Beckhoff EP4374-0002 Documentation

Documentation

EP4374

EtherCAT Box with analog inputs and outputs

2.3

2019-07-15

Version:

Date:

Table of contents

EP4374 3Version: 2.3

Table of contents

1 Foreword ....................................................................................................................................................5

1.1 Safety instructions .............................................................................................................................5

1.2 Notes on the documentation..............................................................................................................6

1.3 Documentation issue status ..............................................................................................................7

2 Product overview.......................................................................................................................................8

2.1 Product group: EtherCAT Box Modules ............................................................................................8

2.2 EP4374 - Introduction........................................................................................................................9

2.3 Technical data .................................................................................................................................10

2.4 Scope of supply ...............................................................................................................................12

2.5 Process image.................................................................................................................................13

3 Mounting and cabling..............................................................................................................................14

3.1 Mounting..........................................................................................................................................14

3.1.1 Dimensions ...................................................................................................................... 14

3.1.2 Fixing ............................................................................................................................... 15

3.2 Cabling ............................................................................................................................................16

3.2.1 Power supply ................................................................................................................... 17

3.2.2 EtherCAT ......................................................................................................................... 20

3.2.3 Analog interfaces ............................................................................................................. 22

3.3 UL Requirements.............................................................................................................................24

3.4 ATEX notes .....................................................................................................................................25

3.4.1 ATEX - Special conditions ............................................................................................... 25

3.4.2 BG2000 - EtherCAT Box protection enclosures .............................................................. 26

3.4.3 ATEX Documentation ...................................................................................................... 27

4 Commissioning and configuration ........................................................................................................28

4.1 Configuration in TwinCAT................................................................................................................28

4.2 Parameterize signal ranges.............................................................................................................28

4.3 Object overview ...............................................................................................................................29

4.4 Object description and parameterization .........................................................................................35

4.4.1 Objects to be parameterized during commissioning........................................................ 35

4.4.2 Objects for regular operation ........................................................................................... 40

4.4.3 Standard objects (0x1000-0x1FFF) ................................................................................. 40

4.4.4 Profile-specific objects (0x6000-0xFFFF) ........................................................................ 45

4.5 Restoring the delivery state .............................................................................................................48

5 Appendix ..................................................................................................................................................49

5.1 General operating conditions...........................................................................................................49

5.2 General note on the introduction of the Beckhoff Identification Code (BIC) ....................................50

5.3 Support and Service ........................................................................................................................52

Table of contents

EP43744 Version: 2.3

Foreword

EP4374 5Version: 2.3

1 Foreword

1.1 Safety instructions

Safety regulations

Please note the following safety instructions and explanations!

Product-specific safety instructions can be found on following pages or in the areas mounting, wiring,

commissioning etc.

Exclusion of liability

All the components are supplied in particular hardware and software configurations appropriate for the

application. Modifications to hardware or software configurations other than those described in the

documentation are not permitted, and nullify the liability of Beckhoff Automation GmbH & Co. KG.

Personnel qualification

This description is only intended for trained specialists in control, automation and drive engineering who are

familiar with the applicable national standards.

Description of instructions

In this documentation the following instructions are used.

These instructions must be read carefully and followed without fail!

DANGER

Serious risk of injury!

Failure to follow this safety instruction directly endangers the life and health of persons.

WARNING

Risk of injury!

Failure to follow this safety instruction endangers the life and health of persons.

CAUTION

Personal injuries!

Failure to follow this safety instruction can lead to injuries to persons.

NOTE

Damage to environment/equipment or data loss

Failure to follow this instruction can lead to environmental damage, equipment damage or data loss.

Tip or pointer

This symbol indicates information that contributes to better understanding.

Foreword

EP43746 Version: 2.3

1.2 Notes on the documentation

Intended audience

This description is only intended for the use of trained specialists in control and automation engineering who

are familiar with the applicable national standards.

It is essential that the documentation and the following notes and explanations are followed when installing

and commissioning these components.

