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EP1518-0001
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Beckhoff EP1518-0001, EP1518-0002 Documentation

Documentation
EP1518-0002
EtherCAT Box with 8 digital inputs and 2 counters
Version: Date:
2.1.0 2018-12-05

Table of contents

Table of contents
1 Foreword ....................................................................................................................................................5
1.1 Notes on the documentation..............................................................................................................5
1.2 Safety instructions .............................................................................................................................6
1.3 Documentation Issue Status..............................................................................................................7
2 Product overview.......................................................................................................................................8
2.1 EtherCAT Box - Introduction..............................................................................................................8
2.2 EP1518 - Introduction......................................................................................................................10
2.3 EP1518 - Technical data .................................................................................................................11
2.4 EP1518 – Process image ................................................................................................................12
3 Installation................................................................................................................................................14
3.1 Mounting..........................................................................................................................................14
3.1.1 Dimensions ...................................................................................................................... 14
3.1.2 Fixing ............................................................................................................................... 15
3.1.3 Nut torque for connectors ................................................................................................ 16
3.2 Connection ......................................................................................................................................18
3.2.1 EtherCAT connection....................................................................................................... 18
3.2.2 EtherCAT - Fieldbus LEDs .............................................................................................. 19
3.2.3 Power Connection ........................................................................................................... 21
3.2.4 EP1518 - Status LEDs for the power supply ................................................................... 24
3.2.5 Power cables ................................................................................................................... 25
3.2.6 Power cable conductor losses M8 ................................................................................... 26
3.2.7 Signal connection ............................................................................................................ 27
3.2.8 Status LEDs at the signal connections ............................................................................ 28
3.3 UL Requirements.............................................................................................................................29
3.4 ATEX notes .....................................................................................................................................30
3.4.1 ATEX - Special conditions ............................................................................................... 30
3.4.2 BG2000-0000 - EtherCAT Box protection enclosure....................................................... 31
3.4.3 ATEX Documentation ...................................................................................................... 32
4 Commissioning and configuration ........................................................................................................33
4.1 Integration in TwinCAT ....................................................................................................................33
4.1.1 Inserting into the EtherCAT network................................................................................ 33
4.1.2 Configuration via TwinCAT .............................................................................................. 36
4.1.3 Distributed Clocks (DC) ................................................................................................... 44
4.1.4 Distributed Clocks and EP1518 ....................................................................................... 46
4.2 Configuration of the EP1518 ...........................................................................................................47
4.2.1 Basic Function Principles................................................................................................. 47
4.2.2 Operation modes ............................................................................................................. 49
4.2.3 Counter settings............................................................................................................... 53
4.2.4 Restoring the delivery state ............................................................................................. 55
4.3 CoE objects .....................................................................................................................................56
4.3.1 Object overview ............................................................................................................... 56
4.3.2 Object description and parameterization ......................................................................... 60
5 Appendix ..................................................................................................................................................69
Table of contents
5.1 General operating conditions...........................................................................................................69
5.2 EtherCAT Box- / EtherCATPBox - Accessories ............................................................................70
5.3 Support and Service ........................................................................................................................71
EP1518-00024 Version: 2.1.0
Foreword

