Recommendations for the design of the

Infrastructure for EtherCAT/Ethernet

Version: 1.0.0
Date: 2009-12-23
 Table of contents

Table of contents
1 Foreword 3
1.1 Notes on the documentation 3
1.1.1 Liability conditions 3
1.1.2 Delivery conditions 3
1.1.3 Brands 3
1.1.4 Patents 3
1.1.5 Copyright 3
1.2 Safety instructions 4
1.2.1 Delivery state 4
1.2.2 Operator's obligation to exercise diligence 4
1.2.3 Description of safety symbols 5

2 Overview 6
2.1 Intention 6
2.2 Summary of the information 6
3 Basic principles 10
3.1 Basic Ethernet principles 10
3.1.1 Establishment of a connection 10
3.2 Overview of the standard environment 11
3.3 Transmission link 13
3.3.1 Performance of a transmission link 14
3.3.1.1 Extract from characteristic values EN50173 Class D 15

4 Components 16
4.1 Cable 16
4.1.1 Cable structure 17
4.1.2 Recommended cables 18
4.1.2.1 Sold by meter 18
4.1.2.2 EtherCAT patch cable 18
4.1.2.3 EtherCAT cable with M12 connectors 19
4.1.2.4 EtherCAT cable, PVC, with M8 connectors 20
4.1.2.5 EtherCAT cable, PUR, Highflex, with M8 connectors 21
4.2 Plug connector 23
4.2.1 Transition points 23
4.2.2 Designs 24
4.2.3 Recommended connectors 25
4.2.4 Recommended control cabinet feed-throughs 26
4.2.5 Other connectors 26

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Table of contents

5 Appendix 27
5.1 Support and Service 27
5.1.1 Beckhoff's branch offices and representatives 27
5.1.2 Beckhoff company headquarters 27

2 KL1904
 Foreword

1 Foreword

1.1 Notes on the documentation

1.1.1 Liability conditions

This documentation has been prepared with care. The products described are, however, constantly under
development. For this reason, the documentation may not always have been fully checked for
consistency with the performance data, standards or other characteristics described. If it should contain
technical or editorial errors, we reserve the right to make changes at any time and without notice. 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.

1.1.2 Delivery conditions

In addition, the general delivery conditions of the company Beckhoff Automation GmbH apply.

1.1.3 Brands

Beckhoff®, TwinCAT®, EtherCAT®, Safety over EtherCAT®, TwinSAFE® and XFC® are registered and
licensed brand names of Beckhoff Automation GmbH. The use by third parties of other brand names or
trademarks contained in this documentation may lead to an infringement of the rights of the respective
trademark owner.

1.1.4 Patents

The EtherCAT technology is patent protected, in particular by the following patent applications and
patents: DE10304637, DE102004044764, DE102005009224, and DE102007017835 with the
corresponding applications and registrations in various other countries.

1.1.5 Copyright

© Beckhoff Automation GmbH.

The copying, distribution and utilization of this document as well as the communication of its contents to
others without express authorization is prohibited. Offenders shall be held liable for damages. All rights
conferred by patent grant or registration of a utility model or registered design are reserved.

Infrastructure for EtherCAT/Ethernet 3

Foreword

1.2 Safety instructions

This description is only intended for the use of trained specialists in control and automation technology
who are familiar with the applicable national standards. It is essential that the following notes and
explanations are followed when installing and commissioning these components. 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.

1.2.1 Delivery state

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.

1.2.2 Operator's obligation to exercise diligence

The operator must ensure that

 the EtherCAT components are used only for the intended purpose.
 the EtherCAT components are only operated if they are in perfect working order.
 only sufficiently qualified and authorized personnel operate the EtherCAT components.
 none of the safety and warning notes attached to the EtherCAT products are removed, and all
notes remain legible.

4 Infrastructure for EtherCAT/Ethernet

 Foreword

1.2.3 Description of safety symbols

The following safety symbols are used in this documentation. They are intended to alert the reader to the
associated safety instructions.

Serious risk of injury!

Failure to follow the safety instructions associated with this symbol directly endangers
DANGER the life and health of persons.

Risk of injury!

Failure to follow the safety instructions associated with this symbol endangers the life
WARNING and health of persons.

Personal injuries!

Failure to follow the safety instructions associated with this symbol can lead to injuries
CAUTION to persons.

Damage to the environment or devices

Failure to follow the instructions associated with this symbol can lead to damage to the
Warning environment or equipment.

