BECKHOFF EP9214-0023 User Manual

Documentation

EP9214-0023 and EP9224-0023

Power Distribution for EtherCAT Box

Version 2.0.0

Date 2015-05-13

					Table of contents
Table of contents
1	Foreword ....................................................................................................................................................				4
	1.1	Notes on the documentation.............................................................................................................			4
	1.2	Safety instructions ............................................................................................................................			5
	1.3	Documentation issue status..............................................................................................................			6
2	Product overview.......................................................................................................................................				7
	2.1	EtherCAT Box - Introduction.............................................................................................................			7
	2.2	EP9214 - Introduction .......................................................................................................................			9
	2.3	EP9224 - Introduction .....................................................................................................................			10
	2.4	Technical data ................................................................................................................................			11
3	Mounting and cabling .............................................................................................................................				12
	3.1	Mounting .........................................................................................................................................			12
		3.1.1	Dimensions .........................................................................................................................		12
		3.1.2	Mounting .............................................................................................................................		13
		3.1.3 Nut torque for connectors ...................................................................................................			13
	3.2	EtherCAT ........................................................................................................................................			15
		3.2.1	EtherCAT connection..........................................................................................................		15
		3.2.2	EtherCAT - Fieldbus LEDs..................................................................................................		16
	3.3	Power supply ..................................................................................................................................			17
		3.3.1	Power Connection...............................................................................................................		17
		3.3.2	Power LEDs ........................................................................................................................		19
		3.3.3	Power cables ......................................................................................................................		20
		3.3.4 Power cable conductor losses ............................................................................................			21
		3.3.5	Power cable 7/8" .................................................................................................................		22
		3.3.6	Conductor losses ................................................................................................................		23
		3.3.7	Power outputs .....................................................................................................................		23
	3.4	Status LEDs and status bits............................................................................................................			25
	3.5	Monitoring and reset contacts.........................................................................................................			26
4	Comissioning and Configuration...........................................................................................................				28
	4.1	Inserting into the EtherCAT network...............................................................................................			28
	4.2	Configuration via TwinCAT .............................................................................................................			31
	4.3	Operation with or without EtherCAT master ...................................................................................			38
	4.4	Switch of behavior ..........................................................................................................................			39
		4.4.1	Switch-off characteristics ....................................................................................................		39
		4.4.2 Current limitation, switching the load circuits off .................................................................			41
		4.4.3 Setting the current limitation ...............................................................................................			42
		4.4.4 Status LEDs and status bits................................................................................................			43
	4.5	EP9214-0023..................................................................................................................................			45
		4.5.1	EP9214-0023 - Object description ......................................................................................		45
		4.5.2	EP9214-0023 - Process image ...........................................................................................		61
	4.6	EP9224-0023..................................................................................................................................			62
		4.6.1	EP9224-0023 - Diagnostic functions...................................................................................		62
		4.6.2	EP9224-0023 - Object description ......................................................................................		75
		4.6.3	EP9224-0023 - Process image .........................................................................................		102
	4.7	Restoring the delivery state ..........................................................................................................			104
5	Appendix ................................................................................................................................................				105
	5.1	General operating conditions........................................................................................................			105
	5.2	EtherCAT Box - Accessories ........................................................................................................			106
	5.3	Support and Service .....................................................................................................................			107
EP9214-0023 and EP9224-0023				Version 2.0.0	3

Foreword

1 Foreword

1.1Notes on the documentation

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.

Disclaimer

The documentation has been prepared with care. The products described are, however, constantly under development.

For that reason the documentation is not in every case checked for consistency with performance data, standards or other characteristics.

In the event that it contains technical or editorial errors, we retain the right to make alterations at any time and without warning.

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®, 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.

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1.2Safety 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 symbols

In this documentation the following symbols are used with an accompanying safety instruction or note. The safety instructions must be read carefully and followed without fail!

Serious risk of injury!