1 Foreword

1.1 Notes on the documentation

Intended audience
This description is only intended for the use of trained specialists in control and automation engineering who are familiar with the applicable national standards. It is essential that the documentation and the following notes and explanations are followed when installing and commissioning these components. It is the duty of the technical personnel to use the documentation published at the respective time of each installation and commissioning.
The responsible staff must ensure that the application or use of the products described satisfy all the requirements for safety, including all the relevant laws, regulations, guidelines and standards.
Disclaimer
The documentation has been prepared with care. The products described are, however, constantly under development.
We reserve the right to revise and change the documentation at any time and without prior announcement.
No claims for the modification of products that have already been supplied may be made on the basis of the data, diagrams and descriptions in this documentation.
Trademarks
Beckhoff®, TwinCAT®, EtherCAT®, EtherCATP®, SafetyoverEtherCAT®, TwinSAFE®, XFC® and XTS® are registered trademarks of and licensed by Beckhoff Automation GmbH. Other designations used in this publication may be trademarks whose use by third parties for their own purposes could violate the rights of the owners.
Patent Pending
The EtherCAT Technology is covered, including but not limited to the following patent applications and patents: EP1590927, EP1789857, DE102004044764, DE102007017835 with corresponding applications or registrations in various other countries.
The TwinCAT Technology is covered, including but not limited to the following patent applications and patents: EP0851348, US6167425 with corresponding applications or registrations in various other countries.
EtherCAT® is registered trademark and patented technology, licensed by Beckhoff Automation GmbH, Germany.
Copyright
© Beckhoff Automation GmbH & Co. KG, Germany. The reproduction, distribution and utilization of this document as well as the communication of its contents to others without express authorization are prohibited. Offenders will be held liable for the payment of damages. All rights reserved in the event of the grant of a patent, utility model or design.
Foreword

1.2 Safety instructions

Safety regulations
Please note the following safety instructions and explanations! Product-specific safety instructions can be found on following pages or in the areas mounting, wiring, commissioning etc.
Exclusion of liability
All the components are supplied in particular hardware and software configurations appropriate for the application. Modifications to hardware or software configurations other than those described in the documentation are not permitted, and nullify the liability of Beckhoff Automation GmbH & Co. KG.
Personnel qualification
This description is only intended for trained specialists in control, automation and drive engineering who are familiar with the applicable national standards.
Description of instructions
In this documentation the following instructions are used. These instructions must be read carefully and followed without fail!
DANGER
Serious risk of injury!
Failure to follow this safety instruction directly endangers the life and health of persons.
WARNING
Risk of injury!
Failure to follow this safety instruction endangers the life and health of persons.
CAUTION
Personal injuries!
Failure to follow this safety instruction can lead to injuries to persons.
NOTE
Damage to environment/equipment or data loss
Failure to follow this instruction can lead to environmental damage, equipment damage or data loss.
Tip or pointer
This symbol indicates information that contributes to better understanding.
EP1518-00026 Version: 2.1.0
Foreword

1.3 Documentation Issue Status

Version Comment
2.1.0 • Update Safety instructions
• Correction chapter Power cable
• Update chapter Mounting
2.0.0 • Migration
• Basic function principles chapter corrected
1.1.0 • Power Connection updated
1.0.0 • First release
Firmware and hardware versions
This documentation refers to the firmware and hardware version that was applicable at the time the documentation was written.
The module features are continuously improved and developed further. Modules having earlier production statuses cannot have the same properties as modules with the latest status. However, existing properties are retained and are not changed, so that older modules can always be replaced with new ones.
Documentation Version
2.1 04 06
2.0.0 04 05
1.0.0 02 00
The firmware and hardware version (delivery state) can be found in the batch number (D-number) printed on the side of the EtherCATBox.
Syntax of the batch number (D-number)
WWYYFFHH
WW - week of production (calendar week) YY - year of production FF - firmware version HH - hardware version
Example with D no.: 55 09 01 00:
55 - week of production 55 09 - year of production 2009 01 - firmware version 01 00 - hardware version 001
EP1518-0002
Firmware Hardware
Product overview

