Frequently Asked Questions onBeckhoff Products Installation, Wiring, and EMC Design Specifications - Expert Advice for Equipment Setup
1. How do you connect an NPN output sensor to a PNP input module?
Connect a 2k resistor between 24V and the module input, and directly connect the NPN sensor's output to the module input.
2. What are the respective functions of the two sets of 24V power input terminals on couplers and controllers?
All Beckhoff couplers and controllers have two sets of 24V power input terminals, Us and Up. Us supplies power for the coupler (controller) operation and K-bus (E-bus) communication, while Up is used to provide power for the coils of the connected output IO modules. The two sets of power sources require isolation.
3. If using a 5V-powered IO module, can a 5V voltage be directly supplied to the second power input terminal of the coupler (controller)?
To use a 5V IO module, you must add a 5V system module KL(EL)9505. You cannot directly supply a 5V voltage to the second power input terminal (Us) of the coupler (controller).
4. In the description of connector ZS2001-0002, what does "1-pin" mean?
On the left side, there are 3 pins, and on the right side, there is 1 pin. The red, blue, and black wires in the diagram all need to be connected additionally.
5.How do I connect the power supply for measuring resistance?
To measure resistance, you need to connect a power supply. How should I connect it?
Just ensure that the purple area is properly powered. Follow the wiring diagram for the connection.
6. Can the controller be protected from damage if there is a high voltage input to the IO module?
No, it can be damaged. Therefore, it is essential to use separate switching power supplies for Us and Up. Us powers the CPU, while Up powers the IO modules. If high voltage were to enter Up, only the IO modules would be damaged.
7. In the wiring diagrams for controllers and couplers, 24v/0v is indicated as the power supply for the e-bus. What do the +/- symbols represent for power supply?
24v/0v provides power to the controller and the e-bus, while +/- is primarily responsible for powering the IO loads. These two circuits require independent power supplies.
8. Can tube terminals be used for wiring EL/KL series modules?
Tube terminals are not necessary if the cables are single-core rigid wires. However, for multi-core flexible cables, especially those used with 16-channel modules, tube terminals must be crimped before wiring. It should be noted that tube terminal crimping requires special crimping tools. Currently, there are two commonly used types of crimping pliers on the market, and the differences between them should be taken into account:
9. Can the GND and PE interfaces on an EL module be interconnected for grounding?
No, they cannot. GND is the signal ground, and PE is the protective ground.
10. What is the recommended distance between the CX2040 controller and the enclosure during installation to ensure proper heat dissipation?
Please refer to the distance indicated in the diagram:
For 8-channel modules, it is recommended to use ZB8700.
For 16-channel modules, it is recommended to use ZB8701.
14.When using the ZB8610 fan, it does not operate after connecting 24V and 0V.
The fan will only start operating when the temperature reaches above 35°C. 
15. When using the ZB8610, the LED light is constantly green, and the temperature has already exceeded 60°C, but the fan still does not rotate.
The constant green LED light indicates that the ZB8610 is in the run state. However, it should be noted that, besides the 24V and 0V power supply, the mode pin must also be wired for the ZB8610. If speed control is not required and full speed is desired, simply connecting it to 24V will suffice.
16. What is the difference between PE (Protective Earth) and FE (Functional Earth)?
Cable Model: ZK1091-1001-0xxx
18. What are the differences between cables made of these three materials (PUR, PVC, PP)?
The first type can be placed in movable locations, while the latter two can only be installed fixedly. PP can withstand temperatures up to 100°C and is resistant to acids and alkalis, while PVC operates within a temperature range of -15°C to 55°C.
19.Solution for Tripping of Servo and Inverter Electrical Control Cabinets Equipped with Leakage Detection Circuit Breakers
For electrical control cabinets equipped with servo drives and inverters, leakage detection circuit breakers should not be installed in their power supply circuits. If it is necessary to install them, an isolation transformer should be added between the circuit breaker and the electrical control cabinet. To ensure that leakage current is properly grounded and does not harm humans, the shells of the electrical control cabinet and isolation transformer should be well grounded, with the grounding resistance of the grounding pile being less than 4 ohms. A 16mm² grounding wire should be used from the grounding pile to the equipment shell. (If a single grounding pile cannot meet the requirement of less than 4 ohms, multiple grounding piles can be installed in parallel until the grounding requirement is met.)
The grounding resistance of the grounding pile can be measured using a Shengli 4105A grounding resistance tester.
20.Method to Avoid Power Supply Damage of CX Controllers
Due to potential instability in the customer's power supply system, such as poor PE grounding or PE intrusion into high voltage, which may cause damage to the power supply of our CX controllers. Therefore, it is recommended that customers install fuses in the power supply circuit of the CX controllers when designing the electrical cabinet, as shown in the following diagram:
Special Note: Fuse protection should be added to both the 0V and 24V power supplies.
This method is equally applicable to BK, BC, BX, CX9000, CX5000, CPxxxx, industrial computers, and other similar devices.
Connect a 2k resistor between 24V and the module input, and directly connect the NPN sensor's output to the module input.
2. What are the respective functions of the two sets of 24V power input terminals on couplers and controllers?
All Beckhoff couplers and controllers have two sets of 24V power input terminals, Us and Up. Us supplies power for the coupler (controller) operation and K-bus (E-bus) communication, while Up is used to provide power for the coils of the connected output IO modules. The two sets of power sources require isolation.
