Beckhoff TwinCAT

Configuring the TwinCAT I/O System

Revision: 1.1 Updated: 16 November 2004

Configuring the TwinCAT I/O System

Table Of Contents
Introduction ......................................................................................3 Configuration of TwinCAT I/O System.......................................................4 2.1. Scan Devices Automatically ............................................................... 4 2.2. Scan Boxes Automatically ................................................................. 6 2.3. Scan Terminals Automatically ............................................................ 8 3. Manual Network Configuration ............................................................. 11 3.1. Add Device Manually ..................................................................... 11 3.2. Add Boxes Manually....................................................................... 13 3.3. Add Terminals Manually ................................................................. 15 4. Active TwinCAT System Configuration.................................................... 18 4.1. Generate Mappings ....................................................................... 18 4.2. Check Configuration ...................................................................... 19 4.3. Activate Configuration ................................................................... 20 5. Testing the TwinCAT I/O System ........................................................... 22 5.1. Free-Run Mode ............................................................................ 22 5.2. Testing Digital Inputs..................................................................... 24 5.3. Testing Analogue Inputs ................................................................. 25 5.4. Testing Digital Outputs .................................................................. 26 5.5. Testing Analogue Outputs ............................................................... 28 1. 2.

Key
Device a master controller for a fieldbus network, usually fitted in the PC Box a slave device connected to the fieldbus network Terminal an I/O terminal block fitted to a bus coupler 1. Numbered statements are actions that the user should perform in TwinCAT

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Configuring the TwinCAT I/O System

1. Introduction
The TwinCAT System Manager is used to configure: The PC-based communications hardware, e.g. PROFIBUS-DP master controller, Ethernet master controller, etc Devices connected to the communications system, e.g. BK3100, BC9000, etc I/O terminals connected to bus coupler devices This allows all inputs and outputs on the system to be made available for use by a higher-level controller, such as TwinCAT PLC or a custom-written external control program.

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Configuring the TwinCAT I/O System

2. Configuration of TwinCAT I/O System

TwinCAT System Manager has a Scan Devices function that allows it to: Scan the PC for known communication devices and place them in System Manager under I/O Devices. Scan the network connected to a device, find any known boxes and place them in System Manager under the appropriate device. Scan the terminals connected to a bus coupler box, e.g. BC9000 Ethernet or BK2000 Lightbus, and place them in System Manager under the appropriate box.

2.1. Scan Devices Automatically

To scan the PC for recognised devices: 1. Right-click on I/O Devices 2. Select Scan Devices

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Configuring the TwinCAT I/O System System Manager will scan the PC for known devices, and place them under I/O devices. It will also scan the network for any known boxes, and determine the configuration of any known boxes that are found. In the example below, System Manager has found an FC2001 Lightbus card in the PC, with a BK2000 (with 4 I/O terminals fitted) connected to the Lightbus network.

NOTE: automatic scanning does not detect all types of hardware within a PC, e.g. Virtual Ethernet Interface. In this case, the master controller or device must be added manually. Refer to section 3.1 on page 11.

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Configuring the TwinCAT I/O System

2.2. Scan Boxes Automatically

If the box configuration has been changed on a network, or a device has been added manually, System Manager can re-scan the boxes connected to the network and update the network configuration. In our example, a Virtual Ethernet master device has been added manually, so System Manager will not have found any Ethernet boxes connected to the Ethernet port. To scan or re-scan the Ethernet network: 1. Right click on the Ethernet device. (Ethernet Master in out example below.) 2. Select Scan Boxes.

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Configuring the TwinCAT I/O System System Manager will scan the Ethernet network and show a list of known boxes that have been found on the network. 3. Select the devices that need to be added to System Manager and click OK

System Manager will add the device(s) selected to the master device. In our example, a BC9000 has been added to Ethernet Master.

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Configuring the TwinCAT I/O System

2.3. Scan Terminals Automatically

Before I/O terminals can only be re-scanned, all existing I/O terminals must be deleted from the configuration. If a box has been added manually, it will not have any terminal configuration and steps 1 to 3 are not required. To delete an existing terminal configuration: 1. Right click on terminal. 2. Select Delete Terminal. 3. Repeat for each terminal. End Term (KL9010)does not need to be deleted.

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Configuring the TwinCAT I/O System To scan the terminals connected to a bus coupler and update the I/O terminal configuration. 4. Right click on the box. (BC9000-22 in the example below.) 5. Select Scan Terminals.

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Configuring the TwinCAT I/O System System Manager will re-scan the bus coupler and update the I/O terminal configuration for the selected box.

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Configuring the TwinCAT I/O System

3. Manual Network Configuration

System Manager can also be configured manually before any hardware is attached to the PC. This allows a TwinCAT system to be designed in software while the hardware is being built and wired up.

3.1. Add Device Manually

To add a device to System Manager manually: 1. Right click on I/O Devices 2. Select Append Device

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Configuring the TwinCAT I/O System 3. Select the required device from the list of all currently supported hardware devices in the Insert Device screen. 4. Give the device a name and click OK.

Our example system requires a Virtual Ethernet Interface, and it has been given the name Ethernet Master.

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3.2. Add Boxes Manually

To add a box to the device in System Manager manually: 1. Right click on the device. (Ethernet master in the example below.) 2. Select Append Box

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Configuring the TwinCAT I/O System 3. Select the required device from the list of all currently supported hardware devices for the network in the Insert Box screen. 4. Give the box a name and click OK.