Failure to follow the safety instructions associated with this symbol directly endangers the life and health of persons.

DANGER

Risk of injury!

Failure to follow the safety instructions associated with this symbol endangers the life and health of persons.

WARNING

Personal injuries!

Failure to follow the safety instructions associated with this symbol can lead to injuries to persons.

CAUTION

Damage to the environment or devices

Failure to follow the instructions associated with this symbol can lead to damage to the environment or equipment.

Attention

Tip or pointer

This symbol indicates information that contributes to better understanding.

Note

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Foreword

1.3Documentation issue status

Version	Comment
2.0.0	•	migration
	• chapter mounting and cabling updated
	• chapter nut torque for connectors extended
	• chapter switch off behavior updated
	•	object descriptions updated
1.1.0	•	EP9224-0023 added
1.0.0	•	first release
0.1	• preliminary version (only German available)

Firm and hardware version

The documentation refers to the firm and hardware status that was valid at the time it was prepared.

The properties of the modules are subject to continuous development and improvement. Modules having earlier production statuses cannot have the same properties as modules with the latest status. Existing properties, however, are always retained and are not changed, so that these modules can always be replaced by new ones.

Documentation	EP9214-0023		EP9224-0023
version	firmware	hardware	firmware	hardware
2.0.0	09	10	04	10
1.1.0	09	06	04	06
1.0.0	07	03	-	-
0.1	07	03	-	-

The firmware and hardware version (delivery state) can be found in the batch number (D number) printed at 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 ser. no.: 55 09 01 00:

55 - week of production 55

09 - year of production 2009

01 - firmware version 01

00 - hardware version 00

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Product overview

2 Product overview

2.1EtherCAT 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.

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Fig. 2: EtherCAT Box with M8 connections for sensors/actuators

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 Documen-
Note	tation for EtherCAT, which is available for download from our website (www.beckhoff.com)
	under Downloads.

XML files

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.

Note

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2.2EP9214 - Introduction

Fig. 4: EP9214

Power distribution for EtherCAT Box (24 VDC)

The EP9214-0023 enables connection of four power supply branches. In each branch the current consumption for the control voltage US and the peripheral voltage UP is monitored, limited, and, if necessary, switched off.

The power distribution is supplied via a 7/8" connector with up to 16 A (per voltage supply US/UP). Several modules can be configured in a cascade arrangement. In the event of a short-circuit in one of the four outputs, the affected output is switched off. The supply for the other branches remains active. The switch-off and control is done in such a way that the input voltage does not fall below 21 V or other modules are going down, caused by undervoltage.

During startup consumers with large capacities can be added without problem.

The master can read diagnostic messages from the individual channels via the EtherCAT interface. Independent switching of individual consumer branches is also possible via the EtherCAT master.

In delivery state the eight outputs of the box (4 times Us, 4 times Up) are activated to enable operation without EtherCAT.

After an error caused the switch off of a channel, this channel remains switched of when you try to switch it on again and has to be set back actively by the EtherCAT master or a hardware reset at the box (lower M8 socket).

Quick links

Installation

Configuration

UL requirements for UL approved modules

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Product overview

2.3EP9224 - Introduction

Fig. 5: EP9224

Power distribution for EtherCAT Box (24 VDC) with data logging

The EP9224-0023 enables connection of four power supply branches. In each branch the current consumption for the control voltage US and the peripheral voltage UP is monitored, limited, and, if necessary, switched off.

The power distribution is supplied via a 7/8" connector with up to 16 A (per voltage supply US/UP). Several modules can be configured in a cascade arrangement. In the event of a short-circuit in one of the four outputs, the affected output is switched off. The supply for the other branches remains active. The switch-off and control is done in such a way that the input voltage does not fall below 21 V or other modules are going down, caused by undervoltage.

During startup consumers with large capacities can be added without problem.

The master can read diagnostic messages from the individual channels via the EtherCAT interface. Independent switching of individual consumer branches is also possible via the EtherCAT master.

