Pulser3 Installation Download PDF

Adding Remote IO to the EtherCAT Line

HSC Studio • Adding EtherCAT Remote IO • User Guide

This guide explains step by step how to add external devices and modules to your EtherCAT line in HSC Studio, how to assign addresses, and how to send the configuration to the device.

1. Basic Concepts

Knowing a few concepts before you start will make your work easier:

  • ESI File: The XML definition file (.xml) provided by the manufacturer of each EtherCAT device. It describes which data (inputs/outputs), parameters and modules the device supports. Brands such as Beckhoff and INVT provide a separate ESI file for each of their devices.
  • Device: A single unit connected to the EtherCAT line. It can be a digital input terminal, a servo drive, or a modular coupler.
  • Coupler (Modular Device): A carrier that has no inputs/outputs of its own and is expanded with modules attached to it. For example, up to 32 modules can be attached to an INVT FK1100 coupler. The coupler appears as a single device on the line; the modules are placed underneath it.
  • Module: An input/output unit (16-channel digital input, analog output, etc.) attached under a coupler. Modules exist only in modular devices (couplers).
  • Classic Device: A structure such as Beckhoff terminals, where each module is added as a separate device. The inputs/outputs of these devices are directly on themselves.
  • Position: The physical order of the devices on the line. The order matters; the physical arrangement on the line must match the order on the screen.

2. How to Add a Device

To add a device, you make a selection from the ESI catalog:

  1. Right-click the Ethercat node in the project tree on the left.
  2. Click Add Device in the menu that opens.
  3. The ESI Viewer window opens.
  4. Click the Open ESI... button at the top of the window and select the device's ESI file (.xml).
  5. Once the file is loaded, the device(s) are listed in the tree on the left. Under each device you will see Sync Managers, RxPDO/TxPDO lists and, if present, modules.
  6. Double-click the device you want to add (or select it and press the Add to Line button at the top).
  7. The device is added to the line and appears under the Ethercat node in the project tree.

Note: The added device is a copy of the catalog definition. Changes you make to the device do not affect the ESI file.

3. How to Add a Module

Modules can only be added to modular devices (couplers). This option is not available on classic devices.

  1. In the project tree, right-click the coupler device you want to add a module to.
  2. Click Add Module in the menu that opens.
  3. The Add Module window opens. This window lists all modules that can be attached to the coupler.
  4. You can search for a module by typing in the filter box at the top (by ModuleIdent, type or name).
  5. Double-click the module you want to add (or select it and press the Add button).
  6. The module is added to the next empty slot under the coupler and appears in the tree.

Important: The order of the modules must be the same as the order in which you physically attached them to the coupler. The first module you attach is slot 0, the second is slot 1, and so on. If the order is wrong, the device may refuse to communicate.

Reordering and Deleting Modules

When you right-click a module:

  • Move Up / Move Down: Moves the module up/down (changes the slot order).
  • Delete Module: Removes the module.

When a module is moved or deleted, the addresses and parameters of the remaining modules are automatically recalculated according to their slot positions.

4. Address Limits

The input/output data of the devices is placed into a specific RAM address range on the Pulser3 side. These ranges are fixed:

Type Start End Total
Input 404 443 40 words
Output 1004 1043 40 words

Points to keep in mind:

  • Each address is 16 bits (1 word) wide.
  • Inputs cannot exceed the 404-443 range, and outputs cannot exceed the 1004-1043 range. If they do, the configuration becomes invalid.
  • Two devices cannot use the same address (address conflict). The system warns you when there is a conflict.
  • The number of words a device occupies is calculated by rounding the bit size of its active input/output data up to 16. For example, an 8-channel digital input = 8 bits = 1 word.
  • On a modular coupler, the data of all modules is placed as a single block starting from the coupler's start address.