2 Product overview

2.1 EtherCAT Box - Introduction

The EtherCAT system has been extended with EtherCAT Box modules with protection class IP67. Through the integrated EtherCAT interface the modules can be connected directly to an EtherCAT network without an additional Coupler Box. The high-performance of EtherCAT is thus maintained into each module.
The extremely low dimensions of only 126x30x26.5 mm (hxw xd) are identical to those of the Fieldbus Box extension modules. They are thus particularly suitable for use where space is at a premium. The small mass of the EtherCAT modules facilitates applications with mobile I/O interface (e.g. on a robot arm). The EtherCAT connection is established via screened M8connectors.
Fig.1: EtherCAT Box Modules within an EtherCAT network
The robust design of the EtherCAT Box modules enables them to be used directly at the machine. Control cabinets and terminal boxes are now no longer required. The modules are fully sealed and therefore ideally prepared for wet, dirty or dusty conditions.
Pre-assembled cables significantly simplify EtherCAT and signal wiring. Very few wiring errors are made, so that commissioning is optimized. In addition to pre-assembled EtherCAT, power and sensor cables, field­configurable connectors and cables are available for maximum flexibility. Depending on the application, the sensors and actuators are connected through M8 or M12connectors.
The EtherCAT modules cover the typical range of requirements for I/O signals with protection class IP67:
• digital inputs with different filters (3.0ms or 10μs)
• digital outputs with 0.5 or 2A output current
• analog inputs and outputs with 16bit resolution
• Thermocouple and RTD inputs
• Stepper motor modules
XFC (eXtreme Fast Control Technology) modules, including inputs with time stamp, are also available.
EP1518-00028 Version: 2.1.0
Fig.2: EtherCAT Box with M8 connections for sensors/actuators
Product overview
Fig.3: EtherCAT Box with M12 connections for sensors/actuators
Basic EtherCAT documentation
You will find a detailed description of the EtherCAT system in the Basic System Documentation for EtherCAT, which is available for download from our website (www.beckhoff.com) under Downloads.
EtherCAT XML Device Description
You will find XML files (XML Device Description Files) for Beckhoff EtherCAT modules on our web­site (www.beckhoff.com) under Downloads, in the Configuration Files area.
Product overview

2.2 EP1518 - Introduction

Fig.4: EP1518-0001 and EP1518-0002
8 digital inputs (24VDC), 2 counters
The EP1518-0002 EtherCAT Box with digital inputs acquires binary control signals from the process level and transfers them, with electrical isolation, to the controller. The signal state is indicated by means of light emitting diodes. Connection is via M12 connectors. The input filters can be set between 0and 100ms via EtherCAT. Inputs 0 and 4 can be used as up/down counters (32-bit). Inputs 1 and 5 operate as GATES and inputs 2 and 6 control Up/Down. The EP1518 has three modes of operation that can be selected via the PDOs using the Sync-Manager:
• 2 digital inputs and 2 counters (delivery state)
• 5 digital inputs and 1 counter
• 8 digital inputs
All inputs continue to be shown in the process image even in the counter operation modes. Signal acquisition takes place with the filter times set via CoE. Irrespective of that, the counter pulses are always counted with a filter of 150µs. Further parameters can be set via the CoE objects. The sensors are supplied via the control voltage US in two groups of four sensors each. Any short circuits on the sensor side are detected and reported to the controller. The load voltage Up is not used in the input module, but may optionally be connected in order to be relayed downstream.
Quick links
• Installation [}14]
• Configuration [}36]
EP1518-000210 Version: 2.1.0
Product overview

2.3 EP1518 - Technical data

Technical data EP1518-0001 EP1518-0002
Fieldbus EtherCAT Fieldbus connection 2 x M8 socket (green) Number of inputs 8, 2 of which can be used as 32-bit up/down counters
Input connections [}27]
Nominal input voltage 24VDC (-15%/+20%) Input filter (binary inputs) adjustable 10µs…100ms Input filter (counter input) 150µs "0" signal voltage -3...+5V (EN61131-2, type3) "1" signal voltage +11...+30V (EN61131-2, type3) Input current typically 3mA (EN61131-2, type3) Module electronic supply derived from control voltage Us Module electronic current consumption typically 120mA Sensor supply derived from control voltage Us Sensor current consumption max. 0.5A per 4 sensors, short-circuit proof Power supply connection Power supply: 1 x M8 plug, 4-pole
Input process image 8 bits data, 8 bits diagnostics, 48 bits counter Output process image 48 bits counter Distributed clocks yes Electrical isolation control voltage/fieldbus 500V Weight approx. 165g Permissible ambient temperature during
operation
M8 M12
Onward connection: 1 x M8 socket, 4-pole
-25°C ... +60°C 0°C ... +55°C (conforms to cULus, see UL requirements [}29])
0°C ... +55°C (conforms to ATEX, see special conditions [}30])
Permissible ambient temperature during storage
Vibration/ shock resistance conforms to EN60068-2-6/ EN60068-2-27 EMC immunity/emission conforms to EN61000-6-2/ EN61000-6-4 Protection class IP65, IP66, IP67 (conforms to EN 60529) Installation position variable Approvals
-40°C ... +85°C
CE, cULus [}29], ATEX [}30]
Product overview

