Pepperl+Fuchs EtherCAT WCS-ECG110 User manual

WCS-ECG110 interface
module
WCS EtherCAT interface
module
FACTORY AUTOMATION
MANUAL

With regard to the supply of products, the current issue of the following document is ap-
plicable: The General Terms of Delivery for Products and Services of the Electrical Indus-
try, published by the Central Association of the Electrical Industry (Zentralverband
Elektrotechnik und Elektroindustrie (ZVEI) e.V.) in its most recent version as well as the
supplementary clause: "Expanded reservation of proprietorship"
WCS-ECG110 interface module

WCS-ECG110 interface module
3
1 Introduction................................................................................. 4
1.1 Content of this Document ................................................................... 4
1.2 Target Group, Personnel...................................................................... 4
1.3 Symbols Used ...................................................................................... 4
2 Product description.................................................................... 6
2.1 Use and application ............................................................................. 6
2.2 Dimensions........................................................................................... 6
2.3 Design of the Device............................................................................ 7
3 Installation................................................................................. 11
3.1 Mounting ............................................................................................. 11
3.2 Electrical Connection ........................................................................ 12
3.3 Dismounting ....................................................................................... 15
4 Commissioning......................................................................... 16
4.1 Introduction ........................................................................................ 16
4.2 Connecting the WCS Reader ............................................................ 17
4.3 Connection to the network................................................................ 18
4.4 Integrating WCS-ECG110 into the Network..................................... 19
4.5 Request byte for read heads............................................................. 22
4.6 Data format for modules.................................................................... 23
5 Appendix ................................................................................... 25
5.1 Cable routing in the RS-485 bus....................................................... 25
5.2 Data cables and accessories ............................................................ 28

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WCS-ECG110 interface module
Introduction
1Introduction
1.1 Content of this Document
This document contains information required to use the product in the relevant phases of the
product life cycle. This may include information on the following:
Product identification
Delivery, transport, and storage
Mounting and installation
Commissioning and operation
Maintenance and repair
Troubleshooting
Dismounting
Disposal
The documentation comprises the following parts:
This document
Datasheet
In addition, the documentation may comprise the following parts, if applicable:
EU-type examination certificate
EU declaration of conformity
Attestation of conformity
Certificates
Control drawings
Instruction manual
Other documents
1.2 Target Group, Personnel
Responsibility for planning, assembly, commissioning, operation, maintenance, and
dismounting lies with the plant operator.
Only appropriately trained and qualified personnel may carry out mounting, installation,
commissioning, operation, maintenance, and dismounting of the product. The personnel must
have read and understood the instruction manual and the further documentation.
Prior to using the product make yourself familiar with it. Read the document carefully.
1.3 Symbols Used
This document contains symbols for the identification of warning messages and of informative
messages.
Note!
For full information on the product, refer to the further documentation on the Internet at
www.pepperl-fuchs.com.

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Introduction
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Warning Messages
You will find warning messages, whenever dangers may arise from your actions. It is
mandatory that you observe these warning messages for your personal safety and in order to
avoid property damage.
Depending on the risk level, the warning messages are displayed in descending order as
follows:
Informative Symbols
Action
This symbol indicates a paragraph with instructions. You are prompted to perform an action or
a sequence of actions.
Danger!
This symbol indicates an imminent danger.
Non-observance will result in personal injury or death.
Warning!
This symbol indicates a possible fault or danger.
Non-observance may cause personal injury or serious property damage.
Caution!
This symbol indicates a possible fault.
Non-observance could interrupt the device and any connected systems and plants, or result in
their complete failure.
Note!
This symbol brings important information to your attention.

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WCS-ECG110 interface module
Product description
2 Product description
2.1 Use and application
The WCS-ECG110 interface module serves as an interface between the WCS reader and the
EtherCAT controller. The device has 2 EtherCAT ports. The data is transferred between the
WCS reader(s) and the WCS-ECG310 via the RS-485 interface, and from the WCS-ECG310
to the control panel via the EtherCAT protocol.
You can connect up to 4 WCS readers of type LS221 or LS121. If you connect several readers,
they must have different addresses. The number of connected readers is configured in the
hardware project settings.
2.2 Dimensions
The interface module housing has the following dimensions.
Figure 2.1 Dimensions
115
100 23