For our example system, select the BC9000 and give it a name. System Manager shows that Ethernet Master with one box (BC9000-22) attached to it.

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3.3. Add Terminals Manually

To add a terminal to the box in System Manager: 1. Right click on the box. (BC9000-22 in the example below.) 2. Select Append Terminal to add an I/O terminal.

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Configuring the TwinCAT I/O System 3. Double click on the type of I/O terminal required (or click once on the + symbol, as shown below) in the Insert Terminal screen.

4. Select the required terminal from the list of available terminals in the category. KL 1002, 2Ch. Input (24V, 3.0ms) is required for our example. 5. Specify the number of terminals of this type that are required. For our example, 2 * KL1002 terminals are required. 6. Give the terminal a name and click OK.

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Configuring the TwinCAT I/O System 7. System Manager will add this terminal to the terminal configuration list for BC9000-22.

8. Repeat steps 1 to 6 for each terminal required for the BC9000-22. The fully configured example system is shown below.

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4. Activate TwinCAT System Configuration

When a system configuration has been completed, it should be saved to disk and saved. To activate the new system configuration, 3 steps must be performed: Generate mappings Check configuration Activate configuration

4.1. Generate Mappings

The first step to activating a TwinCAT I/O system configuration is to generate the mappings. This refreshes all links and I/O points within System Manager. 1. Click the Generate Mappings icon ( ) on the TwinCAT System Manager toolbar.

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4.2. Check Configuration

The second step is to check the configured system for errors. TwinCAT System Manager will scan the entire system configuration to ensure that the configuration is valid. 1. Click the Check Configuration icon ( ) on the TwinCAT System Manager toolbar.

TwinCAT may give the warning message shown below. This message appears because the system has not yet been linked to a TwinCAT device that will drive the TwinCAT system. This does not prevent the TwinCAT I/O system from being activated. 1. Click OK to clear the warning message.

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4.3. Activate Configuration

The third step is to activate the TwinCAT I/O system. TwinCAT System Manager will scan the entire system configuration to ensure that the configuration is valid. 1. Click the Activate Configuration icon ( toolbar. ) on the TwinCAT System Manager

TwinCAT will ask for confirmation to activate the configuration. 2. Click OK to continue system activation.

TwinCAT may also display the warning seen during he Check Configuration sequence. 3. Click OK to continue system activation.

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Configuring the TwinCAT I/O System TwinCAT will ask for confirmation to restart the TwinCAT system in Run Mode. 4. Click OK to restart the TwinCAT I/O system.

TwinCAT will restart the system in the RUN mode. This can be seen in the bottom right of the screen, where Running will be displayed in white text on the green background.

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5. Testing the TwinCAT I/O System

5.1. Free-Run Mode
As the TwinCAT I/O system has not been linked to another device that can drive the I/O, it must put into Free-RUN mode. This is a special mode that activates all the I/O terminals and allows each input and output to be tested. To enter Free-Run mode: 1. Click the Set/Reset TwinCAT to Config Mode icon ( Manager toolbar. ) on the TwinCAT System

2. Click OK to restart TwinCAT I/O System in Config mode.

3. Click Yes to load the I/O Devices.

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Configuring the TwinCAT I/O System 4. Click Yes to Activate Free Run mode.

The TwinCAT I/O System will restart in Config Mode with Free Run active. This can be seen in the bottom right hand corner of System Manager where the status window will alternate between Config Mode on blue and Free Run on red.

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5.2. Testing Digital Inputs

To check the state of a digital input: 1. Double click on the digital input terminal name. 2. Double click on the digital input channel. 3. Select the digital input channel name. (Input in the example below.) 4. Select the Online tab.

The Value field will show the current status of the digital input, and the oscilloscope display will show the recent history of the digital input.

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5.3. Testing Analogue Inputs

To check the state of an analogue input: 1. Double click on the analogue input terminal name. 2. Double click on the analogue input channel. 3. Select the analogue input channel name. (Data In in the example below.) 4. Select the Online tab.

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5.4. Testing Digital Outputs

To toggle the state of a digital output: 1. Double click on the digital output terminal name. 2. Double click on the digital output channel. 3. Select the digital output channel name. (Output in the example below.) 4. Select the Online tab. 5. Click on the Write button.

TwinCAT System Manager will display the Write Value screen. As digital outputs are boolean, they can only be set to 0 or 1: 6. Click the 1 or 0 buttons to set and reset the digital output.

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Configuring the TwinCAT I/O System TwinCAT System Manager will set the digital output value to 1 and display the new output status. The status light on the digital output terminal will also switch on.

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5.5. Testing Analogue Outputs

To toggle the state of a digital output: 1. Double click on the analogue output terminal name. 2. Double click on the analogue output channel. 3. Select the analogue output channel name. (Data Out in the example below.) 4. Select the Online tab. 5. Click on the Write button.

TwinCAT System Manager will display the Write Value screen. As digital outputs are boolean, they can only be set to 0 or 1: 6. Enter the new value in the appropriate box.

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Configuring the TwinCAT I/O System TwinCAT System Manager will set the analogue output value to the new value and display the new output status. +32767 is the full scale positive value, so 16384 will produce +5V on a KL4032 analogue output terminal.

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