X20 IO via EtherCAT: Only Outputs working

Hello,

I have small test-setup in which I try to connect X20 IO to a third party PLC via EtherCAT.

I set up my cluster in Automation Studio / FieldbusDesigner

Then build the configuration and imported the generated ESI/XML file into the PLC software, added it to the structure and connected some variables etc.

I then downloaded the project and basic communication is working fine. I also can set the outputs of my DO or AO card (LED is switching and I can measure the voltage), but I can’t see my inputs on both my digital and analog card.

  • On the DI card channel ten is always set to true, even though there is no wire connected, other channels are always false
  • On the AI card all values are frozen around zero

What do I miss?

The same setup, just with Profinet (Using X20BC00E3 instead of X20BC00G3) the inputs are working fine, so it must be something in the EtherCAT configuration.

Let me know if you need more input from me

Thanks

Hi,

honestly spoken, I haven’t much experience with Ethercat. And I don’t have any Ethercat master to do some testing → maybe someone else here in the Community has some Master (also B&R Ethercat master on B&R PLC should be suitable for a basic test?).

From what you’re describing, it sounds like that there’s something going wrong in the Input register handling / Input image between the filedbus device and the master.
I created the same configuration and checked the output of Automation Studio.
As output, AS generates the configuation files for the Ethercat master, and a HTML based documentation.

I would first recommend to check this generated documentation against the masters configuration in your master environment, if you see any difference in the masters configuration regarding the DataTypes, Size or Offsets.

Regarding the inputs, especially check if the PowerSupply module is handled right because it also has input signals and influences therefore the Input image, which is not the case at your outputs configuration.

And not to forget: please tell us the exact version of Automation Studio you use (I played around with AS4.12.9.18), thanks!

Best regards!

Hello,

I did a short test with a X20CP1685 and an X20IF10G1-1 as Ethercat master. Attached to this is a X20BC00G3 with your mentioned IO modules.

My project contains 2 Configurations:

The first one (like you did) with the BC00G3 and its attached IO modules:

The created ESI file was imported and used in my second configuration which consists of the mentioned PLC with the Ethercat master

I then set an output and physically connected output1 to input1 and as you can see forcing the output triggered the input

So I would assume it works as intended :slight_smile:

2 Likes

Hello Alexander, Hello Oliver,

thanks for your replies. I am working with AS 6.5.0.306.

Master is an ABB AC500 - programmed in Automation Builder 2.9

To make sure that there is no mapping error I reduced my test setup to just one DI-Card

image

I could not find a issue with the mapping

But still input looks likte this:

There is nothing connected to Input 9.

Any ideas? Thanks

You can share your ESI file here and I can try. If it works on my side then I suppose the issue is not the ESI file and rather your hardware (probably damaged) or the used PLC or program in any way

BuR_X20BC00G3_ST1.zip (5.8 KB)

Hello Oliver, see attached the files

1 Like

Using your ESI file without any modification I do NOT get any input:

If I then connect input 1 to 24V (from an external source) I do get a logic “TRUE”

This also works as expected and I am sorry to tell but I cannot tell why it does not work on your side as it works just fine on my side using a B&R PLC (as we do not own ABB PLCs)

What I just noticed (I overlooked this - sorry) is that your digital input module does not give “modulOK”

Did you try to exchange the module ?

Since there is no error indication I assumed that was due to the same issue

Since the same module is working with both, Profinet (on AC500) and PowerLink on a X20, I don’t think it is an hardware issue.

Thanks for you work, since you could not find anything obviously wrong I’ll ask AC500 support.

3 Likes

Thanks for the feedback !

1 Like