expertYour Automation

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Controlling EtherCAT network

џ Meet EtherCAT

Technology Group (ETG)

standards and grant

additional KPA features

џ Available for numerous

operating systems, as well

as OS-less systems

џ Hardware extensions for

Xilinx/Intel FPGA (Altera)

and Texas Instruments

PRUSS Sitara CPU

џ Master Redundancy for

exceptional fault

tolerance

џ Online configuration

including bus scan and

automatic bus configuring

џ Process image logging for

data transferring into

Analytic tools

Key Features Feature packages

Feature Packs and KPA Extensions which can be included into Basic and Standard packages.

Features

Process Data Exchange

Network Configuration

Mailbox support

CoE

FoE

Synchronization with Distributed Clock (DC)

DC support

Time distribution (Slaves synchronization)

Slave-to-Slave Communication

Explicit Device Identification

EoE

SoE

AoE

VoE

Continuous Propagation Delay compensation

Sync window monitoring

Synchronization of Master with Slaves

Feature Packs

FP External Synchronization

FB Cable redundancy

FB Hot Connect

FB Mailbox Gateway

KPA Extensions

Data logger

Frame logger

PI Snapshot

Events handler

PI logger

CAN DBC driver

VCOM driver

Online configuration

Master redundancy

Optimized drivers and HW Extensions

Basic Standard Premium

KPA EtherCAT Master is a comprehensive product for industrial automation specialists who intend to add high-speed

communication capabilities to their applications and solutions. This software stack was ported to various real-time

operating systems and hardware platforms, and its unique features facilitate better integration and performance

increase.

ETG Standards Compliant

KPA EtherCAT Master can be delivered as a standard or customized feature package subject to customer’s demands.

Two standard packages are available in accordance with EtherCAT Technology Group ETG.1500 standard: Class A

(Standard package) and Class B (Basic package). Moreover, it introduces a new class, Premium, which integrates

several additional features, opening unprecedented abilities to create innovative, feature-rich applications.

Operating systems

KPA EtherCAT Master is available for numerous operating systems, including Windows, INtime, RTX/RTX64, Linux,

Linux+Xenomai, FreeRTOS, Nucleus, QNX, VxWorks, ReWorks, Integrity, as well as OS-less systems. Upon request,

any customer operating system can be supported.

Hardware extensions for Xilinx/Intel FPGA (Altera) and Texas Instruments PRUSS Sitara CPU

Availability of IP Cores for Xilinx and for Intel FPGA (Altera) FPGAs, PRUss co-program for Texas Instrument Sitara

CPUs (AM47x and AM57x) increases productivity and data processing efficiency. Implementation for AM6x is

available upon request.

Master Redundancy for exceptional fault tolerance

EtherCAT technology allows avoiding problems with the connection between Slave devices and the Master via cable

redundancy. Master Redundancy is the KPA patented technology that allows protecting the control system from the

point of view of errors of the target system on which the control system is running. A typical example: the system is

no longer controlled at all as a result of a power failure at the target.

The KPA patented technology is implemented as a separate feature of the Master. It allows several EtherCAT Masters

to co-exist in a network segment, providing backup for seamless EtherCAT operation during possible Master failures.

Online/Auto configuration

Master can configure bus on the fly without the necessity of usage of EtherCAT configuration tools. The Online

Configurator module allows the user application to select the slave’s configuration (based on ESI file or extended by

KPA uESI) that will be applied. Then the module generates the Master configuration file (ENI) with applied uESI.

Further, this ENI will be used at Master work.

The Online Configurator functionality may be used to switch between different configurations of the slave, e.g.

position control of the drive and velocity control, or to switch between bus configurations with a different number of

slaves.

Process image logging for data transferring into Analytic tools

PI logger allows real time data to collect for transfer to other levels without influence on the real-time behavior of the

controlled system. Corresponding data can be transferred to MATLAB, LabView (TDMS format) and any other analytic

tools. Additionally, koenig-pa GmbH has designed Python extension for the module to provide the possibility of data

gathering via well-known by Data scientist interfaces to collect them into any format (e.g. CSV-file) for the following

investigations.