2.4 EP1518 – Process image

The process image depends on the selected operation mode [}49].
Operation mode: 2 counters and 2 digital inputs (delivery state)
The input data of the 1st counter can be found under CNT Input Channel1.
The adoption of the Set counter bit from CNT Output Channel 1 is displayed with Set counter done.
The adoption of the Inhibit counter bit from CNT Output Channel 1 is displayed with Counter inhibited.
Status of input UD shows the status of the Up/Down counter
input of the 1st counter.
Status of input clock shows the status of the input clock input of the 1st counter.
Sync Error, TxPDO State and TxPDO Toggle are standard EtherCAT process data.
The input data of the 2nd counter can be found under CNT Input Channel2. Their structure corresponds to that of the 1st counter.
DIG Inputs shows the states of the individual inputs irrespective of the selected operation mode.
Error channel 1 displays a short circuit of the supply voltage Us to digital inputs 0 to 3. Error channel 2 displays a short circuit of the supply voltage Us to digital inputs 4 to 7.
The output data of the 1st counter can be found under CNT Output Channel1. The setting of Set counter activates the adoption of the Set Counter Value into the Counter Value of the 1st counter. The setting of Inhibit Counter disables the 1st counter. Alternatively the counter can be disabled or enabled by the physical GATE input. The two values are XORed.
The output data of the 2nd counter can be found under CNT Output Channel1. Their structure corresponds to that of the 1st counter.
EP1518-000212 Version: 2.1.0
Operation mode: 1 counter and 5 digital inputs
The input data of the 1st counter can be found under CNT Input Channel1.
The adoption of the Set counter bit from CNT Output Channel 1 is displayed with Set counter done.
The adoption of the Inhibit counter bit from CNT Output Channel 1 is displayed with Counter inhibited.
Status of input UD shows the status of the Up/Down counter
input of the 1st counter.
Status of input clock shows the status of the input clock input of the 1st counter.
Sync Error, TxPDO State and TxPDO Toggle are standard EtherCAT process data.
DIG Inputs shows the states of the individual inputs irrespective of the selected operation mode.
Error channel 1 displays a short circuit of the supply voltage Us to digital inputs 0 to 3. Error channel 2 displays a short circuit of the supply voltage Us to digital inputs 4 to 7.
Product overview
Operation mode: 8 digital inputs
The output data of the 1st counter can be found under CNT Output Channel1. The setting of Set counter activates the adoption of the Set Counter Value into the Counter Value of the 1st counter.
The setting of Inhibit Counter disables the 1st counter. Alternatively the counter can be disabled or enabled by the physical GATE input. The two values are XORed.
DIG Inputs shows the states of the individual inputs irrespective of the selected mode.
Error channel 1 displays a short circuit of the supply voltage Us to digital inputs 0 to 3.
Error channel 2 displays a short circuit of the supply voltage Us to digital inputs 4 to 7.
Installation

3 Installation

3.1 Mounting

3.1.1 Dimensions

Fig.5: Dimensions of the EtherCAT Box Modules
All dimensions are given in millimeters.
Housing properties
EtherCAT Box lean body wide bodies
Housing material PA6 (polyamide) Casting compound Polyurethane Mounting two fastening holes Ø3mm for M3 two fastening holes Ø3mm for M3
two fastening holes Ø4.5mm for M4 Metal parts Brass, nickel-plated Contacts CuZn, gold-plated Power feed through max. 4A (M8)
max. 16A (7/8“)
max. 15.5A (B17 5G 1.5mm2) Installation position variable Protection class IP65, IP66, IP67 (conforms to EN 60529) when screwed together Dimensions
(HxWxD)
app. 126 x 30 x 26.5mm app. 126 x 60 x 26,5mm
app. 150 x 60 x 26.5mm (without 7/8", B17)
EP1518-000214 Version: 2.1.0
Installation