Tip or pointer

This symbol indicates information that contributes to better understanding.

Note

Infrastructure for EtherCAT/Ethernet 5

Overview

2 Overview

2.1 Intention
The market is growing for Ethernet as a physical medium for the transport of real time fieldbus protocols
in the industrial environment. So that basic network principles from the office area are not applied
unreflected to industrial concerns, it is necessary to sensitize planners and users to the technological
aspects.

As a real-time protocol, EtherCAT relies on Ethernet as a physical carrier, and is dependent on the long-
term stable operation of the Ethernet connection. The underlying high frequency technology was
mastered many years ago and is described in the relevant standards. Certified components provide for
commissioning without problem and for compatibility.

As with other fast transmission systems, disruptive effects can also occur with the high frequency
Ethernet technology in operation or during commissioning if it is used inappropriately. These disruptions
are simple to locate or avoid completely if a few basic principles are followed. This documentation is
intended to provide users with a guideline, without any obligatory character or legally binding effect, to
enable them to plan and design reproducibly reliable Ethernet cabling for the industrial environment.

The topics of installation and testing/acceptance are dealt with in separate documents.

This document makes no claim to be complete and, in particular, does not replace normative installation
directives such as ISO/IEC 61784, fundamental communication directives such as
ISO/IEC11801/EN50173 or specific installation directives. This document is mainly intended for the
European market.

2.2 Summary of the information

Based on the following chapters, the fundamental information is summarized as follows:

Standardized performance classes

These performance classes are defined for Europe in the EN50173-1 standard, e.g. ‘Class D’. If a
transmission 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 according to EN50346.

European and US standards

Distinction must be made between Ethernet components certified according to
 the European standard series: EN50173 (similar to ISO/IEC11801)
 US standard series EIA/TIA 568
The two standards differ slightly and also still use the same terms, such as Cat 5 or Class D. But:
components certified in accordance with TIA568 may not be used in cabling installed according to
EN50173 – although it will work (in all probability), the cabling or the entire permanent link respectively no
longer meets the EN standard [EN50173-3, chapter 1].

Standard series for industrial concerns

Extended standard series (ISO24702, EN51918 et al.) have been drawn up especially for industrial
concerns and deal with environmental conditions or with protocol-specific regulations, for example.
However, they do not affect the basic electro-technical principles according to EN50173.

Definition of the Ethernet transmission link (channel)

An Ethernet transmission link (channel) is characterized by a (technically related) capability to reliably

6 Infrastructure for EtherCAT/Ethernet

 Overview

guarantee a defined data throughput [Mbit/s] under all defined operating conditions and, hence, high
service quality.

Structure of the connecting link

According to EN50173-1, the maximum permissible configuration for an Ethernet link is 90 meters of
permanently laid cable plus 2 device connecting cables of 5 meters each, with a maximum of four
intermediate connectors. Hence, a total channel length of 100 meters. Other configurations, such as a
direct 100 meter long connection, are to be designed in accordance with EN50173-3, appendix B and
tested in the field for conformity to the performance class.

Required connection performance

In the EtherCAT application area, only the connection performance of Fast Ethernet (100 Mbit/s)
according to EN50173 Class D [up to100 MHz] is required and is dealt with below. It is permissible for the
user to demand connection classes with a higher performance (classes E [up to 250 MHz], EA, F [up to
600 MHz], FA), but this is not technically justified.

Application-specific cabling
A transmission link for the transmission of Ethernet telegrams can be implemented according to the
requirements of these application-neutral standards; however, it does not have to be. It is then considered
to be application-specific cabling. Experience has shown that cabling that lies far outside the normative
specification also (sometimes) works. If necessary, specifications and restrictions imposed by the
component manufacturer are to be observed. Hence, for example, length limitations may typically be
defined with regard to certain types of cable. In particular, there are now many industrial Ethernet cables
on the market that go beyond the normative specifications and therefore represent application-specific
cabling according to the manufacturer’s specification. A certification test is to be carried out for the
conformity of such a cable section to the connection class.

Reaching agreement
It is recommended that agreement be reached between suppliers and users on the properties and
acceptance procedures with regard to the Ethernet cabling used.

Avoidance of borderline cabling

Borderline Ethernet cabling can work reliably under acceptance conditions, but fail under operating
conditions (aging, EMC, temperature, movement/impact).