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Product description
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2.3 Design of the Device
Device components
Figure 2.2 Interface module overview
1RS-485 bus termination slide switch
2X1: RS-485 interface
3Mounting bracket
4X2: Connection for power supply
5X3: EtherCAT communication interface
6Front panel with rotary coding switches and indicator lights
3
4
1
6
2
5

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WCS-ECG110 interface module
Product description
Front panel
Figure 2.3 Front panel overview
Power:
The "Power" LED is green: The WCS-ECG110 interface module is correctly connected to the
power supply.
State:
The "State" LED is green: Data is being exchanged with the WCS readers. Using the 4 "Error
No/Select ID" LEDS, the number of the currently polled WCS reader is displayed.
The "State" LED is red: The interface module has detected an error or a warning. The interface
module displays the binary coded error and/or warning number via the "Error No/Select ID"
LEDs.
ErrorNo/Select ID Reader address
8421
00010
00101
01002
10003
Table 2.1 Display via the four "ErrorNo/Select ID" LEDs when the "State" LED lights up green.
Error no. 1...5: Switch the interface module off and back on. If the error occurs
again, the module must be replaced.
Warning no. 6...15: The warning provides information. The interface module displays
the warning for one minute and then resets automatically.
Power/State
1
2
4
8
S4 S5
State
WCS-ECG110 Modul
A
B
C
D
0
1
2
3
4
5
6
7
8
9
A
B
C
D
0
1
2
3
4
5
6
7
8
9
Bus State
Bus Power Link/Act. In Link/Act. Out
EtherCAT

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Product description
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Rotary coding switches S4 and S5
The two switches control the operating modes. Ensure that the two switches are at position 0
to enable the data exchange mode.
EtherCAT State:
ErrorNo/Select ID LED Error number Error description
LED8 LED4 LED2 LED1
0000 0 Reserved
0001 1 Hardware error
0010 2 EEPROM error
0011 3 Internal memory error
0100 4 Fieldbus hardware error or incorrect
fieldbus ID
0101 5 Script error
0110 6 Reserved
0111 7 WCS reader communication, RS
send buffer overflow
1000 8 WCS reader communication, RS
receive buffer overflow
1001 9 WCS reader communication, RS
timeout
1010 10 General fieldbus error
1011 11 Parity error or frame check error
1100 12 Reserved
1101 13 Fieldbus configuration error
1110 14 Fieldbus data buffer overflow
1111 15 Reserved
Table 2.2 Meaning of the error codes (display via the four "Error No/Select ID" LEDs when the "State"
LED lights up red and thus indicates an error or a warning)
ERR State (red LED)Error Description
Off No error The EtherCAT communication of the
device is ready for operation.
Flashing Invalid configuration General Configuration error (example:
wrong object settings)
1 x flashing Unprompted status change The application changed the EtherCAT
state independently: The parameter
"Change" in the AL-status register is set
to 0x01: Change/Error
2 x flashing Application Watchdog
Timeout
A timeout of the application has occurred
(example: 10 ms IR error)

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WCS-ECG110 interface module
Product description
The states of the LEDs are defined as follows:
EtherCAT Power:
The "EtherCAT" LED is green: The LED is connected directly to the electrically isolated supply
voltage of the PROFINET side.
EtherCAT Link/Activity In:
The "Link/Activity" LED at the IN port is directly activated by the EtherCAT processing unit and
lights up green when the gateway at the RJ45(In) is located on an operational network (link
pulses are received) and flickers in case of network data traffic (activity).
EtherCAT Link/Activity Out:
The "Link/Activity" LED at the OUT port is directly activated by the EtherCAT processing unit
and lights up green when the gateway at the RJ45(Out) is located on an operational network
(link pulses are received) and flickers in case of network data traffic (activity).
RUN State (green
LED)Status Description
Off INIT The device is in the INIT status.
flashing PRE-OPERATIONAL The device is in PRE-OPERATIONAL
status.
1 x flashing SAFE OPERATIONAL The device is in the SAFE-
OPERATIONAL status.
on OPERATIONAL The device is in OPERATIONAL status.
LED status Definition
on The LED is permanently on.
Off The LED is permanently off.
Flashing The LED changes the state from ON to OFF at a frequency of 2.5 Hz:
ON for 200 ms, followed by OFF for 200 ms.
1 x flashing The LED lights up briefly (200 ms), followed by a long OFF phase
(1000 ms).
2 x flashing The LED shows a series of short flashes twice (200 ms), separated by
an OFF phase (200 ms). The series is completed with a long OFF
phase (1000 ms).

