Beckhoff EL3783 Operator's manual

Documentation
EL3783
EL3783 - Power monitoring oversampling terminal for 690 V
1.1
2019-05-10
Version:
Date:

Table of contents
EL3783 3Version: 1.1
Table of contents
1 Foreword ....................................................................................................................................................5
1.1 Notes on the documentation..............................................................................................................5
1.2 Safety instructions .............................................................................................................................6
1.3 Documentation issue status ..............................................................................................................7
1.4 Version identification of EtherCAT devices .......................................................................................7
1.5 Start .................................................................................................................................................12
2 Product overview.....................................................................................................................................13
2.1 Introduction......................................................................................................................................13
2.2 Technical data .................................................................................................................................14
2.3 Technology ......................................................................................................................................15
3 Basics communication ...........................................................................................................................17
3.1 EtherCAT basics..............................................................................................................................17
3.2 EtherCAT cabling – wire-bound.......................................................................................................17
3.3 General notes for setting the watchdog...........................................................................................18
3.4 EtherCAT State Machine.................................................................................................................20
3.5 CoE Interface...................................................................................................................................22
3.6 Distributed Clock .............................................................................................................................27
4 Mounting and wiring................................................................................................................................28
4.1 Instructions for ESD protection........................................................................................................28
4.2 Installation on mounting rails ...........................................................................................................29
4.3 Connection system ..........................................................................................................................32
4.4 Positioning of passive Terminals .....................................................................................................36
4.5 Prescribed installation position ........................................................................................................37
4.6 LEDs and connection ......................................................................................................................38
5 Commissioning........................................................................................................................................42
5.1 TwinACT..........................................................................................................................................42
5.1.1 TwinCAT Quick Start ....................................................................................................... 42
5.1.2 TwinCAT Development Environment............................................................................... 67
5.2 General Notes - EtherCAT Slave Application..................................................................................99
5.3 Basic function principles ................................................................................................................107
5.4 Oversampling terminals/boxes and TwinCAT Scope ....................................................................111
5.4.1 TwinCAT 3 procedure.................................................................................................... 112
5.4.2 TwinCAT 2 procedure.................................................................................................... 120
5.5 Process data..................................................................................................................................129
5.6 Object description and parameterization .......................................................................................138
5.6.1 Restore object................................................................................................................ 138
5.6.2 Configuration data ......................................................................................................... 139
5.6.3 Input data....................................................................................................................... 140
5.6.4 Information and diagnostic data..................................................................................... 140
5.6.5 Standard objects............................................................................................................ 141
5.7 Notices on analog specifications ...................................................................................................147
5.7.1 Full scale value (FSV).................................................................................................... 147
5.7.2 Measuring error/ measurement deviation ...................................................................... 148

Table of contents
EL37834 Version: 1.1
5.7.3 Temperature coefficient tK [ppm/K] ............................................................................... 148
5.7.4 Single-ended/differential typification .............................................................................. 150
5.7.5 Common-mode voltage and reference ground (based on differential inputs)................ 155
5.7.6 Dielectric strength .......................................................................................................... 155
5.7.7 Temporal aspects of analog/digital conversion.............................................................. 156
6 Diagnosis................................................................................................................................................160
6.1 Diagnostics – basic principles of diag messages ..........................................................................160
7 Appendix ................................................................................................................................................170
7.1 Firmware Update EL/ES/EM/ELM/EPxxxx ....................................................................................170
7.1.1 Device description ESI file/XML..................................................................................... 171
7.1.2 Firmware explanation .................................................................................................... 174
7.1.3 Updating controller firmware *.efw................................................................................. 175
7.1.4 FPGA firmware *.rbf....................................................................................................... 176
7.1.5 Simultaneous updating of several EtherCAT devices.................................................... 180
7.2 Firmware compatibility...................................................................................................................181
7.3 Restoring the delivery state ...........................................................................................................181
7.4 Support and Service ......................................................................................................................182

Foreword
EL3783 5Version: 1.1
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
© 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.

Foreword
EL37836 Version: 1.1
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
EL3783 7Version: 1.1
1.3 Documentation issue status
Version Comment
1.1 • Update Example program
• Update revision status
• Update structure
1.0 • Addenda & corrections
• 1st public issue
0.8 • Addenda & corrections
0.7 • Update object description
0.6 • Addenda & corrections
0.5 • Addenda & corrections
0.4 • Addenda & corrections
0.3 • Addenda & corrections
0.2 • Addenda & corrections
0.1 • preliminary documentation for EL3783
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.
• 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

Foreword
EL37838 Version: 1.1
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
• Terminals with factory calibration certificate and other measuring terminals

Foreword
EL3783 9Version: 1.1
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
EL378310 Version: 1.1
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
EL3783 11Version: 1.1
Fig.8: ELM3604-0002 terminal with unique ID number (QR code) 100001051 and serial/ batch number
44160201

Foreword
EL378312 Version: 1.1
1.5 Start
For commissioning:
• Install the EL3783 as described in section Mounting and wiring [}28].
• configure the EL3783 in TwinCAT as described in the chapter Commissioning.