Custom Development

koenig-pa offers specific software development for customers who require additional support for integrating EtherCAT

capabilities into their applications or solutions. Our company has extensive experience in fieldbuses, embedded

systems, real-time operating environments, industrial automation solutions for various fields of application.

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EtherCAT configuration tool

Key Features

KPA EtherCAT Studio is a second generation of a user-friendly tool for EtherCAT bus

configuration and diagnostics. This lightweight, high-performance standalone Windows

application natively supports all the advanced features of KPA EtherCAT Master.

џ ETG standards compliance

KPA EtherCAT Studio is compliant with

EtherCAT Technology Group (ETG) standards

and can create ENI (EtherCAT Network

Information) files for third-party EtherCAT

masters.

џ Extended Slaves Library

Slaves Library is a list of available ESI

(EtherCAT Slave Information) files which can

be used to build up the project configuration.

KPA EtherCAT Studio provides an opportunity

to work with several Slaves Library collections,

change an active collection by using a custom

collection and manage Slaves Library view by

setting user attributes for slaves.

џ Remote Slaves Library

KPA EtherCAT Studio allows to connect Local

Slave Libraries to the Remote Slaves Library.

The Remote Slaves Library centrally stores

the latest correct data and ensures protection

from uncontrolled data editing which may

cause system errors.

џ Several feature package modifications

KPA EtherCAT Studio is delivered as a

Basic, Standard, Premium or customized

feature package depending on customer’s

demands.

џ Available for integration

KPA EtherCAT Studio can be integrated into

any custom application using .NET

Remoting.

џ Customization of features in the package

Features in the delivered package can be

activated or deactivated according to the

customer need. Moreover, there is a

possibility to customize brand data, such as

the product name, logo, copyright and

contacts.

џ Problem diagnostics

KPA EtherCAT Studio includes system

problem diagnostics, which provides clear

data interpretation for further successful

problem solving.

Plug-ins which can be included into Basic, Standard and Premium packages.

Feature packages

Basic Standard PremiumFeatures

Studio

Scaling Signal Values

Automation interface

Slaves Library

Studio/Emergency OutPut

Watch Viewer

Master Output

Plug-ins for configuring specific devices

CANopen Master/Slave (EL6751)

Profibus slave (El6731)

Bridge terminals (EL6692/EL6695)

Modular Devices

Virtual Serial COM

MDP Profibus Master Gateway Profile 3100

Tools

Topology Viewer

Snapshot Viewer

Chart Viewer

Diagnostic scanner

S2S Communication Editor

EEPROM Editor

Comparing tools

Data logging tools

Common

DC

Tasks/Sync Units

Power calculation via LVDS

Master

Cyclic Commands

ENI Export

External task

PI Alignment

Master Watchdog

Master Mailbox. AoE

Master Mailbox. EoE

ENI Export. XSLT Scheme support

Cable Redundancy

Slave

Mailbox. CoE

Mailbox. FoE

Slave Watchdog

Slave Mailbox. AoE

Slave Mailbox. EoE

Mailbox. SoE

Configuring Init Commands

FMMU/SM

Direct Memory access

Direct EEPROM access

Explicit identification

Hot Connect

Motion control library

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џ Implementation of Single-Axis, Synchronized Axis and 3D-Axis functionality

џ Time-optimal trajectory generation on the fly within one control cycle

џ Multi-thread processing for multi-core CPUs and optimized for low end CPUs

Key Features

џ Native EtherCAT support due to own-developed EtherCAT Master

џ Remote usage of product capabilities provided by proxy development kit. Advantage of this solution is the opportunity of non-real time OS usage on the client side with the possibility of instant drive communication due to real-time OS on the server side.

Versatility and Flexibility

KPA Motion functionality can range from

basic speed specification, positioning,

and synchronized movement of axes with

electronic cams, right through to robotics,

where multiple axes are required to follow

a precisely defined spherical curve.

The KPA Motion control library platform

helps users to achieve quickly their goal

due to an efficient engineering solution.

