Beckhoff EP9521-0020 Operator's manual

Documentation | EN
EP9521-0020
EtherCAT media converter, optical fibre/copper (multimode), IP67
2021-06-07 | Version: 1.2

Table of contents
EP9521-0020 3Version: 1.2
Table of contents
1 Foreword ....................................................................................................................................................5
1.1 Notes on the documentation..............................................................................................................5
1.2 Safety instructions .............................................................................................................................6
1.3 Documentation issue status ..............................................................................................................7
2 EtherCAT Box - Introduction ....................................................................................................................8
3 Product overview.....................................................................................................................................10
3.1 Introduction......................................................................................................................................10
3.2 Technical Data.................................................................................................................................11
3.2.1 Additional checks............................................................................................................. 11
3.3 Scope of supply ...............................................................................................................................11
4 Mounting and connection.......................................................................................................................13
4.1 Mounting..........................................................................................................................................13
4.1.1 Dimensions ...................................................................................................................... 13
4.1.2 Fixing ............................................................................................................................... 14
4.1.3 Functional earth (FE) ....................................................................................................... 14
4.1.4 Tightening torques for plug connectors ........................................................................... 14
4.2 Connection ......................................................................................................................................15
4.2.1 EtherCAT ......................................................................................................................... 15
4.2.2 Optical fiber cables .......................................................................................................... 17
4.2.3 Supply voltages ............................................................................................................... 20
4.3 UL Requirements.............................................................................................................................22
5 Commissioning/Configuration ...............................................................................................................23
5.1 Integration in TwinCAT ....................................................................................................................23
5.2 Application notes .............................................................................................................................24
5.3 Restoring the delivery state .............................................................................................................28
5.4 Diagnostic LEDs ..............................................................................................................................29
6 Appendix ..................................................................................................................................................30
6.1 General operating conditions...........................................................................................................30
6.2 Accessories .....................................................................................................................................31
6.3 Version identification of EtherCAT devices .....................................................................................32
6.3.1 Beckhoff Identification Code (BIC)................................................................................... 36
6.4 Support and Service ........................................................................................................................38

Table of contents
EP9521-00204 Version: 1.2

Foreword
EP9521-0020 5Version: 1.2
1 Foreword
1.1 Notes on the documentation
Intended audience
This description is only intended for the use of trained specialists in control and automation engineering who
are familiar with the applicable national standards.
It is essential that the documentation and the following notes and explanations are followed when installing
and commissioning these components.
It is the duty of the technical personnel to use the documentation published at the respective time of each
installation and commissioning.
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.
Disclaimer
The documentation has been prepared with care. The products described are, however, constantly under
development.
We reserve the right to revise and change the documentation at any time and without prior announcement.
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.
Trademarks
Beckhoff®, TwinCAT®, TwinCAT/BSD®, TC/BSD®, EtherCAT®, EtherCATG®, EtherCATG10®, EtherCATP®,
SafetyoverEtherCAT®, TwinSAFE®, XFC®, XTS® and XPlanar® 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 Technology is covered, including but not limited to the following patent applications and
patents: EP1590927, EP1789857, EP1456722, EP2137893, DE102015105702 with corresponding
applications or registrations in various other countries.
EtherCAT® is registered trademark and patented technology, licensed by Beckhoff Automation GmbH,
Germany.
Copyright
© Beckhoff Automation GmbH & Co. KG, Germany.
The reproduction, distribution and utilization of this document as well as the communication of its contents to
others without express authorization are prohibited.
Offenders will be held liable for the payment of damages. All rights reserved in the event of the grant of a
patent, utility model or design.

Foreword
EP9521-00206 Version: 1.2
1.2 Safety instructions
Safety regulations
Please note the following safety instructions and explanations!
Product-specific safety instructions can be found on following pages or in the areas mounting, wiring,
commissioning etc.
Exclusion of liability
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 & Co. KG.
Personnel qualification
This description is only intended for trained specialists in control, automation and drive engineering who are
familiar with the applicable national standards.
Description of instructions
In this documentation the following instructions are used.
These instructions must be read carefully and followed without fail!
DANGER
Serious risk of injury!
Failure to follow this safety instruction directly endangers the life and health of persons.
WARNING
Risk of injury!
Failure to follow this safety instruction endangers the life and health of persons.
CAUTION
Personal injuries!
Failure to follow this safety instruction can lead to injuries to persons.
NOTE
Damage to environment/equipment or data loss
Failure to follow this instruction can lead to environmental damage, equipment damage or data loss.
Tip or pointer
This symbol indicates information that contributes to better understanding.