Factors influencing the performance

The performance (i.e. the reliable transmission of 10/100/1000 Mbit/s) of Ethernet cabling generally
depends on the following factors:
 the cable quality (attenuation, cross-section, cable structure, screening) of the individual
subsections
 the plug quality (fit, screening, cable suitability)
 the number of connectors
 the ambient temperature (20 to 60 °C, specified with derating according to EN50173)
 Environmental influences (e.g. MICE classification according to EN50173-1, chapter 5:
Mechanical/Ingress/Climatic/Electromagnetic rating)

Fewest possible connectors

The number of connectors between the end points is to be reduced to the necessary minimum.

Permissible categories
In order to achieve this performance class, only Ethernet components conforming to EN50173 Cat. 5 and
higher are permissible (see EN50173-3, chapter 1.2, among others). Components conforming to
EN50173 Cat. 5 are thus adequate. When using wall bushings/double couplers, these must conform to
EN50173 Cat. 6 in order to achieve performance class D for the entire link.

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Overview

Use of four-core/two-pair cables

Four-core/two-pair cables are frequently used for industrial Fast Ethernet, as opposed to the fully
configured eight-core/four-pair cables normally used in office communication. This is to be considered
during the acceptance test.

Cable structure
A paired cable structure is usual in general networking, i.e. each 2 cores used as an electrically
differential pair are twisted together as a pair. The pairs created are twisted again and sheathed by a
screen if necessary.
Since the electrical characteristic values and mechanical stability are more difficult to guarantee in
particular in moving cables (e.g. drag chain operation) when twisting in pairs, total twisting as a star quad
with a four-core configuration is preferred in the industrial environment. Cords or separation stars are
used as core elements/cores.

Recommended color coding

Color coding based on TIA-568B is recommended for the signals TD+, TD-, RD+, RD- and the screen for
a four-core/two-pair industrial Ethernet cable (see chapter 4.2.5).

Recommended cable cross-sections

The following cable cross-sections are recommended for general use:
 Wire structure: stranded or rigid core
 Cross-section: AWG26/7 to AWG22/1 accordingly 7 cores 0.14 mm² (stranded) up to 0.34 mm²
rigid. Up to AWG26/19 is in use for highly flexible cables.

Use exclusively screened Ethernet cables

It is recommended to use exclusively screened Ethernet cables according to EN50288-2 (STP, SF/UTP).
The screen should contact the connectors over a circumference of 360°.

Avoidance of excessively long ‘patch cables’

Be careful when using so-called ‘patch cables’ with lengths of over 5 meters! Commercially available
patch cables are subject to considerably more generous limit values according to EN50173-1, chapter 9
than cables that are intended for fixed installation in accordance with EN50288. Series connection or an
over-length configuration is to be avoided and, if necessary, checked at least by verification. A simple
continuity test is not sufficient!
Application-specific patch cables manufactured from goods sold by the meter are also to be checked for
their suitability. In this context, take into consideration any length limitations on the part of the component
supplier.

Rigid Ethernet cables are preferable

If possible, it is recommended to employ rigid Ethernet cables instead of stranded cables, because rigid
Ethernet cables have the better electrical characteristics (Attenuationstranded > Attenuationrigid).

Larger core cross-sections are preferable

If possible, it is recommended to employ larger core cross-sections (e.g. AWG22 instead of AWG26),
because larger core cross-sections have 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!

Check Ethernet cabling before commissioning

It is recommended to check the installed Ethernet cabling before commissioning.

Monitor Ethernet cabling during operation

It is recommended to monitor installed Ethernet cabling during operation using software diagnostic tools
(e.g. Beckhoff TwinCAT).

8 Infrastructure for EtherCAT/Ethernet

 Overview

In consideration of the specified standards, a verification decision on a cable section can thus be made as
follows:

Is a specified connection class to

be verifiably complied with?

y n

Were only certified components used for the

installation or do manufacturer’s approvals exist? Is
the installation correct and does the section design
follow the standards?

y n

no checking necessary
Compliance with the connection Certification of the connecting no checking necessary
class can be assumed in the link is necessary after installation Function test adequate
case of a correct installation

Figure 2-1: Verification decision

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Basic principles

3 Basic principles

3.1 Basic Ethernet principles

Ethernet is used at present in different performance classes, depending on the data transfer rate:
10, 100 or 1000 Mbit/s. The Fast Ethernet (100 Mbit/s) dealt with exclusively here as a physical
transmission method according to ISO/IEC 8802-3 is characterized as

 type 100Base-TX

 full duplex, hence collision avoidance according to CSMA/CD is not necessary

 use of only 2 of the 4 possible core pairs (cores 1/2 and 3/6). A four-core cable is therefore
adequate.

 point-to-point connection between 2 intelligent devices, which dynamically negotiate parts of the
connection establishment via the connection ICs

The 100 Mbit/s usable data stream is triple-encoded:

1. 4Bit/5Bit encoding (ISO9314, for clock recovery), results in 125 Mbit/s gross data stream

2. NRZI (Non Return to Zero Inverted) encoding for frequency reduction (a level change means
1bin), results in a maximum frequency of 62.5 MHz.