In delivery state the eight outputs of the box (4 times Us, 4 times Up) are activated to enable operation without EtherCAT.

After an error caused the switch off of a channel, this channel remains switched of when you try to switch it on again and has to be set back actively by the EtherCAT master or a hardware reset at the box (lower M8 socket).

Additional to this basic functionality that is also provided by EP9214, the EP9224 displays the voltage values of PowerIn supply and all current values of inputs and outputs within the process data.

The box has got an internal log file, that is writing the system values continuously into a ring buffer. This data logging has to be activated at the startup.

In error case it is stopped, so a history of the system parameters from before the error case can be read out. This enables a much quicker error localization.

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Quick links

Installation

Configuration

UL requirements for UL approved modules

2.4Technical data

Technical data	EP9214-0023	EP9224-0023
Rated voltage	24 VDC (-15 % / +20 %)
Power supply	Feed: Plug 7/8", max. 16 A for each Us/Up
	Onward connection: Socket 7/8", max. 16 A for each Us/Up
Number of load outputs	4 x M8, for each Us and Up
Voltage drop VON in the load	90 mV / Ampere
circuits
Parallel connection of several load	not permissible
outputs
Overload switch-off	dependent on selected load curve (20 ms at 3 x IN, see time/current
	characteristics)
Temperature switch-off	Internal temperature switch-off
Switch-on delay	10, 100 or 200 ms (adjustable via CoE)
Selectivity	in case of an error, the channel concerned is switched off
Signalling contact	1
Reset contact	1
Connections for signal and reset	in : 1 x M8 plug
contacts	out : 1 x M8 socket
Fieldbus	EtherCAT
Fieldbus connection	2 x M8 sockets, screened, marked green
Electrical isolation	Control voltage/fieldbus: 500 V
Supply of the module circuitry	from the control voltage Us
Current consumption of the module	typically 110 mA from Us,
circuitry	typically 40 mA from Up
Process image	Inputs: 5 x 16 bit	Inputs: 16 x 16 Bit
	Outputs: 5 x 16 bit	Outputs: 5 x 16 Bit
Data logging	-	40 samples ( 1 ms - 1000 ms
		sample time)
Permissible ambient temperature	-25°C ... +60°C
during operation
Permissible ambient temperature	-25 °C... +85°C
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
Dimensions	126 mm x 60 mm x 40 mm
Weight	approx. 450 g
Installation position	variable
Protection class	IP65, IP66, IP67 (according to EN 60529)
Approvals	CE, UL in preparation

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Mounting and cabling

3 Mounting and cabling

3.1Mounting

3.1.1Dimensions

Fig. 6: Dimensions of the EtherCAT Box Modules

All dimensions are given in millimeters.

Housing properties

EtherCAT Box	lean body	wide body
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
Installation position	variable
Protection class	IP65, IP66, IP67 (conforms to EN 60529) when screwed together
Dimensions (H x W x D)	ca. 126 x 30 x 26,5 mm	ca. 126 x 60 x 26,5 mm
Weight	approx. 125 g, depending on module type	approx. 250 g, depending on module
		type
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Mounting and cabling

3.1.2Mounting

EP9214 modules are mounted using two M3 bolts in the mounting holes located in the corners or using two M4 bolts in the centrally located mounting holes.

The bolts must be longer than 15 mm. The mounting holes in the modules have no thread.

Protect connectors against soiling

Protect all module connections from soiling during installation!The protection classes IP65, IP66, IP67 (in accordance with EN 60529) are ensured only if all connectors are wired or

Note sealed! Unused connectors must be sealed with suitable protective caps (see Beckhoff catalogue for connector sets and protective caps)!

Cooling plate

The EP9214 module has a cooling plate on the underside. For the effective dissipation of the resultant power loss, the box must be bolted to a metal base, e.g. the machine bed, if

Note possible making contact over the entire surface.A temperature-related automatic switch-off of the box can occur if care is not taken to ensure that the power loss from the module is dissipated via the cooling plate. A corresponding temperature error bit is then set!

