Beckhoff ELX3152, ELX3158 User Manual
Operating manual | EN
ELX3152 and ELX3158
Two- and eight-channel analog input terminals, 0/4 … 20 mA,
single ended, 16 Bit, Ex i
2020-11-10 | Version: 2.1.0
Table of contents
Table of contents
1 Foreword ....................................................................................................................................................5
1.1 Notes on the documentation..............................................................................................................5
1.2 Safety instructions .............................................................................................................................6
1.3 Documentation Issue Status..............................................................................................................7
1.4 Marking of ELX terminals ..................................................................................................................8
2 Product overview.....................................................................................................................................12
2.1 ELX3152 - Introduction....................................................................................................................12
2.2 ELX3158 - Introduction....................................................................................................................13
2.3 Technical data .................................................................................................................................14
2.4 Intended use....................................................................................................................................15
3 Mounting and wiring................................................................................................................................16
3.1 Special conditions of use for ELX terminals ....................................................................................16
3.2 Installation notes for ELX terminals .................................................................................................16
3.3 Arrangement of ELX terminals within a bus terminal block .............................................................18
3.4 Installation position and minimum distances ...................................................................................21
3.5 Installation of ELX terminals on mounting rails................................................................................22
3.6 Connection ......................................................................................................................................23
3.6.1 Connection system .......................................................................................................... 23
3.6.2 Wiring............................................................................................................................... 24
3.6.3 Proper line connection ..................................................................................................... 26
3.6.4 Shielding and potential separation................................................................................... 26
3.6.5 ELX3152 - Contact assignment ....................................................................................... 27
3.6.6 ELX3158 - Contact assignment ....................................................................................... 29
4 Basic function principles........................................................................................................................31
4.1 EtherCAT basics..............................................................................................................................31
4.2 Notices on analog specifications .....................................................................................................31
4.2.1 Full scale value (FSV)...................................................................................................... 31
4.2.2 Measuring error/ measurement deviation ........................................................................ 31
4.2.3 Temperature coefficient tK [ppm/K] ................................................................................. 32
4.2.4 Single-ended/differential typification ................................................................................ 33
4.2.5 Common-mode voltage and reference ground (based on differential inputs).................. 36
4.2.6 Dielectric strength ............................................................................................................ 36
4.2.7 Temporal aspects of analog/digital conversion................................................................ 37
4.3 NAMUR basic information ...............................................................................................................40
5 Parameterization and programming ......................................................................................................41
5.1 TwinCAT Quick Start .......................................................................................................................41
5.1.1 TwinCAT 2 ....................................................................................................................... 44
5.1.2 TwinCAT 3 ....................................................................................................................... 54
5.2 TwinCAT Development Environment ..............................................................................................67
5.2.1 Installation of the TwinCAT real-time driver..................................................................... 68
5.2.2 Notes regarding ESI device description........................................................................... 73
5.2.3 TwinCAT ESI Updater ..................................................................................................... 77
5.2.4 Distinction between Online and Offline............................................................................ 77
ELX3152 and ELX3158 3Version: 2.1.0
Table of contents
5.2.5 OFFLINE configuration creation ...................................................................................... 78
5.2.6 ONLINE configuration creation ........................................................................................ 83
5.2.7 EtherCAT subscriber configuration.................................................................................. 91
5.3 General Notes - EtherCAT Slave Application................................................................................100
5.4 Process data and operation modes...............................................................................................108
5.4.1 Parameterization............................................................................................................ 108
5.4.2 Settings and operating modes ....................................................................................... 108
5.4.3 Process data.................................................................................................................. 114
5.4.4 Data stream and measurement ranges ......................................................................... 119
5.5 TwinSAFE SC................................................................................................................................123
5.5.1 TwinSAFE SC - operating principle ............................................................................... 123
5.5.2 TwinSAFE SC - configuration ........................................................................................ 123
5.5.3 TwinSAFE SC process data ELX3152-0090 ................................................................. 127
5.6 CoE object description and parameterization................................................................................128
5.6.1 Restore object................................................................................................................ 128
5.6.2 Configuration data ......................................................................................................... 129
5.6.3 Input data....................................................................................................................... 130
5.6.4 Output data .................................................................................................................... 130
5.6.5 Standard objects............................................................................................................ 130
5.6.6 Objects TwinSAFE Single Channel (ELX3152-0090).................................................... 134
5.7 Error messages and diagnosis ......................................................................................................135
6 Appendix ................................................................................................................................................136
6.1 EtherCAT AL Status Codes...........................................................................................................136
6.2 UL notice .......................................................................................................................................136
6.3 FM notice.......................................................................................................................................137
6.4 Support and Service ......................................................................................................................138
ELX3152 and ELX31584 Version: 2.1.0
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.
