Beckhoff EJ9576 User guide
Documentation
EJ9576
Brake chopper module
Version:
Date:
1.1
2019-11-12
Table of contents
Table of contents
1 Foreword ....................................................................................................................................................5
1.1 Notes on the documentation..............................................................................................................5
1.2 Safety instructions .............................................................................................................................6
1.3 Intended use......................................................................................................................................7
1.4 Signal distribution board ....................................................................................................................7
1.5 Documentation issue status ..............................................................................................................7
1.6 Marking of EtherCAT plug-in modules...............................................................................................7
1.6.1 Beckhoff Identification Code (BIC)................................................................................... 10
1.6.2 Certificates....................................................................................................................... 12
2 System overview .....................................................................................................................................13
3 Product overview.....................................................................................................................................14
3.1 EJ9576 - Introduction ......................................................................................................................14
3.2 EJ9576 - Technical data..................................................................................................................15
3.3 EJ9576 - Pinout ...............................................................................................................................16
3.4 EJ9576 - LEDs ................................................................................................................................17
4 Installation of EJ modules ......................................................................................................................18
4.1 Power supply for the EtherCAT plug-in modules.............................................................................18
4.2 EJxxxx - dimensions........................................................................................................................20
4.3 Installation positions and minimum distances .................................................................................21
4.3.1 Minimum distances for ensuring installability................................................................... 21
4.3.2 Installation positions ........................................................................................................ 22
4.4 Codings ...........................................................................................................................................24
4.4.1 Color coding..................................................................................................................... 24
4.4.2 Mechanical position coding.............................................................................................. 25
4.5 Installation on the signal distribution board .....................................................................................26
4.6 Extension options ............................................................................................................................28
4.6.1 Using placeholder modules for unused slots ................................................................... 28
4.6.2 Linking with EtherCAT Terminals and EtherCAT Box modules via an Ethernet/EtherCAT
connection ....................................................................................................................... 29
4.7 IPC integration.................................................................................................................................30
4.8 Disassembly of the signal distribution board ...................................................................................32
5 Basics communication ...........................................................................................................................33
5.1 EtherCAT basics..............................................................................................................................33
5.2 EtherCAT devices - cabling - wired .................................................................................................33
5.3 General notes for setting the watchdog...........................................................................................34
5.4 EtherCAT State Machine.................................................................................................................36
5.5 CoE Interface...................................................................................................................................38
5.6 Distributed Clock .............................................................................................................................43
6 Commissioning........................................................................................................................................44
6.1 TwinCAT Quick Start .......................................................................................................................44
6.1.1 TwinCAT2 ....................................................................................................................... 47
6.1.2 TwinCAT 3 ....................................................................................................................... 57
6.2 TwinCAT Development Environment ..............................................................................................69
EJ9576 3Version: 1.1
Table of contents
6.2.1 Installation of the TwinCAT real-time driver..................................................................... 69
6.2.2 Notes regarding ESI device description........................................................................... 75
6.2.3 TwinCAT ESI Updater ..................................................................................................... 79
6.2.4 Distinction between Online and Offline............................................................................ 79
6.2.5 OFFLINE configuration creation ...................................................................................... 80
6.2.6 ONLINE configuration creation ........................................................................................ 85
6.2.7 EtherCAT subscriber configuration.................................................................................. 93
6.3 General notes for commissioning of the EtherCAT slave..............................................................102
6.4 Parameterization ...........................................................................................................................111
6.5 Note on documentation EL9576 ....................................................................................................112
7 Appendix ................................................................................................................................................113
7.1 EtherCAT AL Status Codes...........................................................................................................113
7.2 EJ9576 - Firmware compatibility ...................................................................................................113
7.3 Firmware Update EL/ES/EM/ELM/EPxxxx ....................................................................................113
7.3.1 Device description ESI file/XML..................................................................................... 114
7.3.2 Firmware explanation .................................................................................................... 117
7.3.3 Updating controller firmware *.efw................................................................................. 118
7.3.4 FPGA firmware *.rbf....................................................................................................... 120
7.3.5 Simultaneous updating of several EtherCAT devices.................................................... 124
7.4 Restoring the delivery state ...........................................................................................................125
7.5 Support and Service ......................................................................................................................126
EJ95764 Version: 1.1
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®, EtherCATG®, EtherCATG10®, EtherCATP®, SafetyoverEtherCAT®,
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.