5. Device Settings

To open a device's settings, double-click the device in the project tree. The window that opens contains several tabs:

Tab: General / Address

The device's basic settings and address assignment:

  • Station Name: A custom label you give to the device (for example, "Conveyor-Output"). Optional.
  • Use Distributed Clock (DC): Whether the device will use Distributed Clock synchronization. Enable it only on devices that require motion/synchronization (such as servo drives). Leave it off for digital/analog I/O and couplers — enabling it unnecessarily may cause communication errors.
  • Input Start / Output Start: The Pulser3 RAM address where the device's input and output data will start. When you enter an address here (for example, 404), the Input Range / Output Range labels below instantly show which range will be used. If it exceeds the range limit, the label turns red.
  • Write Ident List (modular devices only): Whether the module list attached to the coupler will be written by the master. The address box next to it specifies the CoE object the list will be written to (default 0xF030). For most modular couplers this option should be enabled and set to 0xF030. You can turn it off for devices that auto-detect their modules.

Tab: PDO Selection

Shows which input/output data (PDOs) the device will use. The view changes depending on the device type:

  • Classic device (Beckhoff): Output PDOs (RxPDO) are shown on the left and input PDOs (TxPDO) on the right, as checkbox lists. You can check/uncheck PDOs that are not Fixed.
  • Modular device (such as INVT): A Module > PDO > channel hierarchy is shown as a tree. This view is read-only, because on modular devices the PDOs are managed automatically by the coupler according to the attached module list. The user cannot select/deselect individual PDOs — it only displays which data is being transferred.

Tab: CoE Parameters

Contains the adjustable parameters of the device and modules. For example, the "input filter time" value of a digital input module is changed here. This tab appears only on devices that have CoE parameters.

  • The table contains the following columns: Index, Sub, Name, Type, Value, Default, Comment.
  • Only the Value column and only editable (rw) parameters can be changed. Read-only parameters are grayed out and disabled.
  • To change a value, double-click the Value cell of the relevant row, type the new value (with a 0x prefix for hex, or as a normal decimal) and press Enter.
  • Values you set differently from the default are shown in blue and bold.
  • If you set a value back to equal the default, the change is automatically removed. Only values different from the default are written to the device — this prevents unnecessary writes.
  • On a modular device, the coupler's own parameters and all module parameters are listed together in a single table. The Index of each row indicates which module it belongs to.

Tab: All Settings

Shows all properties of the device as a categorized property list (PropertyGrid). It is for advanced inspection and editing.

6. Viewing the Address Map

To see at a glance which Pulser3 addresses all devices and modules on the line are assigned to, use the address map:

  1. Right-click the Ethercat node in the project tree.
  2. Click Show Address Map in the menu that opens.
  3. The EtherCAT Address Map window opens.

This window shows a hierarchical table:

  • Device row (bold): The device's total input/output block range (for example, input 404-406).
  • Module row (italic): For modular devices, the slot position and type of each module.
  • Channel row: The exact address of each input/output channel. Analog channels are shown as a full word (for example, "406"), and digital channels with a bit range (for example, "405 bit0-7").

For example, when you add an analog input module, you can see here which channel falls to which address: such as "Ch0 → 406, Ch1 → 407". The status bar at the bottom of the window shows the used/total word capacity.

7. Sending the Configuration to the Pulser3

After setting up the line and assigning the addresses, download the PLC program again to transfer the configuration to the Pulser3. The configuration is stored in the PLC program area and is read by the EtherCAT master at device startup to set up the line automatically.

Do not forget to save the project when the configuration changes.

8. Tips and Common Situations

  • Device does not communicate / stays in SafeOp: On modular devices, make sure the module order on the screen matches the physical arrangement. If the order or module type does not match, the device rejects it.
  • Distributed Clock: Enable it only on servo/motion devices. It should be off on couplers and I/O devices. On a mixed line (some devices DC, some not), each device's own setting applies.
  • Address conflict warning: If you gave two devices the same address, or a device exceeded its range, you get a warning. Review the addresses; each device's word block must not overlap with the previous one.
  • CoE parameter has no effect: Make sure the parameter you changed is writable (rw) on the device. Read-only (grayed out) parameters cannot be changed.
  • Module parameters: Use the CoE Parameters tab to change a module's settings such as filter time. If a module is deleted and re-added, the settings specific to that module are reset.
Pulser3NET API Reference Guide