BECKHOFF EP1908 User Manual

Operating instructions for

EP1908

TwinSAFE EtherCAT Box with eight fail-safe inputs

Version: 1.2.1
Date: 2015-03-11

Table of contents

Table of contents

1 Foreword 3

1.1 Notes on the manual 3

1.1.1 Disclaimer 3

1.1.2 Brands 3

1.1.3 Patents 3

1.1.4 Copyright 3

1.1.5 Delivery conditions 3

1.2 Safety instructions 4

1.2.1 Delivery state 4

1.2.2 Operator's obligation to exercise diligence 4

1.2.3 Description of safety symbols 5

1.2.4 Origin of the document 5

1.2.5 Documentation issue status 5

2 System description 6

2.1 EtherCAT Box Modules 6

3 Product description 7

3.1 EP1908-0002 7

3.2 Intended use 8

3.3 Technical data 9

3.4 Safety parameters 10

3.5 Dimensions 10

4 Operation 11

4.1 Installation 11

4.1.1 Safety instructions 11

4.1.2 Transport / storage 11

4.1.3 Address settings on the TwinSAFE EtherCAT Box 12

4.1.4 Mounting 13

4.1.5 Connection 14

4.2 Operating modes 21

4.3 EP1908 process image 23

4.4 Diagnostics 24

4.4.1 Run LED diagnostics 24

4.4.2 Diagnostic objects 25

EP1908-0002 1

Table of contents

4.5 EL1908 configuration in the TwinCAT System Manager 27

4.5.1 Adding an EtherCAT device 27

4.5.2 Adding a EP1908 27

4.5.3 Entering a TwinSAFE address and parameters in the System Manager 28

4.6 Maintenance 37

4.6.1 Cleaning 37

4.6.2 Service life 37

4.7 Decommissioning 38

4.7.1 Disposal 38

5 Appendix 39

5.1 Protection classes according to IP code 39

5.1 Beckhoff Support and Service 40

5.1.1 Beckhoff branches and partner companies Beckhoff Support 40

5.1.2 Beckhoff company headquarters 40

5.2 Certificate 41

2

EP1908-0002

Foreword

1 Foreword

1.1 Notes on the manual

This description is only intended for the use of trained specialists in control and automation technology
familiar with the applicable national standards. It is essential that the following notes and explanations are
followed when installing and commissioning these components.
The responsible staff must ensure that the application or use of the products described satisfy all the
safety requirements, including all the relevant laws, regulations, guidelines and standards.

1.1.1 Disclaimer

This documentation has been prepared with care. The products described are, however, constantly under
development. For this reason, the documentation may not always have been fully checked for
consistency with the performance data, standards or other characteristics described.
If it should contain technical or editorial errors, we reserve the right to make changes at any time and
without notice.
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.

1.1.2 Brands

Beckhoff®, TwinCAT®, EtherCAT®, Safety over EtherCAT®, TwinSAFE® and XFC® are registered
trademarks of and licensed by Beckhoff Automation GmbH.
The use by third parties of other brand names or trademarks contained in this documentation may lead to
an infringement of the rights of the respective trademark owner.

1.1.3 Patents

The EtherCAT technology is patent protected, in particular by the following applications and patents:
EP1590927, EP1789857, DE102004044764, DE102007017835 with the corresponding applications and
registrations in various other countries.

The TwinCAT technology is patent protected, in particular by the following applications and patents:
EP0851348, US6167425 with the corresponding applications and registrations in various other countries.

1.1.4 Copyright

©

Beckhoff Automation GmbH & Co. KG.
The copying, distribution and utilization of this document as well as the communication of its contents to
others without express authorization is prohibited. Offenders shall be held liable for damages. All rights
conferred by patent grant or registration of a utility model or registered design are reserved.

1.1.5 Delivery conditions

In addition, the general delivery conditions of the company Beckhoff Automation GmbH & Co. KG apply.

EP1908-0002 3

Foreword

1.2 Safety instructions

1.2.1 Delivery state

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.

1.2.2 Operator's obligation to exercise diligence

The operator must ensure that

• the TwinSAFE products are only used as intended (see section Product description);

• the TwinSAFE products are only operated in sound condition and in working order (see chapter

Cleaning).

• the TwinSAFE products are operated only by suitably qualified and authorized personnel.

