Beckhoff EP1122-0001 User Manual

Documentation | EN

EP1122-0001

2-port EtherCAT junction

2020-09-15 | Version: 1.2

Table of contents

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 EtherCAT Box - Introduction ....................................................................................................................8

3 Product overview.....................................................................................................................................10

3.1 Introduction......................................................................................................................................10

3.2 Technical data .................................................................................................................................11

3.3 Scope of supply ...............................................................................................................................12

4 Basic function principles of EtherCAT junctions.................................................................................13

5 Mounting and connection.......................................................................................................................21

5.1 Dimensions......................................................................................................................................21

5.2 Fixing ...............................................................................................................................................22

5.3 Connection ......................................................................................................................................23

5.3.1 Overview.......................................................................................................................... 23

5.3.2 EtherCAT ......................................................................................................................... 24

5.3.3 Supply voltages ............................................................................................................... 26

5.4 UL Requirements.............................................................................................................................28

5.5 ATEX notes .....................................................................................................................................29

5.5.1 ATEX - Special conditions ............................................................................................... 29

5.5.2 BG2000 - EtherCAT Box protection enclosures .............................................................. 30

5.5.3 ATEX Documentation ...................................................................................................... 31

6 Commissioning........................................................................................................................................32

6.1 Integration in TwinCAT ....................................................................................................................32

7 Appendix ..................................................................................................................................................33

7.1 General operating conditions...........................................................................................................33

7.2 Accessories .....................................................................................................................................34

7.3 Version identification of EtherCAT devices .....................................................................................35

7.3.1 Beckhoff Identification Code (BIC)................................................................................... 39

7.4 Support and Service ........................................................................................................................41

EP1122-0001 3Version: 1.2

Table of contents

EP1122-00014 Version: 1.2

Foreword

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®, 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

© 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.

EP1122-0001 5Version: 1.2

Foreword

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 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.

EP1122-00016 Version: 1.2

Foreword

1.3 Documentation Issue Status

Version Comment

1.2 • First publication in PDF format

1.1 • Foreword updated

• Mounting and 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 Firmware Hardware

1.2 02 05

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

Further information on this topic: Version identification of EtherCAT devices [}35].

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

EP1122-0001 7Version: 1.2

EtherCAT Box - Introduction

2 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, field­configurable connectors and cables are available for maximum flexibility. Depending on the application, the
sensors and actuators are connected through M8 or M12connectors.

The EtherCAT modules cover the typical range of requirements for I/O signals with protection class IP67:

• digital inputs with different filters (3.0ms or 10μs)

• digital outputs with 0.5 or 2A output current

• analog inputs and outputs with 16bit resolution

• Thermocouple and RTD inputs

• Stepper motor modules

XFC (eXtreme Fast Control Technology) modules, including inputs with time stamp, are also available.

EP1122-00018 Version: 1.2

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

EtherCAT Box - Introduction

Fig.3: EtherCAT Box with M12 connections for sensors/actuators

Basic EtherCAT documentation

You will find a detailed description of the EtherCAT system in the Basic System Documentation for
EtherCAT, which is available for download from our website (www.beckhoff.com) under Downloads.

EtherCAT XML Device Description

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.

EP1122-0001 9Version: 1.2

Product overview

3 Product overview

3.1 Introduction

EP1122-0001 | 2-port EtherCAT junction

The 2-port EtherCAT junction enables configuration of EtherCAT star topologies. A modular EtherCAT star
can be realised by using several EP1122 units in a station.

Individual devices or complete EtherCAT strands can be connected at the junction ports. The EtherCAT
junctions are connected via shielded M8 screw connectors with direct display of link and activity status. The
Run LED indicates the status of the EP1122. Through TwinCAT and other suitable EtherCAT masters the
EP1122 also supports coupling and uncoupling of EtherCAT strands during operation (Hot Connect).

Quick links

Technical data [}11]
Connections [}23]

EP1122-000110 Version: 1.2

Product overview

3.2 Technical data

All values are typical values over the entire temperature range, unless stated otherwise.

