EtherCAT the Ethernet Fieldbus

Contents

A bus system might not be everything

EtherCAT at a glance

EtherCAT Technology Group

Why use EtherCAT?

10
10
11
12
14
16
18
19

The Technology in Detail

EtherCAT: Based on Ethernet Technology
How does EtherCAT work?
The EtherCAT Protocol
Flexible Topology
Distributed Clocks for High-Precision Synchronization
Diagnostics and Error Localization
High Availability Requirements

20 System Overview
22
24
26
29

Safe Data Transfer with Safety over EtherCAT

Communication Profiles
Plant-wide communication with the EtherCAT Automation Protocol (EAP)
Integration of other Bus Systems

30
32
34
36

Implementing EtherCAT Interfaces

Implementing a Master Device
Implementing a Slave Device
Conformance and Certification

39 Contact

A bus system might not be everything

but the machine is nothing without it!

Not only is it a central part of the system
architecture, but its performance also
determines whether the entire system is
able to reach its full performance. The bus
system is also a key factor in determining
system costs, commissioning time, and
robustness. Thats why a good engineer
selects the right bus technology as the
first step to system design.
Weve written this brochure to introduce you to EtherCAT, the Ethernet
fieldbus. Not only will you get to know
EtherCAT you will also learn what makes
EtherCAT the fastest Industrial Ethernet

standard. This brochure also introduces

the EtherCAT Technology Group (ETG),
the worlds largest fieldbus organization.
Most importantly, we hope to convey why
EtherCAT is the right choice for your application. If you have any questions, feel
free to contact us. Were passionate about
EtherCAT and look forward to hearing
from you.

On behalf of the
EtherCAT Technology Group Team,
Martin Rostan, Executive Director,
EtherCAT Technology Group

Martin Rostan, Executive Director,

EtherCAT Technology Group

The worldwide ETG Team

at a Global Strategy Meeting.

EtherCAT at a glance

EtherCAT is a high-performance, low-cost,

easy to use Industrial Ethernet technology
with a flexible topology. It was introduced
in 2003 and has been an international
standard since 2007. The EtherCAT Technology Group promotes EtherCAT and is
responsible for its continued development.
EtherCAT is also an open technology: anyone is allowed to implement or use it.

How it works
EtherCATs key functional principle lies in
how its nodes process Ethernet frames:
each node reads the data addressed to it
and writes its data back to the frame all
while the frame is moving downstream.
This leads to improved bandwidth utilization (one frame per cycle is often sufficient
for communication) while also eliminating
the need for switches or hubs.

Network Performance
The unique way EtherCAT process frames
makes it the fastest Industrial Ethernet
Technology; no other technology can top
EtherCATs bandwidth utilization or the
corresponding performance.

Flexible Topology
In addition it its speed, an EtherCAT network can support up to 65,535 devices
without placing restrictions on their topology: line, bus, tree, star or any combination thereof. Fast Ethernet Physics allows
two devices to be up to 100m (330 ft.)
apart, and greater distances are possible
with the use of fiber optics. EtherCAT also
has additional features that offer further
topological flexibility, such as Hot Connect
and Hot Swap for devices, and added
redundancy through a ring topology.

Its versatile
EtherCAT is suitable for both centralized
and decentralized system architectures.
It can support master-slave, mastermaster, and slave-slave communication as
well as incorporate subordinate fieldbuses.
At the factory-level, the EtherCAT Automation Protocol has communication covered
all with the existing infrastructure.

Its easy
When compared to a classic fieldbus system, EtherCAT is the obvious choice: node
addresses can be set automatically, theres
no need for network tuning, and onboard
diagnostics with fault localization make
pinpointing errors a snap. Despite these
advanced features, EtherCAT is also easier
to use than Industrial Ethernet: there are
no switches to configure, and no complicated handling of MAC or IP addresses is
required.

Its low-cost

Open Technology

EtherCAT delivers all of the advantages of

Industrial Ethernet at fieldbus prices. How?
Firstly, EtherCAT doesnt require any active
infrastructure components. The master
device doesnt require a special interface
card and the slave devices use highly-integrated, cost-effective chips available from
a variety of suppliers. Additionally, theres
no need for costly IT experts to commission
or maintain the system.

EtherCAT is an internationally standardized open technology, meaning anyone is

free to use the technology in a compatible
form. However, being an open technology
doesnt mean that anyone can arbitrarily
change EtherCAT to suit his or her needs.
This would be the end of interoperability. The EtherCAT Technology Group, the
worlds largest fieldbus organization, is
responsible for the further development
of EtherCAT so it remains both open and
interoperable.

Industrial Ethernet
EtherCAT also supports common internet
technologies without jeopardizing the networks real-time capability. Its Ethernet
over EtherCAT protocol transports FTP,
http, TCP/IP and Co.

Functional Safety
Safety over EtherCAT is just like EtherCAT
itself lean and fast. Functional safety is
built directly into the bus with options for
both centralized and decentralized safety
logic. Thanks to the Black-Channel approach, it is also available for other bus
systems.

Its proven in use

EtherCAT is currently in use across the
globe in an unrivaled range of applications. EtherCAT is used in machine control,
measurement equipment, medical devices,
automobiles and mobile machines, as well
as in innumerable embedded systems.

ETG Trade Show Booths present

the technology itself as well as the
EtherCAT product variety.

ETG holds regional member

meetings on a regular basis.

EtherCAT Technology Group

The EtherCAT Technology Group keeps

EtherCAT technology open for all potential
users. It brings EtherCAT device manufacturers, technology providers, and users
together to further the technology. It provides multiple Technical Working Groups
where experts carefully work on various
specific aspects of EtherCAT. All of these
activities are focused on one common goal:
keeping EtherCAT stable and interoperable.
Thats why there is only a single version of
EtherCAT, and not a new version each year.
The ETG holds multiple Plug Fests in
Europe, Asia, and America each year. The
Plug Fests bring EtherCAT device developers together to test and ensure device
interoperability. Using the official EtherCAT
Conformance Test Tool, each manufacturer
conformance tests its EtherCAT devices
prior to their release. The ETG awards the
manufacturer a Conformance Certificate
following a successful test in an accredited
test lab.
The ETG also holds international
seminars and workshops and represents
EtherCAT at tradeshows throughout the
globe. It also provides product guides, joint
tradeshow booths, and seminar exhibits
to help its members market their EtherCAT
products.