Note when mounting that the overall height is increased further by the fieldbus connections. See the Accessories section

3.1.3Nut torque for connectors

M8 connectors

It is recommended to pull the M8 connectors tight with a nut torque of 0.4 Nm.

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.

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Fig. 8: EtherCAT Box with M8 and M12 connectors

7/8" connectors

It is recommended to pull the 7/8" connectors tight with a nut torque of 1.5 Nm.

Fig. 9: 7/8" connectors

Torque socket wrenches

Fig. 10: ZB8800 torque socket wrench

Ensure the right torque

Use the torque socket wrenches available by Beckhoff to pull the connectors tight (see accessories)!

Note

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Also see about this

2 EtherCAT Box - Accessories [} 106]

3.2EtherCAT

3.2.1EtherCAT 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: M8 60 mm housing (EP9214 for example )

Fig. 13: Coupler Box: M12

Assignment

There are various different standards for the assignment and colors of connectors and cables for Ethernet/ EtherCAT.

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Mounting and cabling

Ethernet/EtherCAT		Plug connector			Cable		Standard
Signal	Descrip-	M8	M12	RJ451	ZB9010, ZB9020,	ZB9031 and old	TIA-568B
	tion				ZB9030, ZB9032,	versions
					ZK1090-6292,	of ZB9030, ZB9032,
					ZK1090-3xxx-xxxx	ZK1090-3xxx-xxxx
Tx +	Transmit	Pin 1	Pin 1	Pin 1	yellow2	orange/white3	white/
	Data+						orange
Tx -	Transmit	Pin 4	Pin 3	Pin 2	orange2	orange3	orange
	Data-
Rx +	Receive	Pin 2	Pin 2	Pin 3	white2	blue/white3	white/green
	Data+
Rx -	Receive	Pin 3	Pin 4	Pin 6	blue2	blue3	green
	Data-
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

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 Note the pre assembled cables with M8 connectors were changed to the colors of EN61918 (yel-

low, orange, white, blue).So different color coding exists. But the electrical properties are absolutely identical.

EtherCAT connectors

The following connectors can be supplied for use in Beckhoff EtherCAT systems.

Designation	Plug connector	Comment
ZS1090-0003	RJ45	four-pin, IP20, for field assembly
ZS1090-0004	M12	four-pin, IP67, for field assembly
ZS1090-0005	RJ45	eight-pin, IP20, for field assembly,
		suitable for Gigabit Ethernet
ZS1090-0006	M8	four-pin, IP67, for field assembly
ZS1090-0007	M8 socket	four-pin, IP67, for field assembly, for ZB903x cable
ZS1090-1006	M8 plug	four-pin, IP67, for field assembly up to OD = 6.5 mm
ZS1090-1007	M8 socket	four-pin, IP67, for field assembly up to OD = 6.5 mm

3.2.2EtherCAT - Fieldbus LEDs

Fig. 14: EtherCAT-LEDs

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			Mounting and cabling
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 Ba-
Note	sic System Documentation for EtherCAT, which is available for download from our website
	(www.beckhoff.com) under Downloads.

3.3Power supply

3.3.1Power Connection

Use cables with suitable cross-sections!

Ensure that the cross-sections of the cables employed are suitable for the load circuit inputs and outputs and the respective rated current being used!

Attention

The supply voltages are fed and relayed onward via two 7/8" connectors in the center of the modules:

•Power In: left-hand 7/8" plug for the feed-in of supply voltages

•Power Out: right-hand 7/8" socket for the onward feeding of supply voltages

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Mounting and cabling

Fig. 15: EP9214-0023 - 7/8" connectors

The contacts of the 7/8" plug connectors can conduct a maximum current of 16 A (40°C). Two LEDs next to the device identifier label indicate the status of the supply voltages.