ELX3152 and ELX3158 5Version: 2.1.0
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.
ELX3152 and ELX31586 Version: 2.1.0
1.3 Documentation Issue Status
Version Comment
2.1.0 • Chapter Basic function principles and Parameterization and programming added
• Technical data updated
2.0.0 • ELX3158 added
1.6.0 • FM notice regarding ANSI/ISA EX added
• Chapter Marking of ELX terminals updated
1.5.0 • Contact assignment extended with sensor illustration
• Chapter Arrangement of ELX terminals within a bus terminal block updated
• Chapter Marking of ELX terminals updated
• Technical data updated
1.4.0 • Chapter Arrangement of ELX terminals at the bus terminal updated
1.3.0 • Chapter Installation notes for ELX terminals updated
1.2.0 • Chapter Marking of ELX-Terminals updated
• Technical data updated
1.1.0 • Chapter Marking of ELX-Terminals updated
1.0.0 • Chapter Intended use updated
• Technical data updated
• Mounting and wiring updated
0.2 • Chapter Intended use added
• Mounting and wiring updated
0.1 • First preliminary version
Foreword
ELX3152 and ELX3158 7Version: 2.1.0
Foreword
1.4 Marking of ELX terminals
Name
An ELX terminal has a 15-digit technical designation, composed of
• family key
• type
• software variant
• revision
example family type software variant revision
ELX1052-0000-0001 ELX terminal 1052: two-channel digital input terminal
for NAMUR sensors, Ex i
ELX9560-0000-0001 ELX terminal 9560: power supply terminal 0000: basic type 0001
Notes
• The elements mentioned above result in the technical designation. ELX1052-0000-0001 is used in
the example below.
• Of these, ELX1052-0000 is the order identifier, commonly called just ELX1052 in the "-0000" revision.
“-0001” is the EtherCAT revision.
• The order identifier is made up of
- family key (ELX)
- type (1052)
- software version (-0000)
• The Revision -0001 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 website.
The revision has been applied to the terminals on the outside, see ELX1052 with date code
3218FMFM, BTN 10000100 and Ex marking.
• The hyphen is omitted in the labeling on the side of the terminal. Example:
Name: ELX1052-0000
Label: ELX1052
• The type, software version and revision are read as decimal numbers, even if they are technically
saved in hexadecimal.
0000
0000: basic type 0001
Identification numbers
ELX terminals have two different identification numbers:
• date code (batch number)
• Beckhoff Traceability Number, or BTN for short (as a serial number it clearly identifies each terminal)
Datecode
The date code is an eight-digit number given by Beckhoff and printed on the ELX terminal. The date code
indicates the build version in the delivery state and thus identifies an entire production batch, but does not
distinguish between the terminals in a batch.
Structure of the date code: WWYYFFHH
WW - week of production (calendar week)
YY - year of production
FF - firmware version
HH - hardware version
Example with date code: 02180100:
02 - week of production 02
18 - year of production 2018
01 - firmware version 01
00 - hardware version 00
ELX3152 and ELX31588 Version: 2.1.0
Beckhoff Traceability Number (BTN)
In addition, each ELX terminal has a unique Beckhoff Traceability Number (BTN).
