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Basics

Infrastructure for EtherCAT/Ethernet

30

Version: 2.1

Note

Data sheets and documentation on plug connectors

Please refer to the associated data sheets and documentation for the technical data of the
plug connectors recommended here; these are available for download on our website
(www.beckhoff.com).

ZS1090-0003

Fig. 23: RJ45 connector, 4-pin, IP 20, for field-assembly

ZS1090-0005

Fig. 24: RJ45 connector, 8-pin, IP 20, for field-assembly, suitable for Gigabit Ethernet

ZS1090-0004

Fig. 25: M12 connector, 4-pin, IP67, for field-assembly, d-coded

ZS1090-0006

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Summary of Contents for EtherCAT

Page 1: ...Documentation Infrastructure for EtherCAT Ethernet Technical recommendations and notes for design implementation and testing 2 1 2017 07 27 Version Date ...

Page 2: ......

Page 3: ...s 18 3 4 2 Notes on Ethernet components plug connections 20 3 4 3 Overview of Beckhoff RJ45 M8 cables for EtherCAT systems 21 3 4 4 Overview of Beckhoff plug connectors for EtherCAT systems 29 3 4 5 Remarks regarding shielding 31 3 5 Assembly notes 34 3 6 Design of an Ethernet cable section 34 4 Commissioning 36 4 1 Measurements of the cable section 36 4 2 Notes on certification 38 4 3 Measurement...

Page 4: ...Table of contents Infrastructure for EtherCAT Ethernet 4 Version 2 1 ...

Page 5: ...ssion link verifiably corresponds to a performance class then it conforms to EN50173 A component manufacturer cable connector can certify its products according to the limit values from EN50173 et al The exclusive use of components certified to EN50173 may be sufficient to ensure the conformity of the transmission link in individual cases it must be verified by means of suitable measuring methods ...

Page 6: ... up to 0 34 mm rigid According to EN50173 1 the maximum permissible configuration for an Ethernet link is 90 meters of permanently installed cable plus 2 device connection cables of 5 metres each with a maximum of four intermediate connectors Other configurations such as a direct 100 m long connection are to be designed in accordance with EN50173 3 appendix B and tested in the field for conformity...

Page 7: ...of the better electrical characteristics Attenuationthin core Attenuationthick core If the length exceeds 50 meters too small a cross section AWG26 can prevent conformity to the performance class It is recommended to check the installed Ethernet cabling before commissioning It is recommended to monitor installed Ethernet cabling during operation using a means of software diagnosis e g Beckhoff Twi...

Page 8: ...the basis of the data diagrams and descriptions in this documentation Trademarks Beckhoff TwinCAT EtherCAT Safety over EtherCAT TwinSAFE XFC and XTS 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 Te...

Page 9: ...ing who are familiar with the applicable national standards Description of symbols In this documentation the following symbols are used with an accompanying safety instruction or note The safety instructions must be read carefully and followed without fail DANGER Serious risk of injury Failure to follow the safety instructions associated with this symbol directly endangers the life and health of p...

Page 10: ...n in ST4 Addenda Update structure 1 8 Addenda chapter Measurements of the cable section Use of the DTX1800 DSX5000 Notes on certification 1 7 Addenda overview of standards 1 6 Addenda corrections 1 5 Addenda 1 4 Addenda 1 3 Addenda 1 2 Screening data 1 1 Channel adaptor instead of PL adaptor for standard measurement 1 0 Public version 0 1 Provisional documentation ...

Page 11: ... http www iso org IEC International Electrotechnical Commission www iec ch EN DIN Committee for European Standards or their German editions through DIN http www cenelec eu TIA EIA US Standards Committee http www tiaonline org As a globally used communication protocol the IEC 61918 standard and the IEC 61784 5 EtherCAT installation profile are authoritative for EtherCAT These contain definitions th...

Page 12: ...Basics Infrastructure for EtherCAT Ethernet 12 Version 2 1 Fig 3 Expanded overview of standards there is no claim for completeness ...

