Beckhoff EP1908 User manual

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Operating Instruction for | EN
EP1908
TwinSAFE EtherCAT Box with 8 fail-safe inputs
2023-03-07 | Version: 3.0.0

Table of contents
EP1908 3Version: 3.0.0
Table of contents
1 Notes on the documentation....................................................................................................................5
1.1 Disclaimer..........................................................................................................................................5
1.1.1 Trademarks........................................................................................................................5
1.1.2 Patents...............................................................................................................................5
1.1.3 Limitation of liability............................................................................................................6
1.1.4 Copyright............................................................................................................................6
1.2 Documentation issue status ..............................................................................................................7
1.3 Staff qualification...............................................................................................................................8
1.4 Safety and instruction........................................................................................................................9
1.4.1 Explanation of symbols ......................................................................................................9
1.5 Beckhoff Support and Service.........................................................................................................10
2 For your safety ........................................................................................................................................11
2.1 Duty of care.....................................................................................................................................11
2.2 Safety image signs..........................................................................................................................12
2.3 General safety instructions..............................................................................................................13
2.3.1 Before operation...............................................................................................................13
2.3.2 In operation ......................................................................................................................13
2.3.3 After operation..................................................................................................................13
3 System description .................................................................................................................................14
3.1 EtherCAT Box Modules...................................................................................................................14
4 Product description ................................................................................................................................15
4.1 EP1908-0002 ..................................................................................................................................15
4.2 Intended use ...................................................................................................................................16
4.3 Technical data.................................................................................................................................17
4.4 Safety parameters...........................................................................................................................18
4.5 Characteristic curve of the inputs....................................................................................................18
4.6 Dimensions .....................................................................................................................................19
5 Operation .................................................................................................................................................20
5.1 Environmental conditions ................................................................................................................20
5.2 Installation .......................................................................................................................................20
5.2.1 Safety instructions............................................................................................................20
5.2.2 Transport / storage...........................................................................................................20
5.2.3 Address settings on the TwinSAFE EtherCAT Box..........................................................21
5.2.4 Mounting ..........................................................................................................................21
5.2.5 Connection.......................................................................................................................22
5.2.6 Signal cables....................................................................................................................28
5.2.7 Description of the EP1908 test pulses .............................................................................29
5.2.8 TwinSAFE reaction times.................................................................................................31
5.3 Operation modes.............................................................................................................................32
5.4 EP1908 process image ...................................................................................................................33
5.5 Diagnostics......................................................................................................................................34
5.5.1 Run LED diagnostics........................................................................................................34
5.5.2 Diagnostic objects............................................................................................................35

Table of contents
EP19084 Version: 3.0.0
5.6 EP1908 configuration in TwinCAT ..................................................................................................36
5.6.1 Adding an EtherCAT device.............................................................................................36
5.6.2 Adding a EP1908 .............................................................................................................36
5.6.3 Entering a TwinSAFE address and parameters in the System Manager.........................38
6 Service life ...............................................................................................................................................46
7 Maintenance and cleaning .....................................................................................................................47
8 Decommissioning ...................................................................................................................................48
8.1 Disposal ..........................................................................................................................................48
8.1.1 Returning to the vendor....................................................................................................48
9 Appendix..................................................................................................................................................49
9.1 Protection classes according to IP code .........................................................................................49
9.2 Volatility...........................................................................................................................................50
9.3 Focus of certificates ........................................................................................................................51
9.4 Certificate ........................................................................................................................................52

Notes on the documentation
EP1908 5Version: 3.0.0
1 Notes on the documentation
1.1 Disclaimer
Beckhoff products are subject to continuous further development. We reserve the right to revise the
operating instructions 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 these
operating instructions.
In these operating instructions we define all permissible use cases whose properties and operating
conditions we can guarantee. The use cases we define are fully tested and certified. Use cases beyond this,
which are not described in these operating instructions, require the approval of Beckhoff Automation GmbH
& Co KG.
1.1.1 Trademarks
Beckhoff®, TwinCAT®, EtherCAT®, EtherCAT G®, EtherCAT G10®, EtherCAT P®, Safety over EtherCAT®,
TwinSAFE®, XFC®, XTS® and XPlanar® are registered and licensed trademarks of Beckhoff Automation
GmbH.
The use of other brand names or designations by third parties may lead to an infringement of the rights of
the owners of the corresponding designations.
1.1.2 Patents
The EtherCAT technology is protected by patent rights through the following registrations and patents with
corresponding applications and registrations in various other countries:
• EP1590927
• EP1789857
• EP1456722
• EP2137893
• DE102015105702
EtherCAT® is a registered trademark and patented technology,
licensed by Beckhoff Automation GmbH.
Safety over EtherCAT® is a registered trademark and patented
technology, licensed by Beckhoff Automation GmbH.

