Beckhoff FC1028 User manual

Manual | EN
FC1028
PCIe EtherCAT Master Card
5/9/2022 | Version: 1.0

Table of contents
FC1028 3Version: 1.0
Table of contents
1 Notes on the documentation....................................................................................................................5
1.1 Representation and structure of warnings ........................................................................................6
1.2 Documentation issue status ..............................................................................................................7
2 Product overview ......................................................................................................................................8
2.1 Structure............................................................................................................................................8
2.2 Interfaces ..........................................................................................................................................9
3 Commissioning .......................................................................................................................................10
3.1 Assembly.........................................................................................................................................10
3.2 Wiring ..............................................................................................................................................10
3.3 Driver note.......................................................................................................................................11
3.4 BIOS settings ..................................................................................................................................11
4 TwinCAT configuration...........................................................................................................................13
4.1 Scan card in TwinCAT ....................................................................................................................13
4.2 Insert EtherCAT master manually ...................................................................................................14
4.3 Use cable redundancy ....................................................................................................................16
4.4 Enabling Distributed Clocks ............................................................................................................19
4.5 Coupling distributed clocks – EtherCAT master..............................................................................22
5 Error handling and diagnostics .............................................................................................................25
5.1 Diagnostic LEDs..............................................................................................................................25
5.2 Faults ..............................................................................................................................................25
6 Technical data .........................................................................................................................................26
7 Appendix..................................................................................................................................................27
7.1 Accessories.....................................................................................................................................27
7.2 Support and Service........................................................................................................................28

Table of contents
FC10284 Version: 1.0

Notes on the documentation
FC1028 5Version: 1.0
1 Notes on the documentation
This description is only intended for the use of trained specialists in control and automation engineering who
are familiar with applicable national standards.
It is essential that the documentation and the following notes and explanations are followed when installing
and commissioning the 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®, TwinCAT/BSD®, TC/BSD®, 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 a registered trademark and patented technology, licensed by Beckhoff Automation GmbH,
Germany
Copyright
© Beckhoff Automation GmbH & Co. KG, Germany.
The reproduction, distribution and utilization of this document as well as the communication of its contents to
others without express authorization are prohibited.
Offenders will be held liable for the payment of damages. All rights reserved in the event of the grant of a
patent, utility model or design.

Notes on the documentation
FC10286 Version: 1.0
1.1 Representation and structure of warnings
The following warnings are used in the documentation. Read and follow the warnings.
Warnings relating to personal injury:
DANGER
Hazard with high risk of death or serious injury.
WARNING
Hazard with medium risk of death or serious injury.
CAUTION
There is a low-risk hazard that can result in minor injury.
Warnings relating to damage to property or the environment:
NOTE
There is a potential hazard to the environment and equipment.
Notes showing further information or tips:
This notice provides important information that will be of assistance in dealing with the product or
software. There is no immediate danger to product, people or environment.

Notes on the documentation
FC1028 7Version: 1.0
1.2 Documentation issue status
Version Comment
1.0 First version.

Product overview
FC10288 Version: 1.0
2 Product overview
The FC1028 EtherCAT card can be used to integrate an Industrial PC as a master in an EtherCAT network.
The card has 16 EtherCAT channels and a total of eight ix-Industrial® type A connectors. Adapter cables type
C9900-K921 are required to connect the EtherCAT devices.
With FC1028 EtherCAT card a total of 16 EtherCAT masters are available. The EtherCAT masters are fully
DC synchronous. No external synchronization is necessary in order to synchronize the EtherCAT masters or
EtherCAT segments with one another. This function is particularly interesting for XTS systems that require
synchronously running EtherCAT masters. The FC1028 EtherCAT card can additionally be used to realize
an EtherCAT redundancy.
2.1 Structure
Fig.1: Example structure of a FC1028 EtherCAT card.
Table1: Legend for the structure of the FC1028 EtherCAT card.
No. Component Description
1 PCI Express x4 bus Requires a PCIe x4 slot that meets the PCIe standard.
2 ix Industrial® interface 8 x ix-Industrial®-type A interfaces. Two EtherCAT masters can be
executed per interface, i.e. a total of 16 EtherCAT masters.
3 2 x 5-pin contact strip Synchronization interface for synchronization of multiple FC1028
EtherCAT cards.
4 Diagnostic LEDs The LEDs P01 to P16 indicate the status of the connection (see:
Diagnostic LEDs [}25]).