Foreword
EP9521-0020 7Version: 1.2
1.3 Documentation issue status
Version Comment
1.2 • First publication in PDF format
• Dimensions updated
• UL requirements updated
1.1 • Structure update
1.0.0 • Migration
0.2.0 • Power connection updated
0.1.0 • First preliminary version
Firmware and hardware versions
This documentation refers to the firmware and hardware version that was applicable at the time the
documentation was written.
The module features are continuously improved and developed further. Modules having earlier production
statuses cannot have the same properties as modules with the latest status. However, existing properties
are retained and are not changed, so that older modules can always be replaced with new ones.
The firmware and hardware version (delivery state) can be found in the batch number (D-number) printed on
the side of the EtherCAT Box.
Syntax of the batch number (D-number)
D: WW YY FF HH
WW - week of production (calendar week)
YY - year of production
FF - firmware version
HH - hardware version
Example with D no. 29 10 02 01:
29 - week of production 29
10 - year of production 2010
02 - firmware version 02
01 - hardware version 01
Further information on this topic: Version identification of EtherCAT devices [}32].

EtherCAT Box - Introduction
EP9521-00208 Version: 1.2
2 EtherCAT Box - Introduction
The EtherCAT system has been extended with EtherCAT Box modules with protection class IP67. Through
the integrated EtherCAT interface the modules can be connected directly to an EtherCAT network without an
additional Coupler Box. The high-performance of EtherCAT is thus maintained into each module.
The extremely low dimensions of only 126x30x26.5 mm (hxw xd) are identical to those of the Fieldbus
Box extension modules. They are thus particularly suitable for use where space is at a premium. The small
mass of the EtherCAT modules facilitates applications with mobile I/O interface (e.g. on a robot arm). The
EtherCAT connection is established via screened M8connectors.
Fig.1: EtherCAT Box Modules within an EtherCAT network
The robust design of the EtherCAT Box modules enables them to be used directly at the machine. Control
cabinets and terminal boxes are now no longer required. The modules are fully sealed and therefore ideally
prepared for wet, dirty or dusty conditions.
Pre-assembled cables significantly simplify EtherCAT and signal wiring. Very few wiring errors are made, so
that commissioning is optimized. In addition to pre-assembled EtherCAT, power and sensor cables, field-
configurable connectors and cables are available for maximum flexibility. Depending on the application, the
sensors and actuators are connected through M8 or M12connectors.
The EtherCAT modules cover the typical range of requirements for I/O signals with protection class IP67:
• digital inputs with different filters (3.0ms or 10μs)
• digital outputs with 0.5 or 2A output current
• analog inputs and outputs with 16bit resolution
• Thermocouple and RTD inputs
• Stepper motor modules
XFC (eXtreme Fast Control Technology) modules, including inputs with time stamp, are also available.

EtherCAT Box - Introduction
EP9521-0020 9Version: 1.2
Fig.2: EtherCAT Box with M8 connections for sensors/actuators
Fig.3: EtherCAT Box with M12 connections for sensors/actuators
Basic EtherCAT documentation
You will find a detailed description of the EtherCAT system in the Basic System Documentation for
EtherCAT, which is available for download from our website (www.beckhoff.com) under Downloads.

Product overview
EP9521-002010 Version: 1.2
3 Product overview
3.1 Introduction
Fig.4: EP9521
Copper – optical fiber - media converter with 2 x M8 EtherCAT/Ethernet port and 1 x optical fiber
multimode EtherCAT/Ethernet port
The EtherCAT/Industrial Ethernet module EP9521-0020 for Industrial Fast Ethernet/100 Mbit/s serves as
media converter from optical fibre to copper and vice versa.
The media converter is suitable for multimode fibre-optic cables and is used for direct transfer between the
two media. The media converter operates bidirectionally and collision-free with constant delay. It can be
diagnosed as a separate EtherCAT device.
In this way, unlike standard media converters, it enables fast link control and the safe closing of the
EtherCAT strand even in the event of a fault
Since the transfer direction (copper to optical fibre | optical fibre to copper) is relevant for the bus, the device
can be configured via a switch. Via this switch “Link Loss Forwarding” for normal Ethernet operation can also
be selected.
The EP9521-0020 is useful in applications where EtherCAT transfers over large distances are required or
where higher EMC loads on the bus line are to be expected.
The load voltage UP is not used in the input module, but may be connected in order to be relayed
downstream.
Quick links
Technical data [}11]
Optical fiber connection [}17]