KPA Motion is a voting member of PLCopen Group focused on the software library for handling moving parts of machines

or robots in a controlled manner development. This software library is compatible with various systems, means that

KPA Motion doesn’t rely on a specific drive model or vendor.

Axes configuration EtherCAT configuration

Motionapplication

Linear Motion Coordinated Motion Robotics

Release FBs

Create Drive Interface

Create Fieldbus Services

Create axes Create axes Create axes

Release FBs Release FBs

Create FBs Create FBs

Sync Begin

Run FBsPLCopen part 1

Run FBsPLCopen part 1,4

Run FBsPLCopen part 1,4

Sync Commit

Sync Commit

Sync Commit

Set Kinematicsmodel

Create FBs

Cyclic partCyclic part Cyclic part

Sync Begin

Add axes to group

Sync Begin

Add axes to group

Release Fieldbus Services

Release Drive Interface

topology.xmlconfig.ini

Industry Standards

KPA Motion supports PLCopen specification with additional extensions.

It implements functional blocks as defined in PLCopen Motion Control

Specifications. In addition, KPA Motion supports commonly used

profiles, which makes it compatible with most of the drives on the

market.

Integration

KPA Motion is not bounded to any specific CPU architecture and is

compatible with various systems, due to developed operating system

abstraction layer which enables adaptation to any operating environment.

Advanced Visualization Solution

џ Unlimited data tags, screens and windows

џ Supports third-party PLCs through OPC Classic, Modbus TCP or custom TCP-based protocol

џ User access control and logging

џ Advanced features: data storage and export, reporting, trends and charts and other

џ Suitable for CFR 21 Part 11 compliant systems

Key Features

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KPA Automation View is a comprehensive software solution for creating advanced Human Machine Interfaces

(HMI) for factory automation and production control. It is a powerful, highly-customizable, fully-programmable

environment with truly unlimited possibilities for designing and programming even the most sophisticated

applications with any desired appearance, logic and connectivity.

Design

џ Design with KPA Automation Studio – powerful integrated development environment

џ Object-oriented approach to all components

џ Intuitive, drag-and-drop user interface

џ Extendable library of controls, styles, and scripts

џ Vector graphic editor

џ Import/export of objects and resources

Runtime

џ Static and animated graphics

џ Unlimited screens

џ Multi-HMI support

џ Protected user actions log

џ Script debugging®

џ Runs on Windows 7 and 10

KPA Automation View KPA Automation Studio

Security Editor

Runtime Design

Control Panel Editor

Dictonary Editor

Scripts Editor

User Management

Visualization Engine

OPC Classic DA Client

PLC with OPC ClassicDA Server

Javascript Engine

Permissions, Users, Groups

Visualization Configuration

Visualization Scripts

Dictionary

Protected Log File

Actions Logging

џ Integrated KPA EtherCAT Master

џ Advanced motion control library to control number of axis according to your application

џ Member of PLCopen since 2018

џ 5 programming languages support according to IEC 61131-3 standard

џ Integrated Motion Configurator

џ OPC UA server

џ Advanced debugging and monitoring tool

џ Easy implementation of redundant systems

џ Cross-platform solution

џ Configuration, programming from a single place

џ Nested user defined function blocks (UFBD)

џ Integrated EtherCAT studio configuration and diagnostic tool

Key Features

KPA AutomationControl System

Advanced PLCopen Motion softwarewith EtherCAT

automation

stratonNC Get trial

version

koenig-pa GmbH offers the cost-effective scalable solution. KPA Automation Straton supports a wide range of

operation systems, including KPA software, and expert support.

All-in-one solution

KPA Automation Straton is a totally integrated solution with built-in KPA EtherCAT Master and

KPA Motion Control Library for any platform. It allows koenig-pa GmbH to offer a full-featured solution suited to

meet all requirements, from the simplest to the most complex requiring advanced functionalities as well as

openness and flexibility.