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Installation
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3Installation
3.1 Mounting
Mounting the Modules
The module is fastened to a DIN mounting rail with a width of 35 mm using a snap-on fixing
method.
Figure 3.1 Mounting
1. Hook the module (1) onto the DIN mounting rail (2) from above and press it down until it
snaps into place.
The module is mounted.
2. You must connect the DIN mounting rail to the switch cabinet's equipotential busbar. The
connection wire must have a cross section of at least 10 mm2.
2
1
Note!
Heat Dissipation
You may place other modules to the left and right of the module.
Above and below the modules, there must be at least 5 cm of free space for heat dissipation.
Note!
Vertical Installation
You can also install the DIN mounting rail vertically, so that the modules can be rotated by 90°
for mounting.

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WCS-ECG110 interface module
Installation
3.2 Electrical Connection
Figure 3.2 Electrical Connection
Plug X1 is located on the top side of the interface module, and plug X2 is located on the
underside.
Connection technology
You must/may use the following connection technology when wiring the assembly:
Standard screw/plug connection (supply + RS)
8-pin RJ45 connection (EtherCAT connection)
When using standard screw terminals, one line per connection point can be clamped. To
tighten the screws, use a screwdriver with a blade width of 3.5 mm.
Permissible cable cross section:
Flexible cable with wire end ferrule: 1 x 0.25 ... 1.5 mm2
Solid cable: 1 x 0.25 ... 1.5 mm2
The plug-in terminal strip combines a standard screw connection and a plug connector. The
plug connector is coded and therefore cannot be plugged in incorrectly.
Danger!
Device damage due to incorrect installation
Faulty installation of cables and connection lines can endanger the function and the electrical
safety of the device.
Note the permissible core cross section of the conductor.
If you are using stranded conductors, crimp the stranded conductors with wire end
ferrules.
Make sure that the insulation on the conductors extends all the way to the terminal.
Observe the tightening torque for the screws on the terminal. The tightening torque is
0.5 Nm.
Using an inappropriate tool may damage the screw heads. Use a slot-head screwdriver of
size 3.5 x 0.5.
Connecting an alternating current can damage the device or cause the device to
malfunction. Connect the device to direct current (DC).
Read head
EtherCAT
Interface
WCS.-LS221
WCS-ECG110
RS 485 -
RS 485 +
24 V (Pwr)
0 V (Pwr)
X2-1
X2-2
X1-4
X1-5
X1-6
X1-7
SUB
GND
SDA
SDB
GND UB+
PE
PE
EtherCAT
2. Port
EtherCAT
RJ45
1. Port
EtherCAT
RJ45
UB+
GND
RS 485+
RS 485- X3
X4
IN
OUT

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Installation
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Connecting the power supply
Connect the operating voltage (10 VDC...33 VDC) to terminals 1 and 2 of the 4-pin plug X2 on
the interface module. In addition, note the label on the module.
The "Power" LED lights up green.
Equipotential bonding connection
The connection to equipotential bonding occurs automatically when attaching to the DIN
mounting rail.
EtherCAT®communication interface
This interface can be found on the interface module in the form of two 8-pin RJ45 sockets on
the bottom of the housing.
Insert the EtherCAT®connectors into one of the RJ45 socket(s) with the inscription "In" (cable
from master) or "Out" (further cable to the next EtherCAT®slave).
Preparing for operation on the RS-485 interface
For operation on an RS-485 interface, the terminals on connector X1 must be connected as
follows:
1. Connect terminal 4 "Rx 422+" to terminal 6 "Tx 422+."
2. Connect terminal 5 "Rx 422-" to terminal 7 "Tx 422-."
Terminal Description
1UB (Pwr) Operating voltage for interface module/
operating voltage for WCS reader
20V(Pwr) Ground for interface module/ground for WCS reader
3not used not used
4not used not used
Table 3.1 Terminal X2
Note!
Ensure that the cable length to the neighboring Ethernet nodes is at least 0.6 m.
Terminal Description
4Rx 422+ RS-485+ data line to WCS reader
5Rx 422- RS-485- data line to WCS reader
6Tx 422+ Connect terminal 6 "Tx 422+" to terminal 4 "Rx 422+"
7Tx 422- Connect terminal 7 "Tx 422-" to terminal 5 "Rx 422-"
Table 3.2 Terminal X1