3. MLT-3 encoding (for frequency reduction, 3 voltage states instead of 2), results in a maximum
signal frequency of 31.25 MHz on the cable. The actual frequency depends on the data stream
and is thus variable.

Taking into account arising harmonics, a connection performance of the total section is sufficient
according to EN50173-1 Class D for signals up to 100 MHz and thus for Fast Ethernet (EtherCAT).

Conversely, Gigabit Ethernet works with a mean signal frequency of 62.25 MHz and needs all 4 core
pairs. In principle a fully-configured Class D link is suitable for transmission. However, since all four core
pairs are used in Gigabit Ethernet, and in fact bi-directionally at the same time, it is recommended to
obtain link certification in accordance with the tightened limit values (crosstalk, return loss) according to
ANSI/TIA/EIA-TSB-6 (TIA Cat. 5e).

3.1.1 Establishment of a connection

The simplest way of diagnosing an Ethernet connection is to observe the link display at both end points: if
an Ethernet cable is connected at each end to a device, both terminals 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 not operative has a
higher current consumption than during normal data traffic!

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 Basic principles

3.2 Overview of the standard environment

A large number of standards are relevant to Ethernet technology. These standards are concerned with:

 Installation
 Communication protocols
 Mechanical/electrical limit values
 Component definitions:

This document deals with the subsection: which components in which constellation result in the desired
performance class for the cable section?

Three normative committees are considered in this introduction:

 ISO: International Organization for Standardization http://www.iso.org

 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/

Figure 3-1: Overview of standards (does not claim to be complete)

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Basic principles

Table 3-1: References

Standards Comment
EN50174-2:2000 Information technology: installation of communication cabling
prEN50174-2:2007  Part 2: Installation planning and installation practices in buildings
EN50288-2-1:2003 Multi-core metallic data and control cables for analogue and digital transmission
EN50288-2-2:2003  Part 2-1: Framework specification for screened cables up to 100 MHz
Cables for the horizontal and vertical areas
 Part 2-2: Device connection cables and switchboard cables
EN60603-7-2 Connectors for electronic facilities
EN60603-7-3  Part 7-2: Detail specification for unscreened free and fixed connectors,
eight-pin, for data transmissions up to 100 MHz
 Part 7-3: Detail specification for screened free and fixed connectors,
eight-pin, for data transmissions up to 100 MHz
EN50173-1:2007 Information technology; application-neutral communication cable systems
EN50173-3:2007  Part 1: General Requirements
IEC24702:2006 Information technology
 Application-neutral cabling, industrially used buildings
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

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 Basic principles

3.3 Transmission link

General Ethernet cabling (twisted pair) according to DIN EN 50173 is characterized by:
 Maximum 90 meters of permanently laid cable (as per EN50288-x-1) plus two device connection
cables, each maximum 5 meters long (as per EN50288-x-2). Results in a maximum total of
100 meters.
 A maximum of four connectors between the end points plus two terminal connectors
 Cable according to EN50288
 Double couplers (for the connection of two RJ45-plugs) are treated separately and normally count
as 2 connectors.
 All cables must exhibit the same nominal characteristic impedance:
100 5  or 120 5  @ 100 MHz

The following illustration shows three models for the sections of a transmission link (channel):

Figure 3-2: Models for the sections of a transmission link (channel):

Model A
Model A illustrates the maximum permissible model according to EN50173-1, consisting of
 maximum 90 m permanent link: permanent link with cable according to EN50288-2-1
 Total of 6 connectors C, including the terminal connection points
 Maximum 2 device connection cables (patch cables) according to EN50288-2-2,

Decisive for acceptance tests is that

 a measurement of the permanent link according to EN50173-1, appendix A includes the two
connection points
 a measurement of the channel according to EN50173-1, chapter 5 does not include the two
connection points
The target market of ISO11801/EN50173 ‘Building services-orientated network cabling’ becomes clear
from the structure (patch bays, intermediate distributors, floor distributors). The maximum of four
connectors can also be distributed in other ways over the cable section, for example in patch bays; see
Model B.
Models B and C
Models B and C represent more typical transmission links for the industrial area; they are discussed in
EN50173-1 or ISO24702.

