Belden lumberg automation LioN-P 0980 ESL 391-111 User manual

Technical manual LioN-P EtherCAT® Digital-I/O
Release 1.0 11/2016
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Technical manual
LioN-P EtherCAT® Multiprotocol
0980 ESL 391-111
0980 ESL 392-111
0980 ESL 393-111
0980 ESL 391-121
0980 ESL 392-121
0980 ESL 393-121
0980 ESL 393-121-DCU1

Contents
2Technical manual LioN-P EtherCAT® Digital-I/O
Release 1.0 11/2016
Contents
1 About this manual 5
1.1 General information 5
1.2 Explanation of symbols 6
1.2.1 Use of danger information 6
1.2.2 Use of general information 6
1.2.3 EtherCAT® trademark information 6
1.3 Version information 7
1.4 Designations and synonyms 7
2 Safety instructions 8
2.1 Intended use 8
2.2 Qualified personnel 9
3 System description 10
3.1 About the LioN-P module series 10
3.2 Special product features 10
3.3 Product overview 11
4 Assembly and wiring 13
1.1 General information 5
4.2 Outer dimensions 15
4.2.1 Module 0980 ESL 39x-111 15
4.2.2 Module 0980 ESL 39x-121 16
4.3 Port assignments 17
4.3.1 EtherCAT® ports 17
4.3.2 Connections for power supply, 7/8", 5-pin 18
4.3.3 Power supply with M12 power L-coded 19
4.3.4 Ports for the sensors/actuators 20
5 Starting operation 22
5.1 Downloading and installing the ESI file 22
5.2 Reading the MAC addresses 22
5.3 Setting the rotary switches 23

Contents
Technical manual LioN-P EtherCAT® Digital-I/O
Release 1.0 11/2016 3
5.4 Configuring the controller 24
5.4.1 PDO Assignments 24
5.4.2 PDO’s for 16DI modules: 0980 ESL 391-xxx 24
5.4.3 16DO modules: 0980 ESL 392-xxx 26
5.4.4 8DI/8DO modules: 0980 ESL 393-xxx 30
5.4.5 Device parameter 35
5.4.6 Configuration example with TwinCAT® 3 37
6 The integrated web server 43
6.1 The Home page 43
6.2 The Configuration page (Config) 44
6.3 The Status page 45
6.4 The System page 46
6.5 The DCU page 47
6.6 The Contact page 47
7 Diagnostics processing 48
7.1 Output channel error 48
7.2 Voltage error at the M12 slots (sensor short- circuit) 49
7.3 Overload of output drivers 49
7.4 Error in the actuator power supply 50
7.5 Error in the system/sensor power supply 51
8 Emergency messages 52
9 Firmware update 54
9.1 Firmware update with EoE 54
9.2 Firmware update with FoE 56
10 Technical data 58
10.1 General 58
10.2 Bus system 58
10.3 Power supply for the module electronics/sensors 59

Contents
4Technical manual LioN-P EtherCAT® Digital-I/O
Release 1.0 11/2016
10.4 Power supply for the actuators 60
10.5 Inputs 60
10.6 Outputs 60
10.7 LEDs 61
11 Accessories 63

About this manual
Technical manual LioN-P EtherCAT® Digital-I/O
Release 1.0 11/2016
1.1 General information
5
1 About this manual
1.1 General information
Please read the assembly and operating instructions in this manual carefully
before starting up the LioN-P modules with EtherCAT®interface. Keep the
manual where it is accessible to all users.
The texts, figures, diagrams and examples used in this manual are used
exclusively to explain how to operate and apply the LioN-P modules with
EtherCAT®interface.
Please contact us if you have any detailed questions on installing and starting
up the devices. We will be happy to help you.
Belden Deutschland GmbH
– Lumberg Automation™ –
Im Gewerbepark 2
58579 Schalksmühle
Germany
Tel. [phone] / 5044-0
Fax [phone]
[e-mail]
www.lumberg-automation.com
Belden Deutschland GmbH – Lumberg Automation™ – reserves the right to
make technical changes or changes to this manual at any time without notice.

