Helmholz PROFINET Coupler PN / EtherCAT User manual

Helmholz GmbH & Co. KG | Hannberger Weg 2 | 91091 Großenseebach | Germany 02.08.2023
Phone [phone] | Fax [phone] | [e-mail] | www.helmholz.de
Quickstart Guide
PN/EtherCAT Coupler
Order number: 700-161-3EC02
Version
en
1

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Content
1Safety instructions ................................................................................................ 3
2Introduction ......................................................................................................... 3
3Function of the PN/EtherCAT Coupler .................................................................. 4
4Connection........................................................................................................... 4
4.1 Power supply ............................................................................................................................... 4
4.2 Network ....................................................................................................................................... 4
5Download and install the GSDML and ESI file....................................................... 5
5.1 Install GSDML file in TIA Portal...................................................................................................... 5
5.2 Install ESI file in TwinCAT V2/V3 ................................................................................................... 6
5.3 Install ESI file in CODESYS............................................................................................................. 6
6Data exchange methodology................................................................................ 8
6.1 Module configuration................................................................................................................... 8
6.2 Byte order (endianness) ................................................................................................................ 9
6.3 Requirements for the exchange of valid data................................................................................. 9
7Configuration of the PROFINET side ................................................................... 10
7.1 Parameters of the PN/EtherCAT coupler...................................................................................... 10
7.2 Assign a name to the PN/EtherCAT coupler................................................................................. 11
8Configuration of EtherCAT side ..........................................................................12
8.1 Add PN/EtherCAT Coupler to project .......................................................................................... 12
8.2 Module configuration................................................................................................................. 13
9The PN/EtherCAT Coupler website ..................................................................... 14
9.1 Firmware-Update........................................................................................................................ 15
10 Status-Byte.......................................................................................................16
10.1 Status-byte on PROFINET side..................................................................................................... 16
10.2 Status-Byte on EtherCAT side ...................................................................................................... 17
11 Diagnostic LED information.............................................................................18
11.1 LED diagnostics for PROFINET interface....................................................................................... 19
11.2 LED diagnostics for EtherCAT interface........................................................................................ 20
12 Technical data .................................................................................................21

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1Safety instructions
Target audience
This description is only intended for trained personnel qualified in control and automation
engineering who are familiar with the applicable national standards. For installation,
commissioning, and operation of the components, compliance with the instructions and
explanations in this operating manual is essential. The specialist personnel are to ensure that
the application or the use of the products described fulfills all safety requirements, including all applicable
laws, regulations, provisions, and standards.
Intended use
The device has a protection rating of IP 20 (open type) and must be installed in an electrical
operating room or a control box/cabinet to protect it against environmental influences. To
prevent unauthorized operation, the doors of control boxes/cabinets must be closed and
possibly locked during operation. The consequences of improper use may include personal
injury to the user or third parties, as well as property damage to the control system, the product, or the
environment. Use the device only as intended!
Operation
Successful and safe operation of the device requires proper transport, storage, setup, assembly,
installation, commissioning, operation, and maintenance. Operate the device only in flawless
condition. The permissible operating conditions and performance limits (technical data) must
be adhered to. Retrofits, changes, or modifications to the device are strictly forbidden.
Security
The device is a network infrastructure component and therefore an important element in the
security consideration of a plant. When using the device, therefore, observe the relevant
recommendations to prevent unauthorized access to installations and systems.
2Introduction
This document explains the initial commissioning of the PN/EtherCAT
Coupler. The latest version of the documentation can be found at
www.helmholz.de or scan the QR code directly.