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Basic principles

3.3.1 Performance of a transmission link

Table 3-2: EN50173-1:2007, chapter 5 defines 8 classes according to the permissible frequency range

Class SRGK A B C D E F RuK-S

Frequency 0.1 MHz 100 kHz 1 MHz 16 MHz 100 MHz 250 MHz 600 MHz 1 GHz
range up
to

Equations according to which the frequency-dependent limit curves (e.g. within the range 1 to 100 MHz,
class D) can be calculated are specified for the Ethernet-relevant performance classes D, E and F.
Depending on the parameter, the measured value must, if necessary as f(f), remain under or above the
limit value curve.

Figure 3-3: Examples of measurements

The illustrations show examples of measurements of insertion losses and crosstalk at the near end of the
cable (NEXT, Near End Cross Talk) in comparison to the respective frequency-dependent limit curve
(red). The following parameters are defined:

Table 3-3: Overview of parameters according to EN50173-1:2007

German English Abbreviation

Rückflussdämpfung Return Loss RL
Einfügedämpfung Insertion Loss, Coupling Attenuation
Nahnebensprechdämpfung near end crosstalk loss NEXT
leistungssummierte power sum NEXT PSNEXT
Nahnebensprechdämpfung
Dämpfungs-Nebensprechdämpfungs- Attenuation to crosstalk ratio near/far ACR-N
Verhältnis, nahes/fernes Ende ACR-F
Leistungssummiertes ACR power sum ACR PSACR
Ausgangsseitige Fernnebensprechdämpfung equal level far end crosstalk ratio ELFEXT
Leistungssummiertes ELFEXT power sum ELFEXT PSELFEXT
Gleichstrom Schleifenwiderstand Resistance -
Gleichstrom Widerstandsunterschied Resistance Difference -
Laufzeit Propagation Delay -
Laufzeitunterschied Delay skew -
TCL Unsymmetriedämpfung Transverse Conversion Loss TCL
Kopplungsdämpfung Coupling Attenuation -

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3.3.1.1 Extract from characteristic values EN50173 Class D

Table 3-4: selected characteristic values for transmission links according to EN50173-1 class D

Characteristic value Channel Permanent Link

Length max. 100 m max. 90 m
max. insertion loss 24 dB 20.4 dB
[dB @ 100 MHz, 100m]
NEXT [dB @ 100 MHz, 100m] 30.1 dB 32.3 dB
max. propagation delay [ns @ 548 ns 491 ns
100MHz]

Comments
 In the (informative) calculations of the max. limit values in EN50173-1, chapter 5.2, the max.
permissible 4 connectors within the channel are assumed.
 A max. signal propagation delay of 548 ns is permitted for EN50173 Class D at 100 MHz. This
limits the use of excessively long cables. Even at an assumed NVPcable of 60%, only a channel
length of 100 m is still possible.
 All limit values are based on the assumption of an ambient temperature of 20°C. A derating of
0.2%/°C is defined in EN50173 up to the region of 60°C. Hence, cable and connector
characteristics worsen as the ambient temperature rises. The maximum permissible channel
length therefore reduces as the temperature rises.

Deviation from the specifications

The specifications of ISO11801/EN50173 quoted above can be deviated from, e.g. by

Note more connectors or cable sections than permissible or by non-conforming cable
material. In this case the transmission link must be calculated according to
ISO11801/EN50173 and verification/certification is recommended after the installation.

Infrastructure for EtherCAT/Ethernet 15

Components

4 Components

4.1 Cable
EN50173-1, chapter 7 requires the use of cables according to EN50288, twisted pairs, for conformity.
This includes both screened and unscreened cables. Since screened cables are recommended for
EtherCAT cable connections, these will be dealt with exclusively below.

The relevant EN50288-2 standard contains sub-chapters on rigid and flexible cables. Twisted pairs or star
quads are allowed as cable structures for both cables. The star quad is more advantageous:
mechanically more stable (moving application, transverse compressive strength), lower space
requirement, better NEXT values.

