Kunbus PR100073 User manual

User Manual
Gateway EtherCAT
3/31/2022

KUNBUS GmbH Table of Contents
Gateway EtherCAT ii
Table of Contents
1 General Information .................................................................................................................................... 3
1.1 Disclaimer ............................................................................................................................................. 3
1.2 Notes Regarding this User Manual ....................................................................................................... 3
1.3 Validity................................................................................................................................................... 3
1.4 Limitation of Liability.............................................................................................................................. 3
1.5 Customer Service.................................................................................................................................. 4
2 Safe Use ....................................................................................................................................................... 5
2.1 Intended Use......................................................................................................................................... 5
2.2 User....................................................................................................................................................... 5
2.3 Symbols ................................................................................................................................................ 5
2.4 Important safety instructions ................................................................................................................. 6
2.5 Environmental Conditions ..................................................................................................................... 6
3 Overview ...................................................................................................................................................... 8
3.1 Functionality .......................................................................................................................................... 8
3.2 Control Elements................................................................................................................................... 9
3.3 Status LEDs .......................................................................................................................................... 11
4 Installation ................................................................................................................................................... 13
4.1 Preparations for Inteference-free Operation ......................................................................................... 13
4.2 Requirements........................................................................................................................................ 14
4.3 Connecting Gateway Components ....................................................................................................... 15
4.4 Installing a Gateway in the Control Cabinet .......................................................................................... 16
4.5 Connecting a Gateway to the Fieldbus ................................................................................................. 16
4.6 Connecting the Power Supply............................................................................................................... 17
5 Configuration............................................................................................................................................... 18
5.1 Supported Size of Process Data ........................................................................................................... 18
5.2 EtherCAT Configuration ........................................................................................................................ 18
5.3 Standard Objects .................................................................................................................................. 18
5.4 EtherCAT In/Outputs............................................................................................................................. 20
5.5 Check status ......................................................................................................................................... 24
6 Technical Data ............................................................................................................................................. 25

Gateway EtherCAT 3
1 General Information
1.1 Disclaimer
© 2022 KUNBUS GmbH, Denkendorf (Germany)
The contents of this document have been prepared by KUNBUS GmbH with the utmost care. Due
to technical developments, KUNBUS GmbH reserves the right to change or replace the contents
of this document without prior notice. You can always obtain the current version of the user
manual on our homepage: www.kunbus.de
KUNBUS GmbH shall be liable exclusively to the extent specified in General Terms and
Conditions (www.kunbus.de/agb.html).
The contents published in this document are protected by copyright. Any reproduction or use for
the user’s in-house requirements is permitted. Reproduction or use for other purposes is not
permitted without the express, written consent of KUNBUS GmbH. Contraventions shall result in
compensation for damages.
Trademark Protection
KUNBUS is a registered trademark of KUNBUS GmbH
Windows® and Microsoft® are registered trademarks of Microsoft Corp.
EtherCAT is a registered trademark and patented technology, licensed by Beckhoff Automation
GmbH, Germany.
KUNBUS GmbH
Heerweg 15 C
73770 Denkendorf
Germany
www.kunbus.com
1.2 Notes Regarding this User Manual
This user manual provides important technical information that will enable you as a user to
integrate the Gateways into your applications and systems efficiently, safely and conveniently. It
is intended for trained, qualified personnel, whose sound knowledge in the field of electronic
circuits and expertise of EtherCAT®is assumed.
As an integral part of the product, the information provided here should be kept and made
available to the user.
1.3 Validity
This document describes the application of the KUNBUS Gateway Module with the product
number:
– PR100073, release 00
1.4 Limitation of Liability
Warranty and liability claims will lapse, if:
– the product has been used incorrectly,
General Information

Gateway EtherCAT 4
– the product is damaged due to non-observance of the operating manual,
– damage is caused by inadequately qualified personnel,
– damage is caused by technical modification to the product (e.g. soldering).
1.5 Customer Service
If you have any questions or suggestions concerning this product, please do not hesitate to contact
us:
KUNBUS GmbH
Heerweg 15 C
73770 Denkendorf
Germany
[email protected]
www.kunbus.com
General Information

Gateway EtherCAT 5
2 Safe Use
2.1 Intended Use
The modular gateway component is part of a gateway that can be combined with another
modular gateway component or a RevPi Core/Connect from KUNBUS as required.
The modular gateway component is designed to forward data from a specific protocol to a
controller or other gateway component.
No other purpose is intended. If you do not use the device as intended, damage to property and
personal injury may result.
2.2 User
The Gateway may only be assembled, installed and put into operation by trained, qualified
personnel. Before assembly, it is absolutely essential that this documentation has been read
carefully and understood. Expertise in the following fields is assumed:
– electronic circuits,
– Basic knowledge of EtherCAT,
– work in electrostatic protected areas,
– locally applicable rules and regulations for occupational safety.
2.3 Symbols
The symbols used have the following meaning:
DANGER
Danger
Always observe this information!
There is a safety hazard that can lead to serious injuries and death.
CAUTION
Caution
There is a safety hazard that can result in minor injuries and material damage.
NOTICE
Note
There is a safety hazard that can result in material damage.
Safe Use