EJ9576 5Version: 1.1
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.
EJ95766 Version: 1.1
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
1.1 • Note Signal distribution board added
• Chapter Version identification of EtherCAT devices replaced by chapter Marking
of EtherCAT plug-in modules
• Update chapter Technical data
• Update chapter Pinout
1.0 First publication EJ9576
1.6 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).
EJ9576 7Version: 1.1
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 24V 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.
EJ95768 Version: 1.1
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
EJ9576 9Version: 1.1
Foreword
1.6.1 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:
EJ957610 Version: 1.1
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.
EJ9576 11Version: 1.1
Foreword
1.6.2 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.
Fig.4: Marking for CE and UL using EJ1008 as an example
EJ957612 Version: 1.1
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.
EJ9576 13Version: 1.1
Product overview
3 Product overview
3.1 EJ9576 - Introduction
Fig.6: EJ9576
Brake chopper terminal
The EJ9576 power supply module contains high-performance capacitors for stabilizing supply voltages.
The EJ9576 can be used, for example, in conjunction with the EL7047 stepper motor terminal, the EJ7342
DC motor module or the EL7211-0010 servo motor module. Low internal resistance and high pulsed current
capability enable good buffering in parallel with a power supply unit.
Return currents are stored, particularly in the context of drive applications, thereby preventing overvoltages.
If the recovery energy exceeds the capacity of the capacitors, energy can be dissipated via an external
ballast resistor. The switching threshold for this can be parameterized via the TwinCAT System Manager.
EJ957614 Version: 1.1
Product overview
3.2 EJ9576 - Technical data
Technical data EJ9576
Technology brake chopper
E-Bus current consumption typ. 85mA
Rated voltage up to 72V
Capacitance 155µF
Ripple current 10A
Internal resistance <5mΩ
Chopper voltage adjustable
Recommended ballast resistor 10Ω, 100W typ. (application-dependent)
Overvoltage control range 1V typ., parameterizable via CoE data
Ballast resistor clock rate load-dependent, max. 1ms, 2-point control
Electrical isolation 1500V (E-bus/field-side)
Diagnostics temperature on the PCB, over-/undervoltage
Special features Adjustable threshold
permissible ambient temperature range during operation 0°C .. +55°C
permissible ambient temperature range during storage -25°C .. +85°C
permissible relative humidity 95%, no condensation
Operation altitude max. 2,000m
Dimensions (W x H x D) approx. 12mm x 66mm x 55mm
Weight approx. 30g
Mounting on signal distribution board
Mounting positon
Pollution degree 2
Position of coding pins [}25]
Color coding grey
Vibration/shock resistance according to EN 60068-2-6/EN 60068-2-27, (with corresponding signal distri-
EMC immunity/emission conforms to EN 61000-6-2 / EN 61000-6-4, (with corresponding signal distri-
Protection class EJ module: IP20
Approval CE, UL
Standard [}22]
6 and 8
bution board)
bution board)
EJ system: dependent on the signal distribution board and housing
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.
EJ9576 15Version: 1.1
Product overview
3.3 EJ9576 - Pinout
Fig.7: EJ9576 - Pinout
The PCB footprint can be downloaded from the Beckhoff homepage.
NOTE
Damage to devices possible!
Before installation and commissioning read the chapters Installation of EJ modules [}18]
and Commissioning [}44]!
