How it Works
Beckhoff
Loading...
EP2918
Operating Instruction
54 pgs9.88 Mb0
Table of contents
Loading...

Beckhoff EP2918 Operating Instruction

Operating Instruction | EN
EP2918
TwinSAFE EtherCAT Box with 8 fail-safe outputs
2020-11-12 | Version: 1.1.0

Table of contents

Table of contents
1 Foreword ....................................................................................................................................................5
1.2.1 Delivery state ..................................................................................................................... 6
1.2.2 Operator's obligation to exercise diligence ........................................................................ 6
1.2.3 Description of instructions.................................................................................................. 7
2 System description ...................................................................................................................................9
3 Product description.................................................................................................................................10
3.1 EP2918-0032...................................................................................................................................10
3.2 Intended use....................................................................................................................................11
3.3 Technical data .................................................................................................................................12
3.4 Safety parameters ...........................................................................................................................13
3.5 Safe output ......................................................................................................................................14
3.6 Dimensions......................................................................................................................................14
4 Operation..................................................................................................................................................15
4.1 Environmental conditions ................................................................................................................15
4.2 Installation .......................................................................................................................................15
4.2.1 Fixing ............................................................................................................................... 15
4.2.2 Connection....................................................................................................................... 15
4.2.3 EP2918 temperature measurement................................................................................. 21
4.2.4 Signal cables ................................................................................................................... 22
4.3 Configuration of the EP2918 in TwinCAT........................................................................................24
4.3.1 Adding an EtherCAT device ............................................................................................ 24
4.3.2 Inserting an EP2918 ........................................................................................................ 24
4.3.3 Using the integrated TwinSAFE Logic functions.............................................................. 24
4.3.4 Project design limits of the EP2918 ................................................................................. 25
4.3.5 Address settings on the TwinSAFE EtherCAT Box ......................................................... 26
4.3.6 Alias devices.................................................................................................................... 27
4.3.7 EP2918 parameters......................................................................................................... 29
4.3.8 Process image of the EP2918 ......................................................................................... 32
4.4 TwinSAFE reaction times ................................................................................................................33
4.5 Diagnostics ......................................................................................................................................35
4.5.1 EtherCAT- Fieldbus LEDs ............................................................................................... 35
4.5.2 Status LEDs..................................................................................................................... 36
4.5.3 Diagnostic LEDs .............................................................................................................. 37
4.5.4 Flash code display ........................................................................................................... 38
4.5.5 Diagnostic objects............................................................................................................ 38
4.5.6 Cycle time of the safety project........................................................................................ 40
4.5.7 Diag History tab ............................................................................................................... 40
4.5.8 Diagnosis History............................................................................................................. 41
EP2918 3Version: 1.1.0
Table of contents
4.6 Maintenance ....................................................................................................................................44
4.7 Service life .......................................................................................................................................45
4.8 Decommissioning ............................................................................................................................45
4.9 Firmware update of TwinSAFE products.........................................................................................46
5 Appendix ..................................................................................................................................................49
5.1 Protection classes according to IP code..........................................................................................49
5.2 Support and Service ........................................................................................................................50
5.3 Certificates.......................................................................................................................................51
EP29184 Version: 1.1.0
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 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 requirements for safety, including all the relevant laws, regulations, guidelines and standards.
Origin of the document
This original documentation is written in German. All other languages are derived from the German original.
Currentness
Please check whether you are using the current and valid version of this document. The current version can be downloaded from the Beckhoff homepage at http://www.beckhoff.com/english/download/twinsafe.htm. In case of doubt, please contact Technical Support [}50].
Product features
Only the product features specified in the current user documentation are valid. Further information given on the product pages of the Beckhoff homepage, in emails or in other publications is not authoritative.
Disclaimer
The documentation has been prepared with care. The products described are subject to cyclical revision. For that reason the documentation is not in every case checked for consistency with performance data, standards or other characteristics. 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.
EP2918 5Version: 1.1.0
Foreword
EtherCAT® and Safety over EtherCAT® are registered trademarks and patented technologies, 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.
Delivery conditions
In addition, the general delivery conditions of the company Beckhoff Automation GmbH & Co. KG apply.

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 chapter Product description);
• the TwinSAFE products are only operated in sound condition and in working order.
• 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.
EP29186 Version: 1.1.0

1.2.3 Description of instructions

In these operating instructions 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 the environment/equipment or data loss
Failure to follow this instruction can lead to environmental damage, equipment damage or data loss.
Foreword
Tip or pointer
This symbol indicates information that contributes to better understanding.