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3Function of the PN/EtherCAT Coupler
With the PN/EtherCAT Coupler a simple and easy connection of a PROFINET machine to an EtherCAT
machine is possible. The PN/EtherCAT Coupler allows the data transfer between a PROFINET controller
and an EtherCAT master.
Output data received on one side of the network
is made available to the PLC as input data on
the other side of the network. The I/O data
exchange takes place live and as fast as possible
without further handling blocks.
The maximum size of the transferable I/O data
for EtherCAT is 600 bytes in both directions. An
additional status byte in the input data enables
a simple evaluation of the current operating
status.
The integration of the PN/EtherCAT coupler
into a PLC engineering tool is made possible by a GSD file on the PROFINET side and an ESI file on the
EtherCAT side. The configuration of the I/O data to be exchanged then also takes place in the respective
engineering tool. Additional configuration software is not required.
4Connection
4.1 Power supply
The PN/EtherCAT coupler must be supplied with DC 24 V at the wide-range input DC 18 ... 28 V via the
supplied connector plug. The power supply is redundant, at least one supply path PS 1 or PS 2 must be
connected.
The housing of the PN/EtherNetIP Coupler is not grounded. Please connect the functional earth
terminal of the PN/PN Coupler properly to the reference potential.
The device is intended to be supplied by an isolated Limited Energy Source according to UL61010-1
(3rd ed cl. 9.4) or according to UL60950-1/UL62368-1 or Class 2 according to NEC. Please use Cu
power supply wires, AWG 28-12. Maximum length of removed insulation is 10 mm. Temperature
cable rating is 87 °C.
4.2 Network
The left RJ45 Ethernet sockets "X1 P1" and "X1 P2" are used to connect the PROFINET network, the right
RJ45 Ethernet sockets "X2/A IN" and "X2/B OUT" are used to connect the EtherCAT network.
The PROFINET-side Ethernet sockets are only intended for connection to computer networks (LANs)
and must not be connected to telephone networks or telecommunications lines.
The EtherCAT-side Ethernet ports are only intended for connection to a dedicated EtherCAT
network. The connection to a "normal" computer network may cause disturbances there.

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5Download and install the GSDML and ESI file
Please go to the product page of the PN/EtherCAT Coupler at www.helmholz.de and
then to the download area or follow the link provided in the QR code. There you can
download the current version of the GSDML and ESI file of the PN/EtherCAT Coupler in
zipped form. Before the installation the zipped files must be unzipped accordingly.
The GSDML file is required for integration into an engineering tool for the PROFINET
side. It has the file extension „.xml“ and is delivered together with an image file in BMP format. The
installation of the GSDML file in the TIA Portal is described below as an example.
The ESI file is used for integration into a corresponding engineering tool for the EtherCAT side and has
the file extension „.xml“. In the following the installation is described using the example of TwinCAT
and CODESYS.
5.1 Install GSDML file in TIA Portal
You can install the GSDML file of the PN/EtherCAT Coupler in the TIA Portal by selecting the directory
with the unzipped GSDML file as source path in the "Extras / Manage device description file (GSD)"
menu. Then the GSDML file is displayed for selection and can be installed via the corresponding button.
After successful installation, the
PN/EtherCAT Coupler can be found in
the hardware catalog of the TIA Portal
under "Other field devices / PROFINET
IO / Gateway / Helmholz GmbH & Co.
KG".

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5.2 Install ESI file in TwinCAT V2/V3
In TwinCAT V2 and V3 there is currently no dialog-based option for installing the ESI file. Instead you
have to copy the unpacked ESI file manually into the following directory:
TwinCAT V2: C:\TwinCAT\IO\EtherCAT
TwinCAT V3: C:\TwinCAT\3.1\Config\Io\EtherCAT
TwinCAT must be restarted so that the PN/EtherCAT Coupler is available afterwards. It can then be
selected in the dialog "Insert EtherCAT device" under "Helmholz GmbH & Co. KG / EtherCAT Coupler".
5.3 Install ESI file in CODESYS
To install the ESI file of the PN/EtherCAT coupler open the "Device Repository" dialog in the "Tools"
menu. Then click on the "Install" button and select the ESI file to be installed using the file dialog that
appears.
After successful installation you can find the PN/EtherCAT Coupler in the dialog "Attach device" as
shown below. For faster selection the manufacturer "Helmholz GmbH & Co. KG" has been preselected as
manufacturer.