Pin assignment

Fig. 16: Pin assignment of 7/8" plug connectors

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		Mounting and cabling
Contact		Voltage
1		GND Up
2		GND Us
3		FE (Functional earth), (as well as contact at central mounting holes)
4		Control voltage Us, +24 VDC
5		Peripheral voltage Up, +24 VDC
	Do not confuse the power output with the EtherCAT connection!
	Never connect the power cables (M8, 24 VDC) to the green-marked EtherCAT sockets of
Attention	the EtherCAT Box Modules. This can cause the destruction of the modules!

Control voltage Us: 24VDC

The fieldbus and the processor logic are supplied from the 24 VDC control voltage Us. The control voltage is electrically isolated from the fieldbus circuitry.

Peripheral voltage Up: 24VDC

The peripheral voltage Up is monitored and fed to the power outputs, but is not used in the EP9214.

Redirection of the supply voltages

The power connections Power In and Power Out are bridged in the module. Hence, the supply voltages Us and Up can be passed from EtherCAT Box to EtherCAT Box in a simple manner.

Observe the maximum current of the 7/8" plug connectors!

Also ensure when relaying the supply voltages Us and Up onward that the maximum permissible current of 16 A / 40 °C for each 7/8" plug connector is not exceeded!

Attention

3.3.2Power LEDs

Status-LEDs for the power supply

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Mounting and cabling

LED	Display	Meaning
Us (control voltage)	off	The power supply voltage, Us, is
		not present
	Green illuminated	The power supply voltage, Us, is
		present
Up (peripheral voltage)	off	The power supply voltage, Up, is
		not present
	Green illuminated	The power supply voltage, Up, is
		present

3.3.3Power cables

Ordering data

Order designation	Power lead	Screw-in	Contacts	Cross-section	Length
		connector
ZK2020-3200-0020	Straight socket, open end	M8	4-pin	0.34 mm2	2.00 m
ZK2020-3200-0050					5.00 m
ZK2020-3200-0100					10.00 m
ZK2020-3400-0020	Angled socket, open end				2.00 m
ZK2020-3400-0050					5.00 m
ZK2020-3400-0100					10.00 m
ZK2020-3132-0001	Straight socket, straight				0.15 m
	socket
ZK2020-3132-0005					0.50 m
ZK2020-3132-0010					1.00 m
ZK2020-3132-0020					2.00 m
ZK2020-3132-0050					5.00 m
ZK2020-3334-0001	Angled socket, angled				0.15 m
	socket
ZK2020-3334-0005					0.50 m
ZK2020-3334-0010					1.00 m
ZK2020-3334-0020					2.00 m
ZK2020-3334-0050					5.00 m

Further available power cables may be found in the Beckhoff catalog or on our internet pages (http://

www.beckhoff.com).

Technical data

Technical data

Rated voltage according to IEC60 664-1	60 VAC / 75 VDC
Contamination level according to IEC 60 664-1	3/2
Insulation resistance IEC 60 512-2	>109W
Current carrying capacity according to IEC 60512-3	4 A
Volume resistance according to IEC 60512-2	< 5 mW
Protection class according to IEC 60529	IP65/66/67, when screwed together
Ambient temperature	-30°C to +80°C

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3.3.4Power cable conductor losses

The ZK2020-xxxx-yyyy power cables should not exceed the total length of 15 m at 4 A (with continuation). When planning the cabling, note that at 24 V nominal voltage, the functionality of the module can no longer be assured if the voltage drop reaches 6 V. Variations in the output voltage from the power supply unit must also be taken into account.

Fig. 17: Power cable conductor losses

Example

8 m power cable with 0.34 mm² cross-section has a voltage drop of 3.2 V at 4 A.

EP92x4 Power Distribution Modules

With EP9214 and EP9224 Power Distribution Modules intelligent concepts for voltage supply are available. Further information may be found under www.beckhoff.com/EP9224.