Product overview
EL3783 13Version: 1.1
2 Product overview
2.1 Introduction
Fig.9: EL3783
Power monitoring oversampling terminal for 690 V
The EL3783 EtherCAT Terminal is designed as a power monitoring terminal for the state monitoring of a 3-
phase AC voltage system (rated mains voltage 400/690Vrms). For each phase voltages up to 520Vrms and
currents up to 6.5Arms are sampled as instantaneous values with a resolution of 16bit.
The six channels are measured simultaneously based on the EtherCAT oversampling principle with a
temporal resolution of 50µs and passed on to the controller. The controller has sufficient computing power
for true RMS or performance calculation and complex custom algorithms based on the measured voltages
and currents.
Through the oversampling principle the terminal is able to measure at significantly shorter intervals than the
cycle time of the controller. AC parameters must be connected and measured with a common reference
potential.
The EL3783 supports distributed clocks for measuring synchronously with other EtherCAT devices, but can
also be operated without distributed clocks.
RMS value (rms) specifications
All AC value specifications in this documentation such as RMS specifications (rms) refer to a
50/60Hz 3-phase mains network with a sinusoidal waveform (crest factor 1.414).
Also see about this
2Technology [}15]
2Basic function principles [}107]

Product overview
EL378314 Version: 1.1
2.2 Technical data
RMS value (rms) specifications
All AC value specifications in this documentation such as RMS specifications (rms) refer to a 50/60
Hz 3-phase mains network with a sinusoidal waveform (crest factor 1.414).
Technical data EL3783
Number of inputs 3 x current, 3 x voltage
Oversampling factor n = 1…100 selectable
Distributed Clocks yes
Accuracy of Distributed Clocks << 1µs
Measuring error < ±0.2% of full scale value
Conversion time Minimum 50µs, all channels measured simultaneously
Mains voltage
(nominal voltage range)
AC accordingly:
400 Vrms (ULX-N) or 690 Vrms (ULX-ULY) (TN network: 600 Vrms)
Technical voltage measuring range 520Vrms (ULX-N) or 897Vrms (ULX-ULY)
common reference potential N/GND
max. time for voltages exceeding 500Vrms (ULx-N) or 863Vrms (ULx-ULy):
tmax < 10 s *
Max. permitted overvoltage max. ±736 V (peak value, ULX-N, equivalent to 520 Vrms) or
max. ±1270 V (peak value, ULX-ULY, equivalent to 897 Vrms)*
Voltage resolution (16-bit including sign) 1 digit ~ 22.5mV
Input resistance voltage circuit typ. 1.5MΩ
Nominal current range AC accordingly:
1 Arms (automatic switching to 5 Arms)
recommended via measuring transformer x A AC/1 A AC
Technical current measuring range 1.84 A (peak value, equivalent to 1.3 Arms) or
9.2 A (peak value, equivalent to 6.5 Arms)
Max. permitted overcurrent max. ±10 A peak value, equivalent to 7 Arms *,
surge overload capacity 60 A (sinusoidal) for 1 sec.,
the upstream use of current-limiting current transformers is recommended
Largest short-term deviation during a specified elec-
trical interference test
< ±0.5% of full scale value for the current measurement
Current resolution (16-bit including sign) 1 digit ~ 56.2µA (~281 µA if 5A range is active)
Input resistance current circuit typ. 3mΩ
Signal type variable
Electrical isolation 4,500 V
(test voltage connecting terminal/E-bus),
production test 2 sec.
Current consumption power contacts -
Current consumption via E-bus typ. 260mA
Special features Technical measuring range for current and voltage 130% of the respective mea-
suring range,
Anti-aliasing filter (see Basic functional principles), adjustable automatic current
range switching, electrically isolated current inputs
Configuration via TwinCAT System Manager
Weight approx. 100 g
Permissible ambient temperature range during oper-
ation
0°C ... +55°C
Permissible ambient temperature range during stor-
age
-25°C ... +85°C
Permissible relative air humidity 95%, no condensation
Dimensions (W x H x D) approx. 27mm x 100mm x 70mm (width aligned: 24mm)
Mounting [}29] on 35mm mounting rail conforms to EN60715
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 IP20
Installation position see notice [}37]!
Approval CE
* operation for longer periods above the rated range can impair the function and/or lead to a shortening of
the service life