Gateway EtherCAT 6
2.4 Important safety instructions
DANGER
Danger of explosion
The modular Gateway component do not meet the requirements of the ATEX directive. Therefore,
they are not suitable for use in potentially explosive environments.
a) Do not use the modular Gateway component in potentially explosive environments.
CAUTION
Electric shock
Switch off all voltages before assembly/disassembly.
a) Failure to observe this warning may result in personal injury.
CAUTION
The devices are „open equipment“ according to the Standard UL61010-2-201.
To fulfill requirements for safe operation with regard to mechanical stability, flame retardation, sta-
bility, and protection against contact, the following alternative types of installation are specified:
a) Installation in a suitable cabinet.
b) Installation in a suitable enclosure.
c) Installation in a suitable equipped, enclosed control room.
NOTICE
Incorrect connection of the power supply
Using an unsuitable power supply can destroy your modules and connected devices.
a) Use a power supply in the approved area for the base modules. The values for this can be
found in the technical data of your base module.
2.5 Environmental Conditions
Operate the device only in an environment that corresponds to the operating conditions in order to
prevent damage.
Suitable environmental conditions are:
Operating temperature -20 °C up to +55 °C
Humidity 93% (non-condensing)
NOTICE
This device is designed for indoor use only.
If you use the device outdoors, it may be destroyed.
a) Use the device indoors only.
Safe Use

Gateway EtherCAT 7
Safe Use

Gateway EtherCAT 8
3 Overview
3.1 Functionality
The KUNBUS Gateway is a protocol converter. It allows communication between networks with
different protocols.
Illustration1: Functionality as a slave
A Gateway consists of 2 gateway components that master one specific protocol each. You can
combine these gateway components as you wish. This design offers you a high degree of flexibility,
since you can exchange the individual gateway components at any time. The following gateway
components are currently available as slaves:
– CANopen
– DeviceNet
– EtherCAT
– EtherNet/IP
– Modbus RTU
– Modbus TCP
– POWERLINK
– PROFIBUS
– PROFINET
– Sercos III
The gateway component for DMX can be operated as a master or slave.
In addition, you can combine the Gateway component with the RevPi Core and the RevPi Connect.
Overview

Gateway EtherCAT 9
3.2 Control Elements
Front view
1
2
Illustration2: Front view
1 Status LEDs
2 Fieldbus connection
two RJ45 sockets for the connection to EtherCAT
Overview

Gateway EtherCAT 10
Top
11
2
Illustration3: Top
1 Interconnect ports
for interconnecting the gateway components.
2 Locking clamps
for securely attaching the gateway component to the DIN rail.
Overview

Gateway EtherCAT 11
Bottom
1
2
Illustration4: Bottom
1 Mains connection
with 24 V supply voltage
2 Locking clamps
for securely attaching the gateway component to the DIN rail
3.3 Status LEDs
The gateway component is equipped with 5 status LEDs. The LED Power provides information
about the state of the gateway component. The other LEDs provide information about the
EtherCAT status.
LED State Meaning
Power
(green/red)
off Gateway component not run-
ning
Overview

Gateway EtherCAT 12
blinks, green Initialization phase not yet com-
pleted
on, green All system components are
functioning perfectly
flashes, red Recoverable error
Check whether the plug-in
jumper is connected correctly to
the interconnect port.
on, red Serious error/defect in the gate-
way component
EC ERROR
(Red)
off No Error
on Fatal error
suddenly flashes
(200ms on / 1000ms off)
As a result of a local error, the
gateway component has auto-
matically changed the EtherCat
status.
flashes twice
(200 ms on /200 ms off / 200
ms on /1000 ms off)
Time limit exceeded
flickers
(50ms on / 50ms off)
An error was detected during
the starting process indicating
that the status INIT was
reached, but a bit error was set
in the Alarm Status Register.
flashes
(200ms on / 200ms off)
Configuration error
EC RUN
(green)
off EtherCAT State: Init
(or gateway component is "off")
flashes
(200ms on / 200ms off)
EtherCAT State: Pre-Opera-
tional
suddenly flashes
(200ms on / 1000ms off)
EtherCAT State: Safe-Opera-
tional
on EtherCAT State: Operational
L/A 1 (EC IN)
(green)
off No connection
flickers
(50ms on / 50ms off)
Connection and data traffic
on Connection
L/A 2 (EC OUT)
(green)
off No connection
flickers
(50ms on / 50ms off)
Connection and data traffic
on Connection
Overview

