Beckhoff EK110x/EK15xx Coupling Guide

Beckhoff EK110x/EK15xx EtherCAT Coupling Complete Guide

Overview of Product Positioning and Selection

In the Beckhoff EtherCAT terminal system, the coupler plays a central role in connecting the upper layer EtherCAT network with the local EL/ES series terminals. It converts the physical layer of Ethernet 100BASE-TX, 100BASE-FX, or POF (polymer fiber) into internal E-bus signals and is responsible for providing 5V communication power to the terminal chain. Different application scenarios - from standard copper cables, anti-interference optical fibers to low-cost plastic optical fibers, from fixed topologies to flexible production lines supporting hot connect - correspond to different types of couplers.

This article is aimed at automation system integration and on-site maintenance engineers, and provides a systematic review EK1100、EK1101、EK1101‑0010、EK1101‑0080、EK1100‑0008、EK1101‑0008、EK1501、EK1501‑0010  The technical differences, installation and wiring specifications, LED diagnosis, fiber power budget calculation, passive terminal placement rules, and explosion-proof (ATEX/IECEx/cFMus) special conditions of the nine EtherCAT couplers and EK1541. Whether you are replacing an old Woodward controller or planning an EtherCAT network for a new production line, this article can provide practical references.

Comparison and selection points of coupler models

2.1 Copper Cable RJ45 Interface Series

Model features, upper layer distance, special functions

EK1100 standard coupler, no ID switch ≤ 100m basic type, does not support Hot Connect

EK1101 with 3-digit hexadecimal ID switch (0-4095) ≤ 100m supports Hot Connect and can dynamically identify replaceable I/O groups

EK1101‑0010 Extended Distance， Support 4-wire system ≤ 300 m (both ends are Extended devices) to break through the 100 m limit of copper cables, suitable for cross workshop connections

EK1101-0080 Fast Hot Connect (FHC) ≤ 100m connection time<1 second, used for fast tool changing or modular production lines

All RJ45 type couplers provide two 100BASE-TX ports (X1 IN/X2 OUT), support auto crossing, and can use direct or crossover Ethernet cables. The maximum power supply capacity of the E-bus is 2 A (-25...+55 ℃), and if it exceeds this, it needs to be plugged into the EL9410 or other power supply input terminals.

2.2 M8 Circular Connector Series

Model Features Applicable Scenarios

EK1100-0008 standard coupler, M8 interface requires a more compact and seismic resistant connection, commonly used in vibration environments

EK1101-0008 with ID switch, M8 interface is the same as EK1101, but equipped with M8 connector

It is recommended to use ZK1090-3131 xxxx cable for M8 interface, with a tightening torque of 0.4 Nm (maximum 0.5 Nm).

2.3 Fiber Optic and POF Series

Characteristics of Maximum Distance for Model Media

EK1501 multimode fiber (50/125 or 62.5/125 μ m) 2 km anti electromagnetic interference, suitable for cross plant or harsh environments

EK1501-0010 single-mode fiber (9/125 μ m) for an ultra long distance of 20 km, needs to be used in conjunction with EK1521-0010

EK1541 POF (polymer fiber, 1 mm core diameter) can be quickly assembled on site at 50 m, with low cost and large bending radius

All fiber couplers support ID switches and Hot Connect (except for EK1100), and are equipped with built-in 1300 nm (EK1501/-0010) or 650 nm (EK1541) lasers (Class 1).

Mechanical installation and power wiring specifications

3.1 DIN rail installation

All EK11xx/EK15xx have a width of 44 mm (RJ45/M8 type) or 49 mm (fiber/POF type) and a height of 100 mm.

Install on a 35 mm guide rail (EN 60715), steps: first hang the guide rail and press it tightly until the lock buckle "clicks" into engagement.

Enhance mechanical load capacity: If there is strong vibration (5g acceleration) on site, TH35-15 guide rails should be used, with mechanical fasteners (such as grounding terminals) clamped at both ends. The total number of terminals should not exceed 64 (12mm width) or 32 (24mm width), and the distance between guide rail fixing points should be ≤ 5cm.

When disassembling, pull the orange buckle strap about 1 cm to release the buckle, and then pull out the terminal.

3.2 Power wiring and potential group

Us (system power supply): The upper spring terminals "24V" and "0V" provide power to the coupler electronic circuit and E-bus. The voltage range is 24V DC ± 20% (19.2-28.8V).

Up (power contacts): The lower three pairs of spring terminals (+/-/±) are used to provide on-site power (24V, maximum 10A) to the bus terminals and are electrically isolated from Us.

The maximum current of the E-bus is 2A, and if it exceeds the limit, EL9410 (power supply input terminal) needs to be inserted. TwinCAT System Manager will automatically calculate the total current of E-bus, and when it is negative, it will prompt the need for power supply.

Fuse: We recommend 1   A slow melting (depending on the load adjustment), Up maximum 10   A slow melting.

Electrical isolation: The withstand voltage between Us and Up is 500   V, and the PE power supply contact is capacitively coupled to the guide rail.

3.3 Special placement rules for passive terminals