Product overview
EL3783 15Version: 1.1
2.3 Technology
Measurement of AC variables with the EL3783
Normal three-phase mains supply
The normal 3-phase low-voltage grids in Central Europe are characterized by the following interrelationship:
rated voltage is usually the effective voltage URMS, e.g. 230 VRMS, as a star voltage between one of the three
live conductors (L1, L2 or L3) and neutral N.
Fig.10: Voltages in three-phase mains supply of Central Europe
With a pure sinusoidal oscillation (unloaded grid) a maximum peak voltage (max. amplitude) of approx.
±325Vpeak to N is calculated from the then valid crest factor from in the star voltage.
A phase-to-phase voltage of (RMS) can be measured between the live
conductors.
RMS value specifications
RMS value (rms) specifications
All AC value specifications in this documentation such as RMS specifications (rms) refer to a
50/60Hz 3-phase mains network with a sinusoidal waveform.
The EL3783 EtherCAT Terminal is a power monitoring terminal for state monitoring of a 3-phase AC voltage
system. The following properties are characteristic of the EL3783:
• 3 channels measure -737...+737 V through analog-to-digital converters in 16-bit resolution as
amplitude value
• 3 channels measure -9.2...+9.2 A through analog-to-digital converters in 16-bit resolution as amplitude
value
• all 6 analog input channels are measured simultaneously
• the EL3783 is an oversampling terminal and can therefore record not just 1, but up to 100 samples per
channel in each PLC/EtherCAT cycle. These are sent as a data packet to the controller via the cyclic
process data.
The minimum sampling time is 50µs, corresponding to 20,000 samples/second.

Product overview
EL378316 Version: 1.1
• The voltage and current curve can have any form; the EL3783 is thus suitable only for AC
measurements
• the EL3783 can be synchronized with other EtherCAT device over Distributed Clocks, but can also be
operated without Distributed Clocks with oversampling
• no pre-evaluations or calculations of the amplitude values take place in the EL3783
Hence, the EL3783 is suitable for very different applications, for example
• 3-phase monitoring: the voltage and current to N are measured for a 3-phase load
• 3-load monitoring: the voltage and current to N can be measured for 3 loads even if connected to the
same phase
• each channel can measure as desired, provided the measured is referred to N
• Measurement of non-sinusoidal amplitude curves, including rectangular
Evaluations and calculations of the raw data sent to the controller, such as active power (P), cumulative
power consumption (W) or power factor (cos φ) must take place in the controller. The controller has sufficient
computing power for true RMS or performance calculation and complex custom algorithms based on the
measured voltages and currents.
Design of voltage measuring range
Low-voltage power supply systems are defined, for example, in IEC 60038. Since 2003 the specifi-
cation here is 230/400VRMS ±10%, corresponding to ±357Vpeak. So that substantial spikes can also
be measured, the EL3783 supports a measuring range of 520VRMS AC, corresponding to ±737Vpeak.

Basics communication
EL3783 17Version: 1.1
3 Basics communication
3.1 EtherCAT basics
Please refer to the EtherCAT System Documentation for the EtherCAT fieldbus basics.
3.2 EtherCAT cabling – wire-bound
The cable length between two EtherCAT devices must not exceed 100 m. This results from the FastEthernet
technology, which, above all for reasons of signal attenuation over the length of the cable, allows a maximum
link length of 5 + 90 + 5 m if cables with appropriate properties are used. See also the Design
recommendations for the infrastructure for EtherCAT/Ethernet.
Cables and connectors
For connecting EtherCAT devices only Ethernet connections (cables + plugs) that meet the requirements of
at least category 5 (CAt5) according to EN 50173 or ISO/IEC 11801 should be used. EtherCAT uses 4 wires
for signal transfer.
EtherCAT uses RJ45 plug connectors, for example. The pin assignment is compatible with the Ethernet
standard (ISO/IEC 8802-3).
Pin Color of conductor Signal Description
1 yellow TD + Transmission Data +
2 orange TD - Transmission Data -
3 white RD + Receiver Data +
6 blue RD - Receiver Data -
Due to automatic cable detection (auto-crossing) symmetric (1:1) or cross-over cables can be used between
EtherCAT devices from Beckhoff.
Recommended cables
Suitable cables for the connection of EtherCAT devices can be found on the Beckhoff website!
E-Bus supply
A bus coupler can supply the EL terminals added to it with the E-bus system voltage of 5V; a coupler is
thereby loadable up to 2A as a rule (see details in respective device documentation).
Information on how much current each EL terminal requires from the E-bus supply is available online and in
the catalogue. If the added terminals require more current than the coupler can supply, then power feed
terminals (e.g. EL9410) must be inserted at appropriate places in the terminal strand.
The pre-calculated theoretical maximum E-Bus current is displayed in the TwinCAT System Manager. A
shortfall is marked by a negative total amount and an exclamation mark; a power feed terminal is to be
placed before such a position.