1.3 Documentation issue status

Version Comment
1.1.0 • Chapter Decommissioning updated
1.0.0 • First release
0.6 • Safety parameters updated
• EN81 notes removed
• Maximum temperature added
0.5 • Data for the functional overcurrent cut-off added
0.4 • Technical data updated
0.3 • Note on commissioning test added
• Note on safe output added
0.2 • Revision following review
• EN81 Notes on TwinSAFE EtherCAT Boxes adapted
• Derating information added
0.1 • First draft
EP2918 7Version: 1.1.0
Foreword

1.4 Version history of the TwinSAFE product

This version history lists the software and hardware version numbers. A description of the changes compared to the previous version is also given.
Updated hardware and software
TwinSAFE products are subject to a cyclical revision. We reserve the right to revise and change the TwinSAFE products at any time and without prior notice. No claims for changes to products already delivered can be asserted from these hardware and/or software changes.
A description of how a firmware (software) update can be performed can be found in chapter Firmware update of TwinSAFE products [}46].
Date Software version Hardware version Modifications
2019-11-14 01 00 First release of the EP2918-0032
EP29188 Version: 1.1.0
System description

2 System description

2.1 EtherCAT Box Modules

The EtherCAT system has been extended with EtherCAT Box modules with protection class IP67. 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 e.g.126x30x26.5mm 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 extend the EtherCAT system with IP67 protection
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.
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.
EP2918 9Version: 1.1.0
Product description

3 Product description

3.1 EP2918-0032

The EP2918-0032 is an EtherCAT Box with digital outputs for 24VDC actuators. The EtherCAT Box has 8 fail-safe outputs, each with a maximum output current of 2A (at 24VDC).
The EP2918-0032 meets the requirements of the following standards:
◦ EN 61508:2010 (SIL 3) ◦ EN 62061:2005/A2:2015 (SIL CL 3) ◦ EN ISO 13849-1:2015 (Cat. 4, PL e)
Fig.2: EP2918-0032 – TwinSAFE EtherCAT Box with 8 fail-safe outputs
The TwinSAFE EtherCAT Box has the usual design of an EtherCAT Box with a width of 60mm and a height of 150mm.
EP291810 Version: 1.1.0
Product description

3.2 Intended use

WARNING
Caution - Risk of injury!
TwinSAFE components may only be used for the purposes described below!
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 actuators such as
• contactors, protective door switches with tumblers, valves etc.
WARNING
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.
WARNING
Power supply from SELV/PELV power supply unit!
The TwinSAFE components must be supplied with 24VDC by an SELV/PELV power supply unit with an out­put voltage limit U
of 36VDC. Failure to observe this can result in a loss of safety.
max
WARNING
System limits
The TÜV SÜD certificate applies to this TwinSAFE component, the function blocks available in it, the docu­mentation and the engineering tool. TwinCAT 3.1 and the TwinSAFE Loader are permitted as engineering tools. Any deviations from these procedures or tools, particularly externally generated xml files for Twin­SAFE import or externally generated automatic project creation procedures, are not covered by the certifi­cate.
WARNING
Commissioning test
Before the EP2918-0032 can be used for the safety task, the user must carry out a commissioning test so that sensor and actuator wiring faults can be ruled out.
CAUTION
Follow the machinery directive!
The TwinSAFE components may only be used in machines as defined in the machinery directive.
CAUTION
Ensure traceability!
The buyer has to ensure the traceability of the device via the serial number.
EP2918 11Version: 1.1.0
Product description