Product overview
FC1028 9Version: 1.0
2.2 Interfaces
Fig.2: EtherCAT interfaces, X1 to X8.
Table2: EtherCAT interfaces X1 to X8, PIN assignment.
PIN Assignment according to
TIA-568B
Description
1 white/orange Pair 1
2 orange
3 not connected Pair 2
4 white/blue Pair 3
5 blue
6 white/green Pair 4
7 green
8 not connected Pair 2
9 white/brown Pair 5
10 brown
C9900-K921 connection cable
With the help of the C9900-K921 connection cable, two RJ45 sockets (P1 and P2) are made from one x-
Industrial® plug (P3).
Fig.3: Connection cable C9900-K921, structure and PIN assignment.

Commissioning
FC102810 Version: 1.0
3 Commissioning
3.1 Assembly
NOTE
Electrostatic discharge
Electrical components can be damaged by electrostatic discharges. Observe ESD protection measures
during assembly. Ensure the environment is well grounded with ESD compliant floors, gloves, clothing and
workstations.
The FC1028 EtherCAT card requires a PCIe x4 slot that complies with the PCIe standard. In principle, the
card can also be operated in longer slots, i.e. also in PCIe x8 or PCIe x16 slots. It is only important that the
slots support four PCIe lanes.
Fig.4: FC1028 EtherCAT card, dimensions.
The EtherCAT card does not require an external power supply. The card is supplied directly from the
Industrial PC via the PCIe bus. The power supply of the Industrial PC has to be adequate for meeting the
power requirement of the EtherCAT cards, particularly if several EtherCAT cards are installed.
Proceed as follows:
1. Before installing the EtherCAT card, switch off the Industrial PC and any external power supplies, and
separate the PC from the mains.
2. Open the housing of the Industrial PC and remove the cover plate in the housing wall of the Industrial PC
at a free PCIe slot of the motherboard.
3. Insert the EtherCAT card into the free PCIe slot and fix it with the screw or device provided. Make sure
that there is enough space between the EtherCAT card and other PC components so that the EtherCAT
card cannot touch any other plug-in cards or motherboard components.
ðAfter a restart, the EtherCAT card is automatically detected. No additional drivers need to be installed.
3.2 Wiring
Connection cables type C9900-K921 are required for the connection of the EtherCAT devices. The
connection cable is a breakout cable with an ix-Industrial® type A plug to 2 x Cat.6 RJ45 socket.

Commissioning
FC1028 11Version: 1.0
Table3: Accessories connection cable, ordering information.
Ordering information Description
C9900-K921 Connection cable ix Industrial® type A 10-pin plug to 2 x Cat.6 RJ45
socket, 1m Cat.6 cable, suitable for FC1028
Fig.5: Connection cable C9900-K921, dimensions.
The card has a total of eight ix-Industrial® type A interfaces, thus up to 16 EtherCAT devices can be
connected to the eight interfaces.
Fig.6: Connection example with two adapter cables of type C9900-K921.
3.3 Driver note
No drivers have to be installed for the operation of the FC1028 EtherCAT card. The card is ready for
operation immediately after mounting. Note that the card is not displayed in the Device Manager or as a
network interface under Windows, but the card can be used under TwinCAT (see: TwinCAT configuration
[}13]).
3.4 BIOS settings
For Industrial PCs that are delivered ex factory with the FC1028 EtherCAT card, the BIOS is configured
appropriately so that the card functions properly.

Commissioning
FC102812 Version: 1.0
If you retrofit a Beckhoff Industrial PC with a FC1028, you must adjust or check the settings in the BIOS to
ensure that the EtherCAT card functions properly. Without the appropriate BIOS settings the card is not
ready for operation and cannot be used in TwinCAT.
Adjust BIOS settings:
1. Restart your Industrial PC and press [Del] to start the BIOS setup.
2. If the [Del] key does not work, another key is displayed on the screen in any case, which can be used to
access the BIOS setup.
3. Navigate to the PCI Configuration menu
4. Disable the Memory Mapped I/O above 4GB option.
5. Press [F4] to save the settings and exit the BIOS setup.
ðThe Industrial PC is restarted. With these settings the FC1028 EtherCAT card is ready for operation and
can be used under TwinCAT.