Basics communication
EL378318 Version: 1.1
Fig.11: System manager current calculation
NOTE
Malfunction possible!
The same ground potential must be used for the E-Bus supply of all EtherCAT terminals in a terminal block!
3.3 General notes for setting the watchdog
ELxxxx terminals are equipped with a safety feature (watchdog) that switches off the outputs after a
specifiable time e.g. in the event of an interruption of the process data traffic, depending on the device and
settings, e.g. in OFF state.
The EtherCAT slave controller (ESC) in the EL2xxx terminals features 2 watchdogs:
• SM watchdog (default: 100 ms)
• PDI watchdog (default: 100 ms)
SM watchdog (SyncManager Watchdog)
The SyncManager watchdog is reset after each successful EtherCAT process data communication with the
terminal. If no EtherCAT process data communication takes place with the terminal for longer than the set
and activated SM watchdog time, e.g. in the event of a line interruption, the watchdog is triggered and the
outputs are set to FALSE. The OP state of the terminal is unaffected. The watchdog is only reset after a
successful EtherCAT process data access. Set the monitoring time as described below.
The SyncManager watchdog monitors correct and timely process data communication with the ESC from the
EtherCAT side.
PDI watchdog (Process Data Watchdog)
If no PDI communication with the EtherCAT slave controller (ESC) takes place for longer than the set and
activated PDI watchdog time, this watchdog is triggered.
PDI (Process Data Interface) is the internal interface between the ESC and local processors in the EtherCAT
slave, for example. The PDI watchdog can be used to monitor this communication for failure.
The PDI watchdog monitors correct and timely process data communication with the ESC from the
application side.
The settings of the SM- and PDI-watchdog must be done for each slave separately in the TwinCAT System
Manager.

Basics communication
EL3783 19Version: 1.1
Fig.12: EtherCAT tab -> Advanced Settings -> Behavior -> Watchdog
Notes:
• the multiplier is valid for both watchdogs.
• each watchdog has its own timer setting, the outcome of this in summary with the multiplier is a
resulting time.
• Important: the multiplier/timer setting is only loaded into the slave at the start up, if the checkbox is
activated.
If the checkbox is not activated, nothing is downloaded and the ESC settings remain unchanged.
Multiplier
Multiplier
Both watchdogs receive their pulses from the local terminal cycle, divided by the watchdog multiplier:
1/25 MHz * (watchdog multiplier + 2) = 100 µs (for default setting of 2498 for the multiplier)
The standard setting of 1000 for the SM watchdog corresponds to a release time of 100 ms.
The value in multiplier + 2 corresponds to the number of basic 40 ns ticks representing a watchdog tick.
The multiplier can be modified in order to adjust the watchdog time over a larger range.

Basics communication
EL378320 Version: 1.1
Example "Set SM watchdog"
This checkbox enables manual setting of the watchdog times. If the outputs are set and the EtherCAT
communication is interrupted, the SM watchdog is triggered after the set time and the outputs are erased.
This setting can be used for adapting a terminal to a slower EtherCAT master or long cycle times. The
default SM watchdog setting is 100 ms. The setting range is 0..65535. Together with a multiplier with a range
of 1..65535 this covers a watchdog period between 0..~170 seconds.
Calculation
Multiplier = 2498 → watchdog base time = 1 / 25MHz * (2498 + 2) = 0.0001seconds = 100µs
SM watchdog = 10000 → 10000 * 100µs = 1second watchdog monitoring time
CAUTION
Undefined state possible!
The function for switching off of the SM watchdog via SM watchdog = 0 is only implemented in terminals
from version -0016. In previous versions this operating mode should not be used.
CAUTION
Damage of devices and undefined state possible!
If the SM watchdog is activated and a value of 0 is entered the watchdog switches off completely. This is
the deactivation of the watchdog! Set outputs are NOT set in a safe state, if the communication is inter-
rupted.
3.4 EtherCAT State Machine
The state of the EtherCAT slave is controlled via the EtherCAT State Machine (ESM). Depending upon the
state, different functions are accessible or executable in the EtherCAT slave. Specific commands must be
sent by the EtherCAT master to the device in each state, particularly during the bootup of the slave.
A distinction is made between the following states:
• Init
• Pre-Operational
• Safe-Operational and
• Operational
• Boot
The regular state of each EtherCAT slave after bootup is the OP state.