Since cable development has undergone technological progress since the creation of these standards,
there are now numerous cables suitable for Ethernet communication on the market which
 have the required electrical characteristics as per EN50173ff as a specification, but which
 do not meet or exceed individual (mechanical) specifications according to EN50288.
Such cables are identified, for example, by the remark ‘Similar to Cat.5’ in the data sheet and can be
used according to the manufacturer’s specifications – this is then a case of application-specific cabling,
which can be subjected to a certification test after the installation if necessary.

These standards contain, for example, the following data:

EN50288-2-1:
 Purpose: screened cables -100 MHz, permanently installed for horizontal/vertical areas
 ‘Rigid wire structure’, solid copper conductors
 Cross-section corresponds approx. to AWG24 to 21
 Insertion loss max. 21.3 dB /100 m at 100 MHz
 DC loop resistance < 19  / 100 m

EN50288-2-2:
 Purpose: screened cables -100 MHz, device connection cable
 ‘Flexible wire structure’, stranded wire – single or multi-strand conductors
 Insertion loss max. 32 dB /100 m at 100 MHz
 DC loop resistance < 29  / 100 m

The data are valid for 20°C. Correction calculations can be performed for other ambient temperatures
according to the standard specification.

In addition, cables can be approved by the manufacturer according to the MICE classification as per
EN50173-1, chapter 5 or appendix G for the ambient conditions specified therein.

Patch cables and attenuation

As can be seen from the technical data above, it is not possible to achieve an
Note EN50173 Class D channel with its permissible insertion loss of 24 dB / 100 m at
100 MHz using a patch cable certified according to EN50288-2-2.

The use of patch cables (according to EN50288-2-2) with a length of over 10 meters or
the series connection of such cables is to be provided for only in acknowledgment of
the technological restrictions.

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 Components

For the combination of cable and plug, the class of the fully assembled patch cables with permissible limit
values is defined in EN50173-1, chapter 9.

Screening

An existing screen may increase the insertion loss of a cable among other things. This
Note effect 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 screened cables.

A screen also improves the return loss RL.

IEC61784-5-12 refers to this in its ‘Installation profile for EtherCAT networks’ by specifying a max.
connection length of 100 m using AWG22 cable (note: type EN50288-2-1).

4.1.1 Cable structure

Cable cross-sections measured according to AWG (American Wire Gage) are specified in the form
AWGxx/y, where xx stands for the cross-section and y for the number of cores. Examples:

 AWG22/1 means cross-section AWG22, one core

 AWG22/7 means total cross-section AWG22, seven cores

The cable structure according to ISO/IEC11801 is specified as follows:

Figure 4-1: Cable structure according to ISO/IEC11801

Screening recommendation

The exclusive use of overall screened transmission links is recommended, e.g.

Note SF/FTP, S/FTP or SF/UTP.
Ensure the correct connection of the screen in the terminal devices!

Auto-crossing

Due to automatic cable detection (auto-crossing) symmetric (1:1) or cross-over cables

Note can be used between EtherCAT devices from BECKHOFF.

Infrastructure for EtherCAT/Ethernet 17

Components

4.1.2 Recommended cables

Beckhoff recommends the following cables for use in EtherCAT systems.

Data sheets and documentation on cables

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

4.1.2.1 Sold by meter

Table 4-1: Sold by meter

Designation Cable
ZB9010 Industrial Ethernet/EtherCAT cable, fixed installation, CAT 5e, 4-wires
ZB9020 Industrial Ethernet/EtherCAT cable, suitable for drag chains, CAT 5e, 4-core
ZB9030 EtherCAT/Ethernet cable, PVC, screened
ZB9031 EtherCAT/Ethernet cable, PUR, suitable for drag chains, screened
ZB9032 EtherCAT/Ethernet cable, PUR, suitable for drag chains, Highflex

4.1.2.2 EtherCAT patch cable

ZK1090-9191-xxxx

Table 4-2: EtherCAT patch cable, 2 x 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

Please refer to the catalogue, the price list or our website (www.beckhoff.com) for the available lengths.

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4.1.2.3 EtherCAT cable with M12 connectors

Table 4-3: EtherCAT cable, 2 x M12 connectors (D-coded), fully assembled

Designation Length
ZK1090-6161-0005 0.5 m
ZK1090-6161-0010 1.0 m
ZK1090-6161-0020 2.0 m
ZK1090-6161-0025 2.5 m
ZK1090-6161-0050 5.0 m
ZK1090-6161-0100 10 m

Please refer to the catalogue, the price list or our website (www.beckhoff.com) for the available lengths.