Technical data EP1122-0001

EtherCAT

Connection 4xM8 socket, 4-pin

(1 input, 3 outputs)
Data transfer medium EtherCAT cables
Cable length up to 100m between two devices (100BASE-TX)
Baud rate 100Mbaud

Supply voltages

Connection Input: 1 x M8 plug, 4-pin, black

Downstream connection: 1 x M8 socket, 4-pin, black
Control voltage U
Nominal voltage 24VDC (-15%/ +20%)
Sum current max. 4A
Current consumption from U
Peripheral voltage U
Nominal voltage 24VDC (-15%/ +20%)
Sum current max. 4A
Current consumption from U

Environmental conditions

Ambient temperature during operation -25…+60°C

Ambient temperature during storage -40…+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
Protection class IP65, IP66, IP67 conforms to EN60529

Mechanics

Dimensions approx. 126x 30x 26.5mm (without connectors)
Weight approx. 165g
Installation position variable

Approvals and conformity

Approvals CE, cURus, ATEX

S

1)

S

P

P

120mA

1)

None. UP is only forwarded.

-25…+55°C according to cURus [}28]

0…+55°C according to ATEX [}29]

see also Additional checks [}11].

1)

This value corresponds to the current carrying capacity of the connections for the supply voltages.

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

EP1122-0001 11Version: 1.2

Product overview

3.3 Scope of supply

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

• 1x EP1122-0001 EtherCAT Box

• 4x 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.

EP1122-000112 Version: 1.2

Basic function principles of EtherCAT junctions

4 Basic function principles of EtherCAT junctions

Some Beckhoff EtherCAT devices can be used for junctions in the EtherCAT segment. These include
EK1122, EK1521, EP1122, CU1128 and EP9128. In the following examples only the EK1122 is used. The
technical and system characteristics of the other devices are similar.

EtherCAT handling in the slaves

With EtherCAT as fieldbus protocol a wide range of bus topologies can be used: line, star and tree topology,
with redundancy support even ring topology. The simplest topology is the line topology, in which each
EtherCAT slave passes data only to the next slave.

Fig.4: EtherCAT line topology

When using EtherCAT Couplers, e.g. EK1100, it is possible to create a junction and therefore a kind of tree
topology.

Fig.5: Line topology with extensions

The basic principle is that internally the Ethernet frame(s) with the EtherCAT protocol data continue to be
transported in a logical ring:

• the EtherCAT master sends the frame via the two outgoing lines of the Ethernet cable

• this frame passes each slave once,

• the last logical slave reverses the frame and

• is returned to the master through each EtherCAT slave via two return lines of the Ethernet cable
without further processing.

EP1122-0001 13Version: 1.2

Basic function principles of EtherCAT junctions

At short cycle times in the order of 50 µs at 20,000 Ethernet frames are in transit in the EtherCAT system
every second, plus acyclic organizational frames. The master awaits the return of the sent frames, which
return the device input data to the master, for example. Telegram transfer between slaves is link-based: An
EtherCAT slave will only forward a frame if a 'link' signal to the next device is present. Normally it can be
assumed that the downstream device correctly processes each EtherCAT telegram and returns or process it
at the end.

The crucial factor for forwarding EtherCAT telegrams is that a link signal is reported only from one slave to
the next if both slaves are actually ready for real-time participation in data processing. Specifically, this
means that an EtherCAT slave should not open the respective Ethernet port until it is ready to receive and
forward an Ethernet frame immediately.

A switch or router is usually used for standard Ethernet traffic forwarding. Any collisions or frame losses are
compensated through frame repetition in the higher-level protocol layers (e.g. TCP). This mode is generally
not used for EtherCAT due to the short cycle times and the real-time requirement. Some Ethernet devices
such as special switches, for example, report a link to the remote terminal even if they will only be ready for
data processing in a few milliseconds. This behavior is particularly noticeable in media converters from
100Base-TX (copper) to 100Base-Fx (optical fiber), which may report a link to the preceding EtherCAT slave
even if the optical fiber connection is interrupted, depending on the setting on the copper side.

Fast link detection is therefore a central component of each ESC (EtherCAT Slave Controller, hardware
processing unit for the EtherCAT protocol). According to the EtherCAT specification an ESC can have and
control 1 to 4 ports. Via an open port it can handle outgoing and incoming Ethernet traffic. Fig. 3 shows the
direction of the data flow in a fully configured ESC. In the EtherCAT datagrams the data are only processed
between ports 0 (A) and 3 (D) in the EtherCAT processing unit.

Fig.6: Direction of data flow in the ESC

EP1122-000114 Version: 1.2

Basic function principles of EtherCAT junctions

Ideally link detection and therefore port handling in the ESC should be fast enough that lost frame events are
avoided even at 100 µs cycle time. Nevertheless, at least one lost frame can never be ruled out if a
connection is disconnected while an Ethernet frame is in transit on this line and in the bus segment
downstream of the separation point.

