BRDGETHC07H/08H

BRIDGE ETHERCAT
Installation
and
Maintenance

Rev.1.7
Date 18.02.2022

ISAC S.r.l. VIA MAESTRI DEL LAVORO, 30 TEL 050 711131

56021 CASCINA (PI) FAX 050 711472
CAPITALE SOCIALE ITALY
100.000,00 €
C.F. e P.I. UNI EN ISO
01252870504 9001:200
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1 INTRODUCTION
This document is a guide for the setting up of the devices.
Before starting read the following general information.

 All dimensions of technical drawings are in mm .

1.1 Wiring rules and recommendations

These are few general rules that must be followed when wiring modules.
UNINTENDED EQUIPMENT OPERATION
Be sure to plug in the correct terminal block or connector into its appropriate,
designed socket, as it is indicated by labels and as it is described into ‘Connection’
paragraph.
WARNING The failure to follow these instruction can result in equipment damage.
DANGER
Remove POWER from ALL devices before removing any covers, and prior to
installing any accessories, hardware, cables or wire.
Terminal blocks must be connected or disconnected with sensor and pre-actuator
voltage switched off.
WARNING Make sure that a proper ground connection exists before applying power to the unit.
Use only the specified voltage.
Recommendations
• Power supply wires and I/O wiring communication must be kept separate from power wires.
Route wiring in separate cable conducting.
• Use proper wire size to meet voltage and current requirements.

1.2 Grounding
Ground connections of the devices are fundamental for the safety of the operators and to make
effective the shielding of electric signals against electric and electromagnetic interferences.
• The ground potential of all devices must be connected to a collection point in the electric
panel which is identified as operational grounding. This collection point must be isolated
from the metal framework of the electric panel and must be connected to the plant
grounding (aka PE) by means of a copper braid of at least 10 mm².
• Electronic monitoring equipment as well as signal connection cable shields must be
connected to the functional ground.
All central units and modules have the grounding terminal marked with the
grounding symbol provided for by the laws in force.

1.3 Cable shielding

Cable shielding is necessary in order to ensure proper operating as the equipment might be
affected by radiated and conducted electromagnetic disturbances.
The equipment has been designed in compliance with EMC minimum requirements as
defined by the law in force, and is provided with CE certification.
Shielded cables must be:
• Measuring transducers cables

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• Analog rate reference cables

• Analog input and analog output signals cable
• Operator panel cables (if remotely controlled).
As recommendation, in an environment with high levels of electromagnetic interference, use a
dedicated +24Vdc power supply and a shielded cable for connecting the supply to the module.

Shield connection must be made at both terminations

On the units and modules side, the shield may be connected in different ways:
• Directly to the Zero Volt terminal of the termination connector;
• Soldered to the connector casing;
• Crimped to a terminal which is tightened to the screw marked with the functional ground
symbol close to the connector.
At the other side, the shield must be connected to the terminal indicated on the equipment.

1.4 Tests of Immunity and electromagnetic emission

Our devices are subjected to the following lab tests, and result to comply with the directives
2006/95/CE of 12 Dec. 2006 and 2004/108/CE of 15 Dec. 2004.
Below are listed the applicable documents.

Reference Title
Electromagnetic compatibility (EMC) – Part 6-2: Generic standards –
EN 61000-6-2 (2005)
Immunity for industrial environment.
Electromagnetic compatibility (EMC) – Part 6-4: Generic standards –
EN 61000-6-4 (2007) + A1 (2011)
Emission standard for industrial environment.
Electromagnetic compatibility (EMC) – Part 4: Testing and
EN 61000-4-2 (2009) measurement Techniques – Section 2: Electrostatic discharge immunity
test. Basic EMC publication.
Electromagnetic compatibility (EMC) – Part 4: Testing and
EN 61000-4-3 (2006) +
measurement techniques – Section 3: Radiated, radio-frequency,
A1 (2008) + A2 (2010)
electromagnetic field immunity test.
Electromagnetic compatibility (EMC) – Part 4: Testing and
EN 61000-4-4 (2012) measurement Techniques – Section 4: Electrical fast transient/burst
immunity test. Basic EMC publication.
Electromagnetic compatibility (EMC) – Part 4: Testing and
EN 61000-4-5 (2006)
measurement techniques – Section 5: Surge immunity test.
Electromagnetic compatibility (EMC) – Part 4: Testing and
EN 61000-4-6 (2014) measurement techniques – Section 6: Immunity to conducted
disturbances, induced by radio-frequency fields.
Electromagnetic compatibility (EMC) – Part 4: Testing and
EN 61000-4-8 (2010) measurement techniques – Section 8: Power frequency magnetic
immunity test.
Information technology equipment – Radio disturbance characteristics –
EN 55022 (2010)
Limits and methods of measurement.
Specification for radio disturbance and immunity measuring apparatus
EN 55016-2-3 (2010) and methods – Part 2-3: Methods of measurement of disturbances and
immunity – Radiated disturbances measurements.

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2 BRIDGE ETHERCAT

2.1 Main Features

The Bridge Unit is a peripheral board based on EtherCAT® fieldbus. It provides the full set of
interfaces to connect to a CNC Machine.

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3 TECHNICAL DATA SUMMARY

Description Parameters Full description
Supply unit +24 Vdc 3.6.3
Electrical Protection for Polarity inversion, overload
unit
Supply led Blue led
Main Fieldbus EtherCAT® 3.6.2
Non-volatile Memory 64KB
Firmware Upgradeable with flash technology via EtherCAT®
fieldbus (FOE)
Hardware diagnostics Green LED + Red LED

Operating temperature 0 … 55 °C
Storage temperature -10 … 70 °C
[The environment during transportation and storage
must be dry and free from dust]
Degree of protection IP20
Axes Interfaces
Mechatrolink Bus Mechatrolink I and II protocols 3.6.4
Pulse Train Output Differential line driver Pulse + Direction according 3.6.8
to standard RS-422.
Maximum Pulse Frequency 1MHz
Up to 6 channels
Analog Output Balanced -10/+10V 3.6.9
1 Channel
Incremental TTL Differential Square Wave 3.6.6
Encoder Input Maximum Pulse Frequency 1MHz
Up to 7 channels
Absolute SSI Differential line driver and receiver according to 3.6.7
Encoder Input EIA standard RS-485
(Option) Maximum clock frequency 2MHz with maximum
resolution 32bit
1 channel
I/O Interfaces
CAN CANopen DS 301, DS 401 Protocols 3.6.5