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6Data exchange methodology
The data exchange between the two network sides is carried out by the PN/EtherCAT Coupler as fast as
possible. This means that as soon as new, valid output data has been received from the controller on one
network side, it is transmitted as input data to the controller on the other network side at the next
possible time. How fast this exchange can ultimately take place is determined primarily by the cycle
times configured on both sides.
6.1 Module configuration
The exact structure of the data to be exchanged between the PROFINET and the EtherCAT side is
determined by the module configuration of the PN/EtherCAT coupler on both interface sides. For this
purpose, 100 slots each and a variety of modules with different data types and array sizes are available in
uni- and bidirectional transmission direction.
Overview of the supported data types:
Data type
Description
Value range
BYTE Byte: 8-Bit-Array 0 .. 256
SINT Short Integer: 8-bit signed integer -128 .. +127
USINT Unsigned Short Integer: 8-bit unsigned integer 0 .. 256
INT Integer: 16-bit signed integer -32.768 .. +32.767
UINT Unsigned Integer: 16-bit unsigned integer 0 .. 65.535
DINT Double Integer: 32-bit signed integer - 2.147.483.648 .. +2.147.483.647
UDINT Unsigned Double Integer: 32-bit unsigned integer 0 .. 4.294.967.296
LINT Long Integer: 64-bit signed integer -9.223.372.036.854.775.808 ..
+9.223.372.036.854.775.807
ULINT Unsigned Long Integer: 64-bit unsigned integer 0 .. 18.446.744.073.709.551.616
REAL Real: 32-bit signed floating point -3,4 ∙ 1038 .. +3,4 ∙ 1038
LREAL Long Real: 64-bit signed floating point -1,7 ∙ 10
308
.. +1,7 ∙ 10
308
The array size specifies how many elements of the same data type make up the data of a module, whereby
the total size of the module data per transfer direction can be a maximum of 128 bytes. The available
array sizes for all data types are 1, 2, 4, 8 and 16. Depending on the data type there can also be the further
array sizes 32, 64 and up to 128. In the module name the array size is specified as multiplier after the
respective data type (e.g. UINT 4x, BYTE 64x, REAL 1x).
For each valid combination of data type and array size a module is available as IN, OUT or IN/OUT
variant depending on the transfer direction.
Module type
Description
IN With this module type the controller of the respective network side can receive data from the controller of
the other network side. The respective module has only input data for this purpose.
On the opposite side, the corresponding OUT type of the module must be configured in the same slot.
OUT With this module type the controller of the respective network side to transmit data to the controller of
the other network side. The respective module has only output data for this purpose.
On the opposite side, the corresponding IN type of the module must be configured in the same slot.
IN/OUT This module type allows a bidirectional data exchange between the controllers of the two network sides.
The modules have both input and output data for this purpose.
On the opposite side, the IN/OUT type of the module must also be configured in the same slot.

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6.2 Byte order (endianness)
Since the byte order is different for the two bus systems PROFINET and EtherCAT - PROFINET uses "Big
Endian" and EtherCAT "Little Endian" - the values are automatically converted in the PN/EtherCAT
coupler.
The conversion is automatically performed by the coupler for all data types that comprise 2, 4 or 8 bytes.
For BYTE, SINT and USINT modules, however, the sequence of the data remains unchanged.
6.3 Requirements for the exchange of valid data
To ensure that the PN/EtherCAT Coupler can correctly exchange data between the bus systems, certain
conditions must be met during configuration.
On the PROFINET side:
•The module configuration contains at least 1 module in the first slot and further modules are lined up
without gaps
•The configured modules match the module configuration of the EtherCAT side regarding data type,
array size and transmission direction
•The controller is connected to the coupler and has established an I/O connection (AR) to the coupler
•The controller is in RUN mode (sends valid output data)
On the EtherCAT side:
•The module configuration contains at least 1 module in the first slot and further modules are lined up
without gaps
•The configured modules match the module configuration of the PROFINET side with regard to data
type, array size and transmission direction
•The controller is connected to the coupler and has successfully switched the coupler to the EtherCAT
state OPERATIONAL
•The coupler receives valid output data from the controller
Whether the currently exchanged I/O data is valid or not can be read in bit 0 of the status byte, which is
provided by the PN/EtherCAT coupler in the cyclic input data on both network sides (see Chap. 10). On
the PROFINET side a diagnostic interrupt can be activated additionally concerning the data validity via
the parameterization of the PN/EtherCAT coupler (see chapter 7.1).