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WCS-ECG110 interface module
Installation
Note!
RS-485 bus termination
If the interface module is operated as the first or last physical device in an RS-485 bus, there
must be a bus termination on this module. To do this, set the "Rx 422 Termination" slide switch
to "Off" and the "Tx 422 Termination" slide switch to "On." This activates the RS-485 terminator
(150 ) built into the interface module.
If you only connect one WCS reader to the interface module, you must always activate the RS-
485 terminator; see also Cable routing in the RS-485 bus.
*) RS485-Termination:
Rx422 = o
Tx422 = on
1
2
3
4
5 6
7
Rx232
Tx232
AP-GND
Rx422+ Rx422-
Tx422+
Tx422-
RS485+ RS485-
Rx422* Termination Tx422*
On O On O
X1

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Installation
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3.3 Dismounting
Dismounting the modules
Use a suitable slot-head screwdriver for dismounting the module.
1. Disconnect all the supply and signal lines.
Figure 3.3 Dismounting
2. Insert the screwdriver (2) into the groove of the mounting bracket (3).
3. Press the screwdriver (2) in the specified direction until the lock on the DIN mounting rail (4)
opens, see figure.
4. Then press the module (1) upwards and lift it out of the DIN mounting rail.
4
3
2
1

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WCS-ECG110 interface module
Commissioning
4 Commissioning
4.1 Introduction
Components
To commission the module, you will require the following components:
WCS-ECG110 interface module
Cordset from the interface module to the reader
Connector for the EtherCAT®connection to the interface module
Ethernet cable
10 VDC...33 VDC power supply
ESI file (the ESI file can be obtained free of charge from our website www.pepperl-
fuchs.com.)
Connecting the interface module
To ensure that the assembly functions correctly, you must carry out the following steps during
commissioning:
1. Assign an EtherCAT®address.
2. Assign an EtherCAT®device name.
3. Connect the module to the EtherCAT®network at the interface with the label "In" (cable
from master) or "Out" (further cable to the next slave).
4. Connect the process device (reader) to the interface module. For information on
commissioning the reader, please refer to the instruction manual for the reader.
5. Ground the DIN mounting rail onto which the assembly is snapped.
6. Connect the direct current to the terminals provided.
7. Use any programming tool for configuration. The ESI file can be downloaded from our
website: www.pepperl-fuchs.com. Simply enter the product name or item number in the
Product/Keyword field and click the "Search" icon.
Warning!
Danger to life due to defective work
Errors during installation and commissioning can cause life-threatening injuries and significant
property damage.
Installation and commissioning must only be carried out by trained personnel in
accordance with the safety regulations.
Note!
On delivery, the module does not yet have an IP address. In normal operation, the IP address
is usually assigned to the module by the EtherCAT®IO controller (PLC).
Note!
On delivery, the module does not yet have a device name. The device name is assigned to the
module via the project planning software.
Note!
A more detailed description of the individual steps is provided on the following pages.

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4.2 Connecting the WCS Reader
If you connect several WCS readers to one interface module, the WCS readers must have
different addresses. This will allow the programmable logic controller to allocate the data to the
correct WCS readers. If you only connect one WCS reader to an interface module, this WCS
reader always receives the address 0. You can connect up to 4 WCS readers to an interface
module via an RS-485 cable. Each WCS reader is supplied with the default address of 0.
Details of how to change the address of the WCS reader can be found in the configuration
instructions for the WCS reader.
The number of connected readers and their operating mode is configured in the hardware
project settings. To the Hardware Configuration, see chapter 4.4.
Setting the number of connected WCS readers
Set the number of connected WCS readers with the rotary switch S4 in accordance with the
table "Rotary switch S4."
Rotary switch S4
WCS reader terminal pin Terminal on interface module
WCS2B WCS3B
2 1 X2-1
4 2 X1-4
1 4 X1-5
3 3 X2-2
Table 4.1 Connection of WCS readers
Switch setting S4 Number of WCS readers Reader address
11 WCS reader 0
22 WCS readers 0, 1
33 WCS readers 0, 1, 2
44 WCS readers 0, 1, 2, 3
51 WCS reader with velocity output 0
62 WCS readers with velocity output 0, 1
73 WCS readers with velocity output 0, 1, 2
84 WCS readers with velocity output 0, 1, 2, 3
Table 4.2 Position of rotary switch S4 for setting the number of WCS readers
Example!
You have connected 3 readers to the interface module and want to use the velocity output.
Move the rotary switch S4 to switch position 7 and set the addresses 0,1,2 on the 3 readers.
Note!
Rotary switch S5
Rotary switch S5 has no function. Always set rotary switch S5 to position 0.