It is the duty of the technical personnel to use the documentation published at the respective time of each

installation and commissioning.

The responsible staff must ensure that the application or use of the products described satisfy all the

requirements for safety, including all the relevant laws, regulations, guidelines and standards.

Disclaimer

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

development.

We reserve the right to revise and change the documentation at any time and without prior announcement.

No claims for the modification of products that have already been supplied may be made on the basis of the

data, diagrams and descriptions in this documentation.

Trademarks

Beckhoff

®

, TwinCAT

®

, EtherCAT

®

, EtherCATG

®

, EtherCATG10

®

, EtherCATP

®

, SafetyoverEtherCAT

®

,

TwinSAFE

®

, XFC

®

, XTS

®

and XPlanar

®

are registered trademarks of and licensed by Beckhoff Automation

GmbH. Other designations used in this publication may be trademarks whose use by third parties for their

own purposes could violate the rights of the owners.

Patent Pending

The EtherCAT Technology is covered, including but not limited to the following patent applications and

patents: EP1590927, EP1789857, EP1456722, EP2137893, DE102015105702 with corresponding

applications or registrations in various other countries.

EtherCAT

®

is registered trademark and patented technology, licensed by Beckhoff Automation GmbH,

Germany.

Copyright

The reproduction, distribution and utilization of this document as well as the communication of its contents to

others without express authorization are prohibited.

patent, utility model or design.

Foreword

EP4374 7Version: 2.3

1.3 Documentation issue status

Version Modifications

2.3 • Technical data corrected and sorted

• Optimizations

2.2 • Preliminary version

2.1 • Safety instructions new layout

• EP4374 - Introduction updated

• Chapter Mounting updated

2.0 • Migration

1.1 • Power Connection updated

1.0 • First release

Firmware and hardware versions

This documentation refers to the firmware and hardware version that was applicable at the time the

documentation was written.

The module features are continuously improved and developed further. Modules having earlier production

statuses cannot have the same properties as modules with the latest status. However, existing properties

are retained and are not changed, so that older modules can always be replaced with new ones.

Documentation

Version

EP4374-0002

Firmware Hardware

2.3 04 08

2.1 04 08

2.0 03 06

1.0 01 00

The firmware and hardware version (delivery state) can be found in the batch number (D-number) printed on

the side of the EtherCATBox.

Syntax of the batch number (D-number)

D: WW YY FF HH

WW - week of production (calendar week)

YY - year of production

FF - firmware version

HH - hardware version

Example with D no. 29 10 02 01:

29 - week of production 29

10 - year of production 2010

02 - firmware version 02

01 - hardware version 01

Beckhoff Identification Code (BIC)

The Beckhoff Identification Code contains additional information about the delivery state of the module:

General note on the introduction of the Beckhoff Identification Code (BIC) [}50].

Product overview

EP43748 Version: 2.3

2 Product overview

2.1 Product group: EtherCAT Box Modules

EtherCAT Box modules are I/O modules for industrial controllers.

They comply with protection class IP67 and are intended for use outside the control cabinet in wet, dirty or

dusty industrial environments.

EtherCAT Box modules communicate with the controller via the EtherCAT fieldbus. They each have two

connections for EtherCAT communication and for the power supply:

• Feed

• Downstream connection

This enables the cabling of EtherCAT Box modules in a line structure:

Power

EtherCAT

...

Fig.1: EtherCAT Box modules: Example of cabling in a line structure

Product overview

EP4374 9Version: 2.3

2.2 EP4374 - Introduction

Fig.2: EP4374-0002

EtherCAT Box with analog inputs and outputs

EP4374-0002 has two analog inputs and two analog outputs. The signal range can be individually

parameterized for each analog input and output:

• -10 .. +10V

• 0 .. 10V

• 0 .. 20mA

• 4 .. 20mA

Quick links

• Installation [}14]

• Configuration [}28]

• UL requirements [}24]