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3.1.1 Part Number

The resources actually present depend on the hardware configuration of the unit. The Axes
and IO interfaces can be supplied according to the following hardware configurations:

Code Description Axes Interfaces IO Interfaces

BRDGETHC07H Bridge pls/dir with feedback + Nr.6 Pulse/Ddirection CAN
Analog Ref. Output with Outputs;
feedback + SSI Input Nr. 1 Analog Ref.
Output;
Nr. 7 ABZ Incr.
Encoder Input.
Nr.1 SSI Transducer
Input

BRDGETHC08H Bridge Mechatrolink + Analog Nr. 1 Analog Ref. CAN

Ref. Output with feedback + Output;
SSI Input Nr.1 ABZ Incr. Encoder
Input;
Nr.1 Mechatrolink Bus
Output.
Nr.1 SSI Transducer
Input

Below are showed the different models.

BRDGETHC07H (Bridge 07H)

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BRDGETHC08H (Bridge 08H)

3.1.2 Hardware Enable Relay

Hardware Enable Relay described in §3.6.10 can be used in applications, in series with Functional
Safety related safe input.
Hardware Enable Relay behavior is defined only by device itself:
• Device closes circuit once slave device enters OP status, in 5ms
• Device opens circuit once slave device leaves OP status, in 5ms. This may occurs because of:
o Explicit master request
o Internal fault
o EtherCAT cable disconnection, or corrupted unrecovered EtherCAT frame. In this case,
device opens circuit in 5ms + 2 EtherCAT cycles
• Relays opens circuit in case of device hardware reset, in 5ms

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3.2 Bridge EtherCAT Slave Structure

The Bridge hardware consists of the following parts:
• Physical Layer: Standard Ethernet Physical Layer Components that implement the
network interface
• Data Link Layer: EtherCAT Slave Controller (ESC) and EEPROM (ESC configuration
data and application specific data)
• Application Layer: Host controller
The physical layer is based on the standards defined by standard Ethernet according to
IEEE802.3. This means Standard Ethernet components (Plug RJ45, Magnetics, PHYs). The ESC
is implemented as the Beckhoff ET1100 Asic. This hardware handles the EtherCAT protocol in real
time. The application layer services are implemented on the host controller. The host controller
supports the following tasks:
• EtherCAT State Machine (ESM) handling
• Process data – Exchange with the application
• Mailbox protocols (CoE, FoE, etc.)
• Object Dictionary Handling
• Handling of Application Parameter
The host controller is implemented as FPGA and the firmware can be updated through the
EtherCAT bus (FoE).
The Bridge EtherCAT device is delivered with an EtherCAT Slave Information (ESI) file in
XML format, loaded in the EEPROM. It describes the identity and all features of the device.
The following figure shows the Bridge EtherCAT Slave Structure and how it is connected to
an EtherCAT master.

3.2.1 EtherCAT wiring

As from EtherCAT specifications, for connecting EtherCAT devices, only Ethernet shielded
cables (SFTP) that meet the requirements of at least category 5 (CAT5), according to EN 50173 or

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ISO/IEC 11801 should be used, but it is recommended to use CAT6 cables that feature more
stringent specifications for crosstalk and system noise.
EtherCAT uses 4 wires for signal transfer.
EtherCAT uses RJ45 connectors. The pin assignment is compatible with the Ethernet
standard (ISO/IEC 8802-3).
The cable length between two EtherCAT devices must not exceed 100 m.

3.3 Layout and Dimensions

The overall dimensions of the Bridge are as follows:

Unit Width Height Depth

BRDGETHC07 [mm] 175 128 50
BRDGETHC08

The unit is equipped with a support which can be mounted on a standard DIN rail. Width
has been measured by using boards equipped with DIN rail supports, non-inserted cables.

Layout BRDGETH07

Layout BRDGETH08

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3.4 LED and Diagnostic Indicators

Five LEDs are available in the Bridge and provide information about the device status.
Moreover an LCD display is available in the Bridge and provides information about the I/O status of
the PLC.

3.4.1 Power LED

The Blue Power LED indicates the power supply and lights when main voltage and internal
charge are present. (Note: the LED off is not an indicator of the absence of DC bus voltage).

3.4.2 Run LED

The Green Run LED indicates the status of the EtherCAT Device according to ETG.1300
Indicator and Labeling Specification. The Run Indicator states are specified in the table below:

Led state Slave State Description

OFF INIT The device is in state INITIALISATION
The device is in state
Blinking PREOP
PRE-OPERATIONAL
The device is in state
Single Flash SAFEOP
SAFE-OPERATIONAL
The device is in state
ON OP
OPERATIONAL
The device is in state BOOTSTRAP
Flikering BOOT
Firmware download operation in progress

3.4.3 Error LED

The Red Error LED indicates errors occurred in the EtherCAT Device according to
ETG.1300 Indicator and Labeling Specification. The ERROR indicator shall show errors such as
watchdog timeouts and unsolicited state changes due to local errors. If, at a given time several
errors are present, the error that occurred first shall be indicated. The Error Indicator states are
specified in the table below:

LED state Error Description

No error in the device. The EtherCAT communication
OFF No Error
of the device is in working condition
Blinking Invalid Configuration General Configuration Error

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3.4.4 Link/Activity LEDs

The Green Link/Activity LEDs indicate the state of the physical link and activity for
EtherCAT port0 and port1. LEDs are located inside the RJ45 connector of the corresponding
EtherCAT port. The Link/Activity indicator states are listed in the table below:

Link code Link Activity Condition

OFF No - Port closed
Flickering Yes Yes Port open
ON Yes No Port open

3.4.5 CAN Diagnostics

Devices supporting CAN interface also provide some diagnostics about the CAN network
status.
Counters give and hint of the degradation of the CAN network in an absolute way, usually
many minutes before an unrecoverable error occurs (bus off or Tx transmission unrecoverable
error).
There are the following diagnostic counters, as described in the Object Dictionary,
:
• Peak Tx/Rx errors detected (OD 5045:1);
• Tx/Rx errors counters (OD 5045:2);
• Number of EtherCAT Sync cycles to wait for a pending transmission without resetting Tx
abort (OD 5045:3);
• Tx Abort issue counter (OD 5045:4);
• Tx buffer full counter (OD 5045:5).