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Commissioning
Connecting the WCS Reader
1. Connect the power supply for the WCS reader to terminals 1 and 2 of the 4-pin connector X2
on the interface module.
2. Connect the RS 485 data line to the WCS reader on terminals 4 and 5 of connector X1.
If you operate the WCS-ECG110 interface module at the beginning or end of the RS485 bus,
you must activate the RS485 terminator.
Activating the RS485 terminator
1. To use with an RS485 interface, slide the switch "Rx 422" to OFF.
2. To activate the RS485 terminator, slide the switch "Tx 422" to ON.
3. To deactivate the RS485 terminator, slide the switch "Tx 422" to OFF.
4. If only one reader is connected, you must always activate the RS485 terminator. For this
purpose, slide the switch "Tx 422" to ON.
4.3 Connection to the network
The connection to the EtherCAT IO is made via the two "RJ 45 EtherCAT IN and OUT" sockets
on the underside of the interface module. The front socket is labeled "X3 IN," and the rear
socket is labeled "X4 OUT." Connect the device to the EtherCAT network at the interface with
the label "In" (cable from master) or "Out" (further cable to the next slave).
Pinout X3 IN & X4 OUT
Connecting the device to the controller
Plug the EtherCAT connector into the RJ45 socket. Use a Cat. 5 data cable.
Setting data exchange mode
Set rotary switch “S5”to position 0. The rotary switch "S4" is set in accordance with the
connected readers.
Terminal Description
1TD+ Transmission line +
2TD- Transmission line -
3RD+ Receive line +
4n.c. Not connected
5n.c. Not connected
6RD- Receive line -
7n.c. Not connected
8n.c. Not connected
Table 4.3 Terminals of the 8-pin "RJ45 EtherCAT IO" sockets
Note!
The cable to the surrounding modules on the Ethernet line must be at least 0.6 m long.

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4.4 Integrating WCS-ECG110 into the Network
You will need an ESI file to operate the module described in this manual. The ESI file must be
imported into the corresponding configuration tool before commissioning the module. The ESI
file can be downloaded from our website: www.pepperl-fuchs.com. Simply enter the product
name or item number in the Product/Keyword field and click the "Search" icon.
Select your product from the list of search results. Click on the information you require in the
product information list, e.g., Software.
A list of all available downloads is displayed.
EtherCAT®address assignment
On delivery, the interface module does not yet have an IP address. In normal operation (data
exchange mode), the IP address is usually assigned to the module by the EtherCAT®IO
controller (PLC). For this purpose, the module has a device name that is used to address it.
EtherCAT®device name
On delivery, the module does not yet have a device name. The device name is assigned to the
module via the project planning software. The following rules from the EtherCAT®
specification apply to the device name:
It consists of one or more name parts separated by a dot
The total length is 1 to 240 characters.
The length of a name part is between 1 and 63 characters.
A name part consists exclusively of lowercase letters, numbers, and the hyphen.
Neither the first nor the last character of a name part is a hyphen.
The first part of the name does not begin with "port-xyz" or "port-xyz-abcde," where a, b,
c, d, e, x, y, and z are digits.
It does not have the form "k.l.m.n," where k, l, m, and n are numbers between 0 and 999.
Caution!
Malfunction due to incorrectly configured devices
Incorrectly configured devices can cause malfunction of the plant.
Only put devices into operation after they have been configured correctly.
Note!
Various configuration tools are available to allow you to configure the interface module. In this
manual, we describe the configuration example for EtherCAT®Master "TwinCAT" by
Beckhoff. If you are using a programmable logic controller (PLC) from a different manufacturer,
the process will be similar to the one described here.

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WCS-ECG110 interface module
Commissioning
Adding the device to the network
1. Download and install the software "TwinCAT 3.1 - eXtended Automation Engineering"
(XAE). The software is available on the website of the manufacturer Beckhoff at ht-
tp://www.beckhoff.com/english.asp?download/tc3-download-xae.htm.
2. After the installation, copy the ESI file into the following folder:
C:\TwinCAT\3.1\Config\Io\EtherCAT
3. Open TwinCAT V3 and check to see if your Ethernet card works with the software. If your
device is displayed in the sub-folder “Installed and ready to use devices”, you can proceed.
4. Open a new TwinCAT project.
5. Click through the device tree until you see a symbol with the label Devices. Right-click the
symbol and select Scan.