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EP1518-0002
User Manual
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Table of contents
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Beckhoff EP1518-0002 User Manual

Documentation | EN
EP1518-0002
EtherCAT Box with 8 digital inputs and 2 counters
2020-09-22 | Version: 2.2

Table of contents

Table of contents
1 Foreword ....................................................................................................................................................5
2 EtherCAT Box - Introduction ....................................................................................................................8
3 Product overview.....................................................................................................................................10
3.1 Introduction......................................................................................................................................10
3.2 Technical data .................................................................................................................................11
3.3 Process image.................................................................................................................................12
4 Installation................................................................................................................................................14
4.1 Mounting..........................................................................................................................................14
4.1.1 Dimensions ...................................................................................................................... 14
4.1.2 Fixing ............................................................................................................................... 15
4.1.3 Tightening torques for plug connectors ........................................................................... 15
4.2 Connection ......................................................................................................................................16
4.2.1 EtherCAT ......................................................................................................................... 16
4.2.2 Supply voltages ............................................................................................................... 18
4.2.3 Signal connection ............................................................................................................ 21
4.2.4 Status LEDs at the signal connections ............................................................................ 22
4.3 UL Requirements.............................................................................................................................23
4.4 ATEX notes .....................................................................................................................................24
4.4.1 ATEX - Special conditions ............................................................................................... 24
4.4.2 BG2000 - EtherCAT Box protection enclosures .............................................................. 25
4.4.3 ATEX Documentation ...................................................................................................... 26
5 Commissioning and configuration ........................................................................................................27
5.1 Integration in TwinCAT ....................................................................................................................27
5.2 Distributed Clocks (DC) ...................................................................................................................28
5.3 Distributed Clocks and EP1518.......................................................................................................30
5.4 Configuration of the EP1518 ...........................................................................................................31
5.4.1 Basic Function Principles................................................................................................. 31
5.4.2 Operation modes ............................................................................................................. 34
5.4.3 Counter settings............................................................................................................... 37
5.4.4 Restoring the delivery state ............................................................................................. 39
5.5 CoE objects .....................................................................................................................................40
5.5.1 Object overview ............................................................................................................... 40
5.5.2 Object description and parameterization ......................................................................... 45
6 Appendix ..................................................................................................................................................54
6.1 General operating conditions...........................................................................................................54
6.2 Accessories .....................................................................................................................................55
6.3 Version identification of EtherCAT devices .....................................................................................56
6.3.1 Beckhoff Identification Code (BIC)................................................................................... 60
6.4 Support and Service ........................................................................................................................62
EP1518-0002 3Version: 2.2
Table of contents
EP1518-00024 Version: 2.2
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G®, EtherCATG10®, EtherCATP®, SafetyoverEtherCAT®, TwinSAFE®, XFC®, XTS® and XPlanar® 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, EP1456722, EP2137893, DE102015105702 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.
EP1518-0002 5Version: 2.2
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: 2.2

1.3 Documentation Issue Status

Version Comment
2.2 • Front page updated
• Scope of supply added
• Structure update
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.
Foreword
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
2.2 04 08
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:
Firmware Hardware
55 - week of production 55 09 - year of production 2009 01 - firmware version 01 00 - hardware version 001
Further information on this topic: Version identification of EtherCAT devices [}56].
EP1518-0002 7Version: 2.2
EtherCAT Box - Introduction

2 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: 2.2
Fig.2: EtherCAT Box with M8 connections for sensors/actuators
EtherCAT Box - Introduction
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.
EP1518-0002 9Version: 2.2
Product overview

3 Product overview

3.1 Introduction

Fig.4: 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
Technical data [}11] Process image [}12] Dimensions [}14] Signal connection [}21]
EP1518-000210 Version: 2.2
Product overview

3.2 Technical data

Technical data 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 [}21]
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
M12
Onward connection: 1 x M8 socket, 4-pole
-25°C ... +60°C 0°C ... +55°C (conforms to cULus, see UL requirements [}23])
0°C ... +55°C (conforms to ATEX, see special conditions [}24])
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 [}23], ATEX [}24]
EP1518-0002 11Version: 2.2
Product overview

3.3 Process image

The process image depends on the selected operation mode [}34].
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: 2.2
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.
EP1518-0002 13Version: 2.2
Installation
119
126
23
30
26.5
13.5
Ø 3.5

4 Installation

4.1 Mounting

4.1.1 Dimensions

Fig.5: Dimensions
All dimensions are given in millimeters.
Housing features
Housing material PA6 (polyamide) Sealing compound polyurethane Mounting two fastening holes Ø 3.5 mm for M3 Metal parts brass, nickel-plated Contacts CuZn, gold-plated Power feed through max. 4A Installation position variable Protection class IP65, IP66, IP67 (conforms to EN 60529) when screwed together Dimensions (H x W x D) approx. 126 x 30 x 26.5 mm (without connectors)
EP1518-000214 Version: 2.2
Installation

4.1.2 Fixing

NOTE
Dirt during assembly
Dirty connectors can lead to malfunctions. Protection class IP67 can only be guaranteed if all cables and connectors are connected.
• Protect the plug connectors against dirt during the assembly.
Mount the module with two M3 screws on the fastening holes in the corners of the module. The fastening holes have no thread.

