Beckhoff CU1521, CU1561 User Manual
Documentation | EN
CU1521-xxxx, CU1561
EtherCAT media converter (RJ45, LWL, POF)
2020-11-06 | Version: 2.4
Table of contents
Table of contents
1 Foreword ....................................................................................................................................................5
1.1 CU15x1 - Product overview...............................................................................................................5
1.2 Notes on the documentation..............................................................................................................5
1.3 Safety instructions .............................................................................................................................7
1.4 Documentation issue status ..............................................................................................................8
1.5 Version identification of EtherCAT devices .......................................................................................8
1.5.1 Beckhoff Identification Code (BIC)................................................................................... 13
2 Product overview.....................................................................................................................................15
2.1 Introduction......................................................................................................................................15
2.2 Technical data .................................................................................................................................17
3 Basic principles .......................................................................................................................................18
3.1 EtherCAT basics..............................................................................................................................18
3.2 EtherCAT cabling – wire-bound.......................................................................................................18
3.3 EtherCAT State Machine.................................................................................................................19
3.4 CoE - Interface: notes......................................................................................................................20
4 Mounting and wiring................................................................................................................................21
4.1 Dimensions......................................................................................................................................21
4.2 Mounting and demounting ...............................................................................................................22
4.3 Recommended mounting rails.........................................................................................................23
4.4 Diagnostic LEDs ..............................................................................................................................24
4.5 UL notice .........................................................................................................................................25
5 Commissioning/application notes .........................................................................................................26
5.1 Application notes .............................................................................................................................26
5.2 Notes on converters with RJ45 fiber-optic connection ....................................................................30
5.2.1 Principles of fiber-optic technology .................................................................................. 30
5.2.2 Notes on suitable optical fiber cables .............................................................................. 35
5.2.3 Application with CU1521 and CU1521-0010 ................................................................... 36
5.2.4 Connecting and disconnecting the fiber cable ................................................................. 37
5.3 Notes on converters with RJ45 POF connection.............................................................................38
5.3.1 Notes regarding suitable POF cables .............................................................................. 38
5.3.2 Connecting and disconnecting the POF cable................................................................. 39
5.4 Notes regarding assembly of POF cables with the connector set ZS1090-0008 ............................40
6 Appendix ..................................................................................................................................................45
6.1 Safety instructions and behavioral rules for Class 1 laser...............................................................45
6.2 Firmware compatibility.....................................................................................................................45
6.3 Firmware Update EL/ES/EM/ELM/EPxxxx ......................................................................................45
6.3.1 Device description ESI file/XML....................................................................................... 46
6.3.2 Firmware explanation ...................................................................................................... 49
6.3.3 Updating controller firmware *.efw................................................................................... 50
6.3.4 FPGA firmware *.rbf......................................................................................................... 52
6.3.5 Simultaneous updating of several EtherCAT devices...................................................... 56
6.4 Support and Service ........................................................................................................................57
CU1521-xxxx, CU1561 3Version: 2.4
Table of contents
CU1521-xxxx, CU15614 Version: 2.4
Foreword
1 Foreword
1.1 CU15x1 - Product overview
CU1521 [}15] - EtherCAT media converter multimode fiber optic
CU1521-0010 [}15] - EtherCAT media converter singlemode fiber optic
CU1561 [}15] - EtherCAT media converter fiber optic (POF)
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®, EtherCATG®, EtherCATG10®, EtherCATP®, SafetyoverEtherCAT®,
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.
CU1521-xxxx, CU1561 5Version: 2.4
Foreword
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.
CU1521-xxxx, CU15616 Version: 2.4
Foreword
1.3 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.
CU1521-xxxx, CU1561 7Version: 2.4
Foreword
1.4 Documentation issue status
Version Modifications
2.4 • Update chapter “Notes on converters with RJ45 fiber-optic connection”
• Update structure
2.3 • Update chapter “Commissioning”
• Update Technical Data
• Update structure
2.2 • Update Technical Data
• Update structure
2.1 • Update Technical Data
• Update structure
2.0 • Migration
1.2 • Update chapter "Technical data"
1.1 • Update chapter "Application notes"
1.0 • Addenda and 1st public issue
0.3 • Addenda
0.2 • Addenda
0.1 • Preliminary version
1.5 Version identification of EtherCAT devices
Designation
A Beckhoff EtherCAT device has a 14-digit designation, made up of
• family key
• type
• version
• revision
Example Family Type Version Revision
EL3314-0000-0016 EL terminal
(12 mm, nonpluggable connection
level)
ES3602-0010-0017 ES terminal
(12 mm, pluggable
connection level)
CU2008-0000-0000 CU device 2008 (8-port fast ethernet switch) 0000 (basic type) 0000
Notes
• The elements mentioned above result in the technical designation. EL3314-0000-0016 is used in the
example below.
