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EJ3255
User Manual
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Beckhoff EJ3255 User Manual

Documentation | EN
EJ3255
5-Channel Potentiometer Measurement with Sensor Supply
2021-03-09 | Version: 1.3

Table of contents

Table of contents
1 Foreword ....................................................................................................................................................5
1.7.1 Beckhoff Identification Code (BIC)................................................................................... 11
1.7.2 Certificates....................................................................................................................... 13
2 System overview .....................................................................................................................................14
3 Product overview.....................................................................................................................................15
3.1 EJ3255 - Introduction ......................................................................................................................15
3.2 EJ3255 - Technical data..................................................................................................................16
3.3 EJ3255 - Pinout ...............................................................................................................................17
3.4 EJ3255 - LEDs ................................................................................................................................18
4 Installation of EJ modules ......................................................................................................................19
4.1 Power supply for the EtherCAT plug-in modules.............................................................................19
4.2 EJxxxx - dimensions........................................................................................................................21
4.3 Installation positions and minimum distances .................................................................................22
4.3.1 Minimum distances for ensuring installability................................................................... 22
4.3.2 Installation positions ........................................................................................................ 23
4.4 Codings ...........................................................................................................................................25
4.4.1 Color coding..................................................................................................................... 25
4.4.2 Mechanical position coding.............................................................................................. 26
4.5 Installation on the signal distribution board .....................................................................................27
4.6 Extension options ............................................................................................................................29
4.6.1 Using placeholder modules for unused slots ................................................................... 29
4.6.2 Linking with EtherCAT Terminals and EtherCAT Box modules via an Ethernet/EtherCAT
connection ....................................................................................................................... 30
4.7 IPC integration.................................................................................................................................31
4.8 Disassembly of the signal distribution board ...................................................................................33
5 EtherCAT basics......................................................................................................................................34
6 Commissioning........................................................................................................................................35
6.1 Note on documentation for the EL3255...........................................................................................35
6.2 EJ3255 - Object description and parameterization..........................................................................35
6.2.1 Restore object.................................................................................................................. 36
6.2.2 Configuration data ........................................................................................................... 36
6.2.3 Profile-specific objects (0x6000-0xFFFF) ........................................................................ 37
6.2.4 Input data......................................................................................................................... 37
6.2.5 Configuration data vendor-specific .................................................................................. 38
6.2.6 Information and diagnostic data....................................................................................... 38
6.2.7 Standard objects (0x1000-0x1FFF) ................................................................................. 38
EJ3255 3Version: 1.3
Table of contents
7 Appendix ..................................................................................................................................................46
7.1 EtherCAT AL Status Codes.............................................................................................................46
7.2 EJ3255 - Firmware compatibility .....................................................................................................46
7.3 Firmware Update EL/ES/EM/ELM/EPxxxx ......................................................................................46
7.3.1 Device description ESI file/XML....................................................................................... 47
7.3.2 Firmware explanation ...................................................................................................... 50
7.3.3 Updating controller firmware *.efw................................................................................... 51
7.3.4 FPGA firmware *.rbf......................................................................................................... 53
7.3.5 Simultaneous updating of several EtherCAT devices...................................................... 57
7.4 Restoring the delivery state .............................................................................................................58
7.5 Support and Service ........................................................................................................................59
EJ32554 Version: 1.3
Foreword

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®, 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.
EJ3255 5Version: 1.3
Foreword

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.
EJ32556 Version: 1.3
Foreword

1.3 Intended use

WARNING
Caution - Risk of injury!
EJ components may only be used for the purposes described below!

1.4 Signal distribution board

NOTE
Signal distribution board
Make sure that the EtherCAT plug-in modules are used only on a signal distribution board that has been developed and manufactured in accordance with the Design Guide.

1.5 Documentation issue status

Version Comment
1.3 • Update chapter Technical data
1.2 • New front page
• Update chapter EJ3255 - Pinout
• Update revision status
• Structural update
1.1 • Chapters Basics communication, TwinCAT Quick Start , TwinCAT development environment and General Notes - EtherCAT Slave Application replaced by references in the chapter Guide through documentation
• Chapter EJ3255 - Object description and parameterization added
• Update chapter EJ3255 - Pinout
1.0 • First publication EJ3255

1.6 Guide through documentation

NOTE
Further components of documentation
The documentations named in the following table are further compontents of the complete documentation. These documentations are required for the use of EtherCAT plug-in mod­ules.
EJ3255 7Version: 1.3
Foreword
No. Title Description
[1]
[2]
[3]
[4] Documentation of the corresponding terminal
EtherCAT System Documentation
Infrastructure for EtherCAT/Ethernet
Design GuideSignal-Distribution-Board for standard EtherCAT plug-in modules
ELxxxx
• System overview
• EtherCAT basics
• Cable redundancy
• Hot Connect
• Distributed Clocks
• Configuration of EtherCAT-Components
• Technical recommendations and notes for design, implementation an testing
Requirements for the design of a Signal­Distribution-Board for standard EtherCAT plug-in modules
• Backplane mounting guidelines
• Module placement
• Routing guidelines
• Notes on the principle of operation and
• Descriptions for configuration and parameterization
are transferable to the corresponding Module EJxxxx (s. note on documentation of ELxxxx [}35]).

