Rich Diagnostic Capabilities Await with Cabinet-free Automation

Brandon Snell
Sep 25
3 min read

How to leverage EtherCAT diagnostics that are built into Beckhoff's cabinet-free MX-System.

The MX-System is fully networked via EtherCAT, providing a wide range of benefits, including powerful built-in diagnostic capabilities.

In machine control technology, system diagnostics are the first line of defense against downtime. As automation systems grow more modular and distributed, the ability to quickly localize and remedy faults or failures becomes even more critical. Whether you’ve been hit with a loose broken connection, signal degradation, or a failing module, the ability to detect, localize, and resolve issues quickly can make the difference between breezing through minutes of simple troubleshooting and sinking in hours of lost production.

That’s why Beckhoff made sure that the cabinet-free MX-System fully leveraged the powerful diagnostic capabilities of EtherCAT from day one.

Breaking free from cabinets, bundling functionality

Beckhoff’s MX-System encapsulates decades of automation know-how in a robust, machine mountable form that eliminates traditional control cabinets. It combines industrial PCs, I/O, drive modules, relay modules, system power, and accessories in a modular, pluggable IP67 design. This approach drastically reduces wiring complexity, documentation, assembly time, and system footprint, while enabling the bulk of installation to be handled by non-specialists.

Each MX-System function module plugs into a baseplate, providing the module with a connection to the EtherCAT network and tapping into the integrated power distribution via the backplane. The baseplate design also allows for certain modules to be hot-swappable, and the system supports decentralized configuration with the flexibility to expand or integrate into existing cabinet-based architectures.

RELATED: Schirmer Reframes Machine Design with Cabinet-Free Automation

Unpacking the diagnostic powers of EtherCAT

EtherCAT – or Ethernet for Control Automation Technology – is an industrial Ethernet fieldbus protocol developed by Beckhoff and standardized under IEC 61158. It enables ultra-fast, deterministic I/O communication by processing data "on the fly": a single frame traverses all distributed nodes, allowing each to read and insert data in transit without polling the network. This greatly reduces cycle times (≤ 100 µs), maximizes bandwidth utilization, and lowers jitter to mere microsecond levels.

The MX-System's EtherCAT diagnostics are accessible in TwinCAT’s system manager and TwinCAT HMI to deliver immediate, clear insights into system health.

Critically, EtherCAT’s design also supports powerful built-in diagnostics: CRC checks, error counters, path quality monitoring, and fast disturbance localization help pinpoint communication issues with precision. Standard tools such as Wireshark (with EtherCAT parsers) can also monitor network traffic for detailed analysis.

In Beckhoff’s TwinCAT software environment, EtherCAT diagnostics are built directly into the main EtherCAT controller and system manager, offering graphical visualization of fieldbus health, topology insights, working counters, and PLC-accessible diagnostic elements.

The MX-System further simplifies what was already quite simple with EtherCAT diagnostics by introducing a Bluetooth-enabled dongle providing read-only access to MX-System modules. An accompanying app for smartphones and tablets provides the user with the ability to quickly diagnose and troubleshoot systems.

Top 5 reasons why EtherCAT diagnostics give MX-System users an edge

The combination of the cabinet-free MX-System and built in EtherCAT diagnostics functionality delivers compelling benefits:

Pinpointed fault detection and resolution

Each MX-System module functions as an EtherCAT device, enabling complete diagnostics at the individual module level. This ensures that any communication or hardware faults—such as CRC errors or link issues—can be quickly detected and localized to specific modules, connections, or linked devices.

Simplified maintenance via visual and remote interfaces

EtherCAT diagnostics accessible within TwinCAT’s system manager, TwinCAT 3 Scope for integrated charting of data, and TwinCAT HMI, deliver immediate, clear insights into system health. Plus, the data is accessible by mobile devices via a Bluetooth interface and app for the MX-System. This enables faster maintenance decisions, well-informed corrective measures, and reduced downtime.

Flexible, modular design and hot-swap capability

Thanks to hot-swapping of certain modules during production and EtherCAT's dynamic detection capabilities, MX-System modules can be replaced with minimal disruption. Diagnostics updates and alerts can be sent in real time, contributing to highly proactive and responsive operations.

Enhanced visibility into your process, even in harsh environments

The MX-System’s IP67-rated design and modular installation capabilities, combined with EtherCAT's diagnostic transparency, allows deployment in challenging industrial environments while providing quick access to control system and network insights.

Lifecycle efficiency from commissioning to expansion

Leveraging diagnostics during commissioning can even speed up installation and configuration, while ongoing monitoring supports operational reliability. Future MX-System expansions remain straightforward thanks to the inherent modularity and increased visibility.

An MX-System application as viewed in TwinCAT 3 HMI Scope which offers a range of tools for visualizing and charting large quantities of data which can further support diagnostics efforts.

A new era of automation insights

Beckhoff’s MX-System transforms traditional cabinet-based control by reducing assembly time, removing many sources of error, and shrinking physical footprint. It does this while retaining full compatibility with standard TwinCAT and EtherCAT infrastructure. Integrated diagnostic capabilities from all of these technologies make the MX-System more than just a collection of rugged, modular hardware. They turn the MX-System into a powerful enabler of data insights and overall equipment effectiveness (OEE).

With each MX-System module functioning as an EtherCAT node, real-time diagnostics, exceptional performance, and network transparency are all built in. This increases uptime, simplifies service, and prepares operations for future expansion—especially for end users who are pressured to deliver the goods under the dueling pressures of maximizing uptime and keeping up with continuous technological innovation.