BECKHOFF EK110x/EK15xx series EtherCAT bus coupler

BECKHOFF EK110x/EK15xx series EtherCAT bus coupler

The official technical manual for the full range of EtherCAT bus couplers EK110x and EK15xx, version V4.4, is aimed at automation field engineers, operations and debugging personnel. It provides a complete introduction to product classification, hardware parameters, communication principles, installation and wiring, wiring specifications, fiber optic applications, fault diagnosis, firmware upgrades, compliance certification, and after-sales service. The core function of this series of couplers is to interconnect the upper layer EtherCAT network with the EL/ES series E-bus terminal module, which is the core infrastructure of the EtherCAT bus system.

Full range product classification and core parameters

Divided into four product lines based on interface types, they are suitable for copper cables, M8 industrial connectors, glass fiber optics, and plastic fiber optics (POF) scenarios. The entire range is IP20 protected, DIN rail mounted, and supports EtherCAT Device Protocol.

2.1 Copper cable RJ45 interface series (EK1100/EK1101 sub models)

1. EK1100

Basic coupling, no ID dialing, no HotConnect function;

Interface: Dual RJ45100BASE-TX;

Cable distance: maximum 100m between devices;

E-bus power supply: 5V/maximum 2A (reduced to 1A when>55 ℃);

Power consumption, size, and weight are the basic specifications of the series.

2. EK1101

Standard configuration includes three hexadecimal ID dialing codes (0~4095), supports standard HotConnect, and can dynamically add I/O groups to the bus topology.

EK1101-0010: Long distance version, maximum 300m between dual devices (Cat5 four wire copper cable), with ordinary device interconnection still at 100m;

EK1101-0080: Fast HotConnect, with a topology switching startup time of less than 1 second, suitable for frequent model changes and quick change scenarios of robotic arms/tools, only compatible with FHC devices of the same specifications.

2.2 M8 Interface Series (EK1100-0008/EK1101-0008)

Adopting industrial M8 threaded joints, it is suitable for small bus boxes and compact equipment on site, with stronger anti vibration ability:

EK1100-0008: Basic version, no ID dialing code;

EK1101-0008: with ID dialing and support for HotConnect;

Communication: 100BASE-TX, maximum cable length of 100m;

The recommended tightening torque for M8 connectors is 0.4Nm, with a maximum not exceeding 0.5Nm.

2.3 Glass Fiber Optic Series (EK1501/EK1501-0010)

Using 100BASE-FX fiber optic transmission, completely avoiding electromagnetic interference, adapting to strong interference and long-distance scenarios, all with ID dialing and HotConnect:

EK1501: Multimode fiber (50/125 μ m, 62.5/125 μ m), SC duplex interface, maximum transmission distance of 2km, emission wavelength of 1300nm;

EK1501-0010: Single mode fiber (9/125 μ m), SC interface, maximum transmission distance of 20km;

Optical power: Distinguish between input and output optical thresholds for versions before and after 2022, and the total attenuation of the link must not exceed the overall optical budget of the machine.

2.4 Plastic Optical Fiber POF Series (EK1541)

Using polymer fiber optic, easy wiring, good bending performance, with ID dialing and HotConnect:

Interface: Versatile Link duplex POF connector;

Wavelength 650nm, Class 1 laser grade;

The maximum transmission distance is 50m, and for every additional joint, the distance is reduced by approximately 6.5m;

Suitable for wiring inside equipment and short distance cabinets.

2.5 General electrical parameters for the entire series

Power supply: standard 24V DC, supporting -15%~+20% voltage fluctuation;

Power supply zoning:

Us: coupler body+E-bus bus bus power supply;

Up: External sensor/actuator power contact, maximum 10A, equipped with 10A slow melting fuse;

Electrical isolation: 500V isolation between power supply, EtherCAT, E-bus;

Working temperature: -25 ℃~+60 ℃, storage -40 ℃~+85 ℃;

Humidity: ≤ 95%, no condensation;

Mechanical: Complies with EN vibration and impact standards, supports enhanced mechanical load installation solutions.