Ex marking
The Ex marking can be found at the top left on the terminal:
II 3 (1) G Ex ec [ia Ga] IIC T4 Gc
II (1) D [Ex ia Da] IIIC
I (M1) [Ex ia Ma] I
IECEx BVS 18.0005X
BVS 18 ATEX E 005 X
Examples
Foreword
Fig.1: ELX2008-0000 with date code 2519HMHM, BTN 0001f6hd and Ex marking
ELX3152 and ELX3158 9Version: 2.1.0
Foreword
Fig.2: ELX9560-0000 with date code 12150000, BTN 000b000 and Ex marking
ELX3152 and ELX315810 Version: 2.1.0
Foreword
Fig.3: ELX9012 with date code 12174444, BTN 0000b0si and Ex marking
ELX3152 and ELX3158 11Version: 2.1.0
Product overview
2 Product overview
2.1 ELX3152 - Introduction
Fig.4: ELX3152 - Two channel, analog input terminal, 0/4 … 20mA, single ended, 16bit, Exi
The ELX3152 analog input terminal is suitable for operation in zone2 and in not explosive areas. It allows
the direct connection of intrinsically safe field devices located in hazardous areas classified Zone 0/20 or
1/21. It supplies measuring transducers located in the field and transmits their analog measuring signals
electrically isolated to the automation device. The EtherCAT terminal indicates the signal state by means of
light emitting diodes. The error LEDs indicate an overload condition and wire breakage.
ELX3152 and ELX315812 Version: 2.1.0
2.2 ELX3158 - Introduction
Product overview
Fig.5: ELX3158 - Eight channel, analog input terminal, 4 … 20mA, single ended, 16bit, Exi
The analog input terminal ELX3158 allows the direct connection of intrinsically safe field devices located in
hazardous areas classified Zone 0/20 or 1/21. It supplies measuring transducers in the field and transmits
their analog measuring signals, electrically isolated, to the automation device. Overload and wire breakage
are indicated by the error LEDs.
ELX3152 and ELX3158 13Version: 2.1.0
Product overview
2.3 Technical data
Technical data ELX3152-0000 ELX3158-0000
Technology intrinsically safe sensors
Number of inputs 2 (single ended) 8 (single ended)
Connection technology 2-wire, 3-wire 2-wire
Nominal voltage 24V
Signal current 0/4…20mA 4…20mA
Technical measuring range 107%*
Resolution 16 bit (incl. sign)
Measuring error < ±0.3% (relative to full scale value)
Measuring resistance typically 100Ω
Input filter limit frequency 5kHz
Conversion time typically 1ms
Supply voltage electronics via E-Bus (5VDC) and Power Contacts (24V
Current consumption from the E-Bus typically 85mA typically 75mA
Current consumption from Power Contacts
(ELX9560 power supply)
Electrical isolation 1500V (E-Bus/ field voltage)
Configuration no address or configuration settings required
Distributed Clocks yes
Bit width in the
process image
standard PDO (default) 2 x 4byte 8 x 4byte
compact PDO 2 x 2byte 8 x 2byte
Special features standard and compact process image, activatable FIR/IIR filters,
Weight app. 60g
Permissible ambient temperature range
during operation
Permissible ambient temperature range
during storage
Permissible relative humidity 95%, no condensation
Permissible air pressure
(operation, storage, transport)
Dimensions (W x H x D) app. 15mm x 100mm x 70mm
Mounting on 35mm mounting rail conforms to EN 60715
Vibration/ shock resistance conforms to EN60068-2-6/ EN60068-2-27
EMC immunity/ emission conforms to EN61000-6-2/ EN61000-6-4
Protect. class IP20
Permissible installation position
Markings/ Approvals CE, UL, ATEX, IECEx, cFMus CE, ATEX, IECEx, cFMus
DC
Ex, feeding by
DC
ELX9560)
typically 10 mA + load
limit value monitoring, NE43 NAMUR
-25°C ... + 60°C
-40°C ... + 85°C
800hPa to 1100hPa
(this corresponds to a height of approx. -690m to 2000m over
sea level assuming an international standard atmosphere)
app. 27mm x 100mm x 70mm
(width aligned: 12mm)
(width aligned: 24mm)
See chapter Installation position and minimum distances [}21]
*) With a technical measuring range of 107% of the nominal range, the terminal also supports commissioning
with sensor values in the limit range and an evaluation according to NAMURNE43.