Page 13: ...dings IEC61784 5 12 WD Industrial communication networks Fieldbus installation profiles Installation profiles for communication profile family 12 EtherCAT IEC61918 Ed 2 0 Industrial communication networks Installation of communication networks in industrial plants EN61935 1 Specification for the testing of IT cabling IEC61156 6 Framework specification for multi core symmetrical cables up to 1000 M...

Page 14: ... begin to synchronize themselves or to maintain synchronization by the continuous transmission reception of a special bit sequence the idle symbol This idle symbol consists of the maximum possible number of level changes since the 1 is transmitted 5 times the transmission of a 1 means a level change in the NRZI process Hence due to the constant exchange of idle symbols an Ethernet device that is n...

Page 15: ...atch bays intermediate distributors floor distributors The maximum of four plug connections can also be distributed in other ways over the cable section for example in patch bays see Model B Model B C Models B and C represent more typical transmission links for the industrial area they are discussed in EN50173 1 or ISO24702 Connector A transition point negatively affects the entire transmission li...

Page 16: ...t transition Performance of a transmission link EN50173 1 2007 chapter 5 defines 8 classes according to the permissible frequency range Table 2 Performance classes according to EN50173 1 Class Frequency range SRKG up to 0 1 MHz A up to 100 kHz B up to 1 MHz C up to 16 MHz D up to 100 MHz E up to 250 MHz F up to 600 MHz RuK S up to 1000 MHz Equations according to which the frequency dependent limit...

Page 17: ... ACR PSACR Ausgangsseitige Fernnebensprechdämpfung equal level far end crosstalk ratio ELFEXT Leistungssummiertes ELFEXT powersum ELFEXT PSELFEXT Gleichstrom Schleifenwiderstand Resistance DC resistance difference Resistance Difference Laufzeit Propagation Delay Laufzeitunterschied Delay skew TCL Unsymmetriedämpfung Transverse Conversion Loss TCL Kopplungsdämpfung Not all parameters are obligatory...

Page 18: ...ch cord adaptors e g Fluke and the patch cord limit values according to EN50173 Max 20 m are specified the attenuation is therefore not specified Only RL and NEXT are measured these are worded more strictly than in the channel 3 4 Components 3 4 1 Notes on Ethernet components cables For conformity EN50173 1 chapter 7 requires the use of cables as per EN50288 twisted pairs This includes both shield...

Page 19: ...g other things This ef fect will only be noticeable in the case of great lengths If the acceptance of a cable section fails for this reason it is preferable for example to use larger core cross sections rather than dispensing with shielded cables A screen improves the return loss RL Note Similar to Cat 5 Since cable development has undergone technological progress since the creation of these stand...

Page 20: ...or the ambient conditions specified therein The plug connection substantially affects the electrical characteristics of the transmission link in particular the parameters screening effect attenuation crosstalk and return loss For transmission link design an insertion loss of 0 4 dB EN50173 1 appendix A is roughly assumed for a single plug connector The following mating faces are in use for Class D...

Page 21: ... pair 5 WH BU 4th pair 7 WH BN 4th pair 8 BN Screen Screening Housing Housing Housing n def n def Screening effect It must be ensured that the screening effect is continued at the transition from the cable material to the connector Also in the area of the connector cable transition the screening material braid foil must join the body of the connector with a low impedance and a large surface area a...

Page 22: ...uitable for drag chains Highflex Fig 14 ZK1090 9191 xxxx Table 7 EtherCAT patch cable 2x RJ45 plug Designation Length ZK1090 9191 0001 0 17 m ZK1090 9191 0002 0 26 m ZK1090 9191 0005 0 5 m ZK1090 9191 0010 1 0 m ZK1090 9191 0020 2 0 m ZK1090 9191 0030 3 0 m ZK1090 9191 0050 5 0 m ZK1090 9191 0100 10 0 m ZK1090 9191 0150 15 00 m ZK1090 9191 0200 20 00 m ZK1090 9191 0250 25 00 m ZK1090 9191 0300 30 ...