usertplc_1.5.pdf

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Reading counters user can check if there are some errors during operation of the machine
and can even do specific tests of correlation between action and error counting to identify the
causes.
For example, user may first read error counters, then he can start and stop repetitively the
spindle, or a EM brake, or others.
Here there are some rule of thumbs to identify the error causes:
• If error counters is 0 but tx buffer full counter is not 0, tx abort set to 20 or more, tx abort
counter is not 0, there is a device chatting and preventing master to transmit. Use CAN dump
tool available in the master (CANopen Enumerator or CAN dump in CANopen Bus Iosource)
to identify its address.
• If error counter is 0 but tx buffer full counter is not 0, tx abort set to 20 or more, tx abort
counter is 0, application is too demanding for CAN bus. Try increasing baud rate. For
example, if machine currently uses 250kb/s try using 500kb/s;
• If error counter is not 0, check wiring, especially connections.
In case loose wiring, check following items:
• Use appropriate cables and their internal and external integrity;
• In case of joints between cables, make sure:
• Shield is electrically continued;
• Shield cover internal cables until last 3cm from connectors;
• Check possible short circuits between cables;
• Keep CAN-H and CAN-L winding until last 3cm from connectors;
• Use connectors to connect wires, not clamps;
• Check wire length to match baud rate used;
• Check termination resistor is used one and only one in the network;
• In case of Y connections used in IP67 devices with just one CAN connector, keep arms
shorter than 3cm.

In case error counters keep running, try use solenoids and wind CAN-H and CAN-L
separately on it, do many revolutions and remove shield, connect shield separately on ground pin
without winding it.
Do not use solenoids winding on the cable directly as it has no effect. See next picture.

Fig. 1: proper winding of solenoid on DESINA cable. Black cable is the shield and it is connected to ground pin

3.5 Release of Software

The current version of the software loaded into the device can be read with SDO messages
in the Version Register of the Object Dictionary (see

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The software loaded into the device can be updated to the latest version at any time, see the
chapter “Updating Firmware” for details.

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3.6 Signals and Connections (Pin-Out)

3.6.1 Ground Terminal

The unit is provided with a ground terminal (PE). Please follow the following
recommendation:
• Ground the unit before applying voltage.
• Ground the unit to the nearest point of the system ground.
• Do not use conduits as protective ground conductors; use a protective ground
conductor.
• The cross section of the protective ground conductor must comply with the
applicable standards.
• Do not consider cable shields to be protective ground conductors.

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3.6.2 EtherCAT bus (CN1,CN2)

3.6.2.1 Resources

Parameter Value / Description

Number of Port 2
Protocol EtherCAT
Supported Services CoE (CAN over EtherCAT),
FoE (File over EtherCAT),
VoE (Vendor Specific over EtherCAT)
Sync0 Period 0.25ms, 0.5ms, 1ms, 2ms, 4ms, 8ms, 16ms

3.6.2.2 Connections

Reference: CN1,CN2 – EtherCAT bus IN/OUT

Connector: RJ45, Shielded
Apply to p/n: All

The pin assignment is compatible with the Ethernet standard (ISO/IEC 8802-3).

Pin Color of conductor Signal Description

1 yellow TD + Transmission Data +
2 orange TD - Transmission Data –
3 white RD + Receiver Data +
6 blue RD - Receiver Data –

Connect the CAT5 cable coming from Master EtherCAT to the IN connector
(CN1) of the Bridge. Connect the cable to the next EtherCAT slave device to
the OUT connector (CN2).

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3.6.3 Power Supply (CN3)

3.6.3.1 Resources

Parameter Value / Description

DC bus Voltage 15…28V dc
Protection Overload
Reverse Polarity

3.6.3.2 Electrical Characteristics

Name Description Min Typ. Max Unit

VDD Input Supply Voltage 15 24 28 V
IDD Input Supply Current 500 mA
Vripple Ripple noise peak Voltage 1 V

The power cables must have the proper section according with the board
consumption, moreover, they could be twisted to limit the electromagnetic
disturbances.

3.6.3.3 Connections

Reference: CN3, Power Supply

Connector: 2 Positions, Removable Terminal Block with Spring Clamp (5.08mm pitch)
Apply to p/n: All

CN3 Pin function descriptions

Pin No. Mnemonic Description
1 +V Positive Input DC Power Supply (VDD)
2 GND Ground Reference

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3.6.4 Mechatrolink bus (CN4)

3.6.4.1 Resources

Parameter Value / Description

Number of controllable axes Up to 30
[The maximum value is subject to limitations due
to Hardware and Software (Size and Settings)]
Protocol Mechatrolink-I and Mechatrolink-II
Mechatrolink port 1
Sync0 period 2ms
(Mechatrolink-I)
Sync0 period Selected from 0.5 to 16ms through software
(Mechatrolink-II) settings
[according to the axes number and the CPU
computing speed]
Bus I 50mt

Mechatrolink interface is active only when device is in OP status.

In case of hardware faults of any I/O device, ISAC master resets and sends all

 slave devices to SAFEOP, so Mechatrolink communication is interrupted, master

reports all servo drives in alarm, and all Mechatrolink drives goes to alarm,
immediately.

If Mechatrolink interface is interrupted, servo drives disable immediately. In

case of axes requiring brake to stop (as vertical axes), take precautions:
• CONNECT BRAKE TO SERVO AND LET SERVO CONTROL IT.
• CUT BRAKE POWER (SO ACTIVATE IT) USING HARDWARE ENABLE
OUTPUT (§3.6.10)

3.6.4.2 Connections

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Reference: CN4, Mechatrolink bus

Connector: USB type-A
Apply to p/n: BRDGETHC08

CN4 Pin function descriptions

Pin No. Mnemonic Description
3 DATA Differential Bidirectional Data Bus
2 /DATA
4 0V Ground Reference

1 NC Not Connected.

The connection from the Bridge Unit and the drives of the motors is made through an USB
standard cable. All the drives are connected in series, as shown in the picture below. The
Mechatrolink output of the Bridge must be connected to the CN6A connector of the first drive;
through the CN6B connector, it is connected to the CN6A of the second drive, and so on.

