Beckhoff EK110x/EK15xx Coupling Guide

7.2 POF coupler EK1541 and on-site assembly

EK1541 uses Versatile Link duplex connectors with a maximum distance of 50 meters. On site assembly steps (using ZS1090-0008 kit):

Peel off the outer layer of the POF wire by about 7mm, exposing the core wire (with a diameter of 1mm).

Insert two optical fibers into the duplex connector separately, paying attention to the Tx → Rx crossover (when the "nose" on the connector is facing up, send left and receive right? In practice, ensure that the optical channels are crossed according to Figure 56 in the manual).

Close the connector until it is securely fastened.

Use sandpaper (600 grit) and polishing pads to polish in an "8-shaped" shape, making the end face flat and smooth.

Insert the coupler socket and lock it with a click sound. Press and release the buckle during disassembly, do not pull or tug on the cable.

Blind plug: Unused fiber optic ports must be plugged into blind plugs to prevent dust and laser glare (although Class 1 lasers are safe, long-term direct viewing may still cause discomfort).

Special conditions for explosion-proof environment (ATEX/IECEx/cFMus)

Many EK couplers (such as EK1100, EK1101, EK1501) have obtained explosion-proof certification, but the following restrictions must be followed when used in Zone 2 or Class I Division 2:

The device must be installed in a casing with an IP54 rating or higher (dustproof and waterproof).

Pollution level ≤ 2 (IEC 60664-1).

Transient overvoltage shall not exceed 140% of the rated voltage (e.g. for a 24V system, transient ≤ 119 V).

Live plugging and unplugging are prohibited: terminals must be disconnected or connected, and ID switches must be adjusted only in a power-off or non explosive environment.

When the temperature at the cable inlet exceeds 70 ° C or the branch point exceeds 80 ° C, a temperature resistant cable should be selected.

When using the device modification CX2900-0107 (USB/RJ45 fixed bracket suitable for explosion-proof areas), the connector must be tied to prevent loosening.

Audio interfaces (such as N020) are not allowed to be used in explosion-proof areas.

Example of certification mark: II 3 G Ex nA IIC T4 Gc (gas) or II 3 D Ex tc IIIC T135 ° C Dc (dust). Please refer to the nameplate on the side of the product for details.

Firmware updates and ESI management (important considerations)

Although EK couplers usually do not have user upgradable firmware, when the EL/ES terminals they are connected to require firmware or FPGA updates, the following specifications must be followed to avoid damage:

Only use TwinCAT 3 (Config/FreeRun mode, no license required) and do not use third-party EtherCAT configuration tools.

Backup calibration data before updating: Some terminals (such as analog) have factory calibration parameters in their EEPROM, which will be overwritten and irrecoverable when updating ESI.

Update process:

Switch TwinCAT to Config/FreeRun with a cycle of 1ms.

Switch the target terminal to BOOTSTRAP state (via CoE or right-click menu).

Select the correct *. efw (controller firmware) or *. rbf (FPGA firmware) file.

Wait for the download to complete (power or internet disconnection is strictly prohibited).

Power on again (briefly disconnect) to activate the new firmware.

Simultaneously update multiple devices: Multiple terminals of the same model can be selected, and batch download can be performed in Boot loader mode.

Common troubleshooting table

Possible causes and solutions for the fault phenomenon

The Us LED does not light up. The 24V power supply is not connected or the fuse is blown. Measure the voltage of the power terminal, check the fuse, and confirm the polarity of the wiring

The Up LED is not lit but the Us power supply contacts are not connected or the load is short circuited. Check the wiring of the lower spring terminal; Measure Up to ground voltage

RUN LED keeps flashing (Pre OP). The main station is not configuring process data correctly or has not switched states. Scan the device in TwinCAT to check if the EtherCAT state machine is blocked

The E-bus LINK/ACT terminal has poor contact, no terminal cover plate at the end, or the E-bus is overloaded. Re plug and unplug the terminal, and confirm that EL9011 is installed at the rightmost end; Check if the total E-bus current exceeds 2A

Fiber coupler LINK/ACT eliminates fiber inversion (Tx → Tx), disconnection, and excessive attenuation when switching Tx/Rx fibers; Measure whether the light intensity at the receiving end is below the sensitivity threshold using an optical power meter

The Hot Connect group cannot recognize that the ID switch is set incorrectly or the main station has not turned on the HC check ID switch (hexadecimal 0-FFF); Configure Group ID and enable Hot Connect in TwinCAT

Fast Hot Connect port error standard device mistakenly connected to FHC port, power off, connect FHC port only to FHC device (such as EK1122-0080)

Passive terminal communication abnormality. Continuously placing more than two passive terminals. Inserting an active terminal (such as EL1004) between the passive terminals

Check the PE connection for frequent system disconnections, frame loss, EMC interference, or poor grounding; Use shielded cables and single ended grounding; Install magnetic ring