Beckhoff EP9214-0023 Operator's manual

Documentation
EP9214-0023 and EP9224-0023
Power Distribution for EtherCAT Box Modules
2.3.1
2018-04-10
Version:
Date:

Table of contents
EP9214-0023 and EP9224-0023 3Version: 2.3.1
Table of contents
1 Foreword ....................................................................................................................................................5
1.1 Notes on the documentation........................................................................................................... 5
1.2 Safety instructions .......................................................................................................................... 6
1.3 Documentation issue status............................................................................................................ 7
2 Product overview.......................................................................................................................................8
2.1 EtherCAT Box - Introduction........................................................................................................... 8
2.2 EP9214 - Introduction ................................................................................................................... 10
2.3 EP9224 - Introduction ................................................................................................................... 11
2.4 Technical data .............................................................................................................................. 12
3 Mounting and cabling .............................................................................................................................13
3.1 Mounting ....................................................................................................................................... 13
3.1.1 Dimensions ......................................................................................................................13
3.1.2 Mounting ..........................................................................................................................14
3.1.3 Nut torque for connectors ................................................................................................15
3.2 EtherCAT ...................................................................................................................................... 16
3.2.1 EtherCAT connection.......................................................................................................16
3.2.2 EtherCAT - Fieldbus LEDs...............................................................................................18
3.3 Power supply ................................................................................................................................ 20
3.3.1 Power Connection............................................................................................................20
3.3.2 Power LEDs .....................................................................................................................22
3.3.3 Power cable conductor losses M8 ...................................................................................23
3.3.4 Power cable 7/8" ..............................................................................................................24
3.3.5 Conductor losses 7/8" ......................................................................................................26
3.3.6 Power outputs ..................................................................................................................27
3.4 Cabling.......................................................................................................................................... 28
3.5 Status LEDs and status bits.......................................................................................................... 30
3.6 Monitoring and reset contacts....................................................................................................... 31
4 Comissioning and Configuration...........................................................................................................32
4.1 Inserting into the EtherCAT network............................................................................................. 32
4.2 Configuration via TwinCAT ........................................................................................................... 35
4.3 Operation with or without EtherCAT master ................................................................................. 43
4.4 Switch of behavior ........................................................................................................................ 44
4.4.1 Switch-off characteristics .................................................................................................44
4.4.2 Current limitation, switching the load circuits off ..............................................................46
4.4.3 Setting the current limitation ............................................................................................47
4.4.4 Status LEDs and status bits.............................................................................................48
4.5 EP9214-0023................................................................................................................................ 50
4.5.1 EP9214-0023 - Object description ...................................................................................50
4.5.2 EP9214-0023 - Process image ........................................................................................65
4.6 EP9224-0023................................................................................................................................ 66
4.6.1 EP9224-0023 - Diagnostic functions................................................................................66
4.6.2 EP9224-0023 - Object description ...................................................................................79
4.6.3 EP9224-0023 - Process image ......................................................................................106
4.7 Restoring the delivery state ........................................................................................................ 107
5 Appendix ................................................................................................................................................109
5.1 General operating conditions...................................................................................................... 109
5.2 EtherCAT Box- / EtherCATPBox - Accessories........................................................................ 110

Table of contents
EP9214-0023 and EP9224-00234 Version: 2.3.1
5.3 Support and Service ................................................................................................................... 111

Foreword
EP9214-0023 and EP9224-0023 5Version: 2.3.1
1 Foreword
1.1 Notes on the documentation
Intended audience
This description is only intended for the use of trained specialists in control and automation engineering who
are familiar with the applicable national standards.
It is essential that the 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®, 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.

Foreword
EP9214-0023 and EP9224-00236 Version: 2.3.1
1.2 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 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!
DANGER
Serious risk of injury!
Failure to follow the safety instructions associated with this symbol directly endangers the
life and health of persons.
WARNING
Risk of injury!
Failure to follow the safety instructions associated with this symbol endangers the life and
health of persons.
CAUTION
Personal injuries!
Failure to follow the safety instructions associated with this symbol can lead to injuries to
persons.
Attention
Damage to the environment or devices
Failure to follow the instructions associated with this symbol can lead to damage to the en-
vironment or equipment.
Note
Tip or pointer
This symbol indicates information that contributes to better understanding.

Foreword
EP9214-0023 and EP9224-0023 7Version: 2.3.1
1.3 Documentation issue status
Version Comment
2.3.1 • chapter Switch of behavior updated
• Nut torque for connectors updated
2.3.0 • Cabling added
2.2.0 • Operation with or without EtherCAT master updated
2.1.0 • Power Connection updated
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
version
EP9214-0023 EP9224-0023
firmware hardware firmware hardware
2.1.0 09 11 04 10
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

Product overview
EP9214-0023 and EP9224-00238 Version: 2.3.1
2 Product overview
2.1 EtherCAT 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, 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.
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.

