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

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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

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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	Failure to follow the safety instructions associated with this symbol directly endangers
		the life and health of persons.
		Caution - Risk of injury!
	WARNING	Failure to follow the safety instructions associated with this symbol endangers the life
		and health of persons.
		Personal injuries!
	CAUTION	Failure to follow the safety instructions associated with this symbol can lead to injuries
		to persons.
		Damage to the environment or devices
	Attention	Failure to follow the instructions associated with this symbol can lead to damage to the
		environment or equipment.
		Tip or pointer
	Note	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	∙	Certificate updated
1.2.0	∙	Company address amended
	∙	Documentation versions added
	∙	DateCode description added
	∙ HFT and element classification according to EN 61508:2010 added
1.1.2	∙	Clock output currents in the technical data amended
	∙ Notes regarding the M8 and M12 connectors expanded
1.1.1	∙	Reference to EN 60068-2-29 removed
1.1.0	∙	First released version

EP1908-0002

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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

You will find a detailed description of the EtherCAT system in the Basic System Note 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

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Product description

3.2 Intended use

Caution - Risk of injury!

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

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

The fail-safe principle

The basic rule for a safety system such as TwinSAFE is that failure of a part, a system WARNING 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

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

Ensure traceability

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

CAUTION

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			typically: 4 ms,
(Read input/write to E-bus)			maximally: see error reaction time
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		(unshielded)	30 m max.(at 0.75 or 1 mm²)
sensor and EtherCAT Box
		(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			8 channels occupied: typically 87 mA
(connected with eight potential-free contacts)			0 channels occupied: typically 80 mA
Current consumption UP			8 channels occupied: approx. 27 mA
(connected with eight potential-free contacts)			0 channels occupied: approx. 6 mA
Power dissipation of the EtherCAT Box			typically 3 watts
Electrical isolation (between the channels)			no
Electrical isolation (between the channels and			yes
EtherCAT)
Insulation voltage (between the channels and			insulation tested with 500 VDC
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			-40 to +85 °C
(transport/storage)
Permissible air humidity			5 % to 95 %, non-condensing
Permissible air pressure			750 hPa to 1100 hPa
(operation/storage/transport)
Impermissible operating conditions			TwinSAFE EtherCAT boxes must not be used under
			the following conditions:
			∙ under the influence of ionizing radiation
			∙ in corrosive environments
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
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!
	WARNING	The TwinSAFE EtherCAT boxes must not be used under the following conditions:
		∙ under the influence of ionizing radiation

∙in corrosive environments

4.1Installation

4.1.1 Safety instructions

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

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

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

EP1908-0002

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