Basic Principles of Communication

3.1 EtherCAT ports and data flow direction

The coupler is equipped with an EtherCAT slave controller (ESC) and features a standard 3-port architecture

Port0: upper EtherCAT entrance;

Port2: Lower EtherCAT export;

Internal port docking with E-bus terminal chain;

Serial forwarding of data, with a typical forwarding delay of 1 μ s, hardware forwarding without protocol parsing to ensure real-time performance.

3.2 EtherCAT State Machine (ESM)

All slave stations follow a five state mechanism, and the state is uniformly controlled by the master station:

Initialize: No communication, the main station initializes the email channel;

Pre op: only email communication, configuring process data FMMU；

Safe op: The process data transmission and reception are normal, and the output is locked in a safe state;

Op (Running): Fully functional and in standard working condition;

Boot: Only used for firmware/ESI updates, disable regular communication.

3.3 Distributed Clock (DC)

Partial high version firmware coupling supports DC synchronization, used for multi axis motion and high-precision synchronization scenarios; The local machine can be set as the reference clock in TwinCAT, and all slave clocks can be synchronized. Whether the device supports DC can be determined by the hardware/firmware version.

3.4 CoE Function

This series of couplers does not have a CoE interface, and the relevant configuration needs to be completed based on the EtherCAT standard protocol.

Installation, wiring and cabling specifications

4.1 DIN rail installation

Compatible with standard TS35/7.5 and TS35/15 rails;

Installation sequence: Install the coupler first, then splice the terminals in sequence. The shell should be seamlessly fitted to ensure good contact between the spring pieces;

Disassembly: Pull the orange unlocking buckle to remove the single ended terminal, and violent disassembly is prohibited;

Enhanced seismic installation: Fixed components are installed at both ends of the guide rail, with a limit on the number of single segment terminals (up to 64 for 12mm terminals and up to 32 for 24mm terminals). The distance between the guide rail fixing points is 5cm.

4.2 Installation posture and heat dissipation

Priority horizontal installation, with sufficient ventilation space reserved above and below;

Prohibit covering the heat dissipation area, and increase the gap between high-power terminals;

Install no more than 2 passive EtherCAT terminals (without E-bus current consumption) continuously, otherwise it will affect signal quality.

4.3 Wiring specifications

Wiring prerequisite: Power off operation must be carried out, following SELV/PELV safety ultra-low voltage specifications;

Terminal type: The entire series adopts spring type terminal blocks, which do not require tool crimping (HD high-density terminals can be directly inserted);

Wire diameter and stripping length:

Conventional terminal: 0.08-2.5mm ² wire, stripped 8-10mm;

HD high-density terminal: maximum wire diameter of 1.5mm;

Grounding requirements: PE protection ground should be given priority contact, and the PE line should be disconnected during insulation testing.

4.4 Copper Cable Wiring (RJ45/M8)

Cable grade: Minimum Cat5 Ethernet cable, only using 1/2/3/6 quad core transmission signals;

Support direct/cross network cable, automatic device recognition;

The link length strictly follows the limits of each model;

E-bus current planning: TwinCAT can view the current of each terminal. When the total current exceeds the load of the coupler, EL9410 and other feeding terminals must be installed.

4.5 Fiber Optic Cabling Special Project (Glass Fiber Optic+POF)

1. General optical parameters

Link loss=fiber loss+connector loss+fusion loss; The total loss must be less than the equipment's optical budget, and it is recommended to reserve a margin of more than 3dB.

The bending radius of the optical fiber strictly follows the specifications and is prohibited from being bent hard;

Idle interfaces must be equipped with dust caps to prevent dirt and scratches on the end faces.

2. Glass fiber optic (EK1501/1501-0010)

Multi mode: suitable for medium to short distances, single mode focuses on ultra long 20km transmission;

The connector is SC duplex, distinguishing Tx/Rx transmission and reception, and direct transmission and reception are strictly prohibited.