LINE TERMINATION
A bus terminator must be plugged in the CN6B connector of the last drive in
the chain. The value of the terminating resistor is 130 Ohm according to the
specifications of the Mechatrolink II Protocol, or 120 Ohm according to the
specifications of the Mechatrolink I Protocol.
The terminating resistor is connected between DATA and /DATA lines, ie
between pins 2 and 3 of Mechatrolink connector.
Inside the Bridge, the terminating resistor is automatically selected with the
proper value.

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MECHATROLINK connection diagram

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3.6.5 CAN bus (CN5)

3.6.5.1 Resources

Parameter Value / Description

Number of Port 1
Protocol CANopen 2.0
Profiles DS-301
DS-401
DSP-402 IP
SYNC support Yes
Buffer of input messages 28
Buffer of output messages 16
Number of supported nodes 63
Supported Baud-rate 1Mb/s, 500Kb/s, 250Kb/s, 125Kb/s
Bus I 30mt up to 400mt according to selected
baud-rate
Characteristic impedance 120 Ohm
Ethercat Cycle Time (Sync0) 1 – 2ms (*)

Note:
(*) The use of CAN peripheral requires a Cycle Time (Interrupt Time or PLC Timer) less than 2ms.

CAN interface is active only when device is in OP status.

In case of hardware faults of any I/O device, ISAC master resets and sends all
slave devices to SAFEOP, so all CAN communication is interrupted, and:
•

master reports all devices disconnected following master rules.
• CAN slave devices goes to PREOP status using Node Guarding and Life Time
Cycle.
If the hardware fault occurs in any connected CAN slave device, the faulty devices
are the ones recorded BEFORE the event of Framework reset.

3.6.5.2 Electrical Characteristics

Name Description Min Typ. Max Unit

VCAN Output positive supply 24 Vdc
ICAN Output current 0.5 A

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3.6.5.3 Connections

Reference: CN5, CANopen bus

Connector: 9 pins, D-sub type, shielded, male (plug)
Apply to p/n: BRDGETHC07, BRDGETHC08

CN5 Pin function descriptions

Pin No. Mnemonic Description
1,4,8 NC Not Connected
2 CANL CAN bus line dominant Low
7 CANH CAN bus line dominant High
3,6 0V CAN Ground reference
5 SH Shield
9 +24V Output DC bus +24V. That could be used to supply
CAN slave nodes with 0.5A maximum.

3.6.5.4 Line termination

According to the specifications of the CAN Protocol, a terminating resistor with value 120
Ohm must be present at both ends of the CAN bus, connected between CANL and CANH lines.
Inside the Bridge, the terminating resistor is present with the proper value. A terminator
must be plugged in the last device in the chain.

3.6.5.5 CAN Cable

The mobile installation with 4 core CAN cable + Shield must feature the following
characteristics:

Conductors format: COUPLED TWISTED

Bare copper class 6 – VDE 0295
CAN signal
Data: 2x0.25 ;
Cable composition: CAN signal and power supply
Data: 2x0.25 ;
Supply: 2 x 0.25

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Colors of the conductors: Supply: Black – noir

Data: white – blue
Shield: Aluminized bend 100% covering + Tinned copper braid on total
covering >=85%
Sheath: Violet polyurethane RAL 4005, diameter D = 11mm
Operating temperature: -20°C + 80°C
Impedance: 120 ohm
Nominal capacity: 50 pF/m
Standard DESINA E244280 F01 80°C 30V FT1 2x2xAWG H2

The max useful cable length can be found in the CAN protocol specifications and depends
on the selected baud-rate. The following table summarizes the recommended max lengths
according to the selected Baud-rate:

Baud-rate Max Length

•1 Mbit/sec 30 mt
•500 Kbit/sec 100 mt
•250 Kbit/sec 200 mt
•125 Kbit/sec 400 mt

CAN interface cards must be cascade connected on the same CAN line by using the bus
connector equipped with the contacts for the forwarding to the following card. On the last card of
the line, there must be placed the termination jumper allowing for impedance adjustment and for
limiting bus reflections.

Each card on the same line must have its own identifier. When a card is cut out, or when
the CAN line is interrupted during operation, CN will stop and all the output of all the cards
connected will be released.
The fixed installation CAN cable must feature the following characteristics

Conductors format: COUPLED TWISTED

Bare copper class 6 – VDE 0295
CAN signals
Data: 2x0.25 ;
Cable composition: CAN signals and power supply
Data: 2x0.25 ;
Power supply 2 x 0.25
Colors of the conductors: Complying with DIN 47100
Shield: Tinned copper braid on the total (LIYCY)

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with covering >=85%

Sheath: PVC – diameter D = 4.40mm
Impedance: 120 ohm
Nominal capacity: 50 pF/m
Operating temperature: -20°C + 80°C
Standard DESINA E244280 F01 80°C 30V FT1 2x2xAWG H2

SHIELD CONNECTION
Use only shielded cables. When connecting CAN devices to the BUS, make the
connection leaving the wires uncovered from the shield for a minimum length
and in any case less than 2cm.

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3.6.6 Incremental Encoder input (CN6, CN7, CN21)

3.6.6.1 Resources

Parameter Value / Description

Number of controllable axes 7
Code Format Two square waves (A / B) in quadrature with standard index
(Z)
Pulse Code Incremental
Counter Resolution 16 bits (65536 increments)
Max Input Frequency 1 MHz
Max Counter Clock 4MHz
Electrical level 5Volt TTL Differential and Single-Ended compatible.
[It requires TTL Line-Driver or Push-Pull. Open-drain or Open-
Collector needs a Pull-Up resistance. See description of
connector.]
Max Cable length 10 meters
Encoder Supply 5 volt (total 500mA Max)
Signals for Error Two
(Internal Controlling, External Trigger – See description of
connector.)