The ETG has the largest number of members out of any fieldbus organization in the
world. The list of members can be found on
its homepage. However, the decisive factor
is not how many members there are, but
how active the members are in the ETG.
Both the number and variety of EtherCAT
devices is unparalleled, and EtherCATs
adoption rate across Europe, Asia, and
America is outstanding.

Become a member
ETG membership is open to all companies,
whether device manufacturers or users.
ETG members:
Receive access to technical specifications and the developers forum
Contribute to the further development
of EtherCAT in the way of Technical
Working Groups
Receive implementation support from
their local ETG office
Receive free software stacks,
software tools, and access to additional
development products
Are permitted to use the EtherCAT
and ETG logos
Display their EtherCAT products and services in the official product guide,
at tradeshows, and at ETG events.
Bylaws, registration form, and
additional information are available
[email protected] and
www.ethercat.org.

International standardization

Global Activities

The EtherCAT Technology Group is an official partner of the IEC. Both EtherCAT and
Safety over EtherCAT are IEC-Standards
(IEC 61158 and IEC 61784). These standards not only include the lower protocol
layers, but also the application layer and
device profiles, e.g. for drives. SEMI
(Semiconductor Equipment and Materials
International) has accepted EtherCAT as a
communication standard (E54.20) for the
semiconductor industry. The various Task
Groups in the ETG Semiconductor Technical Working Group (TWG) have defined
industry specific device profiles and implementation guidelines.
The EtherCAT Specification is available
in English, Japanese, Korean, and Chinese.

The EtherCAT Technology Group is active

worldwide. Experts in the ETG offices in
Germany, China, Japan, Korea, and the USA
support ETG members before, during and
after implementation.
The technology is maintained in the
Technical Working Groups (TWG), which
define enhancements and also uniform
device behavior by means of device profiles
and implementation guidelines. All members are encouraged to contribute actively
to the TWGs.

In many countries EtherCAT also is a

national standard, such as in Korea.

EtherCAT Milestones

2003

2006

EtherCAT
introduced

EtherCAT
ASIC

ETG founded

2008
EtherCAT
Conformance
Test Tool

2011

2013

EtherCAT interface
in Standard
P + C

2014

Member 2500

Member 3000

Test Center
in China

Test Center in
North America
EtherCAT is
Chinese Standard

2005
Safety over
EtherCAT

2007
EtherCAT is
IEC Standard

2009

2012

Member 1000

Member 2000

Test Centers in
Germany and Japan

Semiconductor Proles

Why use EtherCAT?

The unique way that EtherCAT works makes it the clear engineers choice. Additionally,
the following features are particularly advantageous for certain applications.

1. Exceptional performance
EtherCAT is by and large the fastest Industrial Ethernet technology, but it also synchronizes with nanosecond accuracy.
This is a huge benefit for all applications in which the target system is controlled or measured via the bus system. The
rapid reaction times work to reduce the
wait times during the transitions between
process steps, which significantly improves
application efficiency. Lastly, the EtherCAT
system architecture typically reduces the
load on the CPU by 25 30 % in comparison
to other bus systems (given the same cycle
time). When optimally applied, EtherCATs
performance leads to improved accuracy,
greater throughput, and thus to lowered
costs.

2. Flexible topology
In EtherCAT applications, the machine
structure determines the network topology,
not the other way around. In conventional
Industrial Ethernet systems, there are limitations on how many switches and hubs can
be cascaded, which thus limits the overall
network topology. Since EtherCAT doesnt
need hubs or switches, there are no such
limitations. In short, EtherCAT is virtually
limitless when it comes to network topology. Line, tree, star topologies and any combinations thereof are possible with a nearly
unlimited number of nodes. Thanks to automatic link detection, nodes and network
segments can be disconnected

during operation and then reconnected

even somewhere else. Line topology is extended to a ring topology for the sake of cable redundancy. All the master device needs
for this redundancy is a second Ethernet
port, and the slave devices already supports
the cable redundancy. This makes switching
out devices during machine operation possible.

3. Its simple and robust

Configuration, diagnostics, and maintenance are all factors that contribute to system costs. The Ethernet fieldbus makes all
of these tasks significantly easier: EtherCAT
can be set to automatically assign addresses, which eliminates the need for manual
configuration. A low bus load and peer-topeer physics improve electromagnetic
noise immunity. The network reliably detects potential disturbances down to their
exact location, which drastically reduces
the time needed for troubleshooting.
During startup, the network compares the
planned and actual layouts to detect any
discrepancies.
EtherCAT performance also helps during system configuration by eliminating
the need for network tuning. Thanks to the
large bandwidth, there is capacity to transmit additional TCP/IP together with the
control data. However, since EtherCAT itself isnt based on TCP/IP, there is no need
to administer MAC-addresses or IP-addresses or to have IT experts configure
switches and routers.

4. Integrated Safety
Functional safety as an integrated part of
the network architecture? Not a problem
with Functional Safety over EtherCAT
(FSoE). FSoE is proven in use through TV
certified devices that have been on the
market since 2005. The protocol fulfills
the requirements for SIL 3 systems and is
suitable for both centralized and decentralized control systems. Thanks to the BlackChannel approach and the particularly lean
Safety-Container, FSoE can also be used
in other bus systems. This integrated approach and the lean protocol help keep system costs down. Additionally, a non-safety
critical controller can also receive and process safety data.

5. Affordability
EtherCAT delivers the features of Industrial
Ethernet at a price similar or even below
that of a classic fieldbus system. The only
hardware required by the master device
is an Ethernet port no expensive interface cards or co-processors are necessary.
EtherCAT slave controllers are available
from various manufacturers in different
formats: as an ASIC, based on FPGA, or
also as an option for standard microprocessor series. Since these inexpensive controllers shoulder all the time-critical tasks,
EtherCAT itself doesnt place any performance requirements on the CPU of slave devices, which keeps device costs down. Since
EtherCAT doesnt require switches or other
active infrastructure components, the costs
for these components and their installation, configuration, and maintenance are
also eliminated.