• the personnel is instructed regularly about relevant occupational safety and environmental

protection aspects, and is familiar with the operating instructions and in particular the safety
instructions contained herein.

• the operating instructions are in good condition and complete, and always available for reference
at the location where the TwinSAFE products are used.

• none of the safety and warning notes attached to the TwinSAFE products are removed, and all
notes remain legible.

4

EP1908-0002

Foreword

1.2.3 Description of safety symbols

The following safety symbols are used in these operating instructions. They are intended to alert the
reader to the associated safety instructions.

Serious risk of injury!

DANGER

WARNING

CAUTION

Attention

Note

Failure to follow the safety instructions associated with this symbol directly endangers

the life and health of persons.

Caution - Risk of injury!
Failure to follow the safety instructions associated with this symbol endangers the life

and health of persons.

Personal injuries!
Failure to follow the safety instructions associated with this symbol can lead to injuries

to persons.

Damage to the environment or devices
Failure to follow the instructions associated with this symbol can lead to damage to the

environment or equipment.

Tip or pointer

This symbol indicates information that contributes to better understanding.

1.2.4 Origin of the document

The operating instructions for the EP1908-0002 EtherCAT Box were originally written in German. All other
languages are derived from the German original.

1.2.5 Documentation issue status

Version Comment

1.2.1

1.2.0

1.1.2

1.1.1

1.1.0

• Certificate updated

• Company address amended

• Documentation versions added

• DateCode description added

• HFT and element classification according to EN 61508:2010 added

• Clock output currents in the technical data amended

• Notes regarding the M8 and M12 connectors expanded

• Reference to EN 60068-2-29 removed

• First released version

EP1908-0002 5

System description

2 System description

2.1 EtherCAT Box Modules

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.

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,
field-configurable connectors and cables are available for maximum flexibility. Depending on the
application, the sensors and actuators are connected through M8 or M12 connectors.

Basic EtherCAT documentation

Note

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.de) under Downloads.

6

EP1908-0002

Product description

3 Product description

3.1 EP1908-0002

The EP1908-0002 is an EtherCAT Box with digital inputs for 24 VDC encoders or for potential-free
contacts. The EtherCAT Box has eight fail-safe inputs.

In addition to the possibility to read potential-free contacts, the EP1908-0002 also supports the
connection of encoders with OSSD signals whose test pulse length does not exceed 350 µs and of safety
mats that operate based on the cross-circuit principle.

Frequency measurement is also supported, in order to enable standstill and speed monitoring. The
frequency below which a logical 1 is reported at the input is specified in steps of 0.1 Hz. The module
supports a minimum frequency of 2 Hz and a maximum frequency of 500Hz. Frequencies above of 500
Hz result in a diagnostic message for the module. In this case all inputs are set to safe state (logical 0).
This message can be reset through a rising edge of the safe output signal ErrAck of the EP1908-0002.

With a two-channel connection, the EP1908-0002 meets the requirements of EN 61508-1:2010 SIL 3 and
DIN EN ISO 13849-1:2006 (Cat 4, PL e).

The control voltage US supplies the module electronics. The sensors are supplied from the control voltage
Up.

The TwinSAFE EtherCAT Box has the typical design of an EtherCAT Box.

EP1908-0002 7

Product description

3.2 Intended use

Caution - Risk of injury!

WARNING

The TwinSAFE EtherCAT Box expands the application range of the Beckhoff system with functions that
enable it to be used for machine safety applications. The TwinSAFE Boxes are designed for machine
safety functions and directly associated industrial automation tasks. They are therefore only approved for
applications with a defined fail-safe state. This safe state is the wattless state. Fail-safety according to the
relevant standards is required.

The TwinSAFE EtherCAT Box allows the connection of:

• 24 VDC sensors such as
emergency stop push buttons, pull cord switches, position switches, two-hand switches, safety
mats, light curtains, light barriers, laser scanners etc.

• initiators and encoders for speed measurement (frequency) with a signal voltage of 24 VDC

WARNING

The TwinSAFE EtherCAT Box may only be used for the purposes described below!

The fail-safe principle

The basic rule for a safety system such as TwinSAFE is that failure of a part, a system
component or the overall system must never lead to a dangerous condition. The safe
state is always the switched off and wattless state.

Follow the machinery directive

CAUTION

CAUTION

The TwinSAFE EtherCAT Box may only be used in machines that meet the
requirements of the Machinery Directive.