About this manual
6
1.2 Explanation of symbols
Technical manual LioN-P EtherCAT® Digital-I/O
Release 1.0 11/2016
1.2 Explanation of symbols
1.2.1 Use of danger information
Danger information is denoted as follows:
1.2.2 Use of general information
General information is denoted as follows:
1.2.3 EtherCAT® trademark information
EtherCAT®is registered trademark and patented technology, licensed by
Beckhoff Automation GmbH, Germany
DANGER
Means that death, serious physical injury or substantial damage to property
will occur if the required safety measures are not taken.
WARNING
Means that death, serious physical injury or substantial damage to property
can occur if the required safety measures are not taken.
CAUTION
Means that minor physical injury or damage to property can occur if the
required safety measures are not taken.
NOTE
Contains important information on the product, on how to manage the
product, or on the respective section of the documentation to which your
special attention is being drawn.

About this manual
Technical manual LioN-P EtherCAT® Digital-I/O
Release 1.0 11/2016
1.3 Version information
7
1.3 Version information
1.4 Designations and synonyms
Index Created Changed
Version number Version 1.0
Date November 2016
Name/department MJ/R&D
Version number
Date
Name/department
Table 1: Overview of manual revisions
Designation / Synonym Description
PDO Process Data Object
TxPDO Transmit Process Data Object (IO-device to controller)
RxPDO Receive Process Data Object (Controller to IO- device)
USINT Unsigned 8 Bit value
UDINT Unsigned 32 Bit value
EC EtherCAT®
X1A...X8A Channel A (contact pin 4) of X1 to X8
X1B...X8B Channel B (contact pin 2) of X1 to X8
Table 2: Designations and synonyms

Safety instructions
8
2.1 Intended use
Technical manual LioN-P EtherCAT® Digital-I/O
Release 1.0 11/2016
2 Safety instructions
2.1 Intended use
The devices described in this manual are decentralized input/output modules
on an EtherCAT®network.
We adhere to all safety standards when developing, producing, testing, and
documenting our products. When you adhere to the handling specifications
and safety instructions described for the configuration, assembly, and correct
operation, there should not normally be any risks for people or equipment.
The modules fulfill the requirements of the EMC guidelines (89/336/EEC,
93/68/EEC and 93/44/EEC) and the low voltage guideline (73/23/EEC).
The modules are designed to be used in the industrial sector. The industrial
environment is distinguished by the fact that the consumer is not connected
directly to the public low voltage network. Additional measures are required
for use in residential areas or in business and commercial sectors.
The proper and safe operation of this product depends on proper
transportation, storage, assembly, and installation, and careful operation.
A completely assembled device housing is required for the proper operation
of the modules. Only connect devices to the modules that fulfill the
requirements of EN 61558-2-4 and EN 61558-2-6.
During the configuration, installation, start-up, maintenance, and testing of
the devices, adhere to the safety and accident-prevention guidelines for the
specific application.
NOTE
This equipment may cause radio interference in residential areas. In this
case the operator may be requested to carry out appropriate measures.

Safety instructions
Technical manual LioN-P EtherCAT® Digital-I/O
Release 1.0 11/2016
2.2 Qualified personnel
9
Only install cables and accessories that fulfill the requirements and
regulations for safety, electromagnetic compatibility, and, where applicable,
telecommunication end devices, as well as the specification information.
Information on which cables and accessories are permitted for the
installation can be obtained from Lumberg Automation™ or is contained in
this manual.
2.2 Qualified personnel
The configuration, installation, start-up, maintenance, and testing of the
devices may only be performed by a qualified electrician who is familiar with
the safety standards of the automation technology.
The personnel requirements are based on the requirement profiles described
by ZVEI, VDMA, or equivalent organizations.
Only electricians who are familiar with the content of this manual are
authorized to install and maintain the devices described. These are persons
who
based on their technical training, knowledge, and experience, and their
knowledge of the pertinent standards, can evaluate the work to be carried
out and identify any potential risks or
based on working for several years in a related sector, have the same
level of knowledge as they would have from the relevant technical
training.
Only Belden Deutschland GmbH – Lumberg Automation™ – is permitted to
make changes to the hardware or software of the products that go beyond
the scope of this manual.
WARNING
Making unqualified changes to the hardware or software, or non-adherence
to the warning information contained in this manual, can result in serious
personal injury or damage to equipment.