3. PO plastic optical fiber (EK1541)

Supporting ZS1090-0008 connector kit, including grinding/polishing consumables;

Cable assembly steps: wire stripping → crimping joints → rough grinding → fine polishing;

Polishing should be done in an "8-shaped" pattern to ensure a smooth end face and improve transmission performance.

4.6 Power Supply and Potential Grouping

The two power supplies are independent of each other: Us supplies the coupler and E-bus, and Up supplies the on-site actuator;

The maximum continuous current of the power contact is 10A, equipped with a slow melting fuse;

The 0V and PE of the entire terminal are kept at equal potential to avoid interference caused by potential differences.

Indicator light diagnosis

The entire series adopts multiple sets of LEDs, including power lights, EtherCAT chain street lights, operation status lights, and E-bus lights. The layout of different sub models' light positions may vary slightly, but the state definitions are unified:

Us/Up (green): Always on=corresponding to normal 24V power supply, off=no voltage;

RUN (running light):

Extinguish: Initialize Init;

Flashing: Pre op pre run;

Single flash: Safe op safe operation;

Always on: Op is running normally;

Flash: Boot upgrade mode;

LINK/ACT (X1 inlet/X2 outlet):

Extinguish: No link;

Always on: Link established, no data;

Flashing: normal data transmission and reception;

E-bus light: Indicates the status of internal terminal links, with the same logic as EtherCAT chain lights.

Configuration and firmware upgrade

6.1 Basic Configuration

ID dialing: EK1101/EK15xx series three digit hexadecimal dialing, set HotConnect group address, the main station can read online;

HotConnect/Fast HotConnect: Adding a heating access group to TwinCAT, FHC devices can only be docked with the same type.

6.2 Firmware/ESI Upgrade (Key)

The coupler itself has no firmware and is mainly used for upgrading EtherCAT slave stations such as EL/ES/EM, only supporting TwinCAT 3:

file type

ESI (XML): Device Description File, stored in EEPROM;

*. efw: Controller firmware;

*. rbf: FPGA communication firmware.

Preconditions for Upgrade: No packet loss or CRC errors on the bus, stable power supply, and no interruption for upgrade.

Operation process:

Switch TwinCAT to Config/FreeRun mode;

Switch the slave station to Boot state and load the corresponding upgrade file;

Upgrade completed, power off and restart, online version verification.

Batch upgrade: Multiple devices with the same firmware version can be synchronously upgraded.

6.3 Data Security Instructions

The device contains volatile/non-volatile storage, and confidential data is recommended to be scrapped to avoid data recovery and leakage.

Maintenance, scrapping, and after-sales service

Daily maintenance: Regularly check joint fastening, cable aging, and heat dissipation and ventilation; Regularly clean the fiber optic end face.

Scrap disposal: Recycle according to local electronic waste regulations and prohibit indiscriminate disposal.

Laser safety (POF/fiber optic version): Class 1 laser, prohibit direct viewing of the beam, aiming at the human body, and prohibit unauthorized disassembly of the optical module.

Technical support: Beifu headquarters and global branches provide technical consultation, on-site service, maintenance, and spare parts. The manual includes official contact information, official website, and download address.

Quick Overview of Core Selection

Model, Interface, Type, Features, Functions, Maximum Distance, Typical Application Scenarios

EK1100 RJ45 basic model, without HotConnect 100m standard control cabinet conventional EtherCAT terminal link

EK1101 RJ45 standard HotConnect, ID dialing 100m requires dynamic topology and production line workstation switching

EK1101-0010 RJ45 long-distance transmission 300m workshop cross area long copper cable wiring

EK1101-0080 RJ45 Fast HotConnect 100m Robot and Tool Fast Switching Scene

EK1100/0008 M8 industrial small connector 100m compact fieldbus box, robotic arm

EK1501 multimode fiber anti-interference, long-distance 2km strong electromagnetic interference workshop, factory wiring

EK1501-0010 single-mode fiber optic ultra long distance transmission 20km across buildings and long-distance stations in the factory area

EK1541 POF plastic fiber optic wiring is simple and flexible, with wiring inside 50m equipment and short distance cabinets