For these reasons, EtherCAT

is often seen in:
Robotics
Machine tools
Packaging machines
Printing presses
Plastic manufacturing equipment
Presses
Semiconductor manufacturing
machines
Test benches
Pick & Place Machines
Measurement systems
Power plants
Substations
Material handling applications
Baggage handling systems
Stage control systems
Automated assembly systems
Pulp and paper machines
Tunnel control systems
Welding machines
Cranes and lifts
Farm machinery
Offshore applications
Sawmills
Window manufacturing equipment
Building automation systems
Iron and steel works
Wind turbines
Furniture manufacturing equipment
Milling machines
Automated guided vehicles
Entertainment automation
Medical devices
Woodworking machines
Flat glass manufacturing equipment
Weighing systems

10

The Technology in Detail

EtherCAT: Based on Ethernet
Technology
EtherCAT is Industrial Ethernet and utilizes standard frames and the physical layer as
defined in the Ethernet Standard IEEE 802.3. However, it also addresses the specific
demands faced in the automation industry, where:
There are hard real-time requirements with deterministic response times.
The system is usually made up of many nodes, each only having a small amount
of cyclic process data.
Hardware costs are even more important than in IT and office applications.
The above requirements make using a standard Ethernet network at the field level practically impossible. If an individual Ethernet telegram is used for each node, the effective
data rate sinks significantly for just a few bytes of cyclic process data: the shortest
Ethernet telegram is 84 bytes long (including the Inter Frame Gap), of which 46 bytes
can be used for process data. For example, if a drive sends 4 bytes of process data for
the actual position and status information and receives 4 bytes of data for the target
position and control information, the effective data rate for both telegrams sinks to
4/84 = 4.8%. Additionally, the drive usually has a reaction time that triggers the transmission of the actual values after receiving the target values. At the end, not much of the
100MBit/s transfer rate remains.
Protocol stacks, such as those used in the IT world for routing (IP) connection (TCP),
require additional overhead for each node and create further delays through the stack
runtimes.

11

How does EtherCAT work?

EtherCAT overcomes the difficulties described in the previous section with its highperforming mode of operation, in which a single frame is usually sufficient to send and
receive control data to and from all nodes!
The EtherCAT master sends a telegram that passes through each node. Each EtherCAT
slave device reads the data addressed to it on the fly, and inserts its data in the frame
as the frame is moving downstream. The frame is delayed only by hardware propagation
delay times. The last node in a segment or branch detects an open port and sends the
message back to the master using Ethernet technologys full duplex feature.
The telegrams maximum effective data rate increases to over 90 %, and due to the
utilization of the full duplex feature, the theoretical effective data rate is even greater
than 100MBits/s.
The EtherCAT Master is the only node within a segment allowed to actively send an
EtherCAT frame; all other nodes merely forward frames downstream. This concept prevents unpredictable delays and guarantees real-time capabilities.
The master uses a standard Ethernet Media Access Controller (MAC) without an additional communication processor. This allows a master to be implemented on any hardware platform with an available Ethernet port, regardless of which real-time operating
system or application software is used.
EtherCAT slave devices use a so-called EtherCAT Slave Controller (ESC) to process
frames on the fly and entirely in hardware, making network performance predictable and
independent of the individual slave device implementation.

The EtherCAT Protocol

12

EtherCAT embeds its payload in a standard Ethernet frame. The EtherCAT frame is identified with the Identifier (Ox88A4) in the EtherType field. Since the EtherCAT protocol is
optimized for short cyclic process data, the use of bulky protocol stacks, such as TCP/IP or
UDP/IP, can be eliminated.

Ethernet header

ECAT

EtherCAT telegram

Ethernet

DA

SA

Type

Frame HDR

Datagram 1

Datagram 2

Datagram n

Pad.

FCS

(6)

(6)

(2/4)

(2)

(10+n+2)

(10+m+2)

(10+k+2)

(032)

(4)

Ethertype Ox88A4

EtherCAT in a standard Ethernet frame (according to IEEE 802.3)

To ensure Ethernet IT communication between the nodes, TCP/IP connections can optionally be tunneled through a mailbox channel without impacting real-time data transfer.
During startup, the master device configures and maps the process data on the slave
devices. Different amounts of data can be exchanged with each slave, from one bit to a
few bytes, or even up to kilobytes of data.
The EtherCAT frame contains one or more Datagrams. The Datagram header indicates
what type of access the master device would like to execute:
Read, write, or read-write
Access to a specific slave device through direct addressing, or access to multiple
slave devices through logical addressing (implicit addressing)
Logical addressing is used for the cyclical exchange of process data. Each Datagram addresses a specific part of the process image in the EtherCAT segment, for which 4GBytes
of address space is available. During network startup, each slave device is assigned one
or more addresses in this global address space. If multiple slave devices are assigned addresses in the same area, they can all be addressed with a single Datagram. Since the Datagrams completely contain all the data access related information, the master device can
decide when and which data to access. For example, the master device can use short cycle
times to refresh data on the drives, while using a longer cycle time to sample the I/O; a
fixed process data structure is not necessary. This also relieves the master device in comparison to in conventional fieldbus systems, in which the data from each node had to be
read individually, sorted with the help of the process controller, and copied into memory.
With EtherCAT, the master device only needs to fill a single EtherCAT frame with new out-

put data, and send the frame via automatic Direct Memory Access (DMA) to the MAC controller. When a frame with new input data is received via the MAC controller, the master
device can copy the frame again via DMA into the computers memory all without the
CPU having to actively copy any data.
In addition to cyclical data, further Datagrams can be used for asynchronous or event
driven communication.

Ethernet header

ECAT HDR

Datagram 1

Datagram 2

Datagram 3

Logical Process
Image Task 1

Logical Process
Image Task 2

Logical Process
Image Task 3

Inserting process data on the fly

In addition to logical addressing, the master device can also address a slave device via its
position in the network. This method is used during network boot up to determine the
network topology and compare it to the planned topology.
After checking the network configuration, the master device can assign each node a
configured node address and communicate with the node via this fixed address. This enables targeted access to devices, even when the network topology is changed during operation, for example with Hot Connect Groups. There are two approaches for slave-to-slave
communication. A slave device can send data directly to another slave device that is connected further downstream in the network. Since EtherCAT frames can only be processed
going forward, this type of direct communication depends on the networks topology, and

13

Ethernet

14

is particularly suitable for slave-to-slave communication in a constant machine design

(e.g. in printing or packaging machines). In contrast, freely configurable slave-to-slave
communication runs through the master device, and requires two bus cycles (not necessarily two control cycles). Thanks to EtherCATs excellent performance, this type of slaveto-slave communication is still faster than with other communication technologies.