Page 23: ...090 6161 0025 2 50 m ZK1090 6161 0030 3 00 m ZK1090 6161 0035 3 50 m ZK1090 6161 0040 4 00 m ZK1090 6161 0045 4 50 m ZK1090 6161 0050 5 00 m ZK1090 6161 0060 6 00 m ZK1090 6161 0100 10 00 m ZK1090 6161 0120 12 00 m ZK1090 6161 0150 15 00 m ZK1090 6161 0200 20 00 m ZK1090 6161 0250 25 00 m ZK1090 6161 0300 30 00 m ZK1090 6161 0400 40 00 m ZK1090 6161 0999 100 00 m Please refer to the catalogue the ...

Page 24: ...le M12 flange RJ45 plug fully assembled Designation Length ZK1090 6292 0005 0 50 m ZK1090 6292 0020 2 00 m ZK1090 6292 0050 5 00 m ZK1090 6292 0100 10 0 m ZK1090 6292 0300 30 0 m Please refer to the catalogue the price list or our website www beckhoff com for the available lengths Fig 17 ZK1090 3131 3xxx ...

Page 25: ...1090 3131 3300 30 00 m ZK1090 3131 3350 35 00 m ZK1090 3131 3400 40 00 m ZK1090 3131 3450 45 00 m ZK1090 3131 3500 50 00 m Please refer to the catalogue the price list or our website www beckhoff com for the available lengths Fig 18 ZK1090 3191 3xxx Table 11 EtherCAT cable PVC 1 x M8 connector 1 x RJ45 fully assembled Designation Length ZK1090 3191 3003 0 30 m ZK1090 3191 3005 0 50 m ZK1090 3191 3...

Page 26: ...M8 connector 1 x open end Designation Length ZK1090 3100 3010 1 00 m ZK1090 3100 3020 2 00 m ZK1090 3100 3050 5 00 m ZK1090 3100 3080 8 00 m ZK1090 3100 3100 10 00 m ZK1090 3100 3200 20 00 m Please refer to the catalogue the price list or our website www beckhoff com for the available lengths Fig 20 ZK1090 3131 0xxx ...

Page 27: ...090 3131 0030 3 00 m ZK1090 3131 0040 4 00 m ZK1090 3131 0050 5 00 m ZK1090 3131 0055 5 50 m ZK1090 3131 0060 6 00 m ZK1090 3131 0070 7 00 m ZK1090 3131 0075 7 50 m ZK1090 3131 0090 9 00 m ZK1090 3131 0100 10 00 m ZK1090 3131 0110 11 00 m ZK1090 3131 0150 15 00 m ZK1090 3131 0155 15 50 m ZK1090 3131 0165 16 50 m ZK1090 3131 0200 20 00 m ZK1090 3131 0205 20 50 m ZK1090 3131 0250 25 00 m ZK1090 3131...

Page 28: ... ZK1090 3191 0035 3 50 m ZK1090 3191 0050 5 00 m ZK1090 3191 0070 7 00 m ZK1090 3191 0080 8 00 m ZK1090 3191 0100 10 00 m ZK1090 3191 0120 12 00 m ZK1090 3191 0125 12 50 m ZK1090 3191 0150 15 00 m ZK1090 3191 0160 16 00 m ZK1090 3191 0165 16 50 m ZK1090 3191 0170 17 00 m ZK1090 3191 0200 20 00 m ZK1090 3191 0205 20 50 m ZK1090 3191 0250 25 00 m ZK1090 3191 0285 28 50 m ZK1090 3191 0300 30 00 m ZK1...

Page 29: ... or our website www beckhoff com for the available lengths Note Further cables Information about further versions and lengths can be found on our website www beck hoff com and in the price list 3 4 4 Overview of Beckhoff plug connectors for EtherCAT systems Beckhoff recommends the following plug connectors for use in EtherCAT systems Table 16 Recommended plug connectors overview Designation Plug Z...