3.6.6.2 Electrical Characteristics

Name Description Min Typ. Max Unit

VENC Encoder Supply 4.8 5.0 5.2 V
IENC Encoder Current for each channel 150 mA
VA-VA, Differential input voltage 0.2 14 V
VB-VB
VZ-VZ
VAL,VBL,VZL Single Ended Low Level input Voltage 1.5 V
VAH,VBH,VZH Single Ended High Level input Voltage 3.5 V

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3.6.6.3 Connections

Reference: CN6, Encoder Input Axis 1 to 3

Connector: 25 pins, D-sub type, shielded, female (socket)
Apply to p/n: BRDGETHC07

CN6 Pin function descriptions

Pin No. Mnemonic Description
1 U1A Differential Input Channel A Encoder no.1
14 /U1A
2 U1B Differential Input Channel B Encoder no.1
15 /U1B
3 U1Z Differential Input Index Z Encoder no.1
16 /U1Z
4 /ALL1 Alarm Input Line no.1
17 U2A Differential Input Channel A Encoder no.2
5 /U2A
18 U2B Differential Input Channel B Encoder no.2
6 /U2B
19 U2Z Differential Input Index Z Encoder no.2
7 /U2Z
20 /ALL2 Alarm Input Line no.2
8 U3A Differential Input Channel A Encoder no.3
21 /U3A
9 U3B Differential Input Channel B Encoder no.3
22 /U3B
10 U3Z Differential Input Index Z Encoder no.3
23 /U3Z
11 /ALL3 Alarm Input Line no.3
12-24 0V Reference Ground for Transducer
13-25 +5V Output Supply for Transducer 5Vdc@500mA
PE Ground. The shield of the cable should be connected

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to the metal shell of the connector.

Reference: CN7, Encoder Input Axis 4 to 6

Connector: 25 pins, D-sub type, shielded, female
Apply to p/n: BRDGETHC07

CN7 Pin function descriptions

Pin No. Mnemonic Description
1 U4A Differential Input Channel A Encoder no.4
14 /U4A
2 U4B Differential Input Channel B Encoder no.4
15 /U4B
3 U4Z Differential Input Index Z Encoder no.4
16 /U4Z
4 /ALL4 Alarm Input Line no.4
17 U5A Differential Input Channel A Encoder no.5
5 /U5A
18 U5B Differential Input Channel B Encoder no.5
6 /U5B
19 U5Z Differential Input Index Z Encoder no.5
7 /U5Z
20 /ALL5 Alarm Input Line no.5
8 U6A Differential Input Channel A Encoder no.6
21 /U6A
9 U6B Differential Input Channel B Encoder no.6
22 /U6B
10 U6Z Differential Input Index Z Encoder no.6
23 /U6Z
11 /ALL6 Alarm Input Line no.6
12-24 0V Reference Ground for Transducer
13-25 +5V Output Supply for Transducer 5Vdc@500mA
PE Ground. The shield of the cable should be connected

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to the metal shell of the connector.

Reference: CN21, Encoder Input Axes 7

Connector: 25 pins, D-sub type, shielded, female
Apply to p/n: BRDGETHC07, BRDGETHC08

CN21 Pin function descriptions

Pin No. Mnemonic Description
1, 8, 17 U7A Differential Input Channel A Encoder no.7
5, 14, 21 /U7A
2, 9, 18 U7B Differential Input Channel B Encoder no.7
6, 15, 22 /U7B
3, 10, 19 U7Z Differential Input Index Z Encoder no.7
7, 16, 23 /U7Z
4, 11, 20 /ALL7 Alarm Input Line no.7
12, 24 0V Reference Ground for Transducer
13, 25 +5V Output Supply for Transducer 5Vdc@500mA
PE Ground. The shield of the cable should be connected
to the metal shell of the connector.

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Input specifications
The measure inputs interface is compatible with transducers that provides Line-driver and
Push-pull outputs with voltage level 5V (TTL).
The Open-Drain and Open Collector types output CANNOT be directly connected. If it is
necessary to use these kind of transducers, you need to insert a Pull-up resistance on its output
pins. The value of the resistance must be calculated according to the voltage supply and the
operating max frequency. Note that with Open Drain you have to reduce the Maximum frequency.

Signal for Error

The counter interface constantly monitors the measuring signals and detects an error if the
integrity of wiring is compromised. This function is active only in differential configuration; while in
single-Ended you have to disable the “Alarm of the Transducer”.
• The Pins 4, 11 and 20 (reverse alarm) can accept an external trigger as source for error.

Use a shielded cable. The shield must be connected to the metal shell of the
connector.
If the transducer does not have ‘differential’ outputs (i.e. does not offer the reverse
signals) the correspondent pins must be left not connected.
WARNING: in this case the ‘transducer alarm’ must be set to ‘disabled’ through
the axes configuration.
Pins 13 and 25 provide a power supply of +5 volts (500mA max) for the
transducer.
If the transducer requires a different voltage, that must be provided externally.
The GND common of that power supply must be the same of the other
peripherals.

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Typical Application Diagram: Differential & Single-Ended

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3.6.7 Absolute SSI Encoder input (CN20)

3.6.7.1 Resources

Parameter Value / Description

Number of controllable axes 1
Code Format SSI

Encoder Resolution Up to 32 bits

Max Input Frequency MHz
(Depending from cable length:
MHz up to 10mt,
1 MHz up to 50mt,
200 KHz up to 100mt.)
Physical layer Complying with EIA-485 standard (Differential)
Max Cable length 100 meters
Encoder Supply 5 Volt (total 500mA Max)

3.6.7.2 Electrical Characteristics

Name Description Min Typ. Max Unit

VENC Encoder Supply 4.8 5.0 5.2 V
IENC Encoder Total Current 500 mA

3.6.7.3 Connections

The SSI encoder signals are alternative to the incremental input encoder signals, as they
are distributed over the same connectors.

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Reference: CN20, Encoder Input Axis 8

Connector: 25 pins, D-sub type, shielded, female (socket)
Apply to p/n: BRDGETHC07, BRDGETHC08

CN20 Pin function descriptions

Pin No. Mnemonic Description
1, 5, 9 DATA1P Differential Data Input Encoder no.1

14, 18, DATA1M

22
3, 7, 11 TCLK1P Differential Clock Output Encoder no.1

16, 20, TCLK1M

24
2, 6, 10, 0V Reference Ground for Transducer
13, 15,
19, 23
4, 8, 12, +5V Output Supply for Transducer 5Vdc@500mA
17, 21,
25
PE Ground. The shield of the cable should be connected
to the metal shell of the connector.