ELX3152 and ELX315814 Version: 2.1.0
Product overview
Technical data for explosion protection ELX3152-0000 ELX3158-0000
Ex marking II 3 (1) G Ex ec [ia Ga] IIC T4 Gc
II (1) D [Ex ia Da] IIIC
I (M1) [Ex ia Ma] I
Certificate numbers IECEx BVS 18.0005X
BVS 18 ATEX E 005 X
Power supply Invariable in connection with ELX9560
Field interfaces UO = 27.7V
IO = 85mA
PO = 565mW
Characteristic curve: linear
Reactance (without consideration
of the simultaneousness)
Ex ia I 43mH 3.45µF 43mH 3.45µF
L
0
C
0
L
0
Ex ia IIA 30mH 2.2µF 30mH 2.2µF
Ex ia IIB 18mH 663nF 18mH 663nF
Ex ia IIC 2mH 85nF 2mH 85nF
Ex ia IIIC 18mH 663nF 18mH 663nF
C
0
2.4 Intended use
WARNING
Endangering the safety of persons and equipment!
The ELX components may only be used for the purposes described below!
CAUTION
Observe ATEX and IECEx!
The ELX components may only be used in accordance with the ATEX directive and the IECEx scheme!
The ELX terminals extend the field of application of the Beckhoff bus terminal system with functions for
integrating intrinsically safe field devices from hazardous areas. The intended field of application is data
acquisition and control tasks in discrete and process engineering automation, taking into account explosion
protection requirements.
The ELX terminals are protected by the type of protection "Increased safety" (Exe) according to
IEC60079-7 and must only be operated in hazardous areas of Zone2 or in non-hazardous areas.
The field interfaces of the ELX terminals achieve explosion protection through the type of protection "intrinsic
safety" (Exi) according to IEC60079-11. For this reason, only appropriately certified, intrinsically safe
devices may be connected to the ELX terminals. Observe the maximum permissible connection values for
voltages, currents and reactances. Any infringement can damage the ELX terminals and thus eliminate the
explosion protection.
The ELX terminals are open, electrical equipment for installation in lockable cabinets, enclosures or
operating rooms. Make sure that access to the equipment is only possible for authorized personnel.
CAUTION
Ensure traceability!
The buyer has to ensure the traceability of the device via the Beckhoff Traceability Number (BTN).
ELX3152 and ELX3158 15Version: 2.1.0
Mounting and wiring
3 Mounting and wiring
3.1 Special conditions of use for ELX terminals
WARNING
Observe the special conditions of use for the intended use of Beckhoff ELX terminals in
potentially explosive areas (ATEX directive 2014/34/EU)!
• The certified components are to be installed in a suitable housing that guarantees an ingress protection
of at least IP54 in accordance with EN60079-0 and EN60529! The prescribed environmental conditions
during installation, operation and maintenance are thereby to be taken into account! Inside the housing,
pollution degree 1 and 2 are permissible.
• If the temperatures during rated operation are higher than 70°C at the feed-in points of cables, lines or
pipes, or higher than 80°C at the wire branching points, then cables must be selected whose temperature data correspond to the actual measured temperature values!
• Observe the permissible ambient temperature range of -25 to +60°C of Beckhoff ELX terminals!
• Measures must be taken to protect against the rated operating voltage being exceeded by more than
40% due to short-term interference voltages! The power supply of the ELX9560 power supply terminal
must correspond to overvoltage categoryII according to EN60664-1
• The individual terminals may only be unplugged or removed from the bus terminal system if all supply
voltages have been switched off or if a non-explosive atmosphere is ensured!
• The connections of the ELX9560 power supply terminal may only be connected or disconnected if all
supply voltages have been switched off or if a non-explosive atmosphere is ensured!
• The fuses of the EL92xx power feed terminals may only be exchanged if all supply voltages have been
switched off or if a non-explosive atmosphere is ensured!
• Address selectors and switches may only be adjusted if all supply voltages have been switched off or if a
non-explosive atmosphere is ensured!
3.2 Installation notes for ELX terminals
NOTE
Storage, transport and mounting
• Transport and storage are permitted only in the original packaging!
• Store in a dry place, free from vibrations.
• A brand new ELX terminal with a certified build version is delivered only in a sealed carton. Therefore,
check that the carton and all seals are intact before unpacking.
• Do not use the ELX terminal if
- its packaging is damaged
- the terminal is visibly damaged or
- you cannot be sure of the origin of the terminal.
• ELX terminals with a damaged packaging seal are regarded as used.