3.1.2 Fixing

Note or pointer
While mounting the modules, protect all connectors, especially the IP-Link, against contamination! Only with connected cables or plugs the protection class IP67 is guaranteed! Unused connectors have to be protected with the right plugs! See for plug sets in the catalogue.
Modules with narrow housing are mounted with two M3 bolts. Modules with wide housing are mounted with two M3 bolts to the fixing holes located at the corners or mounted with two M4 bolts to the fixing holes located centrally.
The bolts must be longer than 15 mm. The fixing holes of the modules are not threaded.
When assembling, remember that the fieldbus connectors increases the overall height. See chapter accessories.
Mounting Rail ZS5300-0001
The mounting rail ZS5300-0001 (500 mm x 129 mm) allows the time saving assembly of modules.
The rail is made of stainless steel, 1.5 mm thick, with already pre-made M3 threads for the modules. The rail has got 5.3 mm slots to mount it via M5 screws to the machine.
Fig.6: Mounting Rail ZS5300-000
The mounting rail is 500 mm long, that way 15 narrow modules can be mounted with a distance of 2 mm between two modules. The rail can be cut to length for the application.
Mounting Rail ZS5300-0011
The mounting rail ZS5300-0011 (500 mm x 129 mm) has in addition to the M3 treads also pre-made M4 treads to fix 60 mm wide modules via their middle holes.
Up to 14 narrow or 7 wide modules may be mixed mounted.
Installation

3.1.3 Nut torque for connectors

M8 connectors
It is recommended to pull the M8 connectors tight with a nut torque of 0.4 Nm. When using the torque control screwdriver ZB8800 is also a max. torque of 0.5Nm permissible.
Fig.7: EtherCAT Box with M8 connectors
M12 connectors
It is recommended to pull the M12 connectors tight with a nut torque of 0.6 Nm.
Fig.8: EtherCAT Box with M8 and M12 connectors
EP1518-000216 Version: 2.1.0
7/8" plug connectors
We recommend fastening the 7/8" plug connectors with a torque of 1.5Nm.
Fig.9: 7/8" plug connectors
Torque socket wrenches
Installation
Fig.10: ZB8801 torque socket wrench
Ensure the right torque
Use the torque socket wrenches available by Beckhoff to pull the connectors tight (ZB8800, ZB8801-0000)!
Installation

3.2 Connection

3.2.1 EtherCAT connection

For the incoming and ongoing EtherCAT connection,
• the EtherCAT Box (EPxxxx) has two M8 sockets, marked in green
• the Coupler Box (FBB-x110) has two M12 sockets
Fig.11: EtherCAT Box: M8, 30mm housing
Fig.12: EtherCAT Box: M860mm housing (example: EP9214)
Fig.13: Coupler Box: M12
Assignment
There are various different standards for the assignment and colors of connectors and cables for Ethernet/ EtherCAT.
EP1518-000218 Version: 2.1.0
Installation
Ethernet/EtherCAT Plug connector Cable Standard
Signal Description M8 M12 RJ45
Tx + Transmit Data+ Pin 1 Pin 1 Pin 1 yellow
Tx - Transmit Data- Pin 4 Pin 3 Pin 2 orange
Rx + Receive Data+ Pin 2 Pin 2 Pin 3 white
Rx - Receive Data- Pin 3 Pin 4 Pin 6 blue
Shield Shield Housing Shroud Screen Screen Screen
1
) colored markings according to EN 61918 in the four-pin RJ45 connector ZS1090-0003
2
) wire colors according to EN 61918
3
) wire colors
1
ZB9010, ZB9020, ZB9030, ZB9032, ZK1090-6292, ZK1090-3xxx-xxxx
2
2
2
2
ZB9031 and old ver­sions of ZB9030, ZB9032, ZK1090-3xxx-xxxx
orange/white
orange
blue/white
3
blue
3
3
3
TIA-568B
white/orange
orange
white/green
green
Assimilation of color coding for cable ZB9030, ZB9032 and ZK1090-3xxxx-xxxx (with M8 connectors)
For unification the prevalent cables ZB9030, ZB9032 and ZK1090-3xxx-xxxx this means the pre as­sembled cables with M8 connectors were changed to the colors of EN61918 (yellow, orange, white, blue).So different color coding exists. But the electrical properties are absolutely identical.
EtherCAT connector
The following connectors can be supplied for use in Beckhoff EtherCAT systems.
Name Connector Comment
ZS1090-0003 RJ45 four-pole, IP20, field-configurable ZS1090-0004 M12, male four-pin, IP67, for field assembly ZS1090-0005 RJ45 eight-pole, IP20, field-configurable, suitable for gigabit Ethernet ZS1090-0006 M8 plug connector four-pole, IP67, field-configurable, for cable type ZB903x ZS1090-0007 M8 socket four-pole, IP67, field-configurable, for cable type ZB903x ZS1090-1006 M8 plug connector four-pole, IP67, field-configurable up to OD=6.5mm ZS1090-1007 M8 socket four-pole, IP67, field-configurable up to OD=6.5mm