Flexible Topology
Line, tree, star, or daisy-chain: EtherCAT supports almost all of topologies.
EtherCAT makes a pure bus or line topology with hundreds of nodes possible without
the limitations that normally arise from cascading switches or hubs.
When wiring the system, the combination of lines with branches or drop lines is particu-

Flexible topology line, tree or star

larly beneficial: the ports necessary to create branches are directly integrated in many
I/O modules, so no additional switches or active infrastructure components are required.
The star topology, the Ethernet classic, can also naturally be utilized.
Modular machines or tool changers require network segments or individual nodes to
be connected and disconnected during operation. EtherCAT slave controllers already include the basis for this Hot Connect feature. If a neighboring station is removed, then the
port is automatically closed so the rest of the network can continue to operate without
interference. Very short detection times <15s guarantee a smooth changeover.
EtherCAT offers a lot of flexibility regarding cable types, so each segment can use the
exact type of cable that best meets its needs. Inexpensive industrial Ethernet cable can be
used between two nodes up to 100m apart in 100BASE-TX mode. The Power over EtherCAT
option (compatible with IEEE 802.3af) enables the connection of devices such as sensors
with a single line. Fiber Optics (such as 100BASE-FX) can also be used, for example for a
node distance greater than 100m. The complete range of Ethernet wiring is also available
for EtherCAT.
Up to 65,535 devices can be connected to one EtherCAT segment, so network expansion is virtually unlimited. Because of the practically unlimited number of nodes, modular
devices such as sliced I/O stations can be designed in such a way that each module is an
EtherCAT node of its own. Hence, the local extension bus is eliminated; the high performance of EtherCAT reaches each module directly and without any delays, since there is no
gateway in the bus coupler or head station any more.

15

16

Distributed Clocks for

High-Precision Synchronization
In applications with spatially distributed processes requiring simultaneous actions, exact
synchronization is particularly important. For example, this is the case for applications in
which multiple servo axes execute coordinated movements.
In contrast to completely synchronous communication, whose quality suffers immediately from communication errors, distributed synchronized clocks have a high degree
of tolerance for jitter in the communication system. Therefore, the EtherCAT solution for
synchronizing nodes is based on such distributed clocks (DC).

Completely hardware-based synchronization with

compensation for propagation delays.

The calibration of the clocks in the nodes is completely hardware-based. The time from
the first DC slave device is cyclically distributed to all other devices in the system. With
this mechanism, the slave device clocks can be precisely adjusted to this reference clock.
The resulting jitter in the system is significantly less than 1s.

Since the time sent from the reference clock arrives at the slave devices slightly delayed,
this propagation delay must be measured and compensated for each slave device in order
to ensure synchronicity and simultaneousness. This delay is measured during network
startup or, if desired, even continuously during operation, ensuring that the clocks are
simultaneous to within much less than 1s of each other.

Synchronicity and simultaneousness scope view of two distributed

devices with 300 nodes and 120 m
cable length.

If all nodes have the same time information, they can set their output signals simultaneously and affix their input signals with a highly precise timestamp. In motion control
applications, cycle accuracy is also important in addition to synchronicity and simultaneousness. In such applications, velocity is typically derived from the measured position, so
it is critical that the position measurements are taken precisely equidistantly (i.e. in exact
cycles). Even very small inaccuracies in the position measurement timing can translate to
larger inaccuracies in the calculated velocity, especially relative to short cycle times. With
EtherCAT, the position measurements are triggered by the precise local clock and not the
bus system, leading to much greater accuracy.
Additionally, the use of distributed clocks also unburdens the master device; since actions such as position measurement are triggered by the local clock instead of when the
frame is received, the master device doesnt have such strict requirements for sending
frames. This allows the master stack to be implemented in software on standard Ethernet
hardware. Even jitter in the range of several microseconds does not diminish the accuracy
of the Distributed Clocks! Since the accuracy of the clock does not depend on when its set,
the frames absolute transmission time becomes irrelevant. The EtherCAT master need
only to ensure that the EtherCAT telegram is sent early enough, before the DC signal in
the slave devices triggers the output.

17

18

Diagnostics and
Error Localization
Experience with conventional fieldbus systems has shown that diagnostic characteristics
play a major role in determining a machines availability and commissioning time.
In addition to error detection, error localization is important during troubleshooting.
EtherCAT features the possibility to scan and compare the actual network topology with
the planned topology during boot up. EtherCAT also has many additional diagnostic
capabilities inherent to its system.
The EtherCAT Slave Controller in each node checks the moving frame for errors with a
checksum. Information is provided to the slave application only if the frame has been received correctly. If there is a bit error, the error counter is incremented and the subsequent
nodes are informed that the frame contains an error. The master device will also detect
that the frame is faulty and discard its information. The master device is able to detect
where the fault originally occurred in the system by analyzing the nodes error counters.
This is an enormous advantage in comparison to conventional fieldbus systems, in which
an error is propagated along the entire party line, making it impossible to localize the
source of the error. EtherCAT can detect and localize occasional disturbances before the
issue impacts the machines operation.
Thanks to EtherCATs unique principle of bandwidth utilization, which is orders of
magnitude better than industrial Ethernet technologies that use single frames, the likelihood of disturbances induced by bit errors within an EtherCAT frame is substantially
lower if the same cycle time is used. And, if in typical EtherCAT fashion much shorter
cycle times are used, the time required for error recovery is significantly reduced. Thus, it
is also much simpler to master such issues within the application.
Within the frames, the Working Counter enables the information in each Datagram to
be monitored for consistency. Every node that is addressed by the Datagram and whose
memory is accessible increments the Working Counter automatically. The master is then
able to cyclically confirm if all nodes are working with consistent data. If the Working
Counter has a different value than it should, the master does not forward this Datagrams
data to the control application. The master device is then able to automatically detect the
reason for the unexpected behavior with help from status and error information from the
nodes as well as the Link Status.
Since EtherCAT utilizes standard Ethernet frames, Ethernet network traffic can be
recorded with the help of free Ethernet software tools. For example, the well-known Wireshark software comes with a protocol interpreter for EtherCAT, so that protocol-specific
information, such as the Working Counter, commandos, etc. are shown in plain text.