EJ957616 Version: 1.1
3.4 EJ9576 - LEDs
Product overview
Fig.8: EJ9576 - LEDs
LEDs
LED Color Display State Meaning
RUN green off Init
blinking Pre-
single flash Safe-
on Operational State of the EtherCAT State Machine: OP = Normal operation mode, mail-
flickering Bootstrap
Out U OK green ON - Supply voltages are OK, there are no errors
OFF - • Supply voltage is incorrect, i.e. too high or too low
Chop. ON Yellow ON - The external resistor is switched on.
Over U Yellow ON - The supply voltage has exceeded the threshold value for overvoltage.
Under U Yellow ON - The supply voltage is too low, or has fallen below the corresponding thresh-
T. Warn. Yellow ON - Temperature threshold value for the temperature on the PCB has been ex-
T. R. Warn. Yellow ON - The I2T warning level threshold value has been exceeded.
Error red ON +
Undervoltage LED
ON +
LED T.R. Warn. +
LED Over U
Operational
Operational
- The supply voltage is not connected or is so low that the supply voltage and
- There is an overtemperature in the temperature simulation for the external
State of the EtherCAT State Machine [}36]: INIT = Initialization of the terminal or BOOTSTRAP = Function for firmware updates of the terminal
State of the EtherCAT State Machine: PREOP = Setting for mailbox communication and variant standard settings
State of the EtherCAT State Machine: SAFEOP = Channel checking of the
Sync Manager [}101] and the Distributed Clocks. Outputs stay in safe oper-
ation mode.
box- and process data communication possible
State of the EtherCAT State Machine: BOOTSTRAP = function for firmware
updates [}113] of the plug-in module
• Overtemperature in the temperature simulation
• Temperature at the module too high
old value in the CoE data.
ceeded.
ResistorCurrent values cannot be read.
resistor.
EJ9576 17Version: 1.1
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 (see Current consumption of
the EJ modules from the E-bus [}109]).
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 3.3V. The
Coupler can accommodate a load up to 2.2A. If a higher current is required, a combination of the coupler
EJ1101-0022 and the power supply units EJ9400 (2.5A) or EJ9404 (12A) 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)
EJ957618 Version: 1.1
Installation of EJ modules
E-bus power supply with CXxxxx and EK1110-0043
The Embedded PC supplies the attached EtherCAT Terminals and the EtherCAT EJ Coupler
• with a supply voltage of 24VDC (-15 %/+20%). This voltage supplies the E-bus and the Bus Terminal
electronics.
The CXxxxx units supply the E-bus with up to 2,000mA E-bus current. If a higher current is required
due to the attached terminals, power feed terminals or power supply plug-in modules must be used for
the E-bus supply.
• with a peripheral voltage Up of 24VDC to supply the field electronics.
The EK1110-0043 EtherCAT EJ Coupler relays the following parameters to the signal distribution board via
the rear connector:
• the E-bus signals,
• the E-bus voltage U
(3.3V) and
EBUS
• the peripheral voltage UP (24VDC).
Fig.10: PCB with Embedded PC, EK1110-0043 and EJxxxx, rear view EK1110-0043
EJ9576 19Version: 1.1
Installation of EJ modules
4.2 EJxxxx - dimensions
The EJ modules are compact and lightweight thanks to their design. Their volume is approx. 50% smaller
than the volume of the EL terminals. A distinction is made between four different module types, depending
on the width and the height:
Module type Dimensions (W x H x D) Sample in figure below
Coupler 44mm x 66mm x 55mm EJ1100 (ej_44_2xrj45_coupler)
Single module 12mm x 66mm x 55mm EJ1809 (ej_12_16pin_code13)
Double module 24mm x 66mm x 55mm EJ7342 (ej_24_2x16pin_code18)
Single module (long) 12mm x 152mm x 55mm EJ1957 (ej_12_2x16pin_extended_code4747)
Fig.11: EJxxxx - Dimensions
The technical drawings can be downloaded from the download finder. The drawings are named as
described in the drawing below.