Product overview
EP9521-0020 11Version: 1.2
3.2 Technical Data
Technical data EP9521-0020
Fieldbus EtherCAT/Ethernet
EtherCAT function Media converter Fast Ethernet/100Mbaud
Cut-through mode
Port handling/link control
Ethernet function Media converter Fast Ethernet/100Mbaud (all IEEE 802.3-based
protocols)
IEEE 802.3u auto-negotiation, half or full duplex, automatic settings
Link-Loss-Forwarding (notification direction configurable)
Store and Forward Mode (FIFO)
unmanaged
Copper fieldbus connection 2 x M8 socket (green)
Copper cable length 100m, twisted-pair or star quad CAT5(e)
Optical fiber connection HARTING PushPull LC Duplex
100BASE-FX multimode glass fiber 50/125µm(MM)
typically 1300nm
Optical fiber cable length max. 2km (100BASE-FX)
Supply of the module circuitry From the control voltage Us
Current consumption of the module
circuitry
typically 120mA
Sensor supply From the control voltage Us
Power supply connection Power supply: 1 x M8 plug, 4-pin
Onward connection: 1 x M8 socket, 4-pin
Electrical isolation Control voltage/fieldbus: yes
Permissible ambient temperature
during operation
-25°C ... +60 °C
0 °C ... +55°C (according to cULus, see UL requirements [}22])
Permissible ambient temperature
during storage
-40°C ... +85 °C
Vibration/ shock resistance conforms to EN60068-2-6/ EN60068-2-27
EMC immunity/ emission conforms to EN61000-6-2/ EN61000-6-4
Protection class IP65, IP66, IP67 (according to EN 60529)
Installation position variable
Weight 300g
Approvals CE, cULus [}22]
3.2.1 Additional checks
The boxes have undergone the following additional tests:
Verification Explanation
Vibration 10 frequency runs in 3 axes
5Hz < f < 60Hz displacement 0.35mm, constant amplitude
60.1Hz < f < 500Hz acceleration 5g, constant amplitude
Shocks 1000 shocks in each direction, in 3 axes
35g, 11ms
3.3 Scope of supply
Make sure that the following components are included in the scope of delivery:
• 1x EtherCAT Box EP9521-0020

Product overview
EP9521-002012 Version: 1.2
• 2x protective cap for EtherCAT socket, M8, green (pre-assembled)
• 1x protective cap for supply voltage input, M8, transparent (pre-assembled)
• 1x protective cap for supply voltage output, M8, black (pre-assembled)
• 10x labels, blank (1 strip of 10)
Pre-assembled protective caps do not ensure IP67 protection
Protective caps are pre-assembled at the factory to protect connectors during transport. They may
not be tight enough to ensure IP67 protection.
Ensure that the protective caps are correctly seated to ensure IP67 protection.

Mounting and connection
EP9521-0020 13Version: 1.2
4 Mounting and connection
4.1 Mounting
4.1.1 Dimensions
117
26.560
Ø 4.5
126
14
All dimensions are given in millimeters.
The drawing is not true to scale.
Housing features
Housing material PA6 (polyamide)
Sealing compound polyurethane
Mounting two fastening holes Ø 4.5 mm for M4
Metal parts brass, nickel-plated
Contacts CuZn, gold-plated
Installation position variable
Protection class IP65, IP66, IP67 (conforms to EN 60529) when screwed together
Dimensions (H x W x D) approx. 126 x 60 x 26.5 mm (without connectors)

Mounting and connection
EP9521-002014 Version: 1.2
4.1.2 Fixing
NOTE
Dirt during assembly
Dirty connectors can lead to malfunctions. Protection class IP67 can only be guaranteed if all cables and
connectors are connected.
• Protect the plug connectors against dirt during the assembly.
Mount the module with two M4 screws in the centrally located fastening holes.
4.1.3 Functional earth (FE)
The fastening holes [}14] also serve as connections for the functional earth (FE).
Make sure that the box is earthed with low impedance via both fastening screws. You can achieve this, for
example, by mounting the box on a grounded machine bed.
FE
FE
Fig.5: Functional earth via the fastening holes
4.1.4 Tightening torques for plug connectors
Screw M8 connectors tight with a torque wrench. (e.g. ZB8801 from Beckhoff)
Torque: 0.4Nm.