High Availability Requirements

For machines or equipment with very high availability requirements, a cable break or a
node malfunctioning should not mean that a network segment is no longer accessible,
or that the entire network fails.
EtherCAT enables cable redundancy with simple measures. By connecting a cable
from the last node to an additional Ethernet port in the master device, a line topology is
extended into a ring topology. A redundancy case, such as a cable break or a node malfunction, is detected by a software add-on in the master stack. Thats all there is to it!
The nodes themselves dont need to be modified, and dont even know that theyre
being operated in a redundant network.
Link detection in the slave devices automatically detect and resolve redundancy cases

Inexpensive cable redundancy with standard EtherCAT slave devices

with a recovery time is less than 15 s, so at maximum, a single communication cycle

is disrupted. This means that even motion applications with very short cycle times can
continue working smoothly when a cable breaks.
With EtherCAT, its also possible to realize master device redundancy with Hot Standby. Vulnerable network components, such as those connected with a drag chain, can be
wired with a drop line, so that even when a cable breaks, the rest of the machine keeps
running.

19

EtherCAT System Overview

EtherCAT Plant Network

EtherCAT Machine Control Network

EtherCAT Automation Protocol (EAP)

EtherCAT Device Protocol

Standard
Ethernet
Interface

Distributed Clocks:
Reference Clock

100BASE-TX
up to 100 m between
two devices

MES

Master to Master

Switch
ERP

Class A or Class B
Master according to
Master Class Directive

Data exchange &

synchronization
between EtherCAT
segments

HMI
WiFi

Centralized
Safety over
EtherCAT Master

Tablet

High availability: Cable redundancy

Slave to
Slave

Decentralized
Safety over EtherCAT
Master

Optical Fibre
up to 20 km between
two devices

e.g.
- IEEE 1588
- GPS
- DCF 77

EBUS LVDS
Backplane

Up to 65535
Slaves
Junction

ID:01

External
Synchronization

Junction

ID:02

Distributed Clocks
providing extremely
accurate synchronization.
Jitter & Simultaneousness:
<<1 s

ID:03

- Hot Connect
- Explicit Device
Identication

Flexible Topology:
- Line
- Tree
- Star
- Branch

Standard Ethernet
integration:
- Ethernet over EtherCAT
(EoE) e.g. TCP/IP

Data & Power

on same line

Power over
EtherCAT

Switchport

Actor

Fieldbus integration:
- Modular Device
Prole (MDP)
- ADS over EtherCAT
(AoE)

Gateway
atew

Sensor

e.g.
- Valves

e.g.
- Encoders

Slave to Master
Other Fieldbuses

Master to Slave

Drive integration:
- CAN application protocol over
EtherCAT (CoE)
with DS402 Drive Prole
- Servo Drive Prole
over EtherCAT (SoE)
- Safety Drive Prole
- Modular Device Prole (MDP)

Safety over EtherCAT

22

Modern communication systems not only realize the deterministic transfer of control data, they also enable the transfer of safety-critical control data through the same medium.
EtherCAT utilizes the protocol Safety over EtherCAT for this very purpose and so allows:
A single communication system for both control and safety data
The ability to flexibly modify and expand the safety system architecture
Pre-certified solutions to simplify safety applications
Powerful diagnostic capabilities for safety functions
Seamless integration of the safety design in the machine design
The ability to use the same development tools for both standard and safety
applications

Relais Logic

Safety over EtherCAT enables simpler and more flexible architectures than with relay logic.

The EtherCAT safety technology was developed according to IEC 61508, is TV certified, and
is standardized in IEC 61784-3. The protocol is suitable for safety applications with a Safety
Integrity Level up to SIL 3.
With Safety over EtherCAT, the communication system is part of a so-called Black Channel, which is not considered to be safety relevant. The standard communication system
EtherCAT makes use of a single channel to transfer both standard and safety-critical data.

Safety Frames, known as Safety Containers, contain safety-critical process data and additional information used to secure this data. The Safety Containers are transported as part of
the communications process data. Whether data transfer is safe does not depend on the underlying communication technology, and isnt restricted to EtherCAT; Safety Containers can
travel through fieldbus systems, Ethernet or similar technologies, and can make use of copper
cables, fiber optics, and even wireless connections.

Ethernet telegram
Ethernet header

ECAT HDR

Datagram 1

Datagram 2

FSC

Safety over EtherCAT frame

CMD

Safe data

CRC_0

Safe data

CRC_1

Conn ID

The Safety Container is embedded in the cyclical communications process data.

Due to this flexibility, safely connecting different parts of the machine becomes more simple. The Safety Container is routed through the various controllers and processed in the
various parts of the machine. This makes emergency stop functions for an entire machine
or bringing targeted parts of a machine to a standstill easily possible even if the parts of
the machine are coupled with other communication systems (e.g. Ethernet).
Implementing the FSoE protocol in a device requires little resources and can lead to a
high level of performance and correspondingly, short reaction times. In the robotics industries, there are applications that use SoE for safe motion control applications in an 8-kHz
closed loop.
Device 1
Controller A
safety
protocol

Device 2
Controller B
safety
protocol

Controller B
safety
protocol

EtherCAT Slave Controller

IN

Controller A
safety
protocol

EtherCAT Slave Controller

OUT

IN

OUT

EtherCAT

Black-Channel-Principle: the standard communication interface can be used.

Further information regarding Safety over EtherCAT can be found on the EtherCAT website:
www.ethercat.org/safety

23

24

Communication Profiles
In order to configure and diagnose slave devices, it is possible to access the variables provided for the network with the help of acyclic communication. This is based on a reliable
mailbox protocol with an auto-recover function for erroneous messages.
In order to support a wide variety of devices and application layers, the following
EtherCAT communication profiles have been established:
CAN application protocol over EtherCAT (CoE)
Servo drive profile, according to IEC 61800-7-204 (SoE)
Ethernet over EtherCAT (EoE)
File access over EtherCAT (FoE)

File system,
bootloader

File access

HTTP, FTP,

IEC 61800-7-204
application
(SERCOS)

CANopen
application

TCP UDP

IDN

Object
Dictionary

IP

Service channel

SDO

Ethernet
FoE

EoE

SoE

Mailbox

CoE

Process data

PDO
mapping

AT
MDT

CoE/SoE

Process data

EtherCAT Slave Controller

Physical layer
Different communication profiles can coexist in the same system.

A slave device isnt required to support all communication profiles; instead, it may
decide which profile is most suitable for its needs. The master device is notified which
communication profiles have been implemented via the slave device description
file.

CAN application protocol over EtherCAT (CoE)

25
With the CoE protocol, EtherCAT provides the same communication mechanisms as in
CANopen-Standard EN 50325-4: Object Dictionary, PDO Mapping (Process Data Objects)
and SDO (Service Data Objects) even the network management is similar. This makes
it possible to implement EtherCAT with minimal effort in devices that were previously
outfitted with CANopen, and large portions of the CANopen Firmware are even reusable.
Optionally, the legacy 8-byte PDO limitation can be waived, and its also possible to use
the enhanced bandwidth of EtherCAT to support the upload of the entire Object Dictionary. The device profiles, such as the drive profile CiA 402, can also be reused for EtherCAT.

Servo drive profile according to IEC 61800 7 204 (SoE)

SERCOS is known as a real-time communication interface, especially for motion control
applications. The SERCOS profile for servo drives is included in the international standard
IEC 61800-7. The standard also contains the mapping of this profile to EtherCAT. The service channel, including access to all drive-internal parameters and functions, are mapped to
the EtherCAT Mailbox.

Ethernet over EtherCAT (EoE)

EtherCAT makes use of physical layers of Ethernet and the Ethernet frame. The term
Ethernet is also frequently associated with data transfer in IT applications, which are
based on a TCP/IP connection.
Using the Ethernet over EtherCAT (EoE) protocol any Ethernet data traffic can be transported within an EtherCAT segment. Ethernet devices are connected to an EtherCAT seg-

Switchport
Webserver

Transparent transmission of standard IT protocols.

26

ment via so-called Switchports. The Ethernet frames are tunneled through the EtherCAT
protocol, similarly to the internet protocols (e.g. TCP/IP, VPN, PPPoE (DSL), etc.) as such,
which makes the EtherCAT network completely transparent for Ethernet devices. The
device with the Switchport property takes care of inserting TCP/IP fragments into the
EtherCAT traffic and therefore prevents the networks real-time properties from being
affected.
Additionally, EtherCAT devices may also support Ethernet protocols (such as HTTP)
and can therefore behave like a standard Ethernet node outside of the EtherCAT segment.
The master device acts as a Layer-2-switch that sends the frames via EoE to the corresponding nodes according to their MAC addresses. In this way, all internet technologies
can also be implemented in an EtherCAT environment, such as an integrated web server,
E-mail, FTP transfer, etc..

File access over EtherCAT (FoE)

This simple protocol similar to TFTP (Trivial File Transfer Protocol) enables file access in
a device and a uniform firmware upload to devices across a network. The protocol has
been deliberately specified in a lean manner, so that it can be supported by boot loader
programs a TCP/IP stack isnt required.

Plant-wide communication with the

EtherCAT Automation Protocol (EAP)
The process control level has special communication requirements that differ slightly from
the requirements addressed by the EtherCAT Device Protocol, described in the previous
sections. Machines or sections of a machine often need to exchange status information
and information about the following manufacturing steps with each other. Additionally,
there is usually a central controller that monitors the entire manufacturing process, provides the user with status information on productivity, and assigns orders to the various
machine stations.
The EtherCAT Automation Protocol (EAP) fulfills all of the above requirements.
The protocol defines interfaces and services for:
Exchanging data between EtherCAT master devices (master-master communication),
Communication to Human Machine Interfaces (HMI),
A supervising controller to access devices belonging to underlying EtherCAT segments
(Routing),
Integration of tools for the machine or plant configuration, as well as for device
configuration.

The communication protocols used in EAP are part of the international standard IEC 61158.
EAP can be transmitted via any Ethernet connection, including a wireless link, for example
making it possible to include automated guided vehicles (AGV), which are common in the
semiconductor and automotive industries.
Cyclic process data exchange with EAP follows either the Push or Poll principle. In
Push mode, each node sends its data either with its own cycle time or in a multiple of
the own cycle time. Each receiver can be configured to receive data from specific senders.
Configuring the sender and receiver data is done through the familiar Object Dictionary.
In Poll mode, a node (often the central controller) sends a telegram to the other nodes,
and each node responds with its own telegram.
The cyclic EAP communication can be directly embedded within the Ethernet frame,
without additional transport or routing protocol. Again, the EtherType Ox88A4 identifies

ERP

HMI
(e.g. OPC,
Thin Client)

Switch

27

EtherCAT Automation Protocol

Process
Control

Conguration
Handheld

EtherCAT Device Protocol processed on the y

Factory-wide Communication with EtherCAT

28

the EtherCAT-specific use of the frame. This enables the exchange of high-performance
data with EAP in a millisecond cycle. If data routing between distributed machines is
required, the process data can also be transmitted via UPD/IP or TCP/IP.
Additionally, with the help of the Safety over EtherCAT Protocol, its also possible
to transmit safety-critical data via EAP. This is common in cases where parts of a large
machine need to exchange safety-critical data to realize a global emergency stop function,
or to inform neighboring machines of an emergency stop.

PROCESS
CONTROL

EtherCAT Automaton Protocol (EAP)

Safety over EtherCAT

Machine module A

Machine module B

Factory-wide communication architecture with the EtherCAT Automation Protocol and Safety over EtherCAT

Machine module C

Integration of other Bus Systems

EtherCATs ample bandwidth makes it possible to embed conventional fieldbus networks
as an underlying system via an EtherCAT Gateway, which is particularly helpful when migrating from a conventional fieldbus to EtherCAT. The changeover to EtherCAT is gradual,
making it possible to continue using automation components that dont yet support an
EtherCAT interface.

Gateway
atew

Gateway
atew

Decentralized fieldbus interfaces

The ability to integrate decentralized gateways also reduces the physical size of the
Industrial PC, sometimes even to an embedded Industrial PC, since extension slots are
no longer necessary. In the past, extension slots were also required to connect complex
devices, such as fieldbus master and slave gateways, fast serial interfaces, and other communication subsystems. In EtherCAT, all that is needed to connect these devices is a single
Ethernet port. The process data from the underlying subsystem is made directly available
in the process image of the EtherCAT system.

29

30

Implementing
EtherCAT Interfaces

31

EtherCAT technology has been specially optimized to enable low-cost design, so adding an
EtherCAT interface to a sensor, I/O device, or embedded controller should not significantly
increase device costs. Furthermore, the EtherCAT interface also doesnt require a more
powerful CPU- the CPU requirements instead are based only on the needs of the target
application.
In addition to hardware and software requirements, development support and the
availability of communication stacks are important when developing an interface. The
EtherCAT Technology Group offers worldwide developer support in quickly answering
questions or addressing technical issues. Finally, evaluation kits available from multiple
manufacturers, developer workshops, as well as free sample code make getting started a
little easier.
For the end user, the most important factor is the interoperability of EtherCAT devices
from various manufacturers. To ensure interoperability, device manufacturers are required
to perform a Conformance Test prior to bringing their device on the market. The test
checks if the implementation follows the EtherCAT specification, and can be performed
with the EtherCAT Conformance Test Tool. The test can also be used during device development to discover and correct implementation issues early on.

32

Implementing a Master Device

The interface for an EtherCAT master device has a single, unbelievably simple, hardware
requirement: an Ethernet port. The implementation uses either the on-board Ethernet
controller or an inexpensive standard network card, so no special interface card is required. That means that with just a standard Ethernet port, a master device can implement a hard real-time network solution.
In most cases the Ethernet controller is integrated via Direct Memory Access (DMA),
so no CPU capacity is required for the data transfer between the master device and the
network. In an EtherCAT network, mapping occurs at the slave devices. Each slave device
writes its data to the right location in the process image and reads the data addressed to
it all while the frame is moving through. Therefore, the process image that arrives at the
master device is already sorted correctly.
Since the master device CPU is no longer responsible for the sorting, its performance
requirements depend only on the desired application and not the EtherCAT interface. Especially for small, mid-sized, and clearly defined applications, implementing an EtherCAT
master is a snap. EtherCAT master devices have been implemented for a wide variety of
operating systems: Windows and Linux in various iterations, QNX, RTX, VxWorks, Intime,
eCos are just a few examples.
ETG members offer a variety of options to support the implementation of an
EtherCAT Master, ranging from free downloads of EtherCAT Master Libraries, sample
Master code, all the way to complete packages (including services) for various real-time
operating systems and CPUs.
In order to operate a network, the EtherCAT master requires the cyclic process data
structure as well as boot-up commands for each slave device. These commands can be
exported to an EtherCAT Network Information (ENI) file with the help of an EtherCAT configuration tool, which uses the EtherCAT Slave Information (ESI) files from the connected
devices.

33

The breadth of available master implementations and their supported functions varies.
Depending on the target application, optional functions are either supported or purposely
omitted to optimize the utilization of hardware and software resources. For this reason,
EtherCAT master devices are categorized into two classes: a Class-A-Master is a standard
EtherCAT master device, while a Class-B-Master is a master device with fewer functions. In
principle, all master implementations should aim for Class A classification. Class B is only
recommended for cases in which the available resources are insufficient to support all
functionalities, such as in embedded systems.
Control task

Process image
description (XML)

System
conguration
tool

EtherCAT network
information (ENI)

XML parser

XML

HW conguration
Init Commands

EtherCAT slave
information (ESI)
XML

HDR

Process data

online functions
EtherCAT master driver
EtherCAT master

Standard Ethernet MAC

Typical EtherCAT Master Architecture

34

Implementing a Slave Device

EtherCAT slave devices use inexpensive EtherCAT Slave Controllers (ESC) in the form of an
ASIC, FPGA, or integrated in a standard microcontroller. Simple slave devices dont even
need an additional microcontroller, because inputs and outputs can be directly connected
to the ESC. For more complex slave devices, the communication performance depends
only minimally on the microcontroller performance, and in most cases, a 8-bit microcontroller is sufficient.
EtherCAT Slave Controllers are available from multiple manufacturers, with the size
of the internal DPRAM and the number of Fieldbus Memory Management Units (FMMUs)
depending on the variation. Different Process Data Interfaces (PDI) for external access
from the application controller to the application memory are also available:
The 32-Bit parallel I/O Interface is suitable for connecting up to 32 digital inputs and
outputs, but also for simple sensors or actuators for which 32 data bits are sufficient
and no application controller is required.
The Serial Peripheral Interface (SPI) is targeted at applications with small amounts
of process data, such as analog I/O devices, encoders, or simple drives.
The parallel 8/16-bit microcontroller interface corresponds to common interfaces of
fieldbus controllers with integrated DPRAM. It is particularly suitable for complex
nodes with larger amounts of data.
Suitable synchronous busses for various microcontrollers have been implemented for
FPGA and On-Chip variations.

35

Host CPU
Process
data

HTTP,
FTP,
Service
data

RAM for TCP/IP

and complex
applications

TCP/IP
(optional)

8 I/O

8 I/O

PDI (Process data interface)

SYNC-manager, FMMU

SII (e.g.
EEPROM)

Registers

RJ 45

Magnetics

PHY

SYNC-manager, FMMU

Slave Hardware:
EtherCAT Slave Controller with Host CPU

Magnetics

SII (e.g.
EEPROM)

Registers

EtherCAT processing unit

and auto-forwarder with loop back

EtherCAT Port n
MII
PHY

ESC
(EtherCAT slave
controller)

Process data
Dual port memory

EtherCAT processing unit

and auto-forwarder with loop back
EtherCAT Port 0
MII

8 I/O

PDI (Process data interface)

ESC
(EtherCAT slave
controller)

Process data
Mailbox
Dual port memory

8 I/O

EtherCAT Port 0
MII
RJ 45

RJ 45

Magnetics

PHY

EtherCAT Port n
MII
PHY

Slave Hardware:
EtherCAT Slave Controller with direct I/O

The hardware configuration is stored a in non-volatile memory (e.g. an EEPROM), the Slave
Information Interface (SII), which contains information about the basic device features,
so that the master can read this at boot-up and operate the device even if the device description file is not available. The EtherCAT Slave Information (ESI) file that comes with
the device is XML based and contains the complete description of its network accessible
properties, such as process data and their mapping options, the supported mailbox protocols including optional features, as well as the supported modes of synchronization. The
Network Configuration Tool uses this information for online and offline configuration of
the network.
Various manufacturers offer evaluation kits for implementing slave devices. These kits
include slave application software in source code, and they sometimes also include a test
master. Using an evaluation kit, a fully functional Master-Slave EtherCAT network can be
commissioned in just a few steps.
The ETG website contains a Slave Implementation Guide with useful tips and hints on
further documentation for implementing slave devices.