• EL3314-0000 is the order identifier, in the case of “-0000” usually abbreviated to EL3314. “-0016” is the
EtherCAT revision.
• The order identifier is made up of
- family key (EL, EP, CU, ES, KL, CX, etc.)
- type (3314)
- version (-0000)
3314 (4-channel thermocouple
terminal)
3602 (2-channel voltage
measurement)
0000 (basic type) 0016
0010 (highprecision version)
0017
CU1521-xxxx, CU15618 Version: 2.4
Foreword
• The revision -0016 shows the technical progress, such as the extension of features with regard to the
EtherCAT communication, and is managed by Beckhoff.
In principle, a device with a higher revision can replace a device with a lower revision, unless specified
otherwise, e.g. in the documentation.
Associated and synonymous with each revision there is usually a description (ESI, EtherCAT Slave
Information) in the form of an XML file, which is available for download from the Beckhoff web site.
From 2014/01 the revision is shown on the outside of the IP20 terminals, see Fig. “EL5021 EL terminal,
standard IP20 IO device with batch number and revision ID (since 2014/01)”.
• The type, version and revision are read as decimal numbers, even if they are technically saved in
hexadecimal.
Identification number
Beckhoff EtherCAT devices from the different lines have different kinds of identification numbers:
Production lot/batch number/serial number/date code/D number
The serial number for Beckhoff IO devices is usually the 8-digit number printed on the device or on a sticker.
The serial number indicates the configuration in delivery state and therefore refers to a whole production
batch, without distinguishing the individual modules of a batch.
Structure of the serial number: KKYYFFHH
KK - week of production (CW, calendar week)
YY - year of production
FF - firmware version
HH - hardware version
Example with
Ser. no.: 12063A02: 12 - production week 12 06 - production year 2006 3A - firmware version 3A 02 hardware version 02
Exceptions can occur in the IP67 area, where the following syntax can be used (see respective device
documentation):
Syntax: D ww yy x y z u
D - prefix designation
ww - calendar week
yy - year
x - firmware version of the bus PCB
y - hardware version of the bus PCB
z - firmware version of the I/O PCB
u - hardware version of the I/O PCB
Example: D.22081501 calendar week 22 of the year 2008 firmware version of bus PCB: 1 hardware version
of bus PCB: 5 firmware version of I/O PCB: 0 (no firmware necessary for this PCB) hardware version of I/O
PCB: 1
Unique serial number/ID, ID number
In addition, in some series each individual module has its own unique serial number.
See also the further documentation in the area
• IP67: EtherCAT Box
• Safety: TwinSafe
• Terminals with factory calibration certificate and other measuring terminals
CU1521-xxxx, CU1561 9Version: 2.4
Foreword
Examples of markings
Fig.1: EL5021 EL terminal, standard IP20 IO device with serial/ batch number and revision ID (since
2014/01)
Fig.2: EK1100 EtherCAT coupler, standard IP20 IO device with serial/ batch number
Fig.3: CU2016 switch with serial/ batch number
CU1521-xxxx, CU156110 Version: 2.4
Fig.4: EL3202-0020 with serial/ batch number 26131006 and unique ID-number 204418
Foreword
Fig.5: EP1258-00001 IP67 EtherCAT Box with batch number/ date code 22090101 and unique serial
number 158102
Fig.6: EP1908-0002 IP67 EtherCAT Safety Box with batch number/ date code 071201FF and unique serial
number 00346070
Fig.7: EL2904 IP20 safety terminal with batch number/ date code 50110302 and unique serial number
00331701
CU1521-xxxx, CU1561 11Version: 2.4
Foreword
Fig.8: ELM3604-0002 terminal with unique ID number (QR code) 100001051 and serial/ batch number
44160201
CU1521-xxxx, CU156112 Version: 2.4
Foreword
1.5.1 Beckhoff Identification Code (BIC)
The Beckhoff Identification Code (BIC) is increasingly being applied to Beckhoff products to uniquely identify
the product. The BIC is represented as a Data Matrix Code (DMC, code scheme ECC200), the content is
based on the ANSI standard MH10.8.2-2016.
Fig.9: BIC as data matrix code (DMC, code scheme ECC200)
The BIC will be introduced step by step across all product groups.