4.1.3 Tightening torques for plug connectors

Screw connectors tight with a torque wrench. (e.g. ZB8801 from Beckhoff)
Connector diameter Tightening torque
M8 0.4Nm M12 0.6Nm
EP1518-0002 15Version: 2.2
Installation
3 1
24

4.2 Connection

4.2.1 EtherCAT

4.2.1.1 Connectors
NOTE
Risk of confusion: supply voltages and EtherCAT
Defect possible through incorrect insertion.
• Observe the color coding of the connectors: black: Supply voltages green: EtherCAT
EtherCAT Box Modules have two green M8 sockets for the incoming and downstream EtherCAT connections.
Fig.6: EtherCAT connectors
Connection
Fig.7: M8 socket
EtherCAT M8
Signal Contact ZB9010, ZB9020, ZB9030, ZB9032,
Tx + 1 yellow
Tx - 4 orange
Rx + 2 white
Rx - 3 blue
Shield Housing Shield Shield Shield
1)
Core colors according to EN61918
connector
Core colors
ZK1090-6292, ZK1090-3xxx-xxxx
1)
1)
1)
1)
ZB9031 and old versions of ZB9030, ZB9032, ZK1090-3xxx­xxxx
orange/white white/orange
orange orange
blue/white white/green
blue green
TIA-568B
Adaptation of core colors for cables ZB9030, ZB9032 and ZK1090-3xxxx-xxxx
For standardization, the core colors of the ZB9030, ZB9032 and ZK1090-3xxx-xxxx cables have been changed to the EN61918 core colors: yellow, orange, white, blue. So there are different color codes in circulation. The electrical properties of the cables have been retained when the core colors were changed.
EP1518-000216 Version: 2.2
Installation
4.2.1.2 Status LEDs
Fig.8: EtherCAT status LEDs
L/A (Link/Act)
A green LED labelled "L/A" is located next to each EtherCAT socket. The LED indicates the communication state of the respective socket:
LED Meaning
off no connection to the connected EtherCAT device lit LINK: connection to the connected EtherCAT device flashes ACT: communication with the connected EtherCAT device
Run
Each EtherCAT slave has a green LED labelled "Run". The LED signals the status of the slave in the EtherCAT network:
LED Meaning
off Slave is in "Init" state flashes uniformly Slave is in "Pre-Operational“ state flashes sporadically Slave is in "Safe-Operational" state lit Slave is in "Operational" state
Description of the EtherCAT slave states
4.2.1.3 Cables
For connecting EtherCAT devices only shielded Ethernet cables that meet the requirements of at least category5 (CAT5) according to EN50173 or ISO/IEC11801 should be used.
EtherCAT uses four wires for signal transmission. Thanks to automatic line detection ("Auto MDI-X"), both symmetrical (1:1) or cross-over cables can be used between Beckhoff EtherCAT.
Detailed recommendations for the cabling of EtherCAT devices
EP1518-0002 17Version: 2.2
Installation
Plug
Input
Socket
Forwarding
3 1
24
3 1
24

4.2.2 Supply voltages

The EtherCAT Box is supplied with two supply voltages. The ground potentials of the supply voltages are galvanically connected together.
• Control voltage U
• Peripheral voltage U
S
P
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!
4.2.2.1 Connectors
NOTE
Risk of confusion: supply voltages and EtherCAT
Defect possible through incorrect insertion.
• Observe the color coding of the connectors: black: Supply voltages green: EtherCAT
Fig.9: Connectors for supply voltages
Fig.10: M8 connector
Contact Function Description Core color
1 U 2 U 3 GND 4 GND
1)
The core colors apply to cables of the type: Beckhoff ZK2020-3xxx-xxxx
S
P
S
P
Control voltage Brown Peripheral voltage White GND to U GND to U
S
P
Blue Black
1)
EP1518-000218 Version: 2.2
4.2.2.2 Status LEDs for the power supply
Fig.11: Status LEDs for the power supply
Installation
All LEDs, green and red, are activated once briefly during the initialization phase of the box.
LED Display Meaning
Us (control voltage) off The supply voltage, Us, is not present
green illuminated The supply voltage, Us, is present red illuminated Due to overload (current > 0.5 A), the sensor supply generated
from the supply voltage Us is switched off for all sensors in group 1 (inputs 0 to 3) or group 2 (inputs 4 to 7) that it supplies.
Up (peripheral voltage)
off The supply voltage, Up, is not present green illuminated The supply voltage, Up, is present
EP1518-0002 19Version: 2.2
Installation
Vert. Faktor: 0,45 cm / V
5 10 15 20
2
4
6
8
10
250
0
12
30
Vert. Faktor: 0,45 cm / V
Voltage drop (V)
Cable length (m)
35
0,25 mm²
0,34 mm²
0,5 mm² 0,75 mm²
I = 2 A
Vert. Faktor: 0,45 cm / V
5 10 15 20
2
4
6
8
10
250
0
12
30
Vert. Faktor: 0,45 cm / V
Voltage drop (V)
Cable length (m)
35
0,25 mm²
0,34 mm²
0,5 mm²
0,75 mm²
I = 4 A
4.2.2.3 Conductor losses
Take into account the voltage drop on the supply line when planning a system. Avoid the voltage drop being so high that the supply voltage at the box lies below the minimum nominal voltage.
Variations in the voltage of the power supply unit must also be taken into account.
Voltage drop on the supply line
EP1518-000220 Version: 2.2
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