3.3 Technical data

Product designation EP2918-0032
Fieldbus EtherCAT Number of outputs 8 Connection of the outputs M12 Status display 8 (one green LED per output), 5 diagnostic LEDs, 2 LEDs for Us/Up, 2 LEDs
Response time (read input/write to E-bus)
Watchdog time adjustable from 2ms to 60s Fault response time ≤ watchdog time Cable length between actuator and EtherCAT Box Unshielded: 100m max. (at 0.75 or 1 mm²)
Safe outputs max. 2.0A (at 24VDC) per channel
Outputs (functional) Functional overcurrent cut-off of the output driver:
Input process image 6 bytes (via FSoE if using the default project) Output process image 7 bytes (via FSoE if using the default project) EP2918 supply voltage 24VDC (–15%/+20%) Current consumption US
(8 output channels switched)
Current consumption U (8 output channels switched, plus load current)
Power dissipation of the EtherCAT Box typically 4.9watts Electrical isolation (between the channels) no Electrical isolation (between the channels and Ether-
CAT) Insulation voltage (between the channels and Ether-
CAT, under common operating conditions) Dimensions (WxHxD) 60(+0.5)mmx150(+0.5)mmx26.5mm Housing material PBT+PET (Valox 855)
Sealing compound Polyurethane PU552L
Weight approx.470g Permissible ambient temperature
(operation) Permissible ambient temperature
(transport/storage) Permissible air pressure
(operation/storage/transport)
Inadmissible operating conditions TwinSAFE EtherCAT boxes must not be used under the following conditions:
EMC tests according to EN61326-3-1:2017(SIL3)
Vibration resistance conforms to EN60068-2-6
Shock resistance conforms to EN60068-2-27
Protection class (when screwed together) IP67 (according to EN 60529) Correct installation position variable Approvals CE, TÜV SÜD
P
for EtherCAT Link/Act typically: 4ms (in the default setting without local TwinSAFE logic),
maximum: see fault response time
Shielded: 100m max. (at 0.75 or 1 mm²)
Diagnostic thresholds: >4.7V -> high signal is detected <1.0V -> low signal is detected
typically between 2.9A and 6.3A (this overcurrent cut-off is implemented purely functionally and cannot be loaded from a safety aspect)
8 channels occupied: typically 120mA 0 channels occupied: typically 80mA (provide a 4A fuse)
8 channels occupied: approx. 70mA 0 channels occupied: approx. 20mA (provide a 16A fuse)
yes
Insulation tested with 500V
Flame Class: V-0
Flame Class: V-0
-25°C to +60°C
-40°C to +85°C
750hPa to 1100hPa (this is equivalent to an altitude of approx. -690m to 2450m above sea level assuming an international standard atmosphere)
• under the influence of ionizing radiation (exceeding the natural background radiation)
• in corrosive environments
IEC61131-2:2017 chapter 6.2 and 7 (ZoneB)
5 Hz ≤ f < 8.4 Hz (3.5 mm peak)
8.4 Hz ≤ f < 150 Hz (10 m/s2 peak)
15g with pulse duration 11ms in all three axes
DC
EP291812 Version: 1.1.0
Product description
Derating table for altitudes above 2000m
The derating table (table 8) from the IEC61131-2:2017 standard can be referred to for the use of the TwinSAFE components above the specified maximum altitude.
Altitude in m Derating factor for the temperature
0 to 2000
2
1.0
1
3000 0.9 4000 0.8 5000 0.7 Note: Linear interpolation is permissible between the altitudes
1)
Ambient temperature of the device at an altitude of 2000m
2)
The air pressure and air density increase as the altitude decreases. Therefore the derating factor for 0 to
2000 m (1.0) is used for altitudes below sea level.
Calculation example
In the following example the calculation is performed for a TwinSAFE component at an operating altitude of 4000m.
Permissible ambient temperature up to 2000 m above sea level = 55°C
Permissible ambient temperature up to 4000m above sea level = 55°C * 0.8 = 44°C
CAUTION
Compliance with the temperature limits
The TwinSAFE component has a maximum internal temperature at which a switch-off takes place. This is designed for the maximum permissible ambient temperature. If the derating factor for the temperature for higher altitudes is used, the user is solely responsible for ensuring that the calculated maximum ambient temperature is complied with.

3.4 Safety parameters

Characteristic numbers EP2918-0032
Lifetime [a] 20 Proof test interval [a] not required PFH
D
4.16E-09 PFD 2.00E-05 MTTF
D
high DC high Performance level PL e Category 4 HFT 1 Element classification
1)
Special proof tests throughout the service life of the EtherCAT Box are not required.
2)
Classification according to IEC 61508-2:2010 (see chapters 7.4.4.1.2 and 7.4.4.1.3)
2
Type B
1
The EP2918-0032 EtherCAT Box can be used for safety-related applications according to IEC61508:2010 up to SIL3 and ENISO13849-1:2015 up to PLe(Cat4).
Further information on calculating or estimating the MTTFD value from the PFHD value can be found in the TwinSAFE Application Guide or in ENISO13849-1:2015, TableK.1.
In terms of safety-related parameters, the Safety-over-EtherCAT communication is already considered with 1% of SIL3 according to the protocol specification.
EP2918 13Version: 1.1.0
Product description

3.5 Safe output

The safe outputs are implemented as a single channel per module. It is essential to pay attention to the following note if two or more outputs run in a common sheathed cable.
DANGER
Clocked signals inside a sheathed cable
If clocked signals from different modules are used inside a single sheathed cable, then a module error such as a cross-circuit or external power supply must lead to the switch-off of all of these modules. This is achieved by setting the Module Fault Link active parameter for all modules involved. This parameter is set to TRUE by default.