Notes on the documentation
EP19086 Version: 3.0.0
1.1.3 Limitation of liability
All components in this product as described in the operating instructions are delivered in a specific
configuration of hardware and software, depending on the application regulations. Modifications and
changes to the hardware and/or software configuration that go beyond the documented options are
prohibited and nullify the liability of Beckhoff Automation GmbH & Co. KG.
The following is excluded from the liability:
• Failure to observe these operating instructions
• Improper use
• Use of untrained personnel
• Use of unauthorized spare parts
1.1.4 Copyright
© Beckhoff Automation GmbH & Co. KG, Germany.
The distribution and reproduction of this document as well as the use and communication of its contents
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.

Notes on the documentation
EP1908 7Version: 3.0.0
1.2 Documentation issue status
Version Comment
3.0.0 • Foreword changed to Notes on the documentation [}5] and For your safety [}11]
• In chapter Technical data [}17] link to download page of certificates added
• In chapter Technical data [}17] “Power consumption US” changed in “Current consumption US”
•Service life [}46] moved
•Maintenance and cleaning [}47] and Decommissioning [}48] adapted
• Appendix adapted and expanded
2.2.0 • Characteristic curve of the inputs added
• Note to earthing connection added
• Description US updated
2.1.1 • Technical data permissible air pressure expanded
2.1.0 • Chapter EP1908 process image added
2.0.0 • Migration and structural adaptation
• Reliability document updated
• Safety parameters updated
• Foreword revised
1.2.2 • Reliability document added
• Description of the test pulses added
• Reaction time updated in the technical data
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
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.de/twinsafe. In case of doubt, please
contact Technical Support (see Beckhoff Support and Service [}10]).
Origin of the document
The original documentation is written in German. All other languages are derived from the German original.
Product features
Only the product properties specified in the current operating instructions are valid. Further information given
on the product pages of the Beckhoff homepage, in emails or in other publications is not authoritative.

Notes on the documentation
EP19088 Version: 3.0.0
1.3 Staff qualification
These operating instructions are intended exclusively for trained specialists in control technology and
automation with the relevant knowledge.
The trained specialist personnel must ensure that the applications and use of the described product meet all
safety requirements. This includes all applicable and valid laws, regulations, provisions and standards.
Trained specialists
Trained specialists have extensive technical knowledge from studies, apprenticeships or technical training.
Understanding of control technology and automation is available. Trained specialists can:
• Independently identify, avoid and eliminate sources of hazard.
• Apply relevant standards and directives.
• Implement specifications from accident prevention regulations.
• Evaluate, prepare and set up the workplaces.
• Evaluate, optimize and execute work independently.

Notes on the documentation
EP1908 9Version: 3.0.0
1.4 Safety and instruction
Read the contents that refer to the activities you have to perform with the product. Always read the chapter
For your safety [}11] in the operating instructions.
Observe the warnings in the chapters so that you can handle and work with the product as intended and
safely.
1.4.1 Explanation of symbols
Various symbols are used for a clear arrangement:
1. The numbering indicates an action that should be taken.
• The bullet point indicates an enumeration.
[…] The square brackets indicate cross-references to other text passages in the document.
[1] The number in square brackets indicates the numbering of a referenced document.
1.4.1.1 Pictograms
In order to make it easier for you to find text passages, pictograms and signal words are used in warning
notices:
DANGER
Failure to observe will result in serious or fatal injuries.
WARNING
Failure to observe may result in serious or fatal injuries.
CAUTION
Failure to observe may result in minor or moderate injuries.
NOTE
Notes
Notes are used for important information on the product. The possible consequences of failure to observe
these include:
• Malfunctions of the product
• Damage to the product
• Damage to the environment
Information
This sign indicates information, tips and notes for dealing with the product or the software.

Notes on the documentation
EP190810 Version: 3.0.0
1.5 Beckhoff Support and Service
Support
Beckhoff Support offers technical advice on the use of individual Beckhoff products and system planning.
The employees support you in the programming and commissioning of sophisticated automation systems.
Hotline: [phone]
E-mail: [email protected]
Web: www.beckhoff.com/support
Training
Training in Germany takes place in our training center at the Beckhoff headquarters in Verl, at subsidiaries
or, by arrangement, at the customer's premises.
Hotline: [phone]
E-mail: [email protected]
Web: www.beckhoff.com/training
Service
The Beckhoff Service Center supports you with after-sales services such as on-site service, repair service or
spare parts service.
Hotline: [phone]
E-mail: [email protected]
Web: www.beckhoff.com/service
Download area
In the download area you can obtain product information, software updates, the TwinCAT automation
software, documentation and much more.
Web: www.beckhoff.com/download
Headquarters
Beckhoff Automation GmbH & Co. KG
Hülshorstweg 20
33415 Verl
Germany
Phone: [phone]
E-mail: [email protected]
Web: www.beckhoff.com
For the addresses of our worldwide locations, please visit our website at Global Presence.

For your safety
EP1908 11Version: 3.0.0
2 For your safety
Read this chapter containing general safety information. In addition, always observe the safety instructions
and warnings in these operating instructions for your own safety, the safety of other persons and the safety
of the product.
When working with control and automation products, many dangers can result from careless or incorrect use.
Work particularly thoroughly, not under time pressure and responsibly towards other people.
2.1 Duty of care
Read entire documentation for TwinSAFE component
• TwinSAFE application manual
• EL6910 TwinSAFE logic terminal operating manual
• TwinSAFE Logic FB documentation manual
The operator must comply with all the requirements and notes specified in these operating instructions in
order to fulfill his duty of care. This includes in particular that you
• comply with the provisions defined in the chapter Limitation of liability [}6].
• only operate the TwinSAFE component when it is in perfect working order.
• provide the operating instructions in a legible condition and complete at the place of use of the
TwinSAFE component.
• do not remove the safety markings attached to the TwinSAFE component and maintain their legibility.
No disposal in domestic waste
Products marked with a crossed-out waste bin must not be disposed of with domestic
waste. The device is considered waste electrical and electronic equipment when it is
disposed of. Observe the national regulations for the disposal of waste electrical and
electronic equipment.

For your safety
EP190812 Version: 3.0.0
2.2 Safety image signs
On Beckhoff products you will find attached or lasered safety pictograms, which vary depending on the
product. They serve to serve to ensure safety for people and to prevent damage to the products. Safety
pictograms must not be removed and must be legible for the user.
Read and observe the operating instructions
Commissioning is only permitted if the operating instructions have been read and understood
beforehand. This applies in particular to the safety instructions and warnings.
Electrostatic sensitive components
Work with and on the TwinSAFE component is only permitted in protected workplaces.

For your safety
EP1908 13Version: 3.0.0
2.3 General safety instructions
2.3.1 Before operation
Use in machines according to the Machinery Directive
Only use the TwinSAFE component in machines that comply with the Machinery Directive. This is how you
ensure safe operation.
Ensure traceability
Ensure the traceability of the TwinSAFE component via the serial number.
Use SELV/PELV power supply
Use a SELV/PELV power supply unit with an output-side voltage limit of Umax = 36VDC to supply the
TwinSAFE component with 24VDC.
Failure to observe this will endanger the safety function of the product. Depending on the machine, death
and danger to life, serious physical injury and damage to the machine may result.
Carry out commissioning test
Before commissioning, wiring faults to the sensors must be excluded. Before commissioning, carry out a
commissioning test. After a successful commissioning test, you can use the TwinSAFE component for the
intended safety-related task.
In case of wiring errors, the safety function of the product is at risk. Depending on the machine, death and
danger to life, serious bodily injury and damage to the machine may result.
2.3.2 In operation
Interference due to emitted interference
Do not operate the following devices in the vicinity of the TwinSAFE component: for example, radio
telephones, radios, transmitters or high-frequency systems.
TwinSAFE components comply with the requirements of the applicable electromagnetic compatibility
standards with regard to interference emission and immunity. If you exceed the limits for emitted interference
specified in the standards, the function of the TwinSAFE component may be impaired.
2.3.3 After operation
De-energize and switch off components before working on them
Check all safety-relevant equipment for functionality before working on the TwinSAFE component. Secure
the working environment. Secure the machine or plant against being inadvertently started up. Observe the
chapter Decommissioning [}48].