Note

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3.3.5Power cable 7/8"

Fig. 18: Power cable 7/8"

Ordering data

Order identifier	Power cable	Screw type	Contacts	Cross-sec-	Length
		connector		tion
ZK2030-1200-0010	Straight socket, open end	7/8"	5-pin	1,50 mm2	1.00 m
ZK2030-1200-0030					3.00 m
ZK2030-1200-0050					5.00 m
ZK2030-1200-0100					10.00 m
ZK2030-1400-0010	Angled socket, open end				1.00 m
ZK2030-1400-0030					3.00 m
ZK2030-1400-0050					5.00 m
ZK2030-1400-0100					10.00 m
ZK2030-1112-0010	Straight socket, straight				1.00 m
ZK2030-1112-0030	plug				3.00 m
ZK2030-1112-0050					5.00 m
ZK2030-1112-0100					10.00 m
ZK2030-1314-0010	Angled socket, angled				1.00 m
	plug
ZK2030-1314-0030					3.00 m
ZK2030-1314-0050					5.00 m
ZK2030-1314-0100					10.00 m

Further available power cables and the associated data sheets can be found in the Beckhoff catalogue or on our website (http://www.beckhoff.com).

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Technical data
Technical data
Rated voltage according to IEC 61076-2-101	300 V (according to IEC 61076-2-101)
Contamination level according to IEC 60664-1	3/2 (according to IEC 60664-1)
Insulation resistance IEC 60512-2	>109W
Current carrying capacity according to	16 A at 40°C (according to IEC 60512-3)
IEC 60512-3
Volume resistance according to IEC 60512-2	< 5 mW
Protection class conforms to IEC 60529	IP65/66/67, when screwed together
Permissible ambient temperature	-30°C to +80°C
Material properties	TPE-U (PUR) halogen-free according to DIN VDE 0472
	Part 815,
	flame-retardant according to cULus 20549
Approbations	UL
Cable outside diameter	7.80 ± 0.20 mm
Bending radius	min. 6 x D (external diameter)
Parameter	Max. speed 5 m/s, max. acceleration 10 m/s²
Number of cycles	At least 10 million cycles with a max. travel path of 20
	meters

3.3.6Conductor losses

In the case of the power cables ZK2030-xxxx-yyy, a total length of 15 m should not be exceeded at 16 A. When wiring, note that with a rated voltage of 24 V the function of the modules can no longer be guaranteed from a voltage drop of 6 V. Variations in the output voltage from the power supply unit must also be taken into account.

Fig. 19: ZK2030-xxxx-yyy - Conductor losses

Alternatively, larger cable cross-section can be used, e.g. 2.5 mm2.

3.3.7Power outputs

The supply voltages are output via four 4-pole M8 sockets in the lower third of the modules (1, 2, 3 and 4).

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Fig. 20: M8 sockets

Pin assignment

Fig. 21: Pin assignment of the M8 sockets

Contact	Voltage
1	Control voltage Us, +24 VDC
2	Peripheral voltage Up, +24 VDC
3	GNDs*	*) can be internally connected to one another depending on the connected
4	GNDp*	module: see individual module descriptions

The contacts of the M8 plug connectors can conduct a maximum current of 4 A.

A LED indicates the status of the power outputs.

Do not confuse the power outputs with the EtherCAT connection

Never connect the power cables (M8, 24 VDC) to the green-marked EtherCAT sockets of the EtherCAT Box Modules. This can cause the destruction of the modules!

Attention

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Control voltage Us: 24 VDC

Power is supplied to the fieldbus, the processor logic, the inputs and the sensors from the control voltage Us (24 VDC). The control voltage is electrically isolated from the fieldbus circuitry.

Peripheral voltage Up: 24 VDC

The peripheral voltage Up (24 VDC) supplies the digital outputs; it can be brought in separately. Hence, if the load voltage is switched off, the fieldbus function as well as the supply and function of the inputs are retained.