Smart and simple integration

џ Hardware independence

џ Highly scalable: select only the features you need

џ Easy integration within a specific embedded application

џ Powerful visual wizards for declaring all OS/CPU conventions

WindowsYour HMI

Application

RuntimeDesign time

PLC

IO’sMotionFB’s

Your app forEtherCAT/Motion

(C++)

Motion Core

Bus Control

YourFieldbus servicefor KPA Motion

ModBus T5 Shared Mem

RealTime

Control/

OSALFor

ANY OS

Bus Hardware

OR

OPC UA

APIAPI

API

PLCopen

ORautomation

stratonNC

automation

d a t aanalytics

џ Maximum profitability, productivity and availability

џ Minimum downtime and Operating cost

џ Customized unlimited reports

џ User access control and logging

џ HTML, PDF, Excel formats

џ Connect to any number of devices on OPC UA/classic & Modbus, TCP & RTU via KPA Automation Server

џ Powerful and scalable software platform for industrial applications

џ Suitable for CFR21 Part 11 compliance systems

Key Features

Innovative reporting solution

#1

#2#3

#4

#5

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automation

d a t aanalytics

KPA Automation Data Analytics is scalable cost-effective application. It is suitable for large companies and

small customers who needs just to collect a bunch of tag values and show a simple table report.

KPA Automation Data Analytics is based on a bundle of two products.

It is available as an Application model and as a Library model.

Data Historian

SQL Server Database

PLC2 PLC3

modbus

KPA Server bridge

ReportingExport

...with OPC

PLC1

XLS XMLPDF

Production optimization

Data Analytics as an Application

Data Analytics as an Application (DAaaA) – Standalone Application developed by koenig-pa GmbH and fully

ready for Production usage.

Data Analytics as an Application consists of a bundle:

џ KPA Automation View

џ KPA Automation Data Analytics Application (Pr oject)

џ Setup component

Data Analytics as a Library Model

Data Analytics as a Library (DAaaL) – a set of controls that enable the User to integrate Data Analytics

capabilities to his HMI Application (KPA Automation View based).

Delivery Package consists of the KPA Automation Data Analytics Controls and Screens Library.

Customization by adding KPA Automation View is available. KPA Automation Data Analytics Project (Data

Analytics Project) is fully developed according KPA Automation Data Analytics requirements for DAaaA Model.

Data Analytics Controls and Screens may be reused at any Customer project where the Data Analytics Control

Library is installed.

Architecture

KPA Automation Control System

Windows-based control computersfor cost-effective automation solutions

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KPA Automation Control System is a family of all-in-one products aimed for building cost-effective factory

automation solutions. These compact systems, equipped with energy-efficient CPUs and advanced SCADA

software, are well suited for complex control tasks while saving extra space and reducing cost of maintenance.

Key Features

џ High performance Intel Core i5 CPUs for the most demanding control tasks

џ Compact integrated casing for saving space and reducing cost of maintenance

џ Windows 10 LTSB IoT pre-installed

џ Advanced software package: HMI with unlimited tags and screens + PLC with unlimited IOs connection

џ Native support for EtherCAT industrial networking

џ Compatible with third-party PLCs with OPC, Modbus TCP/IP or custom TCP/IP protocols

Hardware specifications

Software bundle

KPA Automation View

KPA Automation View is a powerful HMI solution with

designer tools for programming appearance and

behavior of every interface control. It provides access

to unlimited tags through OPC DA, Modbus TCP/IP or

any customized TCP/IP-based protocol. Advanced

controls bundle includes basic interface elements,

data connections, database access, archiving,

reporting and many other.

KPA Automation Control

KPA Automation Control is a solution for building

powerful software PLC that complies to IEC 61131-3

standard. Native EtherCAT bus support is provided by

comprehensive own-developed Master driver; Profibus

and CAN are supported with respective EtherCAT

gateways.