Implementation: EL terminal

A standard EtherCAT slave such as a Beckhoff EL terminal has 2 ports:

• one for incoming frames (port 0 [A])

• one for outgoing frames (e.g. port [D]).

The other two ports are internally closed in the ESC. An EtherCAT telegram enters the processing unit via
port 0 (A)/top and is forwarded to the next slave via port 3 (D)/left, if a link to this port exists - see green
arrows. This is the case if a further EL terminal is connected to the right.

If no link exists, the frame is forwarded to port 1(B) via the purple route. This and port 2 (C) have no link and
therefore return the frame to port 0 (A), where the frame leaves via the same Ethernet port through which it
arrived at the slave. This is the case if the terminal acts as end terminal.

An EtherCAT device with a single port is therefore only of limited use, since it can only be used as end
device.

Implementation: EK1100 EtherCAT Coupler

Three of the four available ports in the EK1100 EtherCAT Coupler are used, thus enabling a connection to
the right to terminals and via an RJ45 socket to further couplers; cf. Fig. Line topology with extensions. In the
EK1100 the processing unit is not used for process data exchange.

Implementation: EK1122 EtherCAT junction

In the EK1122 all four ESC ports can be connected. two via the internal E-Bus and two via the RJ45 sockets
with Ethernet configuration. In the TwinCAT System Manager the link statuses of ports 0, 1, 2 and 3 are
indicated via the online display as port A, B, C and D, see Fig. Topology display for interrupted line.

Implementation: EK1521/EK1521-0010/EK1561 EtherCAT junction

As in the EK1100, three ESC ports can be connected in these junctions. Two via E-bus within the terminal
and one via the SC socket/versatile link and optical fiber cable/POF line.

Implementation: CU1128 and EP9128 EtherCAT junctions

The CU1128 integrates three ESCs, which means eight ports in total are available to users. The three ESCs
are interconnected via E-bus.

Example configuration with EK1122

The following section describes the link characteristics under TwinCAT and its representation in the System
Manager.

EP1122-0001 15Version: 1.2

Basic function principles of EtherCAT junctions

Fig.7: Example configuration with EK1122

The wiring diagram is shown in the TwinCAT online topology, see Fig. Online topology. The EK1122 is
selected, so that further information is shown. The green bars above the slaves indicate the correct RUN
state in all slaves.

EP1122-000116 Version: 1.2

Basic function principles of EtherCAT junctions

Fig.8: Online topology

An error is now generated by disconnecting the link between the upper RJ45 socket (X1) and the EL3102
device. Within a few µs the ESC in the EK1122 detects the lost link and automatically closes the affected
port. This has the effect that the next incoming EtherCAT telegram is immediately forwarded to port D (port

3) and the EL4732. The link is missing here; the System Manager indicates this in the online display, see
Fig. Example configuration with interrupted cable.

EP1122-0001 17Version: 1.2

Basic function principles of EtherCAT junctions

Fig.9: Example configuration with interrupted cable

The System Manager messages can be interpreted as follows:

• Address 1002 - EK1122: "OP LNK:MIS D": The slave is in OP state, although a link is missing at port D
(3) that should be present according to the configuration

• Address 1003 - EK1100: "INIT NO_COMM": since communication with this slave is interrupted its state
is shown as INIT

• Address 1004 - EL3104: ditto.

Logger output

The logger output can be displayed in the lower part of the System Manager (Display--> Show Log­ger Output). This may be helpful for diagnostic purposes (for link interruptions and other situations).

In the topology view this interruption is indicated by a red border around the affected slaves, see figure
below.

EP1122-000118 Version: 1.2

Basic function principles of EtherCAT junctions

Fig.10: Topology view with interrupted line

Note the display of the acyclic frames in Fig. Example configuration with EK1122 and Fig. Example
configuration with interrupted line.

Fig.11: Comparison of the frame displays

The image on the left shows a small number (2) of acyclic frames sent by the master during the respective
second - all slaves are operating properly. The image on the right shows a significant increase (currently 77
acyclic frames/sec): The EtherCAT master has quickly detected that not all slaves are properly taking part in
the data exchange. Once the master has located the fault, it continuously tries to restore the connection.