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7Configuration of the PROFINET side
The data exchange between the PROFINET and the EtherCAT side of the PN/EtherCAT coupler is defined
via the Simatic Engineering Tool - here using the example of "TIA Portal". The I/O data for exchange can
be created in the slots of the PROFINET configuration. Up to 100 slots are available for this purpose.
After installing the GSDML file (see chapter 5.1) and inserting and connecting the PN/EtherCAT coupler
in the project, the desired modules from the hardware catalog can be inserted into the slots of the
coupler. Please make sure that there is no gap in the list. The I/O addresses for the PLC can be chosen
arbitrarily for each slot.
The data sizes must match the configuration of the EtherCAT side slot by slot.
7.1 Parameters of the PN/EtherCAT coupler
The PN/EtherCAT coupler has 4 parameters:
PS1 / PS2 failure diagnostic:
If active, a diagnostic alarm is triggered if there is no sufficient
power supply via the corresponding PS1 or PS2 port.
Data validity diagnostic: If active, a diagnostic interrupt is
triggered whenever there is no valid data exchange between
both network sides.
Status webpage: When active, the coupler provides a status webpage that can be accessed from the
network on the PROFINET side. In addition to displaying status information, a firmware update can also
be performed via the web page.

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7.2 Assign a name to the PN/EtherCAT coupler
When the configuration of the PN/EtherCAT Coupler in the PROFINET Engineering Tool is completed, it
can be imported into the PLC.
So that the PN/EtherCAT coupler can be found by the PROFINET controller, the PROFINET device name
must be assigned to the PN/EtherCAT coupler. For this use the function "Assign device name" which you
can reach with the right mouse button or in the menu “Online” if the PN/EtherCAT Coupler is selected.
With the button "Update list" the network can be searched for PROFINET devices. With "Assign name"
the PROFINET device name can be assigned to the device.
The unique identification of the PN/EtherCAT coupler is guaranteed by the MAC address of the
PROFINET interface of the device. This MAC address is printed on the front panel of the PN/EtherCAT
coupler.
If the PN/EtherCAT Coupler has received the correct PROFINET name, then it is recognized and
configured by the PLC. If the configuration is correct, the PROFINET "BF" LED should be off.
The Helmholz IPSet tool, which can be downloaded free of charge from the Helmholz
website, can also be used to set the PROFINET device name. Please follow the link in the
QR code on the right.

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8Configuration of EtherCAT side
The configuration of the EtherCAT side of the PN/EtherCAT coupler is explained below using CODESYS
V3.5 as an example. The configuration should be similar with other tools.
8.1 Add PN/EtherCAT Coupler to project
Precondition for a configuration is that there is already an EtherCAT master in the project.
To add the PN/EtherCAT coupler in the device list with right click on the desired EtherCAT master and
select the entry "Add device" in the menu to add the coupler behind already existing EtherCAT slaves.
Alternatively right click on an EtherCAT slave in the device list and select the entry "Insert device" in the
menu to insert the coupler in front of the selected EtherCAT slave.
In both cases the following dialog appears where the PN/EtherCAT coupler can be selected and attached
or inserted in the EtherCAT network.
The sequence/arrangement of the EtherCAT slaves to the EtherCAT master must match the actual
topology of the EtherCAT network.