System description
10
3.1 About the LioN-P module series
Technical manual LioN-P EtherCAT® Digital-I/O
Release 1.0 11/2016
3 System description
3.1 About the LioN-P module series
LioN modules (Lumberg input/output Network) function as the interface in an
industrial fieldbus system: They enable a central controller on the
management level to communicate with the decentralized sensors and
actuators on the field level. The line topologies (logical ring topology only for
EtherCAT®) can be used to create not only ensure reliable data
communication but also significantly reduce the cables required and thus
also the costs for installation and maintenance. They additionally enable
easy, quick extension.
The modules of the LioN-P series have a very sturdy metal housing made of
die-cast zinc. The completely cast device housing protects the module
electronics from environmental effects and allows the device to be used in a
wide temperature range. Despite the sturdy construction, the modules have
compact dimensions and a low weight. They are especially suitable for use
in machines and installations with a moderate I/O concentration over
separate assemblies.
3.2 Special product features
Robust design:
The connection option provided by the module series is the widely-used
M12 connector with A coding for the I/O signals and D coding for the
network. The connectors are also color-coded to prevent the ports from
being mixed up. The output power circuits are electrically isolated from
the rest of the network and the sensor electronics. This reliably protects
the control devices from interference signals.
Integrated switch:
The integrated 2-port Ethernet switch of the modules allows a line
topology to be set up for the EtherCAT®network.

System description
Technical manual LioN-P EtherCAT® Digital-I/O
Release 1.0 11/2016
3.3 Product overview
11
Failsafe function:
The modules with output functions (variants 16DO and 8DI/8DO) provide
a failsafe function. This allows you to define the behavior of every single
output channel in the case of an interruption or a loss of communication.
Integrated web server:
The integrated web server provides status information, forcing of the
inputs and outputs for installation, checks and firmware update
functionality.
Multiprotocol support:
The multiprotocol modules allow you to select different protocols for
communication within a fieldbus system. In this way the multiprotocol
modules can be integrated into different networks without it being
necessary to purchase modules specific for each protocol.
3.3 Product overview
The LioN-P module series consists of 3 variants of modules with different I/O
functions. Detailed information is provided in the following table.
Item number Description I/O ports Design
LioN-P module with 16 digital inputs
0980 ESL 391-111
Order number: 934 882-001
(7/8’’ power, multiprotocol)
0980 ESL 391-121
Order number: 934 879-001
(M12 power, multiprotocol)
16DI 8 x M12 Sturdy/metal
LioN-P module with 16 digital outputs
0980 ESL 392-111
Order number: 934 882-002
(7/8’’ power, multiprotocol)
0980 ESL 392-121
Order number: 934 879-002
(M12 power, multiprotocol)
16DO 8 x M12 Sturdy/metal
Table 3: Overview of module variants of the LioN-P series

System description
12
3.3 Product overview
Technical manual LioN-P EtherCAT® Digital-I/O
Release 1.0 11/2016
LioN-P module with
8 digital inputs and 8 digital outputs
0980 ESL 393-111
Order number: 934 882-003
(7/8’’ power, multiprotocol)
0980 ESL 393-121
Order number: 934 879-003
(M12 power, multiprotocol)
0980 ESL 393-121-DCU1
Order number: 934 879-005
(M12 power, multiprotocol with distributed
control unit)
8DI/8DO 8 x M12 Sturdy/metal
Item number Description I/O ports Design
Table 3: Overview of module variants of the LioN-P series

Assembly and wiring
Technical manual LioN-P EtherCAT® Digital-I/O
Release 1.0 11/2016
4.1 General information
13
4 Assembly and wiring
4.1 General information
Mount the module with 2 screws (M4x25/30) for LioN-P on a level surface.
The torque required here is 1 Nm. Use washers for all fastening methods as
per DIN 125. For the mounting holes, use a distance of 190.3 to 191.8 mm
for LioN-P modules with 7/8" connector/socket, and a distance of 196.8mm
to 198.3 mm for LioN-P modules with M12 power L-coded.
Note
The modules have a ground connection with an M4 thread for the
conduction of interference currents and the EMC immunity. This is labeled
with the symbol for the ground and the designation "XE"
Note
Use a low-impedance connection to connect the module to the reference
ground. When using a grounded mounting surface, you can make the
connection directly via the fixing screws.
Note
If the mounting surface not grounded, use a ground strap or a suitable PE
line. Use an M4 screw to connect the ground strap or the PE line to the
ground point and if possible put a washer and a toothed washer below the
fixing screw.

Assembly and wiring
14
4.1 General information
Technical manual LioN-P EtherCAT® Digital-I/O
Release 1.0 11/2016
Note
For UL application:
Be sure to use a UL-certified cable with a suitable evaluation to connect the
devices (CYJV or PVVA). To program the control, please see the OEM
information, and only use suitable accessories.
Note
For UL application:
Only approved for interior use. Please note the maximum elevation of 2000
meters. Approved up to a maximum soiling level of 2.
WARNING
Terminals, housings field-wired terminal boxes or components can exceed
temperatures of 60 °C.
WARNING
For UL application:
Use temperature-resistant cables with the following properties:
For the modules 0980ESL3x1-111 and 0980 ESL3x1-121 heat-resistant up
to at least 85 °C.
For the modules 0980ESL3x2-1x1 and 0980 ESL3x3-1x1 heat-resistant up
to at least 96 °C.