Mounting and connection
EP9521-0020 15Version: 1.2
4.2 Connection
4.2.1 EtherCAT
4.2.1.1 Connectors
NOTE
Risk of confusion: supply voltages and EtherCAT
Defect possible through incorrect insertion.
• Observe the color coding of the connectors:
black: Supply voltages
green: EtherCAT
EtherCAT Box Modules have two green M8 sockets for the incoming and downstream EtherCAT
connections.
Fig.6: EtherCAT connectors
Connection
3 1
24
Fig.7: M8 socket
EtherCAT M8
connector
Core colors
Signal Contact ZB9010, ZB9020, ZB9030, ZB9032,
ZK1090-6292,
ZK1090-3xxx-xxxx
ZB9031 and old versions of
ZB9030, ZB9032, ZK1090-3xxx-
xxxx
TIA-568B
Tx + 1 yellow1) orange/white white/orange
Tx - 4 orange1) orange orange
Rx + 2 white1) blue/white white/green
Rx - 3 blue1) blue green
Shield Housing Shield Shield Shield
1) Core colors according to EN61918
Adaptation of core colors for cables ZB9030, ZB9032 and ZK1090-3xxxx-xxxx
For standardization, the core colors of the ZB9030, ZB9032 and ZK1090-3xxx-xxxx cables have
been changed to the EN61918 core colors: yellow, orange, white, blue. So there are different color
codes in circulation. The electrical properties of the cables have been retained when the core colors
were changed.

Mounting and connection
EP9521-002016 Version: 1.2
4.2.1.2 Status LEDs
Fig.8: EtherCAT Status LEDs
L/A (Link/Act)
A green LED labelled "L/A" is located next to each EtherCAT socket. The LED indicates the communication
state of the respective socket:
LED Meaning
off no connection to the connected EtherCAT device
lit LINK: connection to the connected EtherCAT device
flashes ACT: communication with the connected EtherCAT device
Run
Each EtherCAT slave has a green LED labelled "Run". The LED signals the status of the slave in the
EtherCAT network:
LED Meaning
off Slave is in "Init" state
flashes uniformly Slave is in "Pre-Operational“ state
flashes sporadically Slave is in "Safe-Operational" state
lit Slave is in "Operational" state
Description of the EtherCAT slave states
4.2.1.3 Cables
For connecting EtherCAT devices only shielded Ethernet cables that meet the requirements of at least
category5 (CAT5) according to EN50173 or ISO/IEC11801 should be used.
EtherCAT uses four wires for signal transmission.
Thanks to automatic line detection ("Auto MDI-X"), both symmetrical (1:1) or cross-over cables can be used
between Beckhoff EtherCAT.
Detailed recommendations for the cabling of EtherCAT devices

Mounting and connection
EP9521-0020 17Version: 1.2
4.2.2 Optical fiber cables
General information on optical fiber types
Optical fiber are available as multimode and single mode types with different step and graded indices.
Step and graded index
Optical fiber cables consist of 2 concentric materials – the core and a cladding. These may be surrounded by
a (colored) protective sheath. The core and the cladding have a different refractive index, causing the light
waves (modes; a mode is a natural wave in the optical fiber) to be reflected back into the core at the
boundary. Due to the step change in the index of refraction this type of fiber is referred to as step index. A
gradual/parabolic transition between the index of refraction in the core and the coating (referred to as graded
index) can be achieved by mixing the materials. In a graded index fiber the modes are gradually diffracted
back to the core, leading to propagation-time compensation and significantly higher quality of the light pulse
at the outlet compared with a multimode step index fiber, where the different light modes have different
signal propagation delays (mode dispersion) with associated front distortion.
Single mode
Single mode fiber cables have a very thin core (9µm) and therefore conduct only a single light mode with
high signal quality and almost without mode dispersion. They are only available as step index fibers. Due to
the high signal quality they are suitable for large transmission bandwidths >10GHz*km and distances
>50km. The refractive index profile of single-mode fibers is dimensioned such that the multipath
propagation (intermodal dispersion), which is a problem with multi-mode fibers, is omitted – the signal light
propagates in a single-mode fiber only in a single guided fiber mode, hence the designation ‘single-mode’.
This makes considerably larger transmission distances and/or transmission bandwidths possible, and the
limiting effect that arises next is the color distortion of the transmitted mode.
Multimode
Multimode fiber optics are manufactured as step index or graded index. Step index multimode fiber cables
are suitable for transmission bandwidths up to 100MHz*km and distances up to 1km. Graded index
multimode fiber cables with core diameters between 50 and 62.5µm reach transmission bandwidths
>1GHz*km and ranges >10km. Multimode means that the core of the optical fiber cable is thick enough to
enable several light modes of the light employed to propagate reflectively in the cable.
Use with the EP9521-0020
The EP9521-0020 is intended for combination with multimode optical fiber cables with the following
properties:
• LC Duplex plug or, in the IP67 version, PushPull LC Duplex Multimode plug (SFP version) made by
HARTING

