LENZE EPL10200-W – Real-Time Digital Input Unit for Packaging, Material Handling & Robotics

Description

Application Scenarios

In a high-speed cartoning line at a European pharmaceutical packaging facility, engineers struggled with missed trigger signals from photoelectric sensors due to slow I/O scan cycles in their legacy fieldbus system. This caused misaligned product insertion and frequent jams. By replacing the old remote I/O with LENZE EPL10200-W terminals directly linked to an i550 servo controller via EtherCAT, they achieved deterministic input sampling at 10 µs intervals. The EPL10200-W’s tight synchronization with motion tasks allowed the robotic inserter to react instantly to product presence—boosting line speed by 18% while reducing waste by 90%. Maintenance staff now praise the EPL10200-W for its plug-and-play setup and clear LED diagnostics during changeovers.

Technical Principles and Innovative Values

Innovation Point 1: Hardware-Level Signal Processing – Unlike standard I/O modules that rely on controller polling, the EPL10200-W uses onboard FPGA logic to timestamp input changes with 1 µs resolution, enabling true event-based triggering for high-speed motion applications like flying shear or registration mark detection.

Innovation Point 2: Seamless Multi-Vendor EtherCAT Interoperability – Certified under the EtherCAT Technology Group (ETG) conformance test, the EPL10200-W integrates effortlessly not only with Lenze i500/ECS drives but also with Beckhoff, Siemens, B&R, and CODESYS-based masters—eliminating vendor lock-in.

Innovation Point 3: Ultra-Compact Footprint – At just 12 mm wide, the EPL10200-W delivers 8 inputs in half the space of conventional modules, reducing cabinet size and wiring complexity in space-constrained machines like labeling units or small robots.

Innovation Point 4: Integrated Diagnostics & Hot Connect – Each channel features a dedicated status LED, and the module supports “hot connect” configuration—allowing online topology changes without restarting the EtherCAT master, crucial for modular production lines.

Application Cases and Industry Value

At an automotive battery module assembly plant in Michigan, a laser-welding station required precise detection of tab alignment before initiating the weld cycle. Previous discrete I/O modules introduced jitter up to 2 ms, causing occasional misfires and electrode damage. After deploying EPL10200-W terminals connected directly to a Lenze i700 multi-axis controller, the system achieved sub-15 µs input-to-motion latency. Over six months, electrode life increased by 40%, and unplanned downtime dropped by 70%. The plant’s automation lead noted: “The EPL10200-W turned our sensor signals into real-time motion commands—not just data.”

Related Product Combination Solutions

LENZE EPL10300-W: 8-channel digital output terminal—pairs with EPL10200-W for complete discrete I/O control.

LENZE i550: Compact servo inverter—natively supports EPL10200-W as a distributed I/O node via integrated EtherCAT master.

LENZE EPL20100-W: 4-channel analog input terminal—for temperature, pressure, or position feedback alongside EPL10200-W digital triggers.

Beckhoff EL1008: Comparable EtherCAT DI module—EPL10200-W offers better integration with Lenze motion ecosystems.

LENZE ECS GPD: Decentralized drive system—can daisy-chain EPL10200-W modules for machine-periphery signal collection.

LENZE X4 Controller: PLC platform with built-in EtherCAT—auto-detects and configures EPL10200-W during startup.

LENZE Smart Motor MCA: Integrated servo motor—uses EPL10200-W inputs for local safety interlocks or homing sensors.

LENZE FAST Software Suite—enables drag-and-drop mapping of EPL10200-W inputs to motion functions like cam switching or error capture.

Installation, Maintenance, and Full-Cycle Support

Installing the EPL10200-W is straightforward: mount it on a DIN rail adjacent to other EPL modules or drives, connect the EtherCAT IN/OUT daisy chain using standard RJ45 or M12 cables, and wire field sensors to the removable screw terminals. No IP address or node ID configuration is needed—the EtherCAT master auto-enumerates the device during network scan. The module’s robust design withstands electrical noise common near VFDs, thanks to optocoupled inputs and 500 V isolation between field and bus sides.

For maintenance, each of the 8 channels has a bright yellow LED that illuminates when active, enabling rapid troubleshooting without tools. In case of failure, the EPL10200-W can be replaced in under 30 seconds—simply unclip, swap, and reconnect terminals. We provide full lifecycle support including GSDML files for major engineering platforms, compatibility matrices for mixed-vendor networks, and application notes for high-speed use cases. All units are RoHS-compliant, CE/UL-certified, and backed by Lenze’s global service network.

Contact us for a customized solution—whether you’re building a new high-speed machine or upgrading legacy I/O for tighter motion integration, the LENZE EPL10200-W delivers the speed, simplicity, and reliability your automation demands.