KPAACS Panel® TMIntel Core i5-4200U Dual-core, 1.6 GHz

8 GB DDR3®Embedded, Intel HD Graphics 4400

64 GB SSD®2 x Intel I211 Ethernet Controller

1 x RGB (VGA), 1 x HDMI, 2 x USB 2.0, 2 x USB 3.0, 4 x RS-232c

Integrated 15”, 1024 x 768, 4:3, resistive or capacitive touch panel

Less than 30W

24V DC

335 x 261 x 50 mm

Front side: IP55, back side: IP20

Active, built-in fan

Temperature: 0..60 °C, Relative humidity 5..85%,non-condensing

Model

CPU

RAM

Display controller

Storage

Networking

Interfaces

Display

Power consumption

Power source

Dimensions

Case protection

Cooling

Working conditions

KPAACS Box® TMIntel Core i5-4460T Quad-core, 1.9 GHz

8 GB DDR3®Embedded, Intel HD Graphics 4600

64 GB SSD®2 x Intel I211 Ethernet Controller

2 x RGB (VGA), 1 x HDMI, 4 x USB 2.0, 2 x USB 3.0, 1 x RS-232c

External analog and/or digital, dual display support

Less than 55W

24V DC

220 x 255 x 70 mm

IP20

Active, built-in fan

Temperature: 0..60 °C, Relative humidity 5..85%, non-condensing

џ Verified with Conformance Test Tool (CTT)

џ Code written in "ANSI C”

џ RAM size depends on size of Object Dictionary (OD):for static OD >= 3 KB Basic (8 KB Standard)

џ ROM (flash) >= 55 KB Basic (64 KB Standard)

џ Small footprint for 8- and 16 Bit- Microcontrollers:

  SAB 80x16x (Infineon)  ARM 3 – 9, ATmega128 (Atmel)   PPC 52xx, MPC8536 (Freescale)  Microblaze (Xilinx)  Sitara AM335x with integrated ESC in

PRUs (TI), C2000 (TI)

Key Features

High-speed network attachment

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KPA EtherCAT Slave Stack is

a software stack designed to

run on microcontrollers,

CPUs or DSPs with or

without any Operating

System (OS). It is provided

either as a source code or as

a compiled library.

Interfaces

џ Compatible with various EtherCAT Slave Controllers (ESC), including Beckhoff (ASIC, IP core) and TI (PRU)

џ IRQ handling of hardware events

џ Polling of Mailbox (MBx) and Process / Service Data

џ Operating System-based or OS-less

џ Hardware Abstraction Layer instead of separate “defines”

Standard Class bundle

џ Mailbox protocols: CoE, EoE, FoE, SoE VoE

џ Runtime generation / changing of Object Dictionary (OD)

џ Adapted to operating system by using Operating System Abstraction Layer (OSAL)

џ Virtual Ethernet card support for EoE (depending on OS)

Basic Class bundle

џ Mailbox protocol: CoE

џ Static Object Dictionary with pointer given from application

џ With / without Interrupt Service Routines (ISR)

API calls Stack events

EtherCAT Slave Stack

API

Mailboxupdate

ObjectDictionary

ProcessData

SDO

AL Eventhandler

IRQhandler

OSVirtual NIC

CoE VoE FoE

SoE

EoE

Operating System Abstraction

ESC Controller

IRQ

EtherCAT Network

Slave Device

Application

EtherCAT Master Redundancy

Reliability and fail-safe operation are vital requirements for any industrial automation system. When an

unexpected downtime happens, the production owner often suffers considerable losses, so he wants to be

sure that his production system is properly protected from various hardware and software failures.

EtherCAT technology is one of the most advanced and high-performance interfaces for communication on the

shop level of the factory. Besides great flexibility and high throughput, it offers some basic fault tolerance

features to withstand possible hardware failures. The most powerful of these features is the cable

redundancy which utilizes physical ring topology to preserve stable bus operation when the ring is actually

broken.

koenig-pa GmbH is one of the experts in EtherCAT and active member of EtherCAT Technology Group. Our

engineers went further and invented the way to protect industrial network from the most severe problem –

malfunction of its control node, a master system that controls the EtherCAT network operation. Our patented

technology, called Master Redundancy, allows to seamlessly recover from the control system failure and stay

operational even in a synchronized environment. You can find it in the latest release of KPA EtherCAT Master

software available from koenig-pa GmbH and its channel partners.