EP1122-0001 19Version: 1.2

Basic function principles of EtherCAT junctions

Reconnection

Once the connection has been restored, the EK1122 reports to the master that a link is present again at port
D (3). The EtherCAT master will then make its process data available again for this section. One the
preparations are complete, it will instruct the EK1122 to re-open port D (3) for regular data exchange. Cyclic
and acyclic data traffic with the other EtherCAT slaves continues normally.

External access to EtherCAT diagnostics

The system offers a wide range of options for accessing status and diagnostic information and
EtherCAT master functions from the PLC. Almost all information displayed by the System Manager
online can also be retrieved via ADS (see figures on this page). System Manager functions can also
be triggered via PLC or ADS. Please refer to the relevant sections in the Beckhoff Information Sys­tem and the notes on EtherCAT diagnostics.

EP1122-000120 Version: 1.2

5 Mounting and connection

119

126

23

3026.5

13.5

Ø 3.5

5.1 Dimensions

Mounting and connection

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
Installation 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 (without connectors)

EP1122-0001 21Version: 1.2

Mounting and connection

5.2 Fixing

NOTE

Dirt during assembly

Dirty connectors can lead to malfunctions. Protection class IP67 can only be guaranteed if all cables and
connectors are connected.

• Protect the plug connectors against dirt during the assembly.

Mount the module with two M3 screws on the fastening holes in the corners of the module. The fastening
holes have no thread.

EP1122-000122 Version: 1.2

5.3 Connection

Port A Port C

Port D

Port B

X40

X41

X1

X2

X60 X61

5.3.1 Overview

Mounting and connection

Name Function Connector Tightening

torque

X1

X2

X40

X41

X60

X61

1)

Mount connectors on these plug connectors using a torque wrench, e.g. ZB8801 from Beckhoff.

EtherCAT junction [}24], Port D

EtherCAT junction [}24], Port B

EtherCAT input [}24], Port A

EtherCAT downstream connection [}24], Port C

Supply voltage input [}26]

Supply voltage downstream connection [}26]

M8 socket 0.4Nm

M8 socket 0.4Nm

M8 socket 0.4Nm

M8 socket 0.4Nm

M8 plug connector 0.4Nm

M8 socket 0.4Nm

1)

1)

1)

1)

1)

1)

EP1122-0001 23Version: 1.2

Mounting and connection

3 1

24

5.3.2 EtherCAT

5.3.2.1 Connectors

NOTE

Risk of confusion: supply voltages and EtherCAT

Defect possible through incorrect insertion.

• Observe the color coding of the connectors:
black: Supply voltages
green: EtherCAT

The EtherCAT connections are implemented as green M8 sockets.

Fig.12: EtherCAT connector

EtherCAT M8

Signal Contact ZB9010, ZB9020, ZB9030, ZB9032,

Tx + 1 yellow

Tx - 4 orange

Rx + 2 white

Rx - 3 blue

Shield Housing Shield Shield Shield

1)

Core colors according to EN61918

connector

Core colors

ZK1090-6292,
ZK1090-3xxx-xxxx

1)

1)

1)

1)

ZB9031 and old versions of
ZB9030, ZB9032, ZK1090-3xxx­xxxx

orange/white white/orange

orange orange

blue/white white/green

blue green

TIA-568B

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

For standardization, the core colors of the ZB9030, ZB9032 and ZK1090-3xxx-xxxx cables have
been changed to the EN61918 core colors: 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.

EP1122-000124 Version: 1.2

Mounting and connection

5.3.2.2 Status LEDs

L/A (Link/Act)

A green LED labelled "L/A" is located next to each EtherCAT socket. The LED indicates the communication
state of the respective socket:

LED Meaning

off no connection to the connected EtherCAT device
lit LINK: connection to the connected EtherCAT device
flashes ACT: communication with the connected EtherCAT device

Run

Each EtherCAT slave has a green LED labelled "Run". The LED signals the status of the slave in the
EtherCAT network:

LED Meaning

off Slave is in "Init" state
flashes uniformly Slave is in "Pre-Operational“ state
flashes sporadically Slave is in "Safe-Operational" state
lit Slave is in "Operational" state

Description of the EtherCAT slave states

5.3.2.3 Cables

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

EP1122-0001 25Version: 1.2

Mounting and connection

Plug

Input

Socket

Forwarding

3 1

24

3 1

24

5.3.3 Supply voltages

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

• Control voltage U

• Peripheral voltage U

S

P

Redirection of the supply voltages

The IN and OUT power connections are bridged in the module (not IP204x-Bxxx and IE204x). The supply
voltages US and UP 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 US and UP, the maximum permissible current for
M8 connectors of 4A must not be exceeded!