Fig.12: Technical drawings from download finder
EJ957620 Version: 1.1
Installation of EJ modules
4.3 Installation positions and minimum distances
4.3.1 Minimum distances for ensuring installability
Note the dimensions shown in the following diagram for the design of the signal distribution board to ensure
safe latching and simple assembly / disassembly of the modules.
Fig.13: Mounting distances EJ module - PCB
Observing the reaching area
A minimum reaching area of 92mm is required for assembly / disassembly, in order to be able to
reach the mounting tabs with the fingers.
Adherence to the recommended minimum distances for ventilation (see section Installation position
[}22]) ensures an adequate reaching area.
The signal distribution board must have a thickness of 1.6mm and a minimum distance of 4mm from the
mounting surface, in order to ensure latching of the modules on the board.
EJ9576 21Version: 1.1
Installation of EJ modules
4.3.2 Installation positions
NOTE
Constraints regarding installation position and operating temperature range
Please refer to the technical data [}15] for the installed components to ascertain whether any restrictions
regarding the mounting position and/or the operating temperature range have been specified. During installation of modules with increased thermal dissipation, ensure adequate distance above and below the modules to other components in order to ensure adequate ventilation of the modules during operation!
The standard installation position is recommended. If a different installation position is used, check whether
additional ventilation measures are required.
Ensure that the specified conditions (see Technical data) are adhered to!
Optimum installation position (standard)
For the optimum installation position the signal distribution board is installed horizontally, and the fronts of
the EJ modules face forward (see Fig. Recommended distances for standard installation position). The
modules are ventilated from below, which enables optimum cooling of the electronics through convection.
"From below" is relative to the acceleration of gravity.
Fig.14: Recommended distances for standard installation position
Compliance with the distances shown in Fig. Recommended distances for standard installation position” is
recommend. The recommended minimum distances should not be regarded as restricted areas for other
components. The customer is responsible for verifying compliance with the environmental conditions
described in the technical data. Additional cooling measures must be provided, if required.
EJ957622 Version: 1.1
Installation of EJ modules
Other installation positions
All other installation positions are characterized by a different spatial position of the signal distribution board,
see Fig. “Other installation positions”.
The minimum distances to ambient specified above also apply to these installation positions.
Fig.15: Other installation positions
EJ9576 23Version: 1.1
Installation of EJ modules
4.4 Codings
4.4.1 Color coding
Fig.16: EJ modules color code; sample: EJ1809
The EJ modules are color-coded for a better overview in the control cabinet (see diagram above). The color
code indicates the signal type. The following table provides an overview of the signal types with
corresponding color coding.
Signal type Modules Color
Coupler EJ11xx No color coding
Digital input EJ1xxx Yellow
Digital output EJ2xxx Red
Analog input EJ3xxx Green
Analog output EJ4xxx Blue
Motion EJ7xxx orange
System EJ9xxx grey
EJ957624 Version: 1.1
Installation of EJ modules
4.4.2 Mechanical position coding
The modules have two signal-specific coding pins on the underside (see Figs. B1 and B2 below). In
conjunction with the coding holes in the signal distribution board (see Figs. A1 and A2 below), the coding
pins provide an option for mechanical protection against incorrect connection. This significantly reduces the
risk of error during installation and service.
Couplers and placeholder modules have no coding pins.
Fig.17: Mechanical position coding with coding pins (B1 and B2) and coding holes (A1 and A2)
The following diagram shows the position of the position coding with position numbers on the left-hand side.
Modules with the same signal type have the same coding. For sample, all digital input modules have the
coding pins at positions one and three. There is no plug protection between modules with the same signal
type. During installation the module type should therefore be verified based on the device name.
Fig.18: Pin coding; sample: digital input modules
EJ9576 25Version: 1.1
Installation of EJ modules
4.5 Installation on the signal distribution board
EJ modules are installed on the signal distribution board. The electrical connections between coupler and EJ
modules are realized via the pin contacts and the signal distribution board.