Depending on the product, it can be found in the following places:
• on the packaging unit
• directly on the product (if space suffices)
• on the packaging unit and the product
The BIC is machine-readable and contains information that can also be used by the customer for handling
and product management.
Each piece of information can be uniquely identified using the so-called data identifier
(ANSIMH10.8.2-2016). The data identifier is followed by a character string. Both together have a maximum
length according to the table below. If the information is shorter, spaces are added to it. The data under
positions 1 to 4 are always available.
The following information is contained:
CU1521-xxxx, CU1561 13Version: 2.4
Foreword
Item
Type of
no.
information
1 Beckhoff order
number
2 Beckhoff Traceability
Number (BTN)
3 Article description Beckhoff article
4 Quantity Quantity in packaging
5 Batch number Optional: Year and week
6 ID/serial number Optional: Present-day
7 Variant number Optional: Product variant
...
Explanation Data
Beckhoff order number 1P 8 1P072222
Unique serial number,
see note below
description, e.g.
EL1008
unit, e.g. 1, 10, etc.
of production
serial number system,
e.g. with safety products
number on the basis of
standard products
Number of digits
identifier
S 12 SBTNk4p562d7
1K 32 1KEL1809
Q 6 Q1
2P 14 2P401503180016
51S 12 51S678294104
30P 32 30PF971, 2*K183
incl. data identifier
Example
Further types of information and data identifiers are used by Beckhoff and serve internal processes.
Structure of the BIC
Example of composite information from item 1 to 4 and 6. The data identifiers are marked in red for better
display:
BTN
An important component of the BIC is the Beckhoff Traceability Number (BTN, item no.2). The BTN is a
unique serial number consisting of eight characters that will replace all other serial number systems at
Beckhoff in the long term (e.g. batch designations on IO components, previous serial number range for
safety products, etc.). The BTN will also be introduced step by step, so it may happen that the BTN is not yet
coded in the BIC.
NOTE
This information has been carefully prepared. However, the procedure described is constantly being further
developed. We reserve the right to revise and change procedures and documentation at any time and without prior notice. No claims for changes can be made from the information, illustrations and descriptions in
this information.
CU1521-xxxx, CU156114 Version: 2.4
2 Product overview
2.1 Introduction
Product overview
Fig.10: CU1561, CU1521
The EtherCAT-capable CU1521, CU1521-0010 and CU1561 devices should be used as media converter for
industrial fast Ethernet/100 Mbaud from optical fiber to copper and vice versa.
Fig.11: Upper picture: one media converter, copper -> fiber optic,
Lower picture: two media converters, copper -> fiber optic -> copper
From the physical layer perspective the CU1521 is suitable for multimode, while the CU1521-0010 is suitable
for single mode optical fiber and therefore for significantly longer transmission links up to 20 km.
The CU1561 is used for interfacing with POF (plastic optical fiber), which are suitable for small-scale
machine installation thanks to relatively inexpensive cable material and field-configurability.
The media converter operates bidirectionally and collision-free. The CU15x1 devices are therefore also
suitable as media converters for any Ethernet traffic. They support "Link Loss Forwarding", which means
that, if the link fails at the outgoing strand, for example due to a broken wire, the link is also withdrawn from
the incoming line, so that the sending device is notified of the link loss.
The CU15x1 devices are characterized by the fact that they support the requirements of an EtherCAT
network for a converter particularly well. This includes fast link control (establishment and disconnection),
diagnosis of communication errors, constant frame deceleration and readable identity (no transparent
operation). If the CU15x1 is set to EtherCAT mode with the rotary switch, it can be diagnosed as a separate
EtherCAT device. Hence, as opposed to standard media converters, he also ensures fast link control and
thus the secure termination of an EtherCAT strand even in the event of a disruption. Since the transfer
direction (copper Þ optical fiber or optical fibers Þ copper) is relevant for the EtherCAT bus, the operating
direction can be configured via the rotary switch.
CU1521-xxxx, CU1561 15Version: 2.4
Product overview
The CU15x1 are useful in applications where EtherCAT transfers over large distances are required or where
higher EMC loads on the bus line are to be expected.
