Beckhoff: Ethernet-APL – A New Communication Standard for the Process Industry
December 3, 2025
Ethernet-APL: How Does It Work?
As digitalization continues in the process industry, the volumes of data provided by intelligent sensors and actuators are also growing. For a long time, however, there was no communication standard to transmit this data quickly and across multiple levels of the automation structure. Certain properties have to be present for use in process industry plants, such as the ability to connect field devices over long distances and the ensuring of explosion protection.
Thus, to meet these requirements, process industry organizations and companies have developed the Ethernet Advanced Physical Layer (Ethernet-APL). This new communication technology is based on the 10BASE-T1L Ethernet standard, which allows a maximum cable length of 1000 meters and a transmission rate of 10 Mbit/s. Power supply limits in all zones throughout the hazardous area are defined by IEC specification 60079-47 (2-WISE). Power and data are transmitted over the same pair of wires (single pair Ethernet) with Ethernet-APL.
To simplify installation and improve the connectivity of the devices used, the project group has also defined port profiles in the TS10186 technical specification: In addition to information on the connection and segment class, a port profile also includes the Ex approval of the respective device connection.
Advantages of Ethernet-APL for the Process Industry
- Power and data transmission via a single pair of wires
- Seamless communication of all field device data
- Long range thanks to flexible topologies
- Transmission rate up to 300 times faster than existing communication standards in the process industry
- Flexible application for various protocols such as PROFINET, EtherNet/IP, and OPC UA
- Proof of intrinsic safety is not required due to defined properties of the connections and cables
- Rapid integration into existing systems through the use of existing cables
- Simple implementation of the NAMUR Open Architecture
Ability to Implement Ethernet-APL on a Modular Basis with Beckhoff
The vision of the Ethernet-APL concept is to implement the entire communication in process technology plants – from the field level to higher-level control systems – on an Ethernet basis. New APL-capable field devices are also required to convert entire plants. Since the technology is still relatively new and involves a high level of development work, the market does not yet offer a broad range of devices. The added value of a transmission rate of 10 MBit/s is also limited for simple digital sensors.
This is why Beckhoff integrates the Ethernet-APL technology into its modular terminal portfolio. The compact ELX6233 can be mounted in the control cabinet in combination with other EtherCAT Terminals. Two Ethernet-APL field devices can be connected via each ELX6233 terminal. As with all EtherCAT Terminals in the ELX series, the ELX6233 enables the direct connection of intrinsically safe field devices from zone 0 and zone 1.
The new EL6233 EtherCAT Terminal is available for applications with less stringent explosion protection requirements. It makes it possible to connect field devices from zone 2 hazardous areas and can also be integrated into the terminal segment on a modular basis.
Benefits of Ethernet-APL Integration with Beckhoff
Modular & Flexible Combination Options
The Beckhoff system solution allows all EtherCAT Terminals to be interconnected without requiring special tools. Both the ELX6233 and the EL6233 feature a standard housing and can therefore be easily integrated into existing terminal segments. When it comes to digitalization, direct connection to CX Embedded PCs in particular offers a whole host of advantages, including enabling gateway applications to process data from the field and filter it before sharing it further.
For more information HERE
Explosion-Proof: Connection of Intrinsically Safe Field Devices
Like many of Beckhoff’s EtherCAT Terminals, the EL6233 and ELX6233 are suitable for mounting in zone 2 hazardous areas. What’s more, the special circuitry means the ports of the ELX terminal offer the highest explosion protection class and allow the connection of intrinsically safe field devices from zone 0. The parameters are adapted to suit the specifications of IEC 60079-47 and follow the SPAA port profile.
For more information HERE
Space Saving Solution
The ELX6233 or EL6233 allows you to create exactly the number of Ethernet-APL channels you need in your control cabinet. Its compact design not only saves you space, but also costs. And with a width of just 12 or 24 mm, the EtherCAT Terminals fit into any application, whether it’s a large process technology plant or a compact test setup.
For more information HERE
Fast Communication with EtherCAT
Unlike in many PROFINET architectures, the controller is located directly in the EtherCAT Terminal and not in the higher-level controller. Since EtherCAT enables a more compact data size of the process image compared to PROFINET, the performance can be significantly increased in terms of cycle times. Data security is also higher than with classic switched networks due to the separation of individual ports and protocols.
For more information HERE
Functional Safety with PROFIsafe
Many of the field devices that will be connected via Ethernet-APL in the future will fulfill safety-related functions. Communication via PROFIsafe is therefore an important component of the Ethernet-APL technology package. PROFIsafe devices are still integrated via the EL6233 or the ELX6233. The only thing that needs to be added to the application is an EL6930.
For more information HERE
Easy Changeover from HART to Ethernet-APL
The modular design of the EtherCAT Terminals enables the EL6233 or ELX6233 to be combined with other EtherCAT Terminals, such as the EL3184 or ELX3184. In brownfield plants in particular, it may make sense to gradually switch from the familiar HART protocol to Ethernet-APL for warehousing reasons and due to the installed base. For these applications, the stations (small controller + terminals) can be preconfigured so that the technology can be changed by maintenance personnel as part of a simple device replacement.
For more information on Beckhoff’s solutions HERE