Product overview

EP437410 Version: 2.3

2.3 Technical data

Technical data EP4374-0002

Fieldbus

Fieldbus EtherCAT

Connection 2 x M8 socket, green

Electrical isolation 500V (fieldbus/ IO)

Process image Inputs: 2 x 16bit

Outputs: 2 x 16bit

Supply

Connection Feed: 1 x M8 plug, 4-pin

Downstream connection: 1 x M8 socket, 4-pin

Current carrying capacity of the connections 4A per U

S

and U

P

Control voltage U

S

24V

DC

(-15% / +20%)

Peripheral voltage U

P

0 .. 30V

DC

Supply of the module electronics from the control voltage U

S

Current consumption of the module

electronics

typically 120mA

Sensor supply

(Analog input channels)

from the peripheral voltage U

P

,

not short-circuit protected

Actuator supply

(Analog output channels)

from the peripheral voltage U

P

,

not short-circuit protected

Analog inputs

Number 2

Connection

M12 sockets, 5-pin. Pin assignment [}22]

Signal range

Parameterizable [}28]:

• -10 .. +10V (default)

• 0 .. 10V

• 0 .. 20mA

• 4 .. 20mA

Electrical specifications [}11]

Analog outputs

Number 2

Connection

M12 sockets, 5-pin. Pin assignment [}22]

Output signal range

Parameterizable [}28]:

• -10 .. +10V (default)

• 0 .. 10V

• 0 .. 20mA

• 4 .. 20mA

Electrical specifications [}11]

Environmental conditions

Ambient temperature during operation -25 .. +60°C

0 .. +55°C according to cURus [}24]

0 .. +55°C according to ATEX [}25]

Ambient temperature during storage -40 .. +85°C

Vibration/ shock resistance conforms to EN60068-2-6/ EN60068-2-27;

see also Additional checks [}12].

EMC immunity/emission conforms to EN61000-6-2/ EN61000-6-4

Protection class IP65, IP66, IP67 conforms to EN60529

Product overview

EP4374 11Version: 2.3

Technical data EP4374-0002

Mechanics

Weight approx.165g

Mounting position variable

Approvals and conformity

Approvals

CE, cURus [}24], ATEX [}25]

Analog inputs

The signal range can be switched during operation. The following table shows the electrical specifications

depending on the selected signal range.

Technical data Signal range

-10 .. 10V 0 .. 10V 0 .. 20mA 4 .. 20mA

Input type Differential

Input resistance >200kΩ >200kΩ 85Ω typ. + diode

voltage

85Ω typ. + diode

voltage

Digital resolution 16-bit 15-bit 15-bit 15-bit

Measuring error < 0.3% relative to full scale value

Conversion time approx. 100µs

Input filter limit frequency 5kHz

Value of the least significant

bit

approx. 305µV approx. 305µV approx. 610µA approx. 488µA

The analog inputs and outputs have a common analog ground potential. The analog ground potential is

electrically isolated from all other ground potentials in the box.

Analog outputs

The output signal range can be switched during operation. The following table shows the electrical

specifications depending on the selected output signal range.

Technical data Output signal range

-10 .. 10V 0 .. 10V 0 .. 20mA 4 .. 20mA

Load resistor / load >5kΩ >5kΩ <500Ω <500Ω

Digital resolution 16-bit 15-bit 15-bit 15-bit

Output error < 0.1 % (ambient temperature 0 °C ... +55 °C)

< 0.2 % (ambient temperature < 0 °C or > 55 °C)

related to the final value.

Conversion time approx. 40µs

Value of the least significant

bit

approx. 305µV approx. 305µV approx. 610µA approx. 488µA

The analog inputs and outputs have a common analog ground potential. The analog ground potential is

electrically isolated from all other ground potentials in the box.

Product overview

EP437412 Version: 2.3

Additional checks

The boxes have been subjected to the following checks:

Verification Explanation

Vibration 10 frequency sweeps in 3 axes

5Hz<f<60Hz displacement 0.35mm, constant amplitude

60.1Hz<f<500Hz acceleration 5g, constant amplitude

Shocks 1000 shocks in each direction, in 3 axes

35g, 11ms

2.4 Scope of supply

Make sure that the following components are included in the scope of delivery:

• 1x EP4374-0002 EtherCAT Box

• 2x protective cap for EtherCAT socket, M8, green (pre-assembled)

• 1x protective cap for supply voltage input, M8, transparent (pre-assembled)

• 1x protective cap for supply voltage output, M8, black (pre-assembled)

• 10x labels, blank (1 strip of 10)

Pre-assembled protective caps do not ensure IP67 protection

Protective caps are pre-assembled at the factory to protect connectors during transport. They may

not be tight enough to ensure IP67 protection.

Ensure that the protective caps are correctly seated to ensure IP67 protection.

Product overview

EP4374 13Version: 2.3

2.5 Process image

AI Inputs Channel1

The data for the first analog channel can be found under AI Inputs Channel1.

• Underrange: Value of the analog input is less than 0/4mA or -10/0V

• Overrange: Value of the analog input is greater than 20mA or +10V

• Limit1: with activated limit 1 (object 0x80x0:07 [}37]= 1) means

1: value less than limit 1 (set in object 0x80x0:13 [}37])

2: value greater than limit 1 (set in object 0x80x0:13 [}37])

3: value equal to limit 1 (set in object 0x80x0:13 [}37])

• Limit2: with activated limit 2 (object 0x80x0:08 [}37]= 1) means

1: value less than limit 2 (set in object 0x80x0:14 [}37])

2: value greater than limit 2 (set in object 0x80x0:14 [}37])

3: value equal to limit 2 (set in object 0x80x0:14 [}37])

• Error: This bit is set if overrange or underrange was detected.

AI Inputs Channel2

The data of the second analog channelhave the same structure as those of the first channel.

AO Outputs Channel3

The data for the third analog channel can be found under AO Outputs Channel3.

AO Outputs Channel4

The data of the forth analog channelhave the same structure as those of the third channel.

Mounting and cabling

EP437414 Version: 2.3

3 Mounting and cabling

3.1 Mounting

3.1.1 Dimensions

119

126

23

3026.5

13.5

Ø 3.5

Fig.3: Dimensions

All dimensions are given in millimeters.

Housing features

Housing material PA6 (polyamide)

Sealing compound polyurethane

Mounting two fastening holes Ø3.5mm for M3

Metal parts brass, nickel-plated

Contacts CuZn, gold-plated

Power feed through max. 4A

Mounting position variable

Protection class IP65, IP66, IP67 (conforms to EN60529) when screwed together

Dimensions (HxWxD) approx. 126 x 30 x 26.5mm

Mounting and cabling

EP4374 15Version: 2.3

3.1.2 Fixing

NOTE

Protect connectors against soiling!

Protection class IP67 can only be guaranteed if all cables and connectors are connected.

Protect the connections against soiling during mounting.

Mount the module with two M3 screws on the fastening holes in the corners of the module. The fastening

holes have no thread.

Mounting and cabling

EP437416 Version: 2.3

3.2 Cabling

Guidelines

Follow these guidelines to ensure IP67 protection:

• Mount plugs with the torque values specified below. Use a torque wrench, e.g. Beckhoff ZB8801.

• Seal unused connectors with protective caps.

• Ensure the correct seating of pre-assembled protective caps.

Protective caps are pre-assembled at the factory to protect connectors during transport. They may not

be tight enough to ensure IP67 protection.

Connector overview

X60 X61

X40 X41

1

2

3

4

Fig.4: Connector overview

Name Connector

type

Tightening

torque

Function

1 M12 0.6Nm

1)

Analog inputs [}22]

2

3 M12 0.6Nm

1)

Analog outputs [}22]

4

X40 M8 0.4Nm

1)

EtherCAT [}20]

X41

X60 M8 0.4Nm

1)

Power supply [}17]

X61

Mounting and cabling

EP4374 17Version: 2.3

3.2.1 Power supply

The EtherCAT Box is supplied with two supply voltages. The supply voltages are electrically isolated in the

EtherCAT Box.