Mounting and connection
EP9521-002018 Version: 1.2
Fig.9: Optical fiber cable with LC Duplex Multimode plugs
• Multimode cable 62.5/125µm or better 50/125µm
Recommended connectors
The PushPull LC DUPLEX plug by HARTING is compulsory for IP67 use of the box. The mechani-
cal construction guarantees the leak-tightness and suitable height offset of the fiber-optic plugs in-
side the protective housing. The plug is available from Beckhoff as a set of 10 under the order des-
ignation ZS1091-0001. Processing requires experience in the assembly of optical fiber cables!
50/125µm or 62.5/125µm
The use of both diameters is possible. However, the use of 50/125µm is recommended due to the
lower attenuation.
In optical fibers the wavelengths 850 and 1300nm are usually used for data transfer. The optical fiber cables
available on the market are mostly optimized for use in one of these ranges, since the attenuation of the
signal (as with copper cables) is frequency-dependent – long ranges of several km can then be achieved
with the respective wavelength. In general, optical fiber cables in the 1300nm window exhibit a lesser
attenuation than in the 850nm window.
In the EP9521-0020 a transceiver with the wavelength of 1300nm is used.
Range and bandwidth product
Optical fiber cables are available in different qualities from reputable manufacturers. One of the rel-
evant parameters for the user is the frequency-dependent bandwidth product of a cable, specified in
[MHzxkm]. The greater the bandwidth product, the lower the attenuation, and therefore the larger
the range that can be achieved with this cable (see ITU-T G-651). For achieving the maximum
range, optical fiber cables with a maximum bandwidth product of 1300nm should therefore be
used; we recommend using class OM2 optical fiber cables (EN50173:2002).
Standard optical fiber cables have a minimum bandwidth product of 500MHz*km at 1300nm,
higher-quality cables are suitable for distances > 500m over >1000MHz*km.
In order to achieve the maximum range, the remote device must also support such ranges.
Routing notes
The following parameters must be taken into account in the installation of optical fiber cables
• permitted bending radius
• permitted tensile strength
• sensitivity of the exposed contact ends
Further information can be found in the following documents:
• ITU recommendation ITU-T G.651 - G.655
• EN 50173:2002

Mounting and connection
EP9521-0020 19Version: 1.2
• EN 60793-2
Connecting the optical fiber cable to the box
NOTE
Do not pull on the optical fiber cable!
So as not to damage the optical fiber cable, never pull the cable when disassembling, always pull the plug
which releases the catch!
Use of crossed optical fiber cables
Please note that when connecting two EP9521-0020 modules together, crossed cables must be
used in order to establish a connection.
Fig.10: Crossed optical fiber connection
Use of blind plugs
To protect the transceiver from environmental influences, unused connection socket should be
sealed with the blind plugs provided!

Mounting and connection
EP9521-002020 Version: 1.2
4.2.3 Supply voltages
The EtherCAT Box is supplied with two supply voltages. The supply voltages are electrically isolated in the
EtherCAT Box.
• Control voltage US
• Peripheral voltage UP
Redirection of the supply voltages
The IN and OUT power connections are bridged in the module (not IP204x-Bxxx and IE204x). The supply
voltages US and UP can thus easily be transferred from EtherCATBox to EtherCATBox.
NOTE
Pay attention to the maximum permissible current!
Pay attention also for the redirection of the supply voltages US and UP, the maximum permissible current for
M8 connectors of 4A must not be exceeded!
4.2.3.1 Connectors
NOTE
Risk of confusion: supply voltages and EtherCAT
Defect possible through incorrect insertion.
• Observe the color coding of the connectors:
black: Supply voltages
green: EtherCAT
Fig.11: Connectors for supply voltages
Plug
Input
Socket
Forwarding
3 1
24
3 1
24
Fig.12: M8 connector
Contact Function Description Core color 1)
1 USControl voltage Brown
2 UPPeripheral voltage White
3 GNDSGND to USBlue
4 GNDPGND to UPBlack
1) The core colors apply to cables of the type: Beckhoff ZK2020-3xxx-xxxx