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8.2 Module configuration
After creating the coupler, the modules can now be added according to the PROFINET configuration.
To add modules right click on the coupler in the device list and select the entry "Append device" in the
menu to add a module behind already existing modules. Alternatively in the device list with right click
on an already existing module and select in the menu the entry "Insert device" to insert a module in front
of the selected module.
In both cases the following dialog appears, in which you can select the desired modules and append or
insert them:
Unfortunately, CODESYS does not group the modules by transmission direction or data type in the
selection dialog, so that the list of available modules is very long and not particularly clear. With the help
of the full text search field, however, you have the option of significantly reducing the number of
modules displayed and thus making the selection easier.
If the PROFINET side has already been configured and commissioned, the coupler can also be read
in automatically with a module configuration that matches the PROFINET side. For this you use the
function "Search devices" at the EtherCAT master.

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9The PN/EtherCAT Coupler website
As soon as the PN/EtherCAT coupler has been configured by the PROFINET PLC, the web interface of the
device is accessible via the IP address configured in PROFINET. The web interface can only be accessed via
the PROFINET side.
The web interface of the PN/EtherCAT coupler provides an overview of the status and configuration of
the device, as well as the possibility to perform a firmware update. In the upper gray line there is the
menu for further web pages.
If the web page of the device is not available, please check the parameter "Status web page" in the
PROFINET configuration (see Chap. 7.1)

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The menu "Module Configuration" shows an overview of the I/O configuration of all slots with a short
view of the current data.
Calling the web page may affect the processing speed of the device.
9.1 Firmware-Update
For a firmware update, please download the latest firmware from the following link:
https://www.helmholz.de/goto/700-161-3EC02
The firmware file can be recognized by the file extension "HUF" (Helmholz Update File) and is encrypted
to protect it from changes.

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10 Status-Byte
To be able to consider the state of the PN/EtherCAT coupler in the respective PLC, the coupler contains a
status byte in the cyclic input data both on the PROFINET and on the EtherCAT side.
The status byte provides information about the validity of the exchanged I/O data, the status of the
respective other network side and the status of the power supply at PS 1 and PS 2.
10.1 Status-byte on PROFINET side
In the PLC on the PROFINET side, the status byte is assigned to the head module and can be accessed
under the "E address" defined there.
Structure of the status byte:
Bit
Name
0 Exchanged I/O data valid
1 EtherCAT I/O connection established
2 EtherCAT & PROFINET I/O configuration match
3 EtherCAT state OPERATIONAL
4 Reserved (0)
5 Reserved (0)
6 Power supply on PS1 OK
7 Power supply on PS2 OK

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10.2 Status-Byte on EtherCAT side
In CODESYS you can find the status byte with the contained bits by double-clicking the coupler in the
device list and then switching to the "EtherCAT I/O image" view.
Structure of the status byte:
Bit
Name
0 Exchanged I/O data valid
1 PROFINET I/O connection (AR) established
2 PROFINET & EtherCAT I/O configuration match
3 PROFINET controller in RUN mode
4 Reserved (0)
5 Reserved (0)
6 Power supply on PS1 OK
7 Power supply on PS2 OK