5.3.3.1 Connectors

NOTE

Risk of confusion: supply voltages and EtherCAT

Defect possible through incorrect insertion.

• Observe the color coding of the connectors:
black: Supply voltages
green: EtherCAT

Fig.13: Connectors for supply voltages

Fig.14: M8 connector

Contact Function Description Core color

1 U
2 U
3 GND
4 GND

1)

The core colors apply to cables of the type: Beckhoff ZK2020-3xxx-xxxx

S

P

S

P

Control voltage Brown
Peripheral voltage White
GND to U
GND to U

S

P

Blue
Black

1)

EP1122-000126 Version: 1.2

Mounting and connection

Vert. Faktor: 0,45 cm / V

5 10 15 20

2

4

6

8

10

250

0

12

30

Vert. Faktor: 0,45 cm / V

Voltage drop (V)

Cable length (m)

35

0,25 mm²

0,34 mm²

0,5 mm²
0,75 mm²

I = 2 A

Vert. Faktor: 0,45 cm / V

5 10 15 20

2

4

6

8

10

250

0

12

30

Vert. Faktor: 0,45 cm / V

Voltage drop (V)

Cable length (m)

35

0,25 mm²

0,34 mm²

0,5 mm²

0,75 mm²

I = 4 A

5.3.3.2 Status LEDs

Fig.15: Status LEDs for the supply voltages

LED Display Meaning

US (control voltage) off Supply voltage US is not present

green illuminated Supply voltage US is present

UP (peripheral voltage) off Supply voltage UP is not present

green illuminated Supply voltage UP is present

5.3.3.3 Conductor losses

Take into account the voltage drop on the supply line when planning a system. Avoid the voltage drop being
so high that the supply voltage at the box lies below the minimum nominal voltage.

Variations in the voltage of the power supply unit must also be taken into account.

Voltage drop on the supply line

EP1122-0001 27Version: 1.2

Mounting and connection

5.4 UL Requirements

The installation of the EtherCAT Box Modules certified by UL has to meet the following requirements.

Supply voltage

CAUTION

CAUTION!

This UL requirements are valid for all supply voltages of all marked EtherCAT Box Modules!
For the compliance of the UL requirements the EtherCAT Box Modules should only be supplied

• by a 24 VDC supply voltage, supplied by an isolating source and protected by means of a fuse (in accor­dance with UL248), rated maximum 4 Amp, or

• by a 24 VDC power source, that has to satisfy NEC class 2.
A NEC class 2 power supply shall not be connected in series or parallel with another (class 2) power
source!

CAUTION

CAUTION!

To meet the UL requirements, the EtherCAT Box Modules must not be connected to unlimited power
sources!

Networks

CAUTION

CAUTION!

To meet the UL requirements, EtherCAT Box Modules must not be connected to telecommunication net­works!

Ambient temperature range

CAUTION

CAUTION!

To meet the UL requirements, EtherCAT Box Modules has to be operated only at an ambient temperature
range of 0 to 55°C!

Marking for UL

All EtherCAT Box Modules certified by UL (Underwriters Laboratories) are marked with the following label.

Fig.16: UL label

EP1122-000128 Version: 1.2

Mounting and connection

5.5 ATEX notes

5.5.1 ATEX - Special conditions

WARNING

Observe the special conditions for the intended use of EtherCAT Box modules in poten­tially explosive areas – directive 94/9/EU.

• The certified components are to be installed with a BG2000-0000 or BG2000-0010 protection enclosure
[}30] that guarantees a protection against mechanical hazards!

• If the temperatures during rated operation are higher than 70°C at the feed-in points of cables, lines or
pipes, or higher than 80°C at the wire branching points, then cables must be selected whose tempera­ture data correspond to the actual measured temperature values!

• Observe the permissible ambient temperature range of 0 to 55°C for the use of EtherCAT Box modules
in potentially explosive areas!

• Measures must be taken to protect against the rated operating voltage being exceeded by more than
40% due to short-term interference voltages!

• The connections of the certified components may only be connected or disconnected if the supply volt­age has been switched off or if a non-explosive atmosphere is ensured!