1.7 Marking of EtherCAT plug-in modules

Designation
A Beckhoff EtherCAT device has a 14-digit technical designation, made up as follows (e.g. EJ1008-0000-0017)
• Order identifier
◦ family key: EJ
◦ product designation: The first digit of product designation is used for assignment to a product
group (e.g. EJ2xxx = digital output module).
◦ Version number: The four digit version number identifies different product variants.
• Revision number: It is incremented when changes are made to the product.
The Order identifier and the revision number are printed on the side of EtherCAT plug-in modules (s. following illustration (A and B).
EJ32558 Version: 1.3
Foreword
Fig.1: Order identifier (A), Revision number (B) and serial number (C) using the example of EJ1008
Product group Example
Product designation Version Revision
EtherCAT Coupler EJ11xx
Digital input modules EJ1xxx
Digital output modules EJ2xxx
Analog input modules EJ3xxx
Analog output modules EJ4xxx
Special function modules EJ5xxx, EJ6xxx
Motion modules EJ7xxx
EJ1101 -0022
EJ1008 8-channel
EJ2521 1-channel
EJ3318 8-channel thermocouple
EJ4134 4-channel
EJ6224 IO-Link master
EJ7211 servomotor
(Coupler with external connectors, power supply module and optional ID switches
-0000 (basic type)
-0224 (2 x 24V outputs)
-0000 (basic type)
-0000 (basic type)
-0090 (with TwinSAFE SC)
-9414 (with ECT, STO and TwinSAFE SC)
Notes
• The elements mentioned above result in the technical designation. EJ1008-0000-0017 is used in the example below.
• EJ1008-0000 is the order identifier, in the case of “-0000” usually abbreviated to EJ1008.
• The revision -0017 shows the technical progress, such as the extension of features with regard to the EtherCAT communication, and is managed by Beckhoff. In principle, a device with a higher revision can replace a device with a lower revision, unless specified otherwise, e.g. in the documentation. Associated and synonymous with each revision there is usually a description (ESI, EtherCAT Slave
Information) in the form of an XML file, which is available for download from the Beckhoff web site.
• The product designation, version and revision are read as decimal numbers, even if they are technically saved in hexadecimal.
-0016
-0017
-0016
-0017
-0019
-0016
-0029
Serial number
The serial number for EtherCAT plug-in modules is usually the 8-digit number printed on the side of the module (see following illustration C). The serial number indicates the configuration in delivery state and therefore refers to a whole production batch, without distinguishing the individual modules of a batch.
EJ3255 9Version: 1.3
Foreword
Fig.2: Order identifier (A), revision number (B) and serial number (C) using the example of EJ1008
Serial number Example serial number: 08 15 08 16
KK - week of production (CW, calendar week) 08 - week of production: 08 YY - year of production 15 - year of production: 2015 FF - firmware version 08 -f irmware version: 08 HH - hardware version 16 - hardware version: 16
EJ325510 Version: 1.3
Foreword