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11 Diagnostic LED information
X1 PROFINET (left side) X2 EtherCAT (right side)
SF-LED (red) ER-LED (red)
System Fault LED for signaling system faults
(see chap. 11.3 for details)
Error LED for signaling various error states
(see chap. 11.4 for details)
BF-LED (red) RN-LED (greed)
Bus fault LED for signaling connection errors
(see chap. 11.3 for details)
RUN LED for signaling the EtherCAT state of the coupler
(see chap. 11.4 for details)
MT-LED (yellow) MT-LED (yellow)
Maintenance LED for signaling maintenance states
(see chap. 11.3 for details)
Maintenance LED for signaling maintenance states
(see chap. 11.4 for details)
PWR-LED (green) PWR-LED (green)
Power LEDs for signaling the status of the power supply via PS1 (PWR left) and PS2 (PWR right)
•LED on: Sufficient voltage supply connected to PS1/PS2
•LED off: No sufficient voltage supply connected to PS1/PS2
RUN (green)
LED for signaling the operational state of the coupler
•LED on: the coupler is ready for operation
•LED off: the coupler is not (yet) ready for operation (after power-on for max. 30 seconds)
If the RUN LED remains permanently off despite sufficient power supply (at least one of the PWR LEDs is on), this could indicate a
hardware or firmware defect of the coupler. In this case, please contact the support.
Link-LED (green) and Activity-LED (orange)
at both Ports X1/P1 + X1/P2
Link-/Activity-LED (green)
at both Ports X2/A IN + X2/B OUT
Two LEDs each for signaling the connection and
communication status of the respective PROFINET port
•both LEDs off: No Ethernet connection
•both LEDs on: Ethernet connection established,
but currently no communication
•green LED on + orange LED flashing:
Ethernet connection with currently
running communication
One LED each for signaling the connection and
communication state of the respective EtherCAT port
•LED off: No Ethernet connection
•LED on: Ethernet connection established,
but currently no communication
•LED flashing: Ethernet connection with currently
running communication

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11.1 LED diagnostics for PROFINET interface
The LED states listed assume that the coupler is in the ready-to-run state, i.e. the central green RUN LED
is lit.
SF-LED
(red)
BF-LED
(red)
MT-LED links
(yellow) Status of the PROFINET interface
Off Off Off Error-free operating state with valid data exchange between the PROFINET and the
EtherCAT control.
On Off Off
Data exchange with the EtherCAT side is not possible for at least one of the following
reasons:
•Invalid module configuration on the PROFINET side (no module configured, module
gap present or maximum size of I/O image exceeded).
•Module configurations of the PROFINET and the EtherCAT side do not fit together
•The EtherCAT side is not in the OPERATIONAL state and therefore does not provide
valid data.
Off On Off
There is no I/O connection to a PROFINET controller with the following possible
causes:
•PROFINET controller not ready for operation or not connected
•In the current project of the controller the coupler is not configured
•No or not the correct PROFINET device name was assigned to the coupler
(see chap. 7.2)
Flashing Flashing Flashing The PROFINET function "LED flashing" for device identification is active.
This function has no influence on the current operating state of the coupler.
Off On Off
A firmware update of the coupler was started via the web interface (see chap. 9.1),
which will end with an automatic restart of the coupler.
During the firmware update, no I/O communication and thus no data exchange takes
place on either interface side.

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11.2 LED diagnostics for EtherCAT interface
The LED states listed assume that the coupler is in the ready-to-run state, i.e. the central green RUN LED
is lit.
LED (color) State Function
ER-LED (rot) Off No error condition
Flashing Request of the controller to the coupler to change to a higher EtherCAT state was
rejected (e.g. due to gap in the module configuration)
strobes
periodically
1x briefly
Self-triggered change to a lower EtherCAT state due to an event or error (e.g.
start of firmware update).
strobes
periodically
2x briefly
Process data or communication watchdog has expired (e.g. by disconnecting the
connection to the controller).
RN-LED (green) Off EtherCAT-State des Couplers: Init (INIT)
Flashing EtherCAT-State des Couplers: Pre-Operational (PREOP)
strobes periodically
1x briefly
EtherCAT-State des Couplers: Safe-Operational (SAFEOP)
On EtherCAT-State des Couplers: Operational (OP)
MT-LED (yellow) Off Error-free operating state with valid data exchange between the EtherCAT and
the PROFINET controller. In this case the ER LED is always off (no error state) and
the RN LED is always on (EtherCAT state OP).
Flashing A firmware update of the coupler was started via the web interface (see chap.
9.1), which will end with an automatic restart of the coupler.
During the firmware update, no I/O communication and thus no data exchange
takes place on either interface side.
On Error-free operating state with valid data exchange between the EtherCAT and
the PROFINET controller.