Ensure traceability

The buyer has to ensure the traceability of the device via the serial number.

8

EP1908-0002

Product description

3.3 Technical data

Product designation EP1908-0002

Fieldbus EtherCAT
Number of inputs 8
Connecting the inputs M12
Status display 8 (one green LED per input)
Reaction time

(Read input/write to E-bus)
Watchdog time adjustable from 2 ms to 60 s
Error reaction time ≤ watchdog time
Frequency range for speed measurement 2 Hz to 500 Hz
Cable length between

sensor and EtherCAT Box

(unshielded) 30 m max.(at 0.75 or 1 mm²)

(shielded) 30 m max.(at 0.75 or 1 mm²)
Output current of the clock outputs typically 10 mA, max. 15 mA
Input process image 6 byte
Output process image 6 byte
Supply voltage for the EP1908 24 VDC (-15%/+20%)
Power consumption Us

(connected with eight potential-free contacts)
Current consumption UP
(connected with eight potential-free contacts)
Power dissipation of the EtherCAT Box typically 3 watts
Electrical isolation (between the channels) no
Electrical isolation (between the channels and

EtherCAT)
Insulation voltage (between the channels and

EtherCAT, under common operating conditions)
Dimensions (W x H x D) 30 mm x 126 mm x 26.5 mm
Housing material PA6-F (polyamide)
Sealing compound polyurethane
Weight approx. 170 g
Permissible ambient temperature (operation) -25 ℃ to +70 ℃
Permissible ambient temperature

(transport/storage)
Permissible air humidity 5 % to 95 %, non-condensing
Permissible air pressure

(operation/storage/transport)
Impermissible operating conditions

EMC immunity/emission according to EN 61000-6-2 / EN 61000-6-4
Vibration / shock resistance according to EN 60068-2-6 / EN 60068-2-27
Shocks 15 g with pulse duration 11 ms in all three axes
Protection class (when screwed together) IP65, IP66, IP67 (according to EN 60529)
Permissible installation position Variable
Approvals CE, TÜV SÜD

typically: 4 ms,
maximally: see error reaction time

8 channels occupied: typically 87 mA
0 channels occupied: typically 80 mA

8 channels occupied: approx. 27 mA
0 channels occupied: approx. 6 mA

yes

insulation tested with 500 VDC

-40 ℃ to +85 °C

750 hPa to 1100 hPa

TwinSAFE EtherCAT boxes must not be used under
the following conditions:

• under the influence of ionizing radiation

• in corrosive environments

EP1908-0002 9

Product description

3.4 Safety parameters

Key figures EP1908-0002

Lifetime [a] 20
Prooftest Intervall [a] not required 1)
PFH 1.56E-09
%SIL3 1.56%
PFD 1.06E-04
%SIL3 10.59%
MTTFd [a] >100
Performance level PL e
Category 4
HFT 1
Element classification* Type A
*) Classification according to EN 61508-2:2010 (see chapters 7.4.4.1.2 and 7.4.4.1.3)

The EP1908-0002 EtherCAT Box can be used for safety-related applications according to IEC 61508 up
to SIL3 and EN ISO 13849-1 up to PL e (Cat4).

1)

Special proof tests throughout the service life of the EtherCAT Box are not required.

3.5 Dimensions

The EP1908 module has the following dimensions.
Width: 30 mm
Height: 126 mm
Depth: 26.5 mm

When fully wired, the connected cables increase the total depth of the module.

10

EP1908-0002

Operation

4 Operation

Please ensure that the TwinSAFE Boxes are only transported, stored and operated under the specified
conditions (see technical data)!

Caution - Risk of injury!

The TwinSAFE EtherCAT boxes must not be used under the following conditions:

WARNING

4.1 Installation

4.1.1 Safety instructions

Read the safety notes in the Foreword of this document before installing and commissioning the
TwinSAFE EtherCAT Box.

• under the influence of ionizing radiation

• in corrosive environments

4.1.2 Transport / storage

When transporting or storing the TwinSAFE EtherCAT Box, always use the original packaging in which it
was delivered.

Note the specified environmental conditions

CAUTION

Please ensure that the digital TwinSAFE EtherCAT Boxes are only transported and
stored under the specified environmental conditions (see technical data).

EP1908-0002 11