Gateway EtherCAT 13
4 Installation
4.1 Preparations for Inteference-free Operation
In the following section we have compiled some general information for you that is important for
interference-free operation. If you are already acquainted with this topic, you can skip to the next
section. There, you will learn about which conditions are necessary for installing the gateway
component.
Cable routing
Route your cables separately in cable groups. This will protect your gateway from any unintended
electromagnetic interferences.
The following groups should be routed separately from each other:
Group Line
A Data and power supply lines for:
DC voltage below 60V
AC voltage below 25V
B Data and power supply lines for:
DC voltage between 60V and 400V
AC voltage between 25 and 400V
C Power supply lines above 400V
– You can route cables of the same group together in cable ducts or bundles.
– Cables of group A and B:
– Route the groups in separate bundles or
– in cable ducts at a minimum distance of 10 cm from each other.
– Cables of group C
– Route the groups in separate bundles or
– in cable ducts at a minimum distance of 50 cm from the other groups.
Shielding
Shield your cables. This will reduce any unintended electromagnetic interferences.
Potential Equalization
Potential differences occur when devices are connected to different earths. These potential
differences cause malfunctions.
To prevent malfunctions, you have to route an equipotential equalization conductor.
When doing so, bear in mind the following points:
– Select an equipotential equalization conductor with low impedance.
– Select the following as a reference value for the cross-section of the potential equalization ca-
ble:
– 16 mm2 for potential equalization cables of up to 200 m in length
– 25 mm2 for potential equalization cables of more than 200 m in length
– Use potential equalization cables made of copper or galvanized steel.
– Connect potential equalization cables extensively with the earth rail.
Installation

Gateway EtherCAT 14
– The smallest surfaces possible should be sandwiched between potential equalization cables
and signal cables.
If the devices of the control system are connected by shielded signal cables that are earthed on
both sides, the impedance must be 10 % of the shielding impedance.
4.2 Requirements
The Gateway module was designed for use in a control cabinet.
üThe protection class of the control cabinet must be equivalent to at least IP54.
üFor installation in the control cabinet you need a DIN rail 35 x 7.5mm (EN50022).
a) Install the DIN rail horizontally in the control cabinet according to the manufacturers' specifica-
tions. Make sure that the Gateway module has sufficient distance to other devices.
NOTICE
Your gateway could be damaged if temperatures are too high.
a) Make sure that the ambient temperature in the control cabinet is less than 60°C.
b) Keep the ventilation slots unobstructed. These must not be covered by cables etc.
c) Maintain sufficient distance from other devices.
Illustration5: Distances for installation
b) Connect each gateway component individually to functional earth. Make sure that the power
supplies of both gateway components have the same ground.
ðYour control cabinet now meets all the requirements for installing the gateway components.
Installation

Gateway EtherCAT 15
4.3 Connecting Gateway Components
In order to attain a fully functional gateway, you have to interconnect both gateway components.
a) Connect an interconnect port to each gateway component using the plug-in jumper provided.
Illustration6: Connecting gateway components
ðYou can now install the gateway in the control cabinet.
NOTICE
Only ever interconnect two gateway components.
If you connect additional components, severe defects could result on all devices.
Installation

Gateway EtherCAT 16
4.4 Installing a Gateway in the Control Cabinet
a) Hold the grid element of the gateway component against the top-hat rail.
b) Press down the locking elements towards the gateway.
c) Make sure that the gateway is firmly attached to the DIN rail.
4.5 Connecting a Gateway to the Fieldbus
To connect the gateway component to EtherCAT, you need two RJ45 connectors.
The pin assignment complies with the Ethernet standard.
Pin Assignment
1 TX+
2 TX-
3 RX+
4 Not assigned.
Pin 4 and 5 are interconnected and laid via a fil-
ter on PE for better EMC response.
5
6 RX-
7 Not assigned.
Pin 7 and 8 are interconnected and laid via a fil-
ter on PE for better EMC response.
8
Installation

Gateway EtherCAT 17
4.6 Connecting the Power Supply
To connect the gateway component to the power supply, you need a spring-loaded terminal (e.g.
Metz-Connect SP995xxVBNC).
Lay a separate supply line to the power supply for each gateway component and make sure that
the GND are connected to each other at the power supply. Connect FE to PE with low resistance.
NOTICE
Connect the two gateway components to the power supply.
a) Ensure in particular that no potential differences occur between the GND pins (2).
Pin assignment:
Pin Assignment
1 24V for module supply
3
124
2 GND
3 Do not connect!
4 Functional earth
Installation