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3.6.8 Pulse/Direction output (CN8,CN9)

3.6.8.1 Resources

Parameter Value / Description

Number of channels 6
Pulse Type Pulse + Direction
Type of signal Differential Line Driver according to standard RS-422.
Max. Output Pulse 1 MHz
Frequency
Signal level 0 .. 5 Volt

3.6.8.2 Electrical Characteristics

Name Description Min Typ. Max Unit

VOH High Level Output Voltage 2.5 3.5 V
VOL Low Level Output Voltage 0.5 V
IOH High Level Output Current 50 mA
IOL Low Level Output Current 50 mA

3.6.8.3 Connections

Reference: CN8, Pulse/Direction Output Axis 1 to 3

Connector: 15 pins, D-sub type, shielded, female (socket)
Apply to p/n: BRDGETHC07

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CN8 Pin function descriptions

Pin No. Mnemonic Description
1 PLS1 Differential Output Pulse Axis no.1
9 /PLS1
2 DIR1 Differential Output Direction Axis no.1
10 /DIR1
11 PLS2 Differential Output Pulse Axis no.2
4 /PLS2
12 DIR2 Differential Output Direction Axis no.2
5 /DIR2
6 PLS3 Differential Output Pulse Axis no.3
14 /PLS3
7 DIR3 Differential Output Direction Axis no.3
15 /DIR3
3-8-13 0V Ground Reference
PE Ground. The shield of the cable should be connected
to the metal shell of the connector.

Reference: CN9, Pulse/Direction output axis 4 to 6

Connector: 15 pins, D-sub type, shielded, female
Apply to p/n: BRDGETHC07

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CN9 Pin function descriptions

Pin No. Mnemonic Description
1 PLS4 Differential Output Pulse Axis no.4
9 /PLS4
2 DIR4 Differential Output Direction Axis no.4
10 /DIR4
11 PLS5 Differential Output Pulse Axis no.5
4 /PLS5
12 DIR5 Differential Output Direction Axis no.5
5 /DIR5
6 PLS6 Differential Output Pulse Axis no.6
14 /PLS6
7 DIR6 Differential Output Direction Axis no.6
15 /DIR6
3-8-13 0V Ground Reference
PE Ground. The shield of the cable should be connected
to the metal shell of the connector.

The output signal level is 5volts. Verify if the driver supports this signal level.
Check if the driver accept differential or not differential input signal, follow the
correspondent schema.

For wirings, use twisted and shielded cables.

The output interface is not opto isolated. If even the input interface of the driver is not
isolated, then use the 0V connection to get the same potential on both interfaces. If
the input interface of the driver is opto isolated, the 0V line can be left open.

For the general description of pulse/direction axes interface refer to the application manual.
Here are described the connection schemas for those drivers that accept differential and
non-differential signals.

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Differential connection

PULSE/DIRECTION
PULSE/DIR PULSE/DIR
OUTPUT
GENERATOR GENERATOR
INTERFACE
CHANNEL 1 CHANNEL 3

PLS ____ ____ ____ ____

CONNECTOR PLS1 PLS1 DIR1 DIR1 PLS3 PLS3 DIR3 DIR3

_____ ___
USER STEP STEP DIR DIR
DRIVER
STEP

Non-differential connection

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3.6.9 Analog Axes Output (CN22)

3.6.9.1 Resources

Parameter Value / Description

Number of Axes 1
Output Voltage range -10 .. 10 V dc
Output Tolerance +/- 1%
Output Voltage settling time 1 ms
Resolution 15 bit + sign (65536 increments)
[LSB value = 0.3 mV]
Digital range -32768 .. 32767
Protection Short circuit

3.6.9.2 Electrical Characteristics

Name Description Min Typ. Max Unit

VREF Analog Output Voltage reference (*)
Single Ended Unipolar (REF+/GND) 0 10 V
Single Ended Bipolar (REF+/GND) -10 10
Balanced (REF+/REF-) -5 5
IREF Analog output Current 10 mA

Note:
(*) The voltage range can be set via software configuration.

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3.6.9.3 Connections

Reference: CN22, Analog Voltage Reference Output Axis 1 to 3

Connector: 9 pins, D-sub type, shielded, female (socket)
Apply to p/n: BRDGETHC07, BRDGETHC08

CN22 Pin function descriptions

Pin No. Mnemonic Description
1, 2, 3 REF7- Negative Output Reference Axis no.7
6, 7, 8 REF7+ Positive Output Reference Axis no.7
4-5-9 0V Ground Reference. All analog output signals should
be referred to this GND voltage.
PE Ground. The shield of the cable should be connected
to the metal shell of the connector.

Typical Application Diagram

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3.6.10 Hardware Enable Output (CN23)

3.6.10.1 Connections
Refers to §3.1.2 for description on how this output works.
Output is a clean contact of a Normally Open Relay that change its status in 5ms.

Reference: CN23, Hardware Enable Output

Connector: 9 pins, D-sub type, shielded, female (socket)
Apply to p/n: BRDGETHC07, BRDGETHC08

CN23 Pin function descriptions

Pin No. Mnemonic Description
2, 5 Hardware Enable Output, NO clean contacts.
30 VDC – 1 A max.
1, 3, 4, Not Connected.
6, 7, 8, 9
PE Ground. The shield of the cable should be connected
to the metal shell of the connector.

IF HARDWARE CONTROL WORD (§7.12) BIT Bit[0] IS SET, RELAY STAYS

CLOSE EVEN AFTER CABLE DISCONNECTION OR ETHERCAT FRAME
CORRUPTION.

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4 UPDATING XML FILE

4.1 Precaution
The update will be done one node at a time without other device connected

4.2 Update xml file in the pc

1) Open the HMI Interface and click ‘Yes’ in the windows that opens

2) Don’t start the framework so as to enter in support mode

3) Go to ‘Settings’ → ‘IOSource’ → ‘Ethercat Offline Configurator’

4) Select all the device under ‘EtherCAT’ heading in the left menu → right click → ‘Remove Device’
→ ‘Yes’

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5) Right click under ‘EtherCAT’ heading in the left menu → ‘Append Device’

6) Check ‘Show Extended Info’ → open ‘Isac s.r.l.’ → open ‘Miscellaneous’ →select yours device
from the list

7) Click ‘Save Changes’ → ‘Yes’ → ‘OK’ → ‘Close’

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8) Click ‘Support commands’ in the top menu oh HMI → ‘Start framework’ → ‘Yes’ → wait while the
framework start → enter in normal mode by clicking ‘Yes’

9) Don’t care about the alarms

4.3 Update xml file in the node

a. Click ‘View’ in the top menu → ‘Options’ → ‘Layout and configuration file’ → uncheck
‘Freeze layout’ → ‘OK’