1.7.1 Beckhoff Identification Code (BIC)

The Beckhoff Identification Code (BIC) is increasingly being applied to Beckhoff products to uniquely identify the product. The BIC is represented as a Data Matrix Code (DMC, code scheme ECC200), the content is based on the ANSI standard MH10.8.2-2016.
Fig.3: BIC as data matrix code (DMC, code scheme ECC200)
The BIC will be introduced step by step across all product groups.
Depending on the product, it can be found in the following places:
• on the packaging unit
• directly on the product (if space suffices)
• on the packaging unit and the product
The BIC is machine-readable and contains information that can also be used by the customer for handling and product management.
Each piece of information can be uniquely identified using the so-called data identifier (ANSI MH10.8.2-2016). The data identifier is followed by a character string. Both together have a maximum length according to the table below. If the information is shorter, it shall be replaced by spaces. The data under positions 1-4 are always available.
The following information is contained:
EJ3255 11Version: 1.3
Foreword
Item no.
1 Beckhoff order
2 Beckhoff Traceability
3 Article description Beckhoff article
4 Quantity Quantity in packaging
5 Batch number Optional: Year and week
6 ID/serial number Optional: Present-day
7 Variant number Optional: Product variant
...
Further types of information and data identifiers are used by Beckhoff and serve internal processes.
Structure of the BIC
Type of informa­tion
number
Number (BTN)
Explanation Data iden-
tifier
Beckhoff order number 1P 8 1P072222
Unique serial number, see note below
description, e.g. EL1008
unit, e.g. 1, 10, etc.
of production
serial number system, e.g. with safety products
number on the basis of standard products
S 12 SBTNk4p562d7
1K 32 1KEL1809
Q 6 Q1
2P 14 2P4015031800
51S 12 51S678294104
30P 32 30PF971 ,
Number of digits incl. data identifier
Example
16
2*K183
Example of composite information from items 1 - 4 and 6. The data identifiers are marked in red for better display:
BTN
An important component of the BIC is the Beckhoff Traceability Number (BTN, item no. 2). The BTN is a unique serial number consisting of eight characters that will replace all other serial number systems at Beckhoff in the long term (e.g. batch designations on IO components, previous serial number range for safety products, etc.). The BTN will also be introduced step by step, so it may happen that the BTN is not yet coded in the BIC
Notice
This information has been carefully prepared. However, the procedure described is constantly being further developed. We reserve the right to revise and change procedures and documentation at any time and without prior notice. No claims for changes can be made from the information, illustrations and descriptions in this information.
EJ325512 Version: 1.3

1.7.2 Certificates

• The EhterCAT plug-in modules meet the requirements of the EMC and Low Voltage Directive. The CE mark is printed on the side of the modules.
• The cRUus imprint identifies devices that meet product safety requirements according to U.S. and Canadian regulations.
• The warning symbol is a request to read the corresponding documentation. The documentations for EtherCAT plug-in modules can be downloaded from the Beckhoff homepage.
Foreword
Fig.4: Marking for CE and UL using EJ1008 as an example
EJ3255 13Version: 1.3
System overview

2 System overview

Electronically, the EJxxxx EtherCAT plug-in modules are based on the EtherCAT I/O system. The EJ system consists of the signal distribution board and EtherCAT plug-in modules. It is also possible to connect an IPC to the EJ system. The EJ system is suitable for mass production applications, applications with small footprint and applications requiring a low total weight. The machine complexity can be extended by means of the following:
• reserve slots,
• the use of placeholder modules,
• linking of EtherCAT Terminals and EtherCAT Boxes via an EtherCAT connection.
The following diagram illustrates an EJ system. The components shown are schematic, to illustrate the functionality.
Fig.5: EJ system sample
Signal distribution board
The signal distribution board distributes the signals and the power supply to individual application-specific plug connectors, in order to connect the controller to further machine modules. Using pre-assembled cable harnesses avoids the need for time-consuming connection of individual wires. Coded components reduce the unit costs and the risk of miswiring. Beckhoff offers development of signal distribution boards as an engineering service. Customers have the option to develop their own signal distribution board, based on the design guide.
EtherCAT plug-in modules
Similar to the EtherCAT terminal system, a module strand consists of a Bus Coupler and I/O modules. Almost all of the EtherCAT Terminals can also be manufactured in the EJ design as EtherCAT plug-in modules. The EJ modules are directly attached to the signal distribution board. The communication, signal distribution and supply take place via the contact pins at the rear of the modules and the PCB tracks of the signal distribution board. The coding pins at the rear serve as mechanical protection against incorrect connection. Color coding on the housing facilitates distinguishing of the modules.
EJ325514 Version: 1.3

3 Product overview

3.1 EJ3255 - Introduction

Product overview
Fig.6: EJ3255
5-channel analog input module, potentiometer measurement with Sensor supply
The EJ3255 EtherCAT plug-in module enables potentiometers to be connected directly. A stabilized power supply in the module for the connected potentiometers and ratiometric measurement of the input voltage offer the prerequisites for precise measuring. On account of its high sampling rate and together with potentiometer position encoders, the compact, 5-channel EtherCAT plug-in module enables a temporally high-resolution and cost-efficient position detection.
The EJ3255 diagnostics detect broken wire, loss of supply voltage and short-circuit for each channel.
The 5 channels are measured simultaneously (at the same time).
EJ3255 15Version: 1.3
Product overview