WARNING
Observe the accident prevention regulations
During mounting, commissioning, operation and maintenance, adhere to the safety regulations, accident
prevention regulations and general technical rules applicable to your devices, machines and plants.
CAUTION
Observe the erection regulations
Observe the applicable erection regulations.
ELX3152 and ELX315816 Version: 2.1.0
Mounting and wiring
NOTE
Protect the terminals against electrostatic discharge (ESD)
Electronic components can be destroyed by electrostatic discharge. Therefore, take the safety measures to
protect against electrostatic discharge as described in DIN EN 61340-5-1 among others. In conjunction with
this, ensure that the personnel and surroundings are suitably earthed.
NOTE
Do not place terminals on E-bus contacts
Do not place the ELX terminals on the E-bus contacts located on the right-hand side. The function of the Ebus contacts can be negatively affected by damage caused by this, e.g. scratches.
NOTE
Protect the terminals against dirt
To ensure the functionality of the ELX terminals they must be protected against dirt, especially on the contact points. For this reason use only clean tools and materials.
NOTE
Handling
• It is forbidden to insert conductive or non-conductive objects of any kind into the interior of the housing
(e.g. through the ventilation slots in the housing).
• Use only the openings provided in the housing front and appropriate tools to actuate the spring-loaded
terminal contacts on the front side for attaching connection cables to the terminal; see chapter Wiring
[}24].
• The opening of the housing, the removal of parts and any mechanical deformation or machining of an
ELX terminal are not permitted!
If an ELX terminal is defective or damaged it must be replaced by an equivalent terminal. Do not carry out
any repairs to the devices. For safety reasons repairs may only be carried out by the manufacturer.
NOTE
Contact marking and pin assignment
The colored inscription labels above the front connection contacts shown in the illustrations in the introduction chapter are only examples and are not part of the scope of delivery!
A clear assignment of channel and terminal designation according to the chapter contact assignment to the
actual terminal point can be made via the lasered channel numbers 1 to 8 on the left above the respective
terminal point as well as via the laser image.
Observe any possible polarity dependency of connected intrinsically safe circuits!
ELX3152 and ELX3158 17Version: 2.1.0
Mounting and wiring
3.3 Arrangement of ELX terminals within a bus terminal block
WARNING
Observe the following instructions for the arrangement of ELX terminals!
• ELX signal terminals must always be installed behind an ELX9560 power supply terminal, without exception!
• Only signal terminals of the ELX series may be installed behind an ELX9560 power supply terminal!
• Multiple ELX9560 power supply terminals may be set in one terminal block as long as one ELX9410 is
placed before each additional ELX9560!
• An ELX9410 power supply terminal must not be mounted to the right of an ELX9560 nor to the left of any
ELX signal terminal!
• The last terminal of each ELX segment is to be covered by an ELX9012 bus end cover, unless two
ELX9410 power supply terminals are installed in direct succession for continuing the same terminal segment with standard Beckhoff EtherCAT terminals (e.g. EL/ES/EK)!
Examples for the arrangement of ELX terminals
Fig.6: Valid arrangement of the ELX terminals (right terminal block).
Fig.7: Valid arrangement - terminals that do not belong to the ELX series are set before and after the ELX
terminal segment. The separation is realized by the ELX9560 at the beginning of the ELX terminal segment
and two ELX9410 at the end of the ELX terminal segment.
Fig.8: Valid arrangement - multiple power supplies by ELX9560, each with an upstream ELX9410.
ELX3152 and ELX315818 Version: 2.1.0
Fig.9: Valid arrangement - ELX9410 in front of an ELX9560 power supply terminal.
Mounting and wiring
Fig.10: Invalid arrangement - missing ELX9560 power supply terminal.
Fig.11: Invalid arrangement - terminal that does not belong to the ELX series within the ELX terminal
segment.
Fig.12: Invalid arrangement - second ELX9560 power supply terminal within the ELX terminal segment
without an upstream ELX9410.
ELX3152 and ELX3158 19Version: 2.1.0
Mounting and wiring
Fig.13: Invalid arrangement - missing ELX9012 bus end cover.
NOTE
Observe the maximum output current of the ELX9560
When configuring the ELX terminal segment, please note the maximum available output current of the
ELX9560 power supply terminal in accordance with the specified technical data.