System description
EP190814 Version: 3.0.0
3 System description
3.1 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, 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 Documentation for
EtherCAT, which is available for download from our website (www.beckhoff.com) under Downloads.

Product description
EP1908 15Version: 3.0.0
4 Product description
4.1 EP1908-0002
Fig.2: 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 500 Hz. 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 (test pulse outputs) are supplied from
the control voltage UP.
The TwinSAFE EtherCAT Box has the typical design of an EtherCAT Box.

Product description
EP190816 Version: 3.0.0
4.2 Intended use
WARNING
Caution - Risk of injury!
TwinSAFE components shall 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 sensors such as
• emergency stop push buttons, pull cord switches, position switches, two-hand switches, safety mats,
light curtains, light barriers, laser scanners etc.
• initiators and encoders for speed measurement (frequency) with a signal voltage of 24 VDC
WARNING
The 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 Umax of 36VDC. Failure to observe this can result in a loss of safety.
CAUTION
Follow the machinery directive!
The TwinSAFE components shall 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.

Product description
EP1908 17Version: 3.0.0
4.3 Technical data
The current certificates of all TwinSAFE products with the underlying standards and directives can be found
at https://www.beckhoff.com/en-en/support/download-finder/certificates-approvals/.
Product designation EP1908-0002
Fieldbus EtherCAT
Number of inputs 8
Connecting the inputs M12
Status display 8 (one green LED per input)
Reaction time
(Read input/write to E-bus)
typically: 5.5ms,
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 sensor and EtherCAT Box Unshielded: 30m max. (at 0.75 or 1mm²)
Shielded: 30m max. (at 0.75 or 1mm²)
Output current of the clock outputs typically 10mA, max. 15mA
Input process image 6bytes
Output process image 6bytes
Supply voltage for the EP1908 24VDC (–15%/+20%)
Current consumption US
(connected with eight potential-free contacts)
8 channels occupied: typically 87mA
0 channel occupied: typically 80mA
Current consumption UP
(connected with eight potential-free contacts)
8 channels occupied: approx. 27mA
0 channel 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 EtherCAT) yes
Insulation voltage (between the channels and EtherCAT, under
common operating conditions)
insulation tested with 500VDC
Dimensions (W x H x D) 30mm x 126mm x 26.5mm
Housing material PA6-F (polyamide)
Sealing compound polyurethane
Weight approx. 170g
Permissible ambient temperature (operation) -25°C to +60°C
Permissible ambient temperature (transport/storage) -40°C to +85°C
Permissible air humidity 5% to 95%, non-condensing
Permissible air pressure (operation/storage/transport) 750hPa to 1100hPa
(this corresponds to a height of approx. -690m to 2450m over sea
level assuming an international standard atmosphere)
Impermissible operating conditions 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
EMC immunity/emission conforms to EN61000-6-2/ EN61000-6-4
Vibration/shock resistance conforms 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

Product description
EP190818 Version: 3.0.0
4.4 Safety parameters
Key figures EP1908-0002
Lifetime [a] 20
Prooftest Interval [a] not required1
PFHD1.56E-09
%SIL3 1,56%
PFD 1.06E-04
%SIL3 10,59%
MTTFdhigh
DC high
Performance level PL e
Category 4
HFT 1
Element classification2Type B
1. Special proof tests throughout the service life of the EtherCAT Box are not required.
2. 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).
For the calculation or estimation of the MTTFd value from the PFHD value, further information can be found in
the TwinSAFE application manual or in ISO 13849-1:2015 Table K.1.
4.5 Characteristic curve of the inputs
The characteristic curve of the inputs is similar to type 3 according to EN 61131-2.
Fig.3: Characteristic curve of the inputs

Product description
EP1908 19Version: 3.0.0
4.6 Dimensions
Fig.4: Dimensions
The modules have 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.

Operation
EP190820 Version: 3.0.0
5 Operation
5.1 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.
5.2 Installation
5.2.1 Safety instructions
Before installing and commissioning the TwinSAFE components please read the safety instructions in the
foreword of this documentation.
5.2.2 Transport / storage
Use the original packaging in which the components were delivered for transporting and storing the
TwinSAFE components.
CAUTION
Note the specified environmental conditions
Please ensure that the digital TwinSAFE components are only transported and stored under the specified
environmental conditions (see technical data).