Quick links
• EtherCAT basics
• Application notes [}26]
• Diagnostic LEDs [}24]
CU1521-xxxx, CU156116 Version: 2.4
Product overview
2.2 Technical data
Technical data CU1521 CU1521-0010 CU1561
Function Ethernet "IP" Media converter Fast Ethernet/100Mbaud (all IEEE 802.3-based
protocols)
IEEE 802.3u auto negotiation, half or full duplex, automatic settings
Link Loss-Forwarding (notification direction configurable)
Store and Forward Mode (FIFO)
unmanaged
Function EtherCAT "EC" Media converter Fast Ethernet/100Mbaud
Cut-through mode
Port handling/link control
Number of Ethernet ports 2
Ethernet interface X1 100BASE-FX
multimode glass fiber
50/125µm (MM)
typically 1300nm
1 x SC Duplex
100BASE-FX single
mode glass fiber
9/125µm (SM)
typically 1300nm
1 x SC Duplex
100BASE-FX-POF
glass fiber 980/1000
µm (POF);
typically 650nm
1 x versatile link for
POF duplex connector
(connector set
ZS1090-0008)
Laser class 1, see note
[}45]
Ethernet interface X2 10BASE-T/100BASE-TX Ethernet/EtherCAT cable (min. CAT 5),
screened
RJ45
Cable length X1 max. max. 2km (100BASE-
FX)
Cable length X2 max. up to 100m twisted pair CAT5 (e)
Diagnostics LED: Supply voltage, link/activity X1/X2
EtherCAT: CRC
Power supply via three-pole spring loaded terminal (+, -, PE)
Supply voltage 24VDC (18VDC to 30VDC), protected against polarity reversal.
Current consumption typ. 95mA typ. 80mA typ. 60mA
Weight approx. 105g
Dimensions without plugs (W x H
x D)
Mounting [}22]
Permissible ambient temperature
range during operation
Permissible ambient temperature
range during storage
Permissible relative humidity 95%, no condensation
Vibration/shock resistance conforms to EN60068-2-6/ EN60068-2-27, EN60068-2-29
EMC immunity/emission conforms to EN 61000-6-2 / EN 61000-6-4
Protection class IP20
Installation position variable
Approval CE
approx. 34mm x 98mm x 77mm
on 35 mm mounting rail (mounting rail according to EN 60715)
-25°C ... +60°C
(extended temperature
range)
-40°C ... +85°C -25°C ... +85°C
cULus [}25]
max. 20km (100BASEFX)
0°C …+55°C
max. 50m (100BASEFX-POF)
CU1521-xxxx, CU1561 17Version: 2.4
Basic principles
3 Basic principles
3.1 EtherCAT basics
Please refer to the EtherCAT System Documentation for the EtherCAT fieldbus basics.
3.2 EtherCAT cabling – wire-bound
The cable length between two EtherCAT devices must not exceed 100 m. This results from the FastEthernet
technology, which, above all for reasons of signal attenuation over the length of the cable, allows a maximum
link length of 5 + 90 + 5 m if cables with appropriate properties are used. See also the Design
recommendations for the infrastructure for EtherCAT/Ethernet.
Cables and connectors
For connecting EtherCAT devices only Ethernet connections (cables + plugs) that meet the requirements of
at least category 5 (CAt5) according to EN 50173 or ISO/IEC 11801 should be used. EtherCAT uses 4 wires
for signal transfer.
EtherCAT uses RJ45 plug connectors, for example. The pin assignment is compatible with the Ethernet
standard (ISO/IEC 8802-3).
Pin Color of conductor Signal Description
1 yellow TD + Transmission Data +
2 orange TD - Transmission Data -
3 white RD + Receiver Data +
6 blue RD - Receiver Data -
Due to automatic cable detection (auto-crossing) symmetric (1:1) or cross-over cables can be used between
EtherCAT devices from Beckhoff.
Recommended cables
It is recommended to use the appropriate Beckhoff components e.g.
- cable sets ZK1090-9191-xxxx respectively
- RJ45 connector, field assembly ZS1090-0005
- EtherCAT cable, field assembly ZB9010, ZB9020
Suitable cables for the connection of EtherCAT devices can be found on the Beckhoff website!
E-Bus supply
A bus coupler can supply the EL terminals added to it with the E-bus system voltage of 5V; a coupler is
thereby loadable up to 2A as a rule (see details in respective device documentation).
Information on how much current each EL terminal requires from the E-bus supply is available online and in
the catalogue. If the added terminals require more current than the coupler can supply, then power feed
terminals (e.g. EL9410) must be inserted at appropriate places in the terminal strand.
The pre-calculated theoretical maximum E-Bus current is displayed in the TwinCAT System Manager. A
shortfall is marked by a negative total amount and an exclamation mark; a power feed terminal is to be
placed before such a position.
CU1521-xxxx, CU156118 Version: 2.4
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