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2) Click ‘View’ in the top menu → ‘IOSource’ → ‘IOSource Main View’ → drag the ‘IOSource Main
View’ window in the middele of the screen and enlarge it

3) Double click on ‘Ethercat Bus (Ethercat)’ in the left menu → select the device (you can see a
black square on the device name) → click on ‘Status’ in the right menu → ‘Clear alarms’ → make
sure that next to ‘Current status’ and ‘Target Status’ is written ‘Init’ otherwise it will not possible to
update the device

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4) In the same window slide the top left menu until ‘EtherCAT’ heading → ‘Advance Setting’ →
‘ESC Access’ → ‘EPROM’ → ‘Smart View’ → in the right window click on ‘Write EPROM’

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5) Check ‘Show Extended Info’ → open ‘Isac s.r.l.’ → ‘Miscellaneous’ → select yours device (the
previously chosen) → ‘OK’ → wait until it finishes writing → ‘OK’ → close ‘IOSource Main View’
window

4.4 Restart

b. Restart the bridge

2) In ‘Spartacus HMI’ click ‘Command’ in the top menu → ‘Restart framework’ → ‘Yes’ → wait
while the framework stop → ‘Yes’ → wait while the framework start → ‘Yes’

3) Check that the green LED on the bridge is on

4) Check that in ‘Spartacus HMI’ there are no errors or alarms

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5 UPDATING FIRMWARE
5.1 Preliminary operations
The software/firmware inside the device can be updated with new releases directly on the
field through the EtherCat bus using the integrated tool in the Isac PLC HMI graphic interface,
without the need for a specific programmer.
The new release of the software is in the form of an encrypted binary file that must be
downloaded from the ISAC website. The file is included in the zip file ‘hwfirmware.zip’ that can be
found in the download area. Be careful to select the proper binary file for the bridge model you are
using (ATTENTION: don’t rename the binary file, the file name must begin with “ECATFW_…”).
A password is required during the firmware upgrade process. Your password is bound to a
keycode associated with your device. If the software version of the device is 2.4.0 or later, the
keycode is stored in the 0x5040 registry of the object dictionary and can be read by Mailslot or by
Coe online. If the software version is previous to 2.4.0, the key code is 0x9424.
Fill the Mailslot as in the following example
Address 1 = 1,
Address 2 = 0x5040,
Address 3 = 0
Address 4 = 0
Max Length = 4
Press the Read button to show the value. In the example, keycode is 0xE598 (first byte is the
least significant).
Note: Mailslot can be read with device in Op status, or SafeOp, or PreOp.

Please download also the file “Vendor Documentation.zip” which includes the document
“Costantino web site customer area.pdf”. In the section “Firmware update” of this document you
can find useful instructions to get the password once you have recovered the keycode

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NOTE: The access to the download area is only permitted for authorized vendors.

CAUTION!
The update will be done one node at a time without other EtherCat devices connected.
To end the procedure successfully please remove all of the bus and devices attached to the
bridge.

5.2 Download the firmware

1) Connect the device being updated to the PC via Ethercat connection. Please be sure this is
the only node in the bus.
2) Start framework from the PC interface
3) From menu ‘View -> IOSource’ in the PLC HMI interface launch ‘Iosource Main View’, to
open the related window (it may be need to unlock the windows layout in the Options by
toggling the flag ‘Freeze layout’)

4) In the ‘IOSource Main View’ interface, on the right side of the window select the item
‘Ethercat’ and on the left side, select the ‘Ethercat Bus’ folder. From this, begin the scan by
pressing the ‘Scan’ button.

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5) The connected device appear in the ‘Ethercat Bus’ list. Press the ‘Save Changes’ button.
6) From the PLC HMI menu restart Framework.
7) Open again the ‘Iosource Main View’ interface and select the device to be upgraded from
the list under ‘EtherCAT Bus’. On the right side of the window select the EtherCAT folder.

8) Here press the ‘Download’ button under the ‘Firmware’ section, then select the binary file
(.bit) to download. Press the ‘Open’ button to confirm.

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9) Enter the password when requested (see ‘Preliminary operations’).

ATTENTION: the password must be prefixed with ‘0x…’
10) Restart the bridge at the end of download.
11) Restart Framework

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6 EMERGENCY MESSAGES
6.1 Emergency Messages

ErCode ErReg ManuEr Description

0xFF00 0x0 0x0000001A ERRORCODE_DC
Synchronization error: bridge sends the message
when the sequence ProcessData-Sync0-ProcessData
or Sync0-ProcessData-Sync0 is not respected. That
condition occurs in two consecutive Sync0 or two
consecutive ProcessData.
0xFF00 0x0 0x00000032 ERRORCODE_DC
PLL Error: the error occurs when the bridge is in OP
state but the DC is not coupled. At every cycle, a
counter is incremented and when the counter reaches
2000000 the message is sent.
0xFF00 0x0 0x00000033 ERRORCODE_DC
Invalid DC IO Error: the error occurs when the Sync0
interrupt inside of bridge comes while updating data
output or when the ProcessData comes while
processing data input.
0xFF01 0x0 0x00008001 ERRORCODE_PWR
Power Supply error: a power supply overvoltage or
undervoltage occurs.
0xFF03 0x0 0x00008002 ERRORCODE_IO
DI error: the number of samples of the Digital Input
has exceeded the maximum limit. The error occurs
when Sync0>16ms.
0xFF03 0x0 0x00008003 ERRORCODE_IO
AI error: the number of samples of the Analog Input
has exceeded the maximum limit. The error occurs
when Sync0>16ms.
0xFF05 0x0 0x0000001A ERRORCODE_PERMANENT_DC
Permanent Synchronization error: bridge sends this
emergency message when the alternation of
ProcessData-Sync0 is not met for 10 consecutive main
cycles.