Standards

The fundamental health and safety requirements are fulfilled by compliance with the following standards:

• EN 60079-0: 2006

• EN 60079-15: 2005

Marking

The EtherCAT Box modules certified for potentially explosive areas bear the following marking:

II 3 GEx nA II T4DEKRA 11ATEX0080 XTa: 0 - 55°C

or

II 3 GEx nA nC IIC T4DEKRA 11ATEX0080 XTa: 0 - 55°C

Batch number (D number)

The EtherCAT Box modules bear a batch number (D number) that is structured as follows:

D: WW YY FF HH

WW - week of production (calendar week)
YY - year of production
FF - firmware version
HH - hardware version

Example with batch number 29 10 02 01:

29 - week of production 29
10 - year of production 2010
02 - firmware version 02
01 - hardware version 01

EP1122-0001 29Version: 1.2

Mounting and connection

5.5.2 BG2000 - EtherCAT Box protection enclosures

WARNING

Risk of electric shock and damage of device!

Bring the EtherCAT system into a safe, powered down state before starting installation, disassembly or
wiring of the modules!

ATEX

WARNING

Mount a protection enclosure!

To fulfill the special conditions according to ATEX [}29], a BG2000-0000 or BG2000-0010 protection enclo­sure has to be mounted over the EtherCAT Box.

Installation

Put the cables for EtherCAT, power supply and sensors/actuators through the hole of the protection
enclosure.

Fig.17: BG2000 - putting the cables

Fix the wires for EtherCAT, power supply and sensors/actuators to the EtherCAT Box.

EP1122-000130 Version: 1.2

Fig.18: BG2000 - fixing the cables

Mount the protection enclosure over the EtherCAT Box.

Mounting and connection

Fig.19: BG2000 - mounting the protection enclosure

5.5.3 ATEX Documentation

Notes about operation of EtherCAT Box Modules (EPxxxx-xxxx) in potentially explo­sive areas (ATEX)

Pay also attention to the continuative documentationNotes about operation of EtherCAT Box Mod­ules (EPxxxx-xxxx) in potentially explosive areas (ATEX) that is available in the download area of
the Beckhoff homepage http:\\www.beckhoff.com!

EP1122-0001 31Version: 1.2

Commissioning

6 Commissioning

6.1 Integration in TwinCAT

The procedure for integration in TwinCAT is described in this Quick start guide.

EP1122-000132 Version: 1.2

Appendix

7 Appendix

7.1 General operating conditions

Protection degrees (IP-Code)

The standard IEC 60529 (DIN EN 60529) defines the degrees of protection in different classes.

1. Number: dust protection and
touch guard

0 Non-protected

1 Protected against access to hazardous parts with the back of a hand. Protected against solid

2 Protected against access to hazardous parts with a finger. Protected against solid foreign ob-

3 Protected against access to hazardous parts with a tool. Protected against solid foreign objects

4 Protected against access to hazardous parts with a wire. Protected against solid foreign objects

5 Protected against access to hazardous parts with a wire. Dust-protected. Intrusion of dust is not

6 Protected against access to hazardous parts with a wire. Dust-tight. No intrusion of dust.

Definition

foreign objects of Ø50mm

jects of Ø12.5mm.

Ø2.5mm.

Ø1mm.

totally prevented, but dust shall not penetrate in a quantity to interfere with satisfactory operation
of the device or to impair safety.

2. Number: water* protection Definition

0 Non-protected

1 Protected against water drops

2 Protected against water drops when enclosure tilted up to 15°.

3 Protected against spraying water. Water sprayed at an angle up to 60° on either side of the ver-

4 Protected against splashing water. Water splashed against the disclosure from any direction

5 Protected against water jets

6 Protected against powerful water jets

7 Protected against the effects of temporary immersion in water. Intrusion of water in quantities

tical shall have no harmful effects.

shall have no harmful effects

causing harmful effects shall not be possible when the enclosure is temporarily immersed in wa­ter for 30min. in 1m depth.

*) These protection classes define only protection against water!

Chemical Resistance

The Resistance relates to the Housing of the IP 67 modules and the used metal parts. In the table below you
will find some typical resistance.