3. If using a 5V-powered IO module, can a 5V voltage be directly supplied to the second power input terminal of the coupler (controller)?
To use a 5V IO module, you must add a 5V system module KL(EL)9505. You cannot directly supply a 5V voltage to the second power input terminal (Us) of the coupler (controller).
4. In the description of connector ZS2001-0002, what does "1-pin" mean?
On the left side, there are 3 pins, and on the right side, there is 1 pin. The red, blue, and black wires in the diagram all need to be connected additionally.
5.How do I connect the power supply for measuring resistance?
To measure resistance, you need to connect a power supply. How should I connect it?
Just ensure that the purple area is properly powered. Follow the wiring diagram for the connection.
6. Can the controller be protected from damage if there is a high voltage input to the IO module?
No, it can be damaged. Therefore, it is essential to use separate switching power supplies for Us and Up. Us powers the CPU, while Up powers the IO modules. If high voltage were to enter Up, only the IO modules would be damaged.
7. In the wiring diagrams for controllers and couplers, 24v/0v is indicated as the power supply for the e-bus. What do the +/- symbols represent for power supply?
24v/0v provides power to the controller and the e-bus, while +/- is primarily responsible for powering the IO loads. These two circuits require independent power supplies.
8. Can tube terminals be used for wiring EL/KL series modules?
Tube terminals are not necessary if the cables are single-core rigid wires. However, for multi-core flexible cables, especially those used with 16-channel modules, tube terminals must be crimped before wiring. It should be noted that tube terminal crimping requires special crimping tools. Currently, there are two commonly used types of crimping pliers on the market, and the differences between them should be taken into account:
9. Can the GND and PE interfaces on an EL module be interconnected for grounding?
No, they cannot. GND is the signal ground, and PE is the protective ground.
10. What is the recommended distance between the CX2040 controller and the enclosure during installation to ensure proper heat dissipation?
Please refer to the distance indicated in the diagram:
- How to Confirm if a Specific Cable Model Supports Drag Chains?
Visit the official website and search for the cable:
https://www.beckhoff.com.cn/zh-cn/products/i-o/accessories/cable-by-the-meter/ethercat-and-fieldbus-cables/
- Wiring Diagram for the M8 Connector of ZS1090-1006
13.Screwdriver Model for Wiring Beckhoff IO Modules
For 8-channel modules, it is recommended to use ZB8700.
For 16-channel modules, it is recommended to use ZB8701.
The fan will only start operating when the temperature reaches above 35°C.
15. When using the ZB8610, the LED light is constantly green, and the temperature has already exceeded 60°C, but the fan still does not rotate.
The constant green LED light indicates that the ZB8610 is in the run state. However, it should be noted that, besides the 24V and 0V power supply, the mode pin must also be wired for the ZB8610. If speed control is not required and full speed is desired, simply connecting it to 24V will suffice.
16. What is the difference between PE (Protective Earth) and FE (Functional Earth)?
protective earth or circuit protective
earth is intended to protect the personals from electric shock during an earth
fault in any appliances he/she is using. This earth conductor will have a
connection from appliances metalic exposed part up to the main earth terminal
in the supply intake room. The fault current will flow through this conductor
to the eart mass which will in turn on the protective devices such as MCB or
RCD to safely open the circuit within 0.4 seconds.
Functional earth is intended to reduce the radio frequency noise, computer
filters to enhance the clarity of signals or other equipments which have always
10mA leakage current. Functional earthing must be separated from installation
earthing except at the main earth terminal connection point.
Cable Model: ZK1091-1001-0xxx
connector Z1190
https://infosys.beckhoff.com/content/1033/cu15x1/2158319627.html?id=2187930038212849660
18. What are the differences between cables made of these three materials (PUR, PVC, PP)?
19.Solution for Tripping of Servo and Inverter Electrical Control Cabinets Equipped with Leakage Detection Circuit Breakers
For electrical control cabinets equipped with servo drives and inverters, leakage detection circuit breakers should not be installed in their power supply circuits. If it is necessary to install them, an isolation transformer should be added between the circuit breaker and the electrical control cabinet. To ensure that leakage current is properly grounded and does not harm humans, the shells of the electrical control cabinet and isolation transformer should be well grounded, with the grounding resistance of the grounding pile being less than 4 ohms. A 16mm² grounding wire should be used from the grounding pile to the equipment shell. (If a single grounding pile cannot meet the requirement of less than 4 ohms, multiple grounding piles can be installed in parallel until the grounding requirement is met.)
The grounding resistance of the grounding pile can be measured using a Shengli 4105A grounding resistance tester.
20.Method to Avoid Power Supply Damage of CX Controllers
Due to potential instability in the customer's power supply system, such as poor PE grounding or PE intrusion into high voltage, which may cause damage to the power supply of our CX controllers. Therefore, it is recommended that customers install fuses in the power supply circuit of the CX controllers when designing the electrical cabinet, as shown in the following diagram:
Special Note: Fuse protection should be added to both the 0V and 24V power supplies.
This method is equally applicable to BK, BC, BX, CX9000, CX5000, CPxxxx, industrial computers, and other similar devices.