• The control voltage U

S

is the supply voltage for:

◦ processor logic

◦ fieldbus logic

◦ analog inputs and outputs

• The peripheral voltage U

P

is the supply voltage for:

◦ External sensors: M12 sockets 1 and 2

◦ External actuators: M12 sockets 3 and 4

3.2.1.1 Connection

NOTE

Supply voltages can destroy EtherCAT interfaces

Connectors for supply voltages have the same design as connectors for EtherCAT. They are not protected

against mismating.

Avoid mismating.

Observe the color coding of the connectors:

Power supply: black

EtherCAT: green

Two M8 connectors at the low-end of the modules are used for feeding and routing the supply voltages:

• IN: left M8 connector for feeding the supply voltages

• OUT: right M8 connector for forwarding the supply voltages

Fig.5: Connections for power supply

Pin assignment

Fig.6: M8 connector

Pin Voltage Core colors

1)

1 Control voltage U

S

Brown

2 Peripheral voltage U

P

White

3 GND

S

Blue

4 GND

P

Black

1)

The core colors apply to Beckhoff ZK2020-xxxx-xxxx cables

Mounting and cabling

EP437418 Version: 2.3

Redirection of the supply voltages

The IN and OUT power connections are bridged in the module (not IP204x-Bxxx and IE204x). The supply

voltages U

S

and U

P

can thus easily be transferred from EtherCATBox to EtherCATBox.

NOTE

Pay attention to the maximum permissible current!

Pay attention also for the redirection of the supply voltages U

S

and U

P

, the maximum permissible current for

M8 connectors of 4A must not be exceeded!

3.2.1.2 Status LEDs

Fig.7: Status LEDs for the power supply

LED Display Meaning

U

S

(control voltage) off Supply voltage, U

S

, is not present

green illuminated Supply voltage, U

S

, is present

U

P

(peripheral voltage) off Supply voltage, U

P

, is not present

green illuminated Supply voltage, U

P

, is present

Mounting and cabling

EP4374 19Version: 2.3

3.2.1.3 Power cable conductor losses M8

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.8: 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.

Mounting and cabling

EP437420 Version: 2.3

3.2.2 EtherCAT

For connecting EtherCAT devices only shielded Ethernet cables that meet the requirements of at least

category5 (CAT5) according to EN50173 or ISO/IEC11801 should be used.

EtherCAT uses four wires for signal transmission.

Thanks to automatic line detection ("Auto MDI-X"), both symmetrical (1:1) or cross-over cables can be used

between Beckhoff EtherCAT.

Detailed recommendations for the cabling of EtherCAT devices can be found at

https://infosys.beckhoff.com/content/1033/ethernetcabling/index.html?id=1661412216745722148.

3.2.2.1 Connection

EtherCAT Box modules have two green M8 sockets for the incoming and outgoing EtherCAT connection.

Fig.9: EtherCAT connection

Pin assignment

Fig.10: M8 socket

EtherCAT M8 connector Core colors

Signal Pin ZB9010, ZB9020, ZB9030, ZB9032,

ZK1090-6292,

ZK1090-3xxx-xxxx

ZB9031 and old versions of

ZB9030, ZB9032, ZK1090-3xxx-

xxxx

TIA-568B

Tx + 1 Yellow

1)

orange/white white/orange

Tx - 4 Orange

1)

Orange orange

Rx + 2 White

1)

blue/white white/green

Rx - 3 Blue

1)

Blue green

Shield Housing Shield Shield Shield

1)

Core colors according to EN61918

Adaptation of core colors for cables ZB9030, ZB9032 and ZK1090-3xxxx-xxxx

For standardization purposes, the core colors of the cables ZB9030, ZB9032 and ZK1090-3xxx-

xxxx have been changed to the core colors of EN61918: yellow, orange, white, blue. So there are

different color codes in circulation. The electrical properties of the cables have been retained when

the core colors were changed.

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