3.2 EJ3255 - Technical data

Technical data EJ3255
Number of analog inputs 5 Power supply via Up contacts Technology ratiometric potentiometer evaluation with own supply, 3-wire
connection Distributed Clocks yes Feed voltage potentiometer typ. 10V±10% Internal resistance >> 100kΩ to wiper connection Input filter limit frequency typ. -3dB at 3kHz and potentiometer 50kΩ Sensor types Potentiometer 300Ω ..50kΩ Output current Max. 0.3A total supply current for the potentiometers Wiring fail indication yes Conversion time typ. 300 ..700µs, dependent on settings,
default setting: approx.. 500µs (5 channels, filter deactivated) Resolution 16bits representation (including sign) Measuring error (total measuring
range) Electrical isolation 500V (E-bus/signal voltage) Current consumption load voltage (Up
contacts) Current consumption via E-bus typ. 80mA Special Features Open-circuit recognition, supply monitoring, activatable filters
Permissible ambient temperature range during operation
Permissible ambient temperature range during storage
Permissible relative air humidity 95%, no condensation Operating altitude max. 2,000m Dimensions (WxHxD) approx. 12mm x 66mm x 55mm Weight app.30g Mounting on signal distribution board Pollution degree 2 Installation position
Position of the coding pins [}26]
Color coding green Vibration/shock resistance according to EN60068-2-6/EN60068-2-27 (with corresponding
EMC immunity/emission according to EN61000-6-2/EN61000-6-4 (with corresponding
Protection class EJ module: IP20
Approval CE
< ± 0.5% (relative to full scale value)
dependent on the potentiometers, max. 125mA
simultaneous measurement of the channels
0°C .. +55°C
-25°C .. +85°C
Standard [}23]
1 and 6
signal distribution board)
signal distribution board)
EJ system: Dependent on the signal distribution board
CE approval
The CE Marking refers to the EtherCAT plug-in module mentioned above. If the EtherCAT plug-in module is used in the production of a ready-to-use end product (PCB in con­junction with a housing), the manufacturer of the end product must check compliance of the overall system with relevant directives and CE certification. To operate the EtherCAT plug-in modules, they must be installed in a housing.
EJ325516 Version: 1.3

3.3 EJ3255 - Pinout

Product overview
Fig.7: EJ3255 - Pinout
The PCB footprint can be downloaded from the Beckhoff homepage.
NOTE
Damage to devices possible!
• The pins named with “NC” must not be connected.
• Before installation and commissioning read the chapters Installation of EJ modules [}19] and Commissioning [}35]!
EJ3255 17Version: 1.3
Product overview

3.4 EJ3255 - LEDs

Fig.8: EJ3255 - LEDs
LED Color Display State Description
RUN green off Init State of the EtherCAT State Machine: INIT = initialization of the plug-in module
flashing Pre-Operational State of the EtherCAT State Machine: PREOP = function for mailbox commu-
single flash Safe-Operational State of the EtherCAT State Machine: SAFEOP = verification of the Sync Man-
on Operational State of the EtherCAT State Machine: OP = normal operating state; mailbox
flickering Bootstrap
Up green off - No 24VDC power supply connected
on - 24VDC power supply connected
ERR1 ERR2 ERR3 ERR4 ERR5
red off - No error
on - There is an error on the corresponding channel:
nication and different default settings set
ager channels and the distributed clocks. Outputs remain in safe state
and process data communication is possible
State of the EtherCAT State Machine: BOOTSTRAP = function for firmware updates [}46] of the plug-in module
• Broken wire on wiper or supply
• Potentiometer outside the specified range (300..50kΩ)
• Short-circuit
• Overload
If channels are not used they can be deactivated via the PDO selection. The corresponding LED goes out.
EJ325518 Version: 1.3
Installation of EJ modules

4 Installation of EJ modules

4.1 Power supply for the EtherCAT plug-in modules

WARNING
Power supply
A SELV/PELV power supply must be used to supply power for the EJ coupler and modules. Couplers and modules have to be connected to SELV/PELV circuits exclusively.
The signal distribution board should have a power supply designed for the maximum possible current load of the module string. Information on the current required from the E-bus supply can be found for each module in the respective documentation in section “Technical data”, online and in the catalog. The power requirement of the module string is displayed in the TwinCAT System Manager.
E-bus power supply with EJ1100 or EJ1101-0022 and EJ940x
The EJ1100 Bus Coupler supplies the connected EJ modules with the E-bus system voltage of 3.3V. The Coupler can accommodate a load up to 2.2A. If a higher current is required, a combination of the coupler EJ1101-0022 and the power supply units EJ9400 (2.5A) or EJ9404 (12A) should be used. The EJ940x power supply units can be used as additional supply modules in the module string.
Depending on the application, the following combinations for the E-bus supply are available:
Fig.9: E-bus power supply with EJ1100 or EJ1101-0022 + EJ940x
In the EJ1101-0022 coupler, the RJ45 connectors and optional ID switches are external and can be positioned anywhere on the signal distribution board, as required. This facilitates feeding through a housing.
The EJ940x power supply plug-in modules provide an optional reset function (see chapter Connection of the documentation for EJ9400 and EJ9404)
EJ3255 19Version: 1.3
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