If required, an additional power supply terminal ELX9560 with an upstream ELX9410 connected (see
mounting examples) must be installed or a completely new terminal block must be assembled.
ELX3152 and ELX315820 Version: 2.1.0
Mounting and wiring
3.4 Installation position and minimum distances
Installation position
For the prescribed installation position the mounting rail is installed horizontally and the mating surfaces of
the ELX terminals point toward the front (see illustration below). The terminals are ventilated from below,
which enables optimum cooling of the electronics through convection. The direction indication “down”
corresponds to the direction of positive acceleration due to gravity.
Minimum distances
Observe the following minimum distances to ensure optimum convection cooling:
• above and below the ELX terminals: 35mm (required!)
• besides the bus terminal block: 20mm (recommended)
Fig.14: Installation position and minimum distances
WARNING
Observe the minimum separation distances according to IEC 60079-14!
Observe the prescribed minimum separation distances between intrinsically safe and non-intrinsically safe
circuits according to IEC 60079-14.
ELX3152 and ELX3158 21Version: 2.1.0
Mounting and wiring
3.5 Installation of ELX terminals on mounting rails
WARNING
Risk of electric shock and damage of device!
Bring the bus terminal system into a safe, powered down state before starting installation, disassembly or
wiring of the bus terminals!
CAUTION
Danger of injury due to power contacts!
For your own protection, pay attention to careful and careful handling of the ELX terminals. In particular, the
left side mounted, sharp-edged blade contacts pose a potential risk of injury.
Assembly
Fig.15: Attaching on mounting rail
The bus coupler and bus terminals are attached to commercially available 35mm mounting rails (DIN rails
according to EN60715) by applying slight pressure:
1. First attach the fieldbus coupler to the mounting rail.
2. The bus terminals are now attached on the right-hand side of the fieldbus coupler. Join the components with tongue and groove and push the terminals against the mounting rail, until the lock clicks
onto the mounting rail.
If the terminals are clipped onto the mounting rail first and then pushed together without tongue and
groove, the connection will not be operational! When correctly assembled, no significant gap should
be visible between the housings.
Fixing of mounting rails
The locking mechanism of the terminals and couplers extends to the profile of the mounting rail. At
the installation, the locking mechanism of the components must not come into conflict with the fixing
bolts of the mounting rail. To mount the mounting rails with a height of 7.5mm under the terminals
and couplers, you should use flat mounting connections (e.g. countersunk screws or blind rivets).
ELX3152 and ELX315822 Version: 2.1.0
Mounting and wiring
Disassembly
Fig.16: Disassembling of terminal
Each terminal is secured by a lock on the mounting rail, which must be released for disassembly:
1. Pull the terminal by its orange-colored lugs approximately 1cm away from the mounting rail. In doing
so for this terminal the mounting rail lock is released automatically and you can pull the terminal out of
the bus terminal block easily without excessive force.
2. Grasp the released terminal with thumb and index finger simultaneous at the upper and lower grooved
housing surfaces and pull the terminal out of the bus terminal block.
Connections within a bus terminal block
The electric connections between the Bus Coupler and the Bus Terminals are automatically realized by
joining the components:
• The six spring contacts of the E-Bus deal with the transfer of the data and the supply of the Bus
Terminal electronics.
• The power contacts deal with the supply for the field electronics and thus represent a supply rail within
the bus terminal block.
The power contacts of the ELX terminals are supplied by the ELX9560 power terminal. This interrupts
the power contacts and thus represents the beginning of a new supply rail.
Power Contacts
During the design of a bus terminal block, the pin assignment of the individual Bus Terminals must
be taken account of, since some types (e.g. analog Bus Terminals or digital 4-channel Bus Terminals) do not or not fully loop through the power contacts.
3.6 Connection
3.6.1 Connection system
WARNING
Risk of electric shock and damage of device!
Bring the bus terminal system into a safe, powered down state before starting installation, disassembly or
wiring of the bus terminals!
The terminals of ELXxxxx series include electronics and connection level in a single enclosure.
ELX3152 and ELX3158 23Version: 2.1.0
Mounting and wiring
Standard wiring
Fig.17: Standard wiring
The terminals of ELXxