CAT5) can be used for
connector
internal wirings in control cabinets.

LED diagnosis

version
identification

state machine

sync manager

FMMU

mailbox

protocols

working
counter

10/02/2009 EtherCAT in practice 3

 RJ45 connector crimping

cable and The crimping of RJ45 connectors often causes

connector
problems in industrial environments.

LED diagnosis • filigree technique in comparison with

version traditional field bus systems
identification
• connector and tool have to match

state machine • assembly time is higher

sync manager • additional tool is required

FMMU

mailbox

protocols

working
counter

10/02/2009 EtherCAT in practice 4

 PIN assignment standard RJ45 connector 1/2

cable and
connector

LED diagnosis

version
identification

state machine
normal assignment turned assignment

sync manager

FMMU Pin Pin

mailbox
1 white-orange 1 white-green
2 orange 2 green

protocols 3 white-green 3 white-orange
4 blue 4 blue

working
counter
5 white-blue 5 white-blue
6 green 6 orange
7 white-brown 7 white-brown
8 brown 8 brown
Nach EIA/TIA-T568B

10/02/2009 EtherCAT in practice 5

 PIN assignment standard RJ45 connector 2/2

cable and
connector
detent

LED diagnosis below

version
identification

state machine

sync manager

FMMU

mailbox

protocols

working
counter

10/02/2009 EtherCAT in practice 6

 Cable standardization

cable and Twisted Pair cable is divided into different categories

connector
according to EIA/TIA* 568-A-5 (ISO/IEC 11801).

LED diagnosis These correspond to the classes of EN50173.

version
identification
Class Applications Category

state machine
Class A Speech-/Data circuit for low-frequency applications up to 100 KHz
for phone and ISDN

sync manager
Class B Data circuit with medium data rates up to 1 MHz for phone and
ISDN

FMMU
Class C Data circuit for up to 16 MHz for phone, ISDN, Token Ting, Cat3

mailbox Ethernet
Class D Data circuits for up to 100/125 MHz for phone, ISDN, Token Cat5, (Cat5e)

protocols Ring, Ethernet (Giga Bit Ethernet) , FDDI, TPDDI, 100 VG
Anylan

working Class E Data circuits for up to 250 MHz for Class D plus ATM and Giga Bit Cat6
counter Ethernet
Class F Data circuits for up to 600 MHz Cat7
Class G CATV-equipments (Video) for up to 1200 MHz with a cable length Cat8
of max. 50 m
*Electronic Industries Alliance / Telecommunications Industry Association
10/02/2009 EtherCAT in practice 7
 Installation for field assembly connector
ZS1090-0003 1/2

cable and Push the housing over Press data module

connector the cable sheath and element together

LED diagnosis
Stripping Remove

version
identification

state machine Form the wires Put on upper shielding

shell

sync manager
Put up splicing element Put on lower shielding

FMMU
shell

mailbox
Put up housing Push housing and

protocols
lock it

working
counter Put the data module Tighten connection
into the assembly tool

10/02/2009 EtherCAT in practice 8

 Installation for field assembly connector
ZS1090-0003 2/2

cable and – assembly with existing tool

connector
– error-secure through color code

LED diagnosis
– industrial capable

version
identification

state machine

sync manager

FMMU

mailbox

protocols

working
counter

10/02/2009 EtherCAT in practice 9

 Link/Act LED

cable and All EtherCAT devices with a connector (e.g. RJ45,

connector
M12), must have a Link/Activity display. Devices

LED diagnosis without connector could have such a display.

version
identification – Status (as with standard Ethernet components)

state machine • LED out: no connection

sync manager • LED on: connection
• LED blinking: communication

FMMU

mailbox

protocols

working
counter

10/02/2009 EtherCAT in practice 10

 RUN LED

cable and The RUN LED indicates the status of the EtherCAT
connector
device -> see State Machine

LED diagnosis

version – Status:
identification
• off: INIT

state machine
• blinking Pre-Operational

sync manager • single flash Safe-Operational

FMMU • on Operational

mailbox • flickering Bootstrap

protocols

working
counter

10/02/2009 EtherCAT in practice 11

 LED‘s at the EK1100

cable and power supply for bus coupler

connector and E-Bus

LED diagnosis power supply for power
contacts

version
identification

state machine

sync manager

FMMU

mailbox

protocols

working
counter

10/02/2009 EtherCAT in practice 12

 LED‘s at the EK1100

cable and
connector

LED diagnosis existing EtherCAT connection

version over cable and E-Bus;
identification status EK1100 INIT

state machine

sync manager

FMMU
existing EtherCAT connection

mailbox over cable and E-Bus;
EK1100 is in status Operational

protocols

working existing EtherCAT connection

counter
over cable; E-Bus disconnected;
Status EK1100 INIT

10/02/2009 EtherCAT in practice 13

 Version identification – Hardware

cable and
connector

LED diagnosis

version
identification

state machine
week of production

sync manager
year of production

FMMU
software version

mailbox

protocols
hardware version

working
counter

10/02/2009 EtherCAT in practice 14

 Version identification – Software

cable and product code,

connector description process image

LED diagnosis

version
identification E²PROM
ESC
(FPGA) communication and diagnosis functionality

state machine
(drop out with ASIC)

sync manager

FMMU
µC terminal specific function

mailbox e. g analog input, SSI etc.
(only for complex terminals)

protocols

working
counter

10/02/2009 EtherCAT in practice 15

 E²PROM

cable and
connector

LED diagnosis

version
identification

state machine

sync manager

FMMU

mailbox

protocols

working
counter

10/02/2009 EtherCAT in practice 16

 FPGA

cable and
connector

LED diagnosis

version
identification

state machine

sync manager

FMMU

mailbox

protocols

working
counter

10/02/2009 EtherCAT in practice 17

 µC

cable and
connector

LED diagnosis

version
identification

state machine

sync manager

FMMU

mailbox

protocols

working
counter

10/02/2009 EtherCAT in practice 18

 EtherCAT State Machine

cable and
connector

LED diagnosis

version
identification

state machine

sync manager

FMMU

mailbox

protocols

working
counter

10/02/2009 EtherCAT in practice 19

 EtherCAT State Machine 1/2

cable and ‚Init‘ State

connector
no process data communication

LED diagnosis
Master can write info register

version
identification
‚Pre-Operational‘ State

state machine
no process data communication

sync manager Master configures Slave

FMMU mailbox communication

mailbox
‚Safe Operational‘ State

protocols
mailbox communication

working
counter
process data communication –> just inputs
outputs are in ‚Safe State‘

10/02/2009 EtherCAT in practice 20

 EtherCAT State Machine 2/2

cable and ‚Operational‘ State

connector
process data communication in- and outputs

LED diagnosis

version ‚Bootstrap‘ State

identification
optional for download of new Firmware

state machine

sync manager

FMMU

mailbox

protocols

working
counter

10/02/2009 EtherCAT in practice 21

 Sync Manager

cable and Prevents simultaneous access to DPRAM -

connector
data consistence

LED diagnosis 3 Buffer operation:

version
- always one cache free for writing
identification - always one cache with consistent data ready to

state machine
read
- assures most actual data

sync manager
- occupied threefold memory opposite to

FMMU 1-cache operation
- default for process data

mailbox
1 Buffer operation

protocols - 1:1 data transmission, no lost of data

working - writing site must write before reading site
counter can write and contrary
- overflow protection
- default for mailbox data
10/02/2009 EtherCAT in practice 22
 Sync Manager

cable and ECAT Next Slave

connector 3 Buffer writing
reading

LED diagnosis
operation Load next buffer,
when new data is available

Bus terminal

version
writing Exchange
identification end Buffer
reading
end

state machine
1 2 3

sync manager DP-RAM

FMMU

mailbox 1 Buffer writing DP-RAM DP-RAM

Reading

protocols
operation The buffer can be
written again as
Bus terminal Bus terminal

working recently as the
counter content was read
writing out. Reading
end end

t
10/02/2009 EtherCAT in practice 23
 Sync Manager

cable and
connector

LED diagnosis

version
identification

state machine

sync manager

FMMU

mailbox

protocols

working
counter

10/02/2009 EtherCAT in practice 24

 FMMU – Field bus Memory Management Unit

cable and Translation of the logical address (within the telegram) into
connector the physical address (within the node).

LED diagnosis Mapping of the local addresses into the global EtherCAT
address space (4 GByte)

version
identification – integrated within the EtherCAT Slave Controller
– bit addressing possible

state machine
– minimal overhead

sync manager

FMMU Advantage: no copying within the controller, as the I/O‘s are

prearanged in the process image

mailbox

protocols -> performance benefit

working
counter

10/02/2009 EtherCAT in practice 25

 Mailbox

cable and For acyclic exchange of parameter data between

connector
Master and Slave

LED diagnosis For configuration of the process image

version
identification

state machine

sync manager

FMMU

mailbox

protocols

working
counter

10/02/2009 EtherCAT in practice 26

 Protocols

cable and ADS over EtherCAT (AoE)

connector
ADS messages over EtherCAT

LED diagnosis
Ethernet over EtherCAT (EoE)

version standard Ethernet frames over EtherCAT
identification
CANopen over EtherCAT (CoE)

state machine
standard access to the object dictionary

sync manager
File Access over EtherCAT (FoE)

FMMU for the download of new Firmware

mailbox Servo Profile (Sercos) over EtherCAT (SoE)

protocols standard access to the Sercos identifier

working
counter

10/02/2009 EtherCAT in practice 27

 Working Counter

cable and Every EtherCAT telegram ends with a

connector 16 bit Working Counter.

LED diagnosis Every Slave Controller in communication who is
completing the command (reading/writing) increases

version
identification
the working counter.
The Master compares the received Working Counter

state machine
with the calculated Working Counter. Through this it

sync manager can be determined if all commands have been
completed.

FMMU
WC=0 WC=1 WC=3 WC=6
node 1 node 2 node 3

mailbox PC DI = read DO=write DI/DO=
1xread+ read+write
WC+1=1 WC+2=3

protocols 1xwrite+ WC+3=6
1+read/ WC=6 WC=6 WC=6
write = 6

working
counter

10/02/2009 EtherCAT in practice 28

 Working Counter

cable and
connector (Mailbox)
(State)

LED diagnosis WC+1

version
identification
WC+1

state machine

sync manager
WC+3

FMMU

mailbox
WC+1

protocols

working
WC+2
counter
WC=8

10/02/2009 EtherCAT in practice 29