Assembly and wiring
Technical manual LioN-P EtherCAT® Digital-I/O
Release 1.0 11/2016
4.2 Outer dimensions
15
4.2 Outer dimensions
4.2.1 Module 0980 ESL 39x-111

Assembly and wiring
16
4.2 Outer dimensions
Technical manual LioN-P EtherCAT® Digital-I/O
Release 1.0 11/2016
4.2.2 Module 0980 ESL 39x-121

Assembly and wiring
Technical manual LioN-P EtherCAT® Digital-I/O
Release 1.0 11/2016
4.3 Port assignments
17
4.3 Port assignments
All the contact arrangements shown in this chapter show the frontal view of
the connection area for the connectors.
4.3.1 EtherCAT® ports
Design: M12 socket, 4-pin, D-coded
Color coding: green
Figure 1: Schematic drawing, ports X01, X02
Port Pin Signal Function
EtherCAT®
Ports X01 (IN),
X02 (OUT)
1 TD+ Transmit Data +
2 RD+ Receive Data +
3 TD- Transmit Data -
4 RD- Receive Data -
Table 4: Assignment of ports X01, X02
Caution
Risk of destruction! Never connect the power supply to the data cables.

Assembly and wiring
18
4.3 Port assignments
Technical manual LioN-P EtherCAT® Digital-I/O
Release 1.0 11/2016
4.3.2 Connections for power supply, 7/8", 5-pin
Color coding: gray
Figure 2: Schematic drawing, port X03 (IN)
Figure 3: Schematic drawing, port X04 (OUT)
Port Pin Signal Signal Function
0980 ESL 391-111 0980 ESL 392-111
0980 ESL 393-111
Power supply
X03, X04
1 *see note GND_UL(0V) Actuator
2 GND (0V) GND_US(0V) System/sensors
3 FE FE Functional earth
4 +24 V US+24 V System/sensors
5 *see note UL(+24 V) Actuator
Table 5: Assignment of ports X03, X04
NOTE
For the input module 0980 ESL 391-111, the two contacts 1 and 5 are not
required for the actuators’ power supply. However, these two contacts are
connected to each other on the connector and socket side to enable 5-pin
transmission of the power supply to a downstream module.

Assembly and wiring
Technical manual LioN-P EtherCAT® Digital-I/O
Release 1.0 11/2016
4.3 Port assignments
19
4.3.3 Power supply with M12 power L-coded
Color coding: gray
Figure 4: Schematic diagram of the M12 L-coding (connector), port X03 (IN)
Figure 5: Schematic diagram of the M12 L-coding (socket), port X04 (OUT)
NOTE
Only use power supply units for the system/sensor and actuator supply that
correspond to PELV (Protective Extra Low Voltage) or SELV (Safety Extra
Low Voltage). Power supplies according to EN 61558-2-6 (transformers) or
EN 60950-1 (switching power supply units) fulfill these requirements.
Port Pin Signal Signal Function
0980 ESL 391-121 0980 ESL 392-121
0980 ESL 393-121
Power supply
X03, X04
1U
s(+24V) Us(+24V) System/sensors
2 * see note GND_ULActuator
3 GND_USGND_USSystem/sensors
4 * see note UL(+24V) Actuator
FE (5) FE FE Functional earth
Table 6: Assignment of X03, X04

Assembly and wiring
20
4.3 Port assignments
Technical manual LioN-P EtherCAT® Digital-I/O
Release 1.0 11/2016
4.3.4 Ports for the sensors/actuators
Design: M12 socket, 5-pin
Color coding: black
Figure 6: Schematic drawing, ports X1 to X8
NOTE
For the input module 0980 ESL 391-121, the two contacts 2 and 4 are not
required for connecting the actuators’ power supply. However, these two
contacts are connected to each other on the connector and socket side to
enable 5-pin transmission of the power supply to a downstream module.
NOTE
Only use power supply units for the system/sensor and actuator supply that
correspond to PELV (Protective Extra Low Voltage) or SELV (Safety Extra
Low Voltage). Power supplies according to EN 61558-2-6 (transformers) or
EN 60950-1 (switching power supply units) fulfill these requirements.