TwinCAT configuration
FC1028 13Version: 1.0
4 TwinCAT configuration
4.1 Scan card in TwinCAT
This step shows how to scan an FC1028 EtherCAT card in TwinCAT and how to create the EtherCAT
masters automatically. For the scan to be successful, active EtherCAT slaves must already be connected to
the interfaces of the card. Otherwise the EtherCAT telegram from an inactive slave is not answered and the
EtherCAT master is not created in TwinCAT.
You should have completed the hardware configuration, so that the scan runs successfully and all EtherCAT
masters and the EtherCAT slaves connected to them are created in TwinCAT.
Proceed as follows:
1. Start TwinCAT and open an empty project.
2. In the tree view on the left, right-click on I/O Devices.
3. Click in the context menu on Scan.
In this example two EtherCAT masters are found because active EtherCAT slaves are connected to
them.
4. Select the devices that you want to use and confirm the selection with OK.
Devices that are actually available are always available for selection.
5. Confirm the request with Yes, in order to look for boxes.
6. Confirm the request whether to enable FreeRun with Yes.
ðThe FC1028 card has been scanned successfully in TwinCAT and is displayed with the available
EtherCAT masters.

TwinCAT configuration
FC102814 Version: 1.0
4.2 Insert EtherCAT master manually
This chapter shows how you can manually create an FC1028 EtherCAT card and its EtherCAT master if no
active EtherCAT slaves are connected to the card. This is especially necessary if you already want to start
with the project planning and the complete hardware configuration is not available.
This is in contrast to the automatic scanning of the card in TwinCAT (see: Scan card in TwinCAT [}13]).
Proceed as follows:
1. Start TwinCAT and open an empty project.
2. In the tree view on the left, right-click on I/O Devices.
3. Click Add New Item and select EtherCAT master to create an EtherCAT master. The window Device
Found At appears.
4. Select the appropriate interface from the list according to the subsequent cabling. The list of interfaces is
continued chronologically from 5 to 20, which corresponds to the total of 16 EtherCAT masters of the
card.
As a reminder, the card has a total of eight ix-Industrial® type A interfaces, thus up to 16 EtherCAT
devices can be connected to the eight interfaces.

TwinCAT configuration
FC1028 15Version: 1.0
5. Create additional or required EtherCAT masters in TwinCAT in this way.
ðYou can start project planning at this point. As soon as the complete hardware configuration is available,
you can scan each EtherCAT master and thus start the search for the EtherCAT slaves connected to it.
The EtherCAT slaves are created in TwinCAT according to your hardware configuration and the cabling
under the respective EtherCAT masters.

TwinCAT configuration
FC102816 Version: 1.0
4.3 Use cable redundancy
The FC1028 EtherCAT card has independent EtherCAT interfaces that can be used for EtherCAT cable
redundancy. Cable redundancy offers resilience for the cabling. Interruptions of the EtherCAT
communication due to broken wires or unplugged LAN cables are avoided. Interference at the individual
terminals is not intercepted by the cable redundancy.
Fig.7: Example configuration of a FC1028 with EtherCAT cable redundancy.
In the example configuration the hardware is wired as EtherCAT ring. For this EtherCAT ring two EtherCAT
masters of the FC1028 are occupied. This intercepts failures in the cabling beyond the C9900-K921 adapter
cable. In this way, for example, a wire break between the two EtherCAT couplers has no effect on the
EtherCAT communication.
Table4: Cable redundancy, hardware for sample configuration.
Type Description
FC1028 Is the EtherCAT master in the example.
C9900-K921 Adapter cable for FC1028. Breakout cable with one ix-
Industrial® type A plug to 2 x Cat.6 RJ45 socket.
With the help of the adapter cable two EtherCAT masters
are executed from one x-Industrial® type A interface.
2 x EK1100 EtherCAT
coupler
The first EtherCAT coupler forwards the EtherCAT signal to
connected EtherCAT Terminals and via the second
Ethernet interface to the second EK1100 EtherCAT coupler.
The second EtherCAT coupler is connected to the adapter
cable via the second Ethernet interface and in this way to
another EtherCAT master.
EtherCAT Terminals Any number of EtherCAT Terminals connected to the
EtherCAT coupler.
Requirements:
• For TwinCAT2 you have to install and license the supplement TS622x | TwinCAT EtherCAT
Redundancy on the Embedded PC: https://www.beckhoff.com/TS622x
• In TwinCAT 3 the supplement is already included and only has to be licensed.
• Hardware wired as EtherCAT ring (see Fig.: Example configuration of a FC1028 with EtherCAT cable
redundancy).
Configure EtherCAT cable redundancy as follows:

TwinCAT configuration
FC1028 17Version: 1.0
1. Click on the left side in the tree view on an EtherCAT master that you want to configure for cable
redundancy.
2. Click on the EtherCAT tab, then Advanced Settings.
3. Click on Redundancy in the tree structure on the left.
4. Click on the Adapter Reference option and then select a second EtherCAT master from the drop-down
menu.
ðYou have successfully configured cable redundancy. The EtherCAT slaves configured for cable
redundancy are displayed in the Online tab.

TwinCAT configuration
FC102818 Version: 1.0
The state of the individual EtherCAT slaves can be found in the State column. If, for example, the cable
connection between the two EK1100 EtherCAT couplers is interrupted, their state changes. The
message "LINK_MIS C" and "LINK_MIS A" then appears in the State column.
Although the connection between the EtherCAT couplers is interrupted, the EtherCAT Terminals
connected to the EK1100 EtherCAT couplers do not have a fault.
If the cable connection is interrupted at the same point without cable redundancy, a fault is displayed for
the terminals in the State column.

TwinCAT configuration
FC1028 19Version: 1.0
4.4 Enabling Distributed Clocks
Distributed clocks are a common part of EtherCAT communication. They enable local, absolute system
synchronization for CPU, I/O and drive units. This enables time-based and simultaneous data processing of
all distributed clocks capable EtherCAT devices.
Principle of operation
Without distributed clocks the devices would no longer work simultaneously in extended EtherCAT networks,
because EtherCAT works on the pass-through principle. In the pass-through principle, the first devices
receive the EtherCAT frame first and those behind significantly later. This would mean, for example, that not
all inputs could be read at the same time or all outputs could be set at the same time.
Fig.8: Example structure of an EtherCAT communication with distributed clocks.
For this purpose a distributed clock is integrated in some specially designed EtherCAT devices. This
distributed clock is an electronic mechanism that runs in this device and is synchronized with other
participants with distributed clocks. Hierarchically, the structure looks like this: there is a master clock or a
reference clock and all other devices with distributed clocks support are then the slave clocks. The EtherCAT
master sends a special telegram in each I/O cycle through the EtherCAT network, which distributes the time
from the master clock to all following slave clocks. For this reason, the master clock must also be at the
beginning before all other slave clocks. By default TwinCAT therefore selects the first distributed clocks-
capable device as reference clock.
Fig.9: Distributed clocks functionality of an EtherCAT slave.
Not all EtherCAT slaves support the distributed clocks method. An EtherCAT slave shows in TwinCAT its
distributed clocks functionality by having the DC tab.
Example structure with FC1028
The activation of the distributed clocks is shown on a small example structure, with an FC1028 as EtherCAT
master and an EK1100 EtherCAT coupler connected to it with EtherCAT Terminals, including two terminals
with distributed clocks functionality.
Activate the distributed clocks as follows:

TwinCAT configuration
FC102820 Version: 1.0
1. Click on the left side in the tree view on the first EtherCAT slave with distributed clocks support. In this
example it is the EL4032.
2. Click the DC tab and select the option DC-Synchron under Operation Mode.
Since it is the first EtherCAT device with distributed clocks support in this example, this EtherCAT device
is used as reference clock for all subsequent EtherCAT devices.
3. Activate further EtherCAT devices with distributed clocks support in your system as shown.
4. Click on the EtherCAT master in the tree view on the left and then on the button Advanced Settings in
the EtherCAT tab.