Electrical isolation

The grounds of the control voltage (GNDs) and peripheral voltage (GNDp) are electrically isolated from each other in order to ensure the electrical isolation of the peripheral devices on Up from the control voltage.

The electrical isolation can be nullified

If you connect digital and analog EtherCAT Box Modules directly to one another via fourpole power lines, then there may no longer be any electrical isolation due to the connected

Attention boxes!

3.4Status LEDs and status bits

Below is a table showing the meaning of the status LEDs and status bits for the power outputs (EP9214 for example):

Fig. 22: EP9214 - status LEDs

Fig. 23: EP9214 - status bits

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Initialization

When switching on the voltage supply to the EP9214 / EP9224, all green LEDs and then all red LEDs are switched on briefly to test the LEDs.

The LED is valid for both voltages and currents (Us and Up; OR).

LED	Status	Warning	Error	Description
	Us / Up		Us / Up
Off	0	0	0	The output is ready
Green	1	0	0	The output is just switching on
Green	1	0	0	The output is switched on. Normal operating status.
Flashing	1	1	0	The output is still operating, but will switch off if conditions
green				remain unchanged (Warning Ux).
Flashing	0	1	1	The output has been switched off. Switching on again is not
red				yet possible (waiting time of 20 seconds)
Red	0	0	1	The output has been deactivated and can be returned to a
				normal state by a reset.

3.5Monitoring and reset contacts

The EP9214 has a monitoring contact (signal contact) and a reset contact. These contacts are fed out via an M8 plug and an M8 socket.

The contacts of this M8 plug and M8 socket are wired together 1:1.

Fig. 24: EP9214 - Monitoring and reset connectors

Pin assignment

Fig. 25: EP9214 - Monitoring and reset contacts

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Contact	Meaning
Pin 1 and 3:	Potential-free signalling contact (normally open contact), closes on application of the
Monitoring	supply voltage and if an error occurs in one of the eight load circuits
Pin 4: Reset	all errors are reset by applying 24 VDC to the Reset contact.

The contacts of the M8 plug connectors can conduct a maximum current of 4 A.

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4 Comissioning and Configuration

4.1Inserting into the EtherCAT network

	Installation of the latest XML device description
	Please ensure that you have installed the latest XML device description in TwinCAT. This
Note	can be downloaded from the Beckhoff website (http://www.beckhoff.de/english/default.htm?
	download/elconfg.htm) and installed according to the installation instructions.

At the Beckhoff TwinCAT System Manager the configuration tree can be build in two different ways:

•by scanning [} 28] for existing hardware (called "online") and

•by manual inserting/appending [} 28] of fieldbus devices, couplers and slaves.

Automatic scanning in of the box

•The EtherCAT system must be in a safe, de-energized state before the EtherCAT modules are connected to the EtherCAT network!

•Switch on the operating voltage, open the TwinCAT System Manager [} 31] (Config mode), and scan in the devices (see Fig. 1). Acknowledge all dialogs with "OK", so that the configuration is in "FreeRun" mode.

Fig. 26: Scanning in the configuration (I/O Devices -> right-click -> Scan Devices...)

Appending a module manually

•The EtherCAT system must be in a safe, de-energized state before the EtherCAT modules are connected to the EtherCAT network!

•Switch on the operating voltage, open the TwinCAT System Manager [} 31] (Config mode)

•Append a new I/O device. In the dialog that appears select the device EtherCAT (Direct Mode), and confirm with OK.

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Fig. 27: Appending a new I/O device (I/O Devices -> right-click -> Append Device...)

Fig. 28: Selecting the device EtherCAT

• Append a new box.

Fig. 29: Appending a new box (Device -> right-click -> Append Box...)

• In the dialog that appears select the desired box (e.g. EP2816-0008), and confirm with OK.

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Fig. 30: Selecting a Box (e.g. EP2816-0008)

Fig. 31: Appended Box in the TwinCAT tree

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