Product overview
EP9214-0023 and EP9224-0023 9Version: 2.3.1
Fig.2: EtherCAT Box with M8 connections for sensors/actuators
Fig.3: EtherCAT Box with M12 connections for sensors/actuators
Note
Basic EtherCAT documentation
You will find a detailed description of the EtherCAT system in the Basic System Documen-
tation for EtherCAT, which is available for download from our website (www.beckhoff.com)
under Downloads.
Note
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.

Product overview
EP9214-0023 and EP9224-002310 Version: 2.3.1
2.2 EP9214 - 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 [}13]
Configuration [}32]

Product overview
EP9214-0023 and EP9224-0023 11Version: 2.3.1
2.3 EP9224 - 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.

Product overview
EP9214-0023 and EP9224-002312 Version: 2.3.1
Quick links
Installation [}13]
Configuration [}35]
2.4 Technical 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
circuits
90mV / Ampere
Parallel connection of several load
outputs
not permissible
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
contacts
in : 1 x M8 plug
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
circuitry
typically 110mA from Us,
typically 40mA from Up
Process image Inputs: 5 x 16bit
Outputs: 5 x 16bit
Inputs: 16x16Bit
Outputs: 5x16Bit
Data logging - 40 samples ( 1ms - 1000ms
sample time)
Permissible ambient temperature
during operation
-25°C ... +60°C
Permissible ambient temperature
during storage
-25 °C... +85°C
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

Mounting and cabling
EP9214-0023 and EP9224-0023 13Version: 2.3.1
3 Mounting and cabling
3.1 Mounting
3.1.1 Dimensions
Fig.6: Dimensions of the EtherCAT Box Modules
All dimensions are given in millimeters.

Mounting and cabling
EP9214-0023 and EP9224-002314 Version: 2.3.1
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
3.1.2 Mounting
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.
Note
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
sealed! Unused connectors must be sealed with suitable protective caps (see Beckhoff cat-
alogue for connector sets and protective caps)!
Note
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
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

Mounting and cabling
EP9214-0023 and EP9224-0023 15Version: 2.3.1
3.1.3 Nut torque for connectors
M8 connectors
It is recommended to pull the M8 connectors tight with a nut torque of 0.4 Nm. When using the torque control
screwdriver ZB8800 is also a max. torque of 0.5Nm permissible.
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.
Fig.8: EtherCAT Box with M8 and M12 connectors

Mounting and cabling
EP9214-0023 and EP9224-002316 Version: 2.3.1
7/8" plug connectors
We recommend fastening the 7/8" plug connectors with a torque of 1.5Nm.
Fig.9: 7/8" plug connectors
Torque socket wrenches
Fig.10: ZB8801 torque socket wrench
Note
Ensure the right torque
Use the torque socket wrenches available by Beckhoff to pull the connectors tight (ZB8800,
ZB8801-0000)!
3.2 EtherCAT
3.2.1 EtherCAT 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

Mounting and cabling
EP9214-0023 and EP9224-0023 17Version: 2.3.1
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.

Mounting and cabling
EP9214-0023 and EP9224-002318 Version: 2.3.1
Ethernet/EtherCAT Plug connector Cable Standard
Signal Description M8 M12 RJ451ZB9010, ZB9020,
ZB9030, ZB9032,
ZK1090-6292,
ZK1090-3xxx-xxxx
ZB9031 and old
versions
of ZB9030, ZB9032,
ZK1090-3xxx-xxxx
TIA-568B
Tx + Transmit Data+ Pin 1 Pin 1 Pin 1 yellow2orange/white3white/orange
Tx - Transmit Data- Pin 4 Pin 3 Pin 2 orange2orange3orange
Rx + Receive Data+ Pin 2 Pin 2 Pin 3 white2blue/white3white/green
Rx - Receive Data- Pin 3 Pin 4 Pin 6 blue2blue3green
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
Note
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
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 male four-pin, IP67, for field assembly, for ZB903x cable
ZS1090-0007 M8 female four-pin, IP67, for field assembly, for ZB903x cable
ZS1090-1006 M8 male four-pin, IP67, for field assembly up to OD = 6.5mm
ZS1090-1007 M8 female four-pin, IP67, for field assembly up to OD = 6.5mm
3.2.2 EtherCAT - Fieldbus LEDs
Fig.14: EtherCAT-LEDs

Mounting and cabling
EP9214-0023 and EP9224-0023 19Version: 2.3.1
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
Note
EtherCAT statuses
The various statuses in which an EtherCAT module may be found are described in the Ba-
sic System Documentation for EtherCAT, which is available for download from our website
(www.beckhoff.com) under Downloads.

Mounting and cabling
EP9214-0023 and EP9224-002320 Version: 2.3.1
3.3 Power supply
3.3.1 Power Connection
Attention
Use cables with suitable cross-sections!
Ensure that the cross-sections of the cables employed are suitable for the load circuit in-
puts and outputs and the respective rated current being used!
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
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.