3.2.2 EtherCAT - Fieldbus LEDs

Fig.14: EtherCAT-LEDs
Installation
LED display
LED Display Meaning
IN L/A off no connection to the preceding EtherCAT module
Lit LINK: connection to the preceding EtherCAT module flashing ACT: Communication with the preceding EtherCAT module
OUT L/A off no connection to the following EtherCAT module
Lit LINK: connection to the following EtherCAT module flashing ACT: Communication with the following EtherCAT module
Run off Status of the EtherCAT module is Init
flashes quickly Status of the EtherCAT module is pre-operational flashes slowly Status of the EtherCAT module is safe-operational Lit Status of the EtherCAT module is operational
EtherCAT statuses
The various statuses in which an EtherCAT module may be found are described in the Basic Sys­tem Documentation for EtherCAT, which is available for download from our website (www.beck- hoff.com) under Downloads.
EP1518-000220 Version: 2.1.0
Installation

3.2.3 Power Connection

The feeding and forwarding of supply voltages is done via two M8 connectors at the bottom end of the modules:
• IN: left M8 connector for feeding the supply voltages
• OUT: right M8 connector for forwarding the supply voltages
Fig.15: EtherCAT Box, Connectors for power supply
Fig.16: Pin assignment M8, Power In and Power Out
Table1: PIN assignment
Pin Voltage
1 Control voltage Us, +24V 2 Auxiliary voltage Up, +24V
DC
DC
3 GNDs* *) may be connected internally to each other depending on the module: see specific 4 GNDp*
module descriptions
The pins M8 connectors carry a maximum current of 4A.
Two LEDs display the status of the supply voltages.
NOTE
Don't confuse the power connectors with the EtherCAT connectors!
Never connect the power cables (M8, 24VDC) with the green marked EtherCAT sockets of the EtherCAT Box Modules! This can damage the modules!
Control voltage Us: 24V
Power is supplied to the fieldbus, the processor logic, the inputs and the sensors from the 24VDC control voltage Us. The control voltage is electrically isolated from the fieldbus circuitry.
DC
Auxiliary voltage Up 24V
DC
The Auxiliary voltage Up supplies the digital outputs; it can be brought in separately. If the load voltage is switched off, the fieldbus functions and the power supply and functionality of the inputs are retained.
Installation
Redirection of the supply voltages
The IN and OUT power connections are bridged in the module (not IP204x-Bxxx and IE204x). The supply voltages Us and Up can thus easily be transferred from EtherCATBox to EtherCATBox.
NOTE
Pay attention to the maximum permissible current!
Pay attention also for the redirection of the supply voltages Us and Up, the maximum permissible current for M8 connectors of 4A must not be exceeded!
EP1518-000222 Version: 2.1.0
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