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7 OBJECT DICTIONARY

7.1 General

Index Sub- Register Read/ Value PDO

index Write map
0x1000 0 Device Type R 0x0191000 –> 401 (IO) No
0x1001 0 Error Register R - No
Refer to EtherCAT
Spec
0x1008 0 Manufacturer R ‘BridgeEtherCAT’ No
device name
0x1009 0 Hardware Version R ‘a.b-d_e_f’ No
a.b: hw ver
d_e_f: fw ver
0x100A 0 Version Register R ‘a_b_c-d.e.f.g.h.m’ No
a_b_c: Global Version
d: MK ver
e: Step ver
f: CAN
g: RetentiveMemory
h: Analog Rif
m: Encoder SSI
0x1018 Identity Object No
0 Numero obj R 4
1 Vendor ID R 0x00000101 (ISAC)
2 Product Code R 0xBECxxxxx
3 Revision Nmb. R 0x------------
4 Serial Nmb. R 0x00000001
0x1C00 Refer to EtherCAT Spec No
0x1C32 Refer to EtherCAT Spec No
0x1C33 Refer to EtherCAT Spec No

7.2 Mechatrolink

Index Sub-index Register Read/ Value Size PDO

Write map
0x2000 [0]: Init struct Mecatrolink W 54 byte No
Init parameters
0x2001 [0]:num of elements Mecatrolink R/W 30 16 byte Yes
[1-30]: Buffer ch[n] Buffer RX/TX

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7.3 F/D

Index Sub-index Register Read/ Size PDO

Write map
0x2104 [0]:nax Time high R/W 16 bit No
[1-nax]:sub-axis
0x2105 [0]:nax Step Counter R 16 bit No
[1-nax]:sub-axis
0x2110 [0]:nax Buffer STEP4 W 36 byte Yes
[1-nax]:sub-axis

7.4 Reference (Analog Axis)

Index Sub-index Register Read/ Size PDO

Write map
0x2200 [0]:nax Analog output R/W 36 byte Yes
[1-nax]:sub-axis

7.5 Axis Common input

Index Sub-index Register Read / Size PDO

Write map
0x2210 [0]:nax Status Word R 16 bit Yes
[1-nax]:sub-axis
0x2216 [0]:nax Actual Position R 16 bit Yes
[1-nax]:sub-axis
0x221A [0]:nax Latch Position R 16 bit Yes
[1-nax]:sub-axis

7.6 Axis Common Output

Index Sub-index Register Read/ Size PDO

Write map
0x2280 [0]:nax Control Word R/W 16 bit Yes
[1-nax]:sub-axis
0x2281 [0]:nax Z-index to Micro Distance Filter R/W 16 bit No
[1-nax]:sub-axis

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7.7 Counters

Index Sub-index Register Read / Size PDO

Write map
0x2401 [0]:nax Counters R 16 bit Yes
[1-nax]:sub-axis

7.8 SSI

Index Sub-index Register Read / Size PDO

Write map
0x2304 [0]:nax Received register LOW R 16 bit Yes
[1-nax]:sub-axis
0x2306 [0]:nax Received register HIGH R 16 bit Yes
[1-nax]:sub-axis
0x2314 [0]:nax Configuration Register 1 LOW R/W 16 bit No
[1-nax]:sub-axis
0x2316 [0]:nax Configuration Register 1 HIGH R/W 16 bit No
[1-nax]:sub-axis
0x231A [0]:nax Configuration Register 2 HIGH R/W 16 bit No
[1-nax]:sub-axis
0x231C [0]:nax Configuration Register 3 R/W 16 bit No
[1-nax]:sub-axis

7.9 Retentive Memory

Index Sub-index Register Read / Size PDO

Write map
0x3000 [0]:num of elements (default 128) Retentive Memory R/W 256 bit No
[1-128]: page index Lower Bank
0x3001 [0]:num of elements (default 128) Retentive Memory R/W 256 bit No
[1-128]: page index Higher Bank

7.10 CAN

Index Sub-index Register Read / Size PDO

Write map
0x4000 [0]: Init struct CANOpen W 2 byte No
Init parameters
0x4001 [0]:num of elements (default16) CANOpen R/W 10 byte Yes
[1-16]: Buffer ch[n] Buffer RX/TX

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7.11 Statistics

Index Sub-index Register Read / Size PDO

Write map
0x5005 [0]:num of elements (6) R 32 bit
1 Minimum SYNC─PKT Time (ns) R 32 bit No
2 Maximum SYNC─PKT Time (ns) R 32 bit No
3 Maximum PDO Time (ns) R 32 bit No
4 Maximum PDI Time (ns) R 32 bit No
5 PKT vs SYNC counter R 32 bit No
6 Error counter R 32 bit No

7.12 BridgeEtherCAT Control WORD

Index Sub-index Register Read / Write Size PDO map

0x5006 0 Control Word R 32 bit No

Bit[0] When set, it disables error checking

Bit[1] When set, it resets statistics (self clear)
Bit[2] When set, the calibration parameters are stored into
FLASH
Bit[3] When set, it restarts the board
Bit[4] When set, it disables error checking for 10 consecutive
cycles (it requires also to set bit0)

7.13 Hardware build date

Index Sub-index Register Read / Write Size PDO map

0x5007 0 0xYYMMGGHH R 32 bit No

7.14 Software build date

Index Sub-index Register Read / Size PDO map

Write
0x5008 0 Ddd Mmm Date hh::mm::ss yyyy R 32 bit No

7.15 Key code

Index Sub-index Register Read / Size PDO map

Write
0x5040 0 KeyCode R 32 bit No
(*)

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(*) Note: Use only the lower 2 bytes (four hexadecimal digit)

7.16 Serial number

Index Sub-index Register Read / Size PDO map

Write
0x5041 0 SerialNumber R 64 bit No

7.17 CAN communication diagnostics (0x5045)

Index Sub-index Register Read / Size PDO map

Write
0x5045 0 Number of entries R 8 bits No
1 Peak Tx/Rx errors detected R/W 32 bits No
2 Tx/Rx error counters R/W 32 bits No
3 Number of EtherCAT Sync cycles to R/W 16 bits No
wait for a pending transmission
without resetting Tx abort
4 Tx Abort issue counter R/W 32 bits No
5 Tx buffer full counter R/W 32 bits No

Tx transmission
unrecoverable error

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8 REVISION HISTORY
Rev. Date Description

Section 2.5.9.3: CN22 Pin function descriptions corrected

Chapter 4 “updating Firmware” updated.
Chapter 6 “Object dictionary” updated (‘Keycode’’ and ‘Serial
number’ objects added).
Description of CAN Diagnostic. Better definition of EtherCAT cable
Section 2.5.5 updated.
2.5 Release of Software added
Section 2.4.5 CAN Diagnostic updated
Section 2.6.3 Power Supply updated
Section 2.6.5 CAN bus updated
§3.1.2 added. §3.6.4, §3.6.5, §3.6.10 modified.

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