How to save the bus when its Master has gone

Let’s recall the basic principles of EtherCAT operation, as it is important to understand the concept that

underlies Master Redundancy feature of KPA EtherCAT Master.

Unlike other Ethernet-based industrial interfaces, EtherCAT utilizes hop-by-hop communication protocol: a

data telegram is common to all the slave devices connected to the bus, and it passes from one device to

another. Master is an agent that cyclically creates a telegram, fills it with read or write requests, output data

(or slots for input data) and sends it to the bus in strict time intervals. Each slave device can insert (write) or

extract (read) the block of data that is addressed explicitly to it.

While it is intended to effectively utilize the bus throughput, this feature is extremely useful for the fault

tolerance: any device connected to the bus is fully aware of the activity of all the slaves and can

transparently acquire, or sniff, the data that is transferred between the bus master and the slaves. You don’t

need to modify any slave devices, add any additional signals, or change the transfer protocol: this feature is

free from any added costs (besides a smarter master device, of course).

This side-effect is used by KPA EtherCAT Master for introducing another bus master (or several masters) to

the bus. During normal operation, this redundant master is passive, being able to sniff the data but not enter

its own telegrams. Passive master is considered secondary, while the active one is primary. As all the

secondary masters are consistent with the bus activity, they are ready to take place of the primary one

anytime when the latter fails.

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Sla

ve 1

Sla

ve 1

.1

Sla

ve 1

.2

Sla

ve 1

.3

PrimaryMaster

Active

Sla

ve N

Sla

ve N

.1

Sla

ve N

.2

Sla

ve N

.3

SecondaryMaster

Sniffing

What’s more important here, to detect the abnormal situation on the bus, a secondary master can does not need

any dedicated control device or additional signal lines. As you have already learned, EtherCAT telegrams come in

regular, strict time intervals. When a secondary passive master is not getting a telegram he expects, he confidently

knows that the bus has no master anymore. There is no need to wait until the current cycle is over – the redundant

master can take over the control immediately, posting his own telegram. And this telegram will be correct and

meaningful, because the secondary master was tracking down all the changes, being a true clone of its failed

counterpart.

How Master Redundancy works

EtherCAT configuration with master redundancy enabled comprises one active (primary) master device and one or

several passive (secondary) masters. Primary master might not be configured to Master Redundancy, but it is

preferable to use KPA EtherCAT Master software to utilize all the advantages of this technology.

Secondary master is connected to the bus as a shadow agent. It is sniffing data telegrams as they pass by without

any changes. At the same time, this master calculates the time when each telegram arrives and tracks possible

delays between expected and actual time of arrival.

When the telegram is delayed, a watchdog timer starts. After the time specified in the master’s settings is elapsed,

the master starts his failover protocol:

џ Internal switch of the master is triggered: now the master is able to write the bus

џ A new telegram prepared by the secondary master is written to the bus

џ In this telegram, a request to free the bus is sent to the active master, because he might be still online but

suffering from some internal troubles. We definitely don’t want the situation when the previously active master

decides to control the bus after recovering

џ Control application of the new bus master is notified about going online

It is possible to return the active master into its passive state with the bus configurator tool; another passive

master will take control automatically.

To enable multiple redundant masters, their watchdog timers are configured differently. It is possible to force

random generation of the watchdog time for each master. Thus, we avoid the situation of collision when two or

more secondary masters can attempt to start the failover protocol.

Contactemail: sales@koenig-pa.detel.:+49 9128 725 614 (Feucht)tel.:+49 9128 725 631 (Feucht)fax.:+49 9128 725 407 (Feucht)

koenig-pa GmbHIm Talesgrund 9a91207 Lauf a.d. Pegnitz Germanywww.koenig-pa.de

koenig-pa GmbH Quality Management Systemcertified according to DIN EN ISO 9001:2015Initial certification in 2008Copyright © koenig-pa GmbH. All rights reserved.EtherCAT ® is registered trademark and patented technology, licensed by Beckhoff Automation GmbH, Germany

OPC Classic / OPC UA

PLC

EtherCAT

HMI

Device

Slaves

Bus