The EJ components must be installed in a control cabinet or enclosure which must provide protection against
fire hazards, environmental conditions and mechanical impact.
WARNING
Risk of injury through electric shock and damage to the device!
Bring the module system into a safe, de-energized state before starting installation, disassembly or wiring
of the modules.
NOTE
Risk of damage to components through electrostatic discharge!
Observe the regulations for ESD protection.
Fig.19: Installation of EJ modules
A1 / A2 Latching lugs top / bottom C1 / C2 Mounting holes
B1 / B2 Coding pins D1 / D2 Coding holes
To install the modules on the signal distribution board proceed as follows:
1. Before the installation, ensure that the signal distribution board is securely connected to the mounting
surface. Installation on an unsecured signal distribution board may result in damage to the board.
2. If necessary, check whether the positions of the coding pins (B) match the corresponding holes in the
signal distribution board (D).
3. Compare the device name on the module with the information in the installation drawing.
4. Press the upper and the lower mounting tabs simultaneously and push the module onto the board
while gently moving it up and down, until the module is latched securely.
The required contact pressure can only be established and the maximum current carrying capacity ensured if the module is latched securely.
5. Use placeholder modules (EJ9001) to fill gaps in the module strand.
EJ957626 Version: 1.1
Installation of EJ modules
NOTE
• During installation ensure safe latching of the modules on the signal distribution board! The consequences of inadequate contact pressure include:
ð loss of quality of the transferred signals,
ð increased power dissipation of the contacts,
ð impairment of the service life.
EJ9576 27Version: 1.1
Installation of EJ modules
4.6 Extension options
Three options are available for modifications and extensions of the EJ system.
• Replacing the placeholder modules with the function modules provided for the respective slot
• Assigning function modules specified for the respective slots for the reserve slots at the end of the
module string
• Linking with EtherCAT Terminals and EtherCAT Box modules via an Ethernet/EtherCAT connection
4.6.1 Using placeholder modules for unused slots
The EJ9001 placeholder modules are used to close temporary gaps in the module strands (see Fig. A1
below). In contrast to the passive terminals of the EL series, the placeholder modules actively participate in
the data exchange. Several placeholder modules can therefore be connected in series, without impairing the
data exchange.
Unused slots at the end of the module strand can be left as reserve slots (see Fig. B1 below).
The machine complexity is extended (extended version) by allocating unused slots (see Figs. A2 below Exchanging placeholder modules and B2 - Assigning reserve slots) according to the specifications for the
signal distribution board.
Fig.20: Sample: Exchanging placeholder modules and assigning reserve slots
E-bus supply
Exchange the placeholder modules with other modules changes the current input from the E-Bus.
Ensure that adequate power supply is provided.
EJ957628 Version: 1.1
Installation of EJ modules
4.6.2 Linking with EtherCAT Terminals and EtherCAT Box modules via an Ethernet/EtherCAT connection
Example of extension via an Ethernet/EtherCAT connection
EJ9576 29Version: 1.1
Installation of EJ modules
4.7 IPC integration
Connection of CX and EL terminals via the EK1110-0043 EtherCAT EJ Coupler
The EK1110-0043 EtherCAT EJ Coupler connects the compact DIN-rail PCs of the CX series and attached
EtherCAT Terminals (ELxxxx) with the EJ modules on the signal distribution board.
The EK1110-0043 is supplied from the power supply unit of the Embedded PC.
The E-bus signals and the supply voltage of the field side UP are routed directly to the PCB via a plug
connector at the rear of the EtherCAT EJ Coupler.
Due to the direct coupling of the Embedded PC and the EL terminals with the EJ modules on the PCB, no
EtherCAT extension (EK1110) or EtherCAT Coupler (EJ1100) is required.
The Embedded PC can be expanded with EtherCAT Terminals that are not yet available in the EJ system,
forexample.
Fig.21: Example PCB with Embedded PC, EK1110-0043 and EJxxxx, rear view EK1110-0043
EJ957630 Version: 1.1
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