Magnetics

RJ 45

36

Conformance and Certification

Two of the most important factors for a communication standard to be successful are
conformance and interoperability. Thats why the EtherCAT Technology Group takes both
of these factors very seriously. In addition to requiring a conformance test for each device
implementation (aided by the automated EtherCAT Conformance Test Tool), the ETG offers a wide variety of activities to ensure the interoperability between EtherCAT master
devices, slave devices, and also the EtherCAT Configuration Tool.

Plug Fests
When trying to test if multiple devices are interoperable, one of the most pragmatic
things to do is to try connecting the devices together. With this approach in mind, the
ETG holds multiple Plug Fests each year, with each Plug Fest usually spanning two days.
During the Plug Fests, master and slave device manufacturers come together to test
how their devices behave together, which improves the usability of devices in the field.
Members can exchange EtherCAT tips and tricks and have their questions answered by
EtherCAT experts. The ETG holds Plug Fests in Europe, North America, and Asia.

Conformance Test Tool

The EtherCAT Conformance Test Tool (CTT) makes it possible to automatically test an
EtherCAT slave devices behavior.
Its a Windows program requiring only a standard Ethernet port. The tool sends
EtherCAT frames to the Device under Test (DuT) and receives its responses. A test case
is marked as passed if the response from the DuT corresponds to the defined response.
The test cases are defined as XML files. This makes it possible to modify or expand the test
cases without having to modify the actual test tool. The TWG Conformance (see above)
is responsible for specifying and releasing the most current valid test cases.
In addition to the protocol tests, the CTT also examines if the values in the EtherCAT
Slave Information (ESI) file are valid. Finally, the CTT also performs device-specific protocol
tests, such as for the CiA 402 drive profile.
All of the testing steps and results are saved in a Test Logger, and can be analyzed or
saved as a documented verification for the device release.
The ETG consistently maintains and adds new test cases to the CTT. It is important
that a device manufacturer always has the most recent version of the tool for testing
products prior to release. To make it easier, the CTT is offered as a subscription. The CTT
is also useful during the design phase to uncover early errors in the interface implementation.

37

Technical Working Group Conformance

The EtherCAT Conformance Test Policy requires device manufacturers to test each device
with a valid version of the EtherCAT Conformance Test Tool before the device is brought
on the market. The manufacturer may conduct this test in-house.
The ETG Technical Committee (TC) established a Technical Working Group (TWG) Conformance, which determines the test procedures, the contents of the test, and the implementation of the Conformance Test Tool. The TWG Conformance is continuously expanding the tests and their depth.
The TWG Conformance also established an Interoperability Tests process, with which
devices can be tested in the context of an entire network.

EtherCAT Test Centers

The official EtherCAT Test Centers (ETC) in Europe, Asia and North America are accredited
by the ETG and perform the official EtherCAT Conformance Test. The EtherCAT Conformance Test includes the automated tests run with the CTT, interoperability tests within a
network, as well as an examination of the devices indicators, markings, and tests of the
EtherCAT interfaces.
Device manufacturers are encouraged but not obligated to have their devices tested
at an ETC. After the Conformance Test is passed, the manufacturer receives an EtherCAT
Conformance Tested certificate for the device. This certificate is only available for devices
that have passed the Conformance Test at an ETC- not for those which have been tested
in-house.
The additional test in an accredited EtherCAT Test Center further increases compatibility and the uniform operation and diagnostics of EtherCAT implementations. End users
should be sure to ask for the EtherCAT Conformance Tested certificate when choosing
devices for their application.
More information on conformance and the EtherCAT Test Centers is available on the ETG
Website: www.ethercat.org/conformance

38

www.ethercat.org
The EtherCAT website provides comprehensive information about the technology
as well as upcoming events, the latest EtherCAT products and the current membership roster. Also, there are focus topics such as functional safety and conformance of EtherCAT devices. Furthermore, the website provides presentations, press
articles and publications in the download section.

EtherCAT Product Guide

The EtherCAT Product Guide is a directory listing EtherCAT products and services
based on information provided by ETG members, and is available online at
www.ethercat.org/products. If you have any questions about the products,
please contact the manufacturer directly, as the ETG itself does not sell any
products.

Event Section
The event section shows the worldwide events hosted by the ETG and those
that are organized in conjunction with the association. In the calendar located
at www.ethercat.org/events important dates can be found, including those
for the technical working group meetings, trade show appearances, EtherCAT
workshops and Industrial Ethernet seminars.

Member Area
Members have insider access to the protected area of the website at
www.ethercat.org/memberarea, which contains valuable additional items
such as all EtherCAT specifications, the online developer forum and a knowledge base with all necessary information for implementation, configuration
and diagnosis of EtherCAT devices and networks.

ETG worldwide

39

Contact
ETG Headquarters
Ostendstrae 196
90482 Nuremberg
Germany
Phone: + 49 (911) 5 40 56 20
Fax:
+ 49 (911) 5 40 56 29
[email protected]

ETG Office North America

Port Orchard, WA, USA
Phone: +1 (877) 384-3722
Fax:
+ 1 (512) 535 1437
[email protected]
ETG Office China
Beijing, P. R. China
Phone: + 86 (10) 5830 1239
Fax:
+ 86 (10) 5830 1286
[email protected]
ETG Office Japan
Yokohama, Japan
Phone: + 81 (45) 650 1610
Fax:
+ 81 (45) 650 1613
[email protected]
ETG Office Korea
Seoul, Korea
Phone: +82 70 4849 0300
Fax:
+ 82 (2) 2107 3969
[email protected]

EtherCAT, Safety over EtherCAT, are trademarks or registered trademarks.

Other designations used in this publication may be trademarks whose use
by third parties for their own purposes could violate the rights of the owners.
11/2014