Gateway EtherCAT 18
5 Configuration
5.1 Supported Size of Process Data
The gateway component for EtherCAT supports an input and output area of 512 bytes each:
NOTICE
Bear in mind that the maximum length of the process data is always determined by
the fieldbus with the shorter data length.
Example:
EtherCAT supports 512 bytes
PROFIBUS supports 488 bytes
In conjunction with EtherCAT / PROFIBUS this means that 488 bytes are transmitted and updated
cyclically.
5.2 EtherCAT Configuration
To configure the gateway component, you have to perform the appropriate settings with the
configuration software of your EtherCAT Master.
You can use the objects listed below to configure the gateway component.
5.3 Standard Objects
Index Object Name Sub-in-
dex
Description Data
Type
Access Remark
1000 h Device Type 00 h Device Types U32 RO 0000 0000h (No pro-
file)
1001 h Error Register 00 h Error Register U8 RO
1008 h Manufacturer device
name
00 h Device name Visible
string
RO "KUNBUS Gateway
EtherCAT"
1009 h Manufacturer hardware
version
00 h Hardware Version Visible
string
RO "R01"
100Ah Manufacturer software
version
00 h Software version Visible
string
RO "majorRevNo".
"minorRevNo".
"SVNRevNo"
1010 h Store Parameters 00 h Number of entries U8 RO
01 h Store all parameters U32 RW Write the value
"0x65766173" in this
index to save all pa-
rameters
1011 h Restore parameters 00 h Number of entries U8 RO
Configuration

Gateway EtherCAT 19
01 h Restore default pa-
rameters
U32 RW Write the value
"0x64616f6c" in this
index to restore all
parameters.
1018 h Identity object 00 h Number of entries U8 RO 04 h
01 h Manufacturer Num-
ber
U32 RO
02 h Product code U32 RO
03 h Revision number U32 RO
04 h Serial number U32 RO
1600 h
...
1603 h
Receive PDO mapping 00 h Number of assigned
objects
U8 RW A mapping can con-
sist of up to 128 as-
signed objects. It
must not be greater
than 128 bytes.
01 h Assigned object #1 U32 RW
02 h Assigned object #2 U32 RW
03 h Assigned object #3 U32 RW
04 h Assigned object #4 U32 RW
05 h Assigned object #5 U32 RW
06 h Assigned object #6 U32 RW
… … U32 RW
80 h Assigned object
#128
U32 RW
1A00h
...
1A03h
Transmit PDO mapping 00 h Number of assigned
objects
U8 RW A mapping can con-
sist of up to 128 as-
signed objects. It
must not be greater
than 128 bytes.
01 h Assigned object #1 U32 RW
02 h Assigned object #2 U32 RW
03 h Assigned object #3 U32 RW
04 h Assigned object #4 U32 RW
05 h Assigned object #5 U32 RW
06 h Assigned object #6 U32 RW
… … U32 RW
80 h Assigned object
#128
U32 RW
1C00h SyncManager Types 00 h Number of entries U8 RO Value: 4
01 h Mailbox Out U8 RW Value: 0x01
02 h Mailbox In U8 RW Value: 0x02
03 h Outputs U8 RW Value: 0x03
04 h Inputs U8 RW Value: 0x04
1C12h SyncManager 3 (Rx
PDOs)
00 h Number of entries U8 RW Rx PDO transmis-
sion
01 h U16 RW
02 h U16 RW
03 h U16 RW
04 h U16 RW
1C13h SyncManager 4 (Tx
PDOs)
00 h Number of entries U8 RW Tx PDO transmission
01 h U16 RW
Configuration

Gateway EtherCAT 20
02 h U16 RW
03 h U16 RW
04 h U16 RW
5.4 EtherCAT In/Outputs
The output data (512 bytes) can be accessed byte-wise, word-wise and double word-wise.
The same data area is accessed here.
Example: 2000h:01h to 2000h:04h maps the same data as 2010h:01h until 2010h:02h and the
same data as 2020h:01h
NOTICE
Gateway component only transfers fieldbus data to the partner gateway component if it is in "Op-
erational" EtherCAT status. Otherwise, "zeros" are transmitted to the partner gateway component.
Fieldbus Output Data (Master Direction)
Index Object Name Sub-in-
dex
Description Data type Access Access type
2000 h Output Buffer 00 h Number of entries U8 RO Byte
01 h Output Buffer
Byte #0
U8 RO
02 h Output Buffer
Byte #1
... ...
80 h Output Buffer
Byte #127
2001 h Output Buffer 00 h Number of entries U8 RO
01 h Output Buffer
Byte #128
U8 RO
02 h Output Buffer
Byte #129
... ...
80 h Output Buffer
Byte #255
2002 h Output Buffer 00 h Number of entries U8 RO
01 h Output Buffer
Byte #256
U8 RO
02 h Output Buffer
Byte #257
... ...
80 h Output Buffer
Byte #383
2003 h Output Buffer 00 h Number of entries U8 RO
01 h Output Buffer
Byte #384
U8 RO
02 h Output Buffer
Byte #385
... ...
Configuration