3.6 Dimensions

Fig.3: EP2918 Dimensions
The EP2918-0032 module has the following dimensions:
Width 60.0(+0.5)mm Height 150.0(+0.5)mm Depth 26.5 mm
When fully wired, the connected cables increase the total depth of the module.
EP291814 Version: 1.1.0
Operation

4 Operation

4.1 Environmental conditions

Please ensure that the TwinSAFE Boxes are only transported, stored and operated under the specified conditions (see technical data)!
WARNING
Risk of injury!
The TwinSAFE EtherCAT boxes must not be used under the following conditions.
• under the influence of ionizing radiation (that exceeds the level of the natural environmental radiation)
• in corrosive environments
NOTE
Electromagnetic compatibility
The TwinSAFE components comply with the current standards on electromagnetic compatibility with regard to spurious radiation and immunity to interference in particular. However, in cases where devices such as mobile phones, radio equipment, transmitters or high-frequency systems that exceed the interference emissions limits specified in the standards are operated near Twin­SAFE components, the function of the TwinSAFE components may be impaired.

4.2 Installation

4.2.1 Fixing

NOTE
Protect connectors against soiling!
Protect all connections from contamination during installation and operation of the modules! Protection class IP67 is only guaranteed if all cables and plug connectors are connected, and unused connections are protected with the appropriate cover plugs! Connector sets see catalog.
• Modules with narrow housing are installed with two M3 screws.
• Modules with wide housing are installed with two M3 screws in the mounting holes in the corners or two M4 screws in the central fastening holes (see also chapter Power connection and grounding).
• The bolts must be longer than 15mm. The fastening holes in the modules have no thread.
• Note when mounting that the overall height is increased further by the fieldbus connections.

4.2.2 Connection

4.2.2.1 Nut torque for connectors
M8 connector
We recommend fastening the M8 connector with a torque of 0.4Nm. A max. torque of 0.5Nm is also permissible if using a torque screwdriver (Beckhoff article ZB8800).
EP2918 15Version: 1.1.0
Operation
Fig.4: EtherCAT Box with M8 plug connectors
M12 connector
We recommend fastening the M12 connector with a torque of 0.6Nm.
Fig.5: EtherCAT Box with M8 and M12 connectors
7/8" plug connectors
We recommend fastening the 7/8" plug connectors with a torque of 1.5Nm.
Fig.6: 7/8" plug connectors
Torque wrench
Fig.7: Torque wrench ZB8801
NOTE
Ensure the proper torque is used
Use torque wrenches available from Beckhoff to tighten the connectors (see accessories)!
EP291816 Version: 1.1.0
Operation
4.2.2.2 EtherCAT connection
The EtherCAT Box (EPxxxx) has two M8 connectors marked green for the incoming and outgoing EtherCAT connection.
Fig.8: EtherCAT connection 30 mm housing M8
Connection
There are various different standards for the assignment and colors of connectors and cables for EtherCAT.
EtherCAT Connector Cable Standard
Signal Description M8 ZB9010, ZB9020,
ZK1090-6292
Tx + Transmit Data+ Pin 1 yellow Tx - Transmit Data- Pin 4 orange Rx + Receive Data+ Pin 2 white Rx - Receive Data- Pin 3 blue
1
1
1
1
Shield Shield Housing Shield Shield Shield
ZB903x, ZK1090-31xx
orange/white orange blue/white blue
2
2
2
TIA-568B
2
white/orange orange white/green green
1)
Core colors according to EN61918
2)
Core colors
4.2.2.3 EtherCAT cables
For connecting EtherCAT devices only Ethernet cables that meet the requirements of at least category 5 (CAT5) according to EN 50173 or ISO/IEC 11801 should be used.
Wiring recommendations
Detailed recommendations for EtherCAT wiring can be found in the documentation "Design recom­mendations for EtherCAT/Ethernet infrastructure", which is available for download from www.Beck- hoff.de.
EtherCAT uses four cable wires for signal transmission. Due to automatic cable detection (auto-crossing) symmetric (1:1) or cross-over cables can be used between EtherCAT devices from BECKHOFF.
4.2.2.4 Power connection and grounding
This chapter provides you with basic information about the power supply and grounding of the EP2918-0032 TwinSAFE EtherCAT Box. In particular, please note that the General information on connecting the functional earth only serves as an example.
Supply voltages (power connection)
The supply and distribution of the supply voltages takes place via the connections:
• Us/Up IN for feeding in the supply voltages
• Us/Up OUT for distribution of the supply voltages.
EP2918 17Version: 1.1.0
Loading...
+ 37 hidden pages
Buy Points How it Works FAQ Contact Us Questions and Suggestions Privacy Policy Cookie Policy Terms of Use