Character Resistance

Steam at temperatures >100°C: not resistant

Sodium base liquor
(ph-Value > 12)

Acetic acid not resistant

Argon (technical clean) resistant

at room temperature: resistant
> 40°C: not resistant

Key

• resistant: Lifetime several months

• non inherently resistant: Lifetime several weeks

• not resistant: Lifetime several hours resp. early decomposition

EP1122-0001 33Version: 1.2

Appendix

7.2 Accessories

Mounting

Ordering information Description

ZS5300-0001 Mounting rail (500mmx129mm)

Labeling material, protective caps

Ordering information Description

ZS5000-0010 Protective cap for M8 sockets, IP67 (50 pieces)
ZS5100-0000 Inscription labels, unprinted, 4 strips of 10
ZS5000-xxxx Printed inscription labels on enquiry

Cables

Ordering information Description

ZK1090-3xxx-xxxx

ZK1093-3xxx-xxxx

ZK2020-3xxx-xxxx

EtherCAT cable M8, green link to the website

EtherCAT cable M8, yellow link to the website

Power cable M8, 4-pin link to the website

A complete overview of pre-assembled cables for EtherCAT Box modules can be found here.

Tools

Ordering information Description

ZB8801-0000 Torque wrench for plugs, 0.4…1.0Nm
ZB8801-0001 Torque cable key for M8/ wrench size 9 for ZB8801-0000

Further accessories

Further accessories can be found in the price list for fieldbus components from Beckhoff and online
at https://www.beckhoff.com.

EP1122-000134 Version: 1.2

Appendix

7.3 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

3314 (4-channel thermocouple
terminal)

3602 (2-channel voltage
measurement)

0000 (basic type) 0016

0010 (high­precision version)

0017

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)

• 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: KKYYFFHH

KK - week of production (CW, calendar week)
YY - year of production
FF - firmware version
HH - hardware version

EP1122-0001 35Version: 1.2

Appendix

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

Examples of markings

Fig.20: EL5021 EL terminal, standard IP20 IO device with serial/ batch number and revision ID (since
2014/01)

EP1122-000136 Version: 1.2

Fig.21: EK1100 EtherCAT coupler, standard IP20 IO device with serial/ batch number

Appendix

Fig.22: CU2016 switch with serial/ batch number

Fig.23: EL3202-0020 with serial/ batch number 26131006 and unique ID-number 204418

EP1122-0001 37Version: 1.2

Appendix

Fig.24: EP1258-00001 IP67 EtherCAT Box with batch number/ date code 22090101 and unique serial
number 158102

Fig.25: EP1908-0002 IP67 EtherCAT Safety Box with batch number/ date code 071201FF and unique serial
number 00346070

Fig.26: EL2904 IP20 safety terminal with batch number/ date code 50110302 and unique serial number
00331701

Fig.27: ELM3604-0002 terminal with unique ID number (QR code) 100001051 and serial/ batch number
44160201

EP1122-000138 Version: 1.2

Appendix

7.3.1 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.28: 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
(ANSIMH10.8.2-2016). 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:

EP1122-0001 39Version: 1.2

Appendix

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.

EP1122-000140 Version: 1.2

Appendix

7.4 Support and Service

Beckhoff and their partners around the world offer comprehensive support and service, making available fast
and competent assistance with all questions related to Beckhoff products and system solutions.

Beckhoff's branch offices and representatives

Please contact your Beckhoff branch office or representative for local support and service on Beckhoff
products!

The addresses of Beckhoff's branch offices and representatives round the world can be found on her internet
pages:

http://www.beckhoff.com

You will also find further documentation for Beckhoff components there.

Beckhoff Headquarters

Beckhoff Automation GmbH & Co. KG

Huelshorstweg 20
33415 Verl
Germany

Phone: [phone]
Fax: [phone]
e-mail: [e-mail]

Beckhoff Support

Support offers you comprehensive technical assistance, helping you not only with the application of
individual Beckhoff products, but also with other, wide-ranging services:

• support

• design, programming and commissioning of complex automation systems

• and extensive training program for Beckhoff system components

Hotline: [phone]
Fax: [phone]
e-mail: [e-mail]

Beckhoff Service

The Beckhoff Service Center supports you in all matters of after-sales service:

• on-site service

• repair service

• spare parts service

• hotline service

Hotline: [phone]
Fax: [phone]
e-mail: [e-mail]

EP1122-0001 41Version: 1.2

More Information:

www.beckhoff.com/ep1122-0001

Beckhoff Automation GmbH & Co. KG
Hülshorstweg 20
33415 Verl
Germany
Phone: [phone]
[e-mail]
www.beckhoff.com