Page 30: ...on for the technical data of the plug connectors recommended here these are available for download on our website www beckhoff com ZS1090 0003 Fig 23 RJ45 connector 4 pin IP 20 for field assembly ZS1090 0005 Fig 24 RJ45 connector 8 pin IP 20 for field assembly suitable for Gigabit Ethernet ZS1090 0004 Fig 25 M12 connector 4 pin IP67 for field assembly d coded ZS1090 0006 ...

Page 31: ...ocket transition see ZK1090 6292 3 4 5 Remarks regarding shielding The IEC61158 2 standard and in particular the IEC61784 5 EtherCAT installation profile demand a fully shielded cable for EtherCAT transmission links This also corresponds to the general state of the art for communication cables Twisting and differential transmission in the so called twisted pair medium provide for fundamental inter...

Page 32: ...d of the cable to the machine earth via an electrically conducting connection with a large surface area and low impedance A pigtail i e the twisting together and point contact of the shield must be avoided Fig 30 Recommended shield connection If the shield is not earthed there is no protection against the influence of magnetic fields It must be ensured by means of sufficient parallel earthing in t...

Page 33: ...ic continuity measurement Beyond that however there are well known and standardized laboratory assisted measuring methods such as the pipe in pipe or drain wire methods which can also determine the high frequency characteristics and the attenuating behavior of the shield and in this way make it possible to check adherence to a coupling attenuation of 40dB EN50174 2 2009 30 100 MHz However these ar...

Page 34: ...ths with which the configured devices are addressed Hubs and switches retarding the cycle time ISO Layer 2 are dispensed with entirely in an EtherCAT network there is no segmenting by routers ISO Layer 3 Note Design rules The sum of frame length and cycle timetotal should be shorter than the available timeframe to the next transmission point Detailed information about the current frame configurati...

Page 35: ... are specified for the attainment of an EN50173 Class D connecting link A wall feed through single plug connector version is not subject to this restriction Practical implementation The exact calculation of permissible cable lengths using the equations from EN50173 is barely usable in the field For that reason it will not be shown here It is recommended that you adhere to the topological specifica...

Page 36: ...ect assignment lack of screen contact poor contacting dirty contacts Fig 32 Continuity test 2 Link control Ethernet devices feature an optical LINK display usually directly on the socket which indicates directly whether a point to point connection could be established between the two end points by exchanging the idle symbol Fig 33 Link LED on Ethernet devices 3 Certification Broadband measurement ...

Page 37: ...ing EMC influences Fig 35 TwinCAT diagnosis Note Notes on measurement The screen measurement is usually only a static continuity measurement It is not possi ble to test the effectiveness of the cable screen in the field at present 2011 see screening notes 31 The measuring devices cable should not be moved during the high frequency measure ment Poor plug contacts cable breakages should be sought pu...

Page 38: ... a channel measurement by the measuring device and the use of appropriate channel adaptors on the measuring device connector compensation Since the end plugs can represent significant sources of error especially in the case of field configured cables with no intermediate patch bays transition points these should be taken into account in the measurement Tip Depending on the measuring device used th...

Page 39: ...ferent limit value curves e g resistance delay NEXT etc Depending upon the set limit value data record a the individual measurements are active b a measurement serves only for informative purposes e g the length measurement in the EN50173 channel specification c or must be fulfilled e g the attenuation measurement of the EN50173 channel specifi cation ð Each data record will trigger complex measur...

Page 40: ... of the cable characteristics the attenuation reduces the signal amplitude per meter of cable the attenuation is given as a positive value in dB 100m SMALLER values are better here the attenuation is frequency dependent the higher the frequency the higher the real attenuation is in the cable As a result the originally square signal from the transmitter is smoothed to the well known eye shape the r...

Page 41: ...ent on the completed installation PSNEXT PowerSum NEXT is calculated for each pair of cores as the sum of the crosstalk from all other pairs If PSNEXT is also applied positively for illustration purposes then LARGER values are better the PSNEXT curves are typically a few dB worse than the NEXT results ACR N ACR F ELFEXT PS ACR N PS ACR F ACR N Attenuation to Crosstalk Ratio Near End is calculated ...

Page 42: ...0 5 100 m Max 6 connectors in between or max 3 double couplers Shielded 4 core cable as per EN50288 2 RJ45 plug at both ends Core assignment 1 2 3 6 screen as per TIA 568B Arbitrary mixture of rigid and permanently installed cables observe design notes The following settings have proven to be standard compliant and usable for the certification of a possibly field configured Ethernet EtherCAT cable...

Page 43: ...paring this documentation it is possible however that the manufacturer of the measuring device may have changed the firmware program user interface at short notice The notes below should be considered to be supplementary to the manufacturer s own operating manual The use of the FLUKE DTX1800 for the certification of Ethernet transmission links is described below as an example Measuring Connect the...

Page 44: ...for NEXT or its ACR and PS Fig 37 Evaluation NEXT ACR from 4 dB insertion loss The reason for this could be the 4 dB rule This is contained only in tests according to ISO11801 EN50173 this rule is not known to TIA The wording of this rule is as follows NEXT ACR is not evaluated as long as the insertion loss of the section is 4 dB For identification the limit line is shown in black as long as the i...

Page 45: ... post measurement of the installation cable certification cable routing transition points shielding shielding connection Interpretation of certification results Attenuation errors usually come from the cable too long attenuation too high NEXT errors usually come from the plug not correctly contacted untwisted too far Differences in the DC resistance between individual pairs cables damaged poor con...

Page 46: ...y the manufacturer Cable damage An unsuitable cable can be damaged by repetitive movement this may not be outwardly visible Example incompatible plug connection leads to intermittent contact In the following example the contacts in the plug are so short that the spring contacts in the socket are pushed beyond the reliable contact point when the plug socket connection is pushed fully together This ...

Page 47: ...The setup is however most disadvantageous for the transmission performance due to the disregard of the high frequency aspects addressed and the use of components not suitable for HF and is immediately noticeable in the test It is thus possible that the transmission link may not work even with short cable lengths In detail Interruption of the screen construction is not in a screened housing Paralle...

Page 48: ...s should be used in Ethernet transmission links The trans mission link should be certified in each case Example 3 poor execution of the cable connector connection In the following example the core pairs are untwisted over an unnecessarily long distance contrary to the manufacturer s instructions therefore local crosstalk is very much facilitated In the test such a connector is noticeable by a high...

Page 49: ...Commissioning Infrastructure for EtherCAT Ethernet 49 Version 2 1 Fig 44 X ray picture of an RJ45 connector ...

Page 50: ...G diameters to the metric format The AWG number refers to the number of times the wire concerned has to be drawn through the drawing in order to manufacture it the thinner the wire the more drawing procedures are necessary mm AWG 0 05 30 0 08 28 0 14 26 0 20 24 0 28 23 0 34 22 0 38 21 0 50 20 0 75 18 1 0 17 1 5 16 2 5 14 4 12 6 10 10 8 16 6 25 4 35 2 50 1 55 1 0 70 2 0 95 3 0 120 4 0 ...

Page 51: ...r Beckhoff components there Beckhoff Headquarters Beckhoff Automation GmbH Co KG Huelshorstweg 20 33415 Verl Germany Phone 49 0 5246 963 0 Fax 49 0 5246 963 198 e mail info beckhoff com 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 ...

Page 52: ... 3131 0xxx 26 Fig 21 ZK1090 3191 0xxx 28 Fig 22 ZK1090 3100 0xxx 29 Fig 23 RJ45 connector 4 pin IP 20 for field assembly 30 Fig 24 RJ45 connector 8 pin IP 20 for field assembly suitable for Gigabit Ethernet 30 Fig 25 M12 connector 4 pin IP67 for field assembly d coded 30 Fig 26 M8 connector 4 pin IP67 for field assembly 31 Fig 27 M12 socket on RJ45 socket straight outlet 31 Fig 28 M12 socket on RJ...

Page 53: ...Table of figures Infrastructure for EtherCAT Ethernet 53 Version 2 1 Fig 43 Result of the NEXT test 48 Fig 44 X ray picture of an RJ45 connector 49 ...

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