Table 4-4: EtherCAT cable, M12 flange – RJ45 plug, fully assembled

Designation Length
ZK1090-6292-0005 0.5 m
ZK1090-6292-0020 2.0 m
ZK1090-6292-0050 5.0 m
ZK1090-6292-0100 10 m

Please refer to the catalogue, the price list or our website (www.beckhoff.com) for the available lengths.

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4.1.2.4 EtherCAT cable, PVC, with M8 connectors

Table 4-5: EtherCAT cable, PVC, fully assembled, 2 x M8 connector

Designation Length
ZK1090-3131-0020 2.0 m
ZK1090-3131-0030 3.0 m
ZK1090-3131-0040 4.0 m
ZK1090-3131-0050 5.0 m
ZK1090-3131-0075 7.5 m
ZK1090-3131-0100 10 m
ZK1090-3131-0150 15 m
ZK1090-3131-0200 20 m
ZK1090-3131-0250 25 m
ZK1090-3131-0300 30 m
ZK1090-3131-0350 35 m
ZK1090-3131-0400 40 m
ZK1090-3131-0450 45 m
ZK1090-3131-0500 50 m
Please refer to the catalogue, the price list or our website (www.beckhoff.com) for the available lengths.

Table 4-6: EtherCAT cable, PVC, 1 x M8 connector, 1 x RJ45, fully assembled

Designation Length
ZK1090-3191-3020 2.0 m
ZK1090-3191-3050 5.0 m

Table 4-7: EtherCAT cable, PVC, 1 x M8 connector, 1 x open end

Designation Length
ZK1090-3100-3020 2.0 m
ZK1090-3100-3050 5.0 m

Please refer to the catalogue, the price list or our website (www.beckhoff.com) for the available lengths.

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4.1.2.5 EtherCAT cable, PUR, Highflex, with M8 connectors

Table 4-8: EtherCAT cable, PUR, Highflex, 2 x M8 connector, fully assembled

Designation Length
ZK1090-3131-0001 0.15 m
ZK1090-3131-0003 0.3 m
ZK1090-3131-0005 0.5 m
ZK1090-3131-0010 1.0 m
ZK1090-3131-0020 2.0 m
ZK1090-3131-0030 3.0 m
ZK1090-3131-0040 4.0 m
ZK1090-3131-0050 5.0 m
ZK1090-3131-0075 7.5 m
ZK1090-3131-0100 10 m
ZK1090-3131-0150 15 m
ZK1090-3131-0200 20 m
ZK1090-3131-0250 25 m
ZK1090-3131-0300 30 m
ZK1090-3131-0350 35 m
ZK1090-3131-0400 40 m
ZK1090-3131-0450 45 m
ZK1090-3131-0500 50 m
Please refer to the catalogue, the price list or our website (www.beckhoff.com) for the available lengths.

Table 4-9: EtherCAT cable, PUR, Highflex, 1 x M8 connector, 1 x RJ45, fully assembled

Designation Length
ZK1090-3191-0020 2.0 m
ZK1090-3191-0050 5.0 m

Please refer to the catalogue, the price list or our website (www.beckhoff.com) for the available lengths.

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Components

Table 4-10: EtherCAT cable, PUR, Highflex, 1 x M8 connector, 1 x open end

Designation Length
ZK1090-3100-0020 2.0 m
ZK1090-3100-0050 5.0 m

Please refer to the catalogue, the price list or our website (www.beckhoff.com) for the available lengths.

Further cables

Information about further versions and lengths can be found on our website
Note (www.beckhoff.com) and in the price list.

22 Infrastructure for EtherCAT/Ethernet

 Components

4.2 Plug connector

4.2.1 Transition points

Each transition point negatively affects the entire transmission link due to attenuation, reflection and
crosstalk between the cable pairs. Therefore the number of permissible transition points for a channel
conforming to EN50173 is limited to six.

A simple plug/socket transition has one transition

point between the two cables.

Figure 4-2: simple plug/socket transition

Figure 4-3: simple plug/socket transition

A double coupler has two transition points

between the two cables.

Figure 4-4: Double coupler

Figure 4-5: Double couplers; left Cat. 5, plastic; right: Cat. 6, all metal

Use double couplers in accordance with Cat. 6

In order for the performance of a transmission link to conform to EN50173 Class D, for
Note which only Cat. 5 components are normally required, double couplers, if used, must be
Cat. 6 compliant (see EN50173-3, appendix B).

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4.2.2 Designs

The connection equipment for Fast Ethernet must meet the electrical and mechanical requirements of
EN50173 Class D. Backwards compatibility thereby exists. Higher class connection equipment can also
be used for achieving Class D.
The plug components can be approved by the manufacturer according to the MICE classification as per
EN50173-1, chapter 5 or appendix G for the ambient conditions specified therein.

The connector substantially affects the electrical characteristics of the transmission link, in particular the
parameters screening effect, attenuation, cross talk and return loss. For transmission link design, an
insertion loss of 0.4 dB (EN50173-1, appendix A) is roughly assumed for a single connector.

The following mating faces are in use for Class D:

EN60607: RJ45

Figure 4-6: Connector according to EN60603-7, for field assembly,

left: four-pin, compatible with Fast-Ethernet*,
right: eight-pin, suitable for Gigabit Ethernet

*) A four-core configuration according to TIA-568B is adequate for Fast Ethernet (100 Mbit/s).

EN61076-2-101: M12

Figure 4-7: Connector EN61076-2-101, type D, four-pin, screened

EN61076-2-101: M8

Figure 4-8: Connector EN61076-2-101, four-pin, screened

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4.2.3 Recommended connectors

Beckhoff recommends the following connectors for use in EtherCAT systems.

Table 4-11: Recommended connectors, overview

Designation Connector
ZS1090-0003 RJ45 connector, 4-pin, IP 20, for field-assembly
ZS1090-0005 RJ45 connector, 8-pin, IP 20, for field-assembly, suitable for Gigabit Ethernet
ZS1090-0004 M12 connector, 4-pin, IP67, for field-assembly, d-coded
ZS1090-0006 M8 connector, 4-pin, IP67, for field-assembly

Data sheets and documentation on connectors

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

ZS1090-0003

RJ45 connector, 4-pin, IP 20,

for field-assembly

ZS1090-0005

RJ45 connector, 8-pin, IP 20,

for field-assembly, suitable for Gigabit Ethernet

ZS1090-0004

M12 connector, 4-pin, IP67,

for field-assembly, d-coded

ZS1090-0006

M8 connector, 4-pin, IP67,

for field-assembly

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Components

4.2.4 Recommended control cabinet feed-throughs

ZK1090-6292-0000

M12 socket on RJ45 socket,

straight outlet

ZK1090-6294-0000

M12 socket on RJ45 socket,

90° angled outlet

Fewest possible transition points

Give preference to control cabinet feed-throughs with only one transition point, i.e.
Note simple plug/socket transition (see ZK1090-6292, page 19)!

4.2.5 Other connectors

Connectors other than those specified above can also be used. These must then meet the electrical and
mechanical requirements according to EN50173-1:2007, appendix D.

Table 4-12: Assignment

Signal Comment RJ45 M12 Cable colour as per Cable colour as per
TIA-568B EN61918
TD+ Transmit data + 1 1 WH/OG YE
TD- Transmit data - 2 2 OG OG
RD+ Receive data + 3 3 WH/GN WH
RD- Receive data - 6 4 GN BU
- 3rd pair + 4 - BU -
- 3rd pair - 5 - WH/BU -
- 4th pair + 7 - WH/BN -
- 4th pair - 8 - BN -
Screen Screening Housing Housing n.def. n.def.

WH=white, OG=orange, GN=green, BU=blue, BN=brown, YE=yellow

26 Infrastructure for EtherCAT/Ethernet

 Appendix

5 Appendix

5.1 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.

5.1.1 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.

5.1.2 Beckhoff company headquarters

Beckhoff Automation GmbH

Eiserstr. 5
33415 Verl
Germany

Phone: + 49 (0) 5246/963-0

Fax: + 49 (0) 5246/963-198
E-mail: [email protected]
Web: www.beckhoff.com

Beckhoff Support
Support offers you comprehensive technical assistance, helping you no only with the application of
individual Beckhoff products, but also with other, wide-ranging services:
 world-wide support
 design, programming and commissioning of complex automation systems
 and extensive training program for Beckhoff system components

Hotline: + 49 (0) 5246/963-157

Fax: + 49 (0) 5246/963-9157
E-mail: [email protected]

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: + 49 (0) 5246/963-460

Fax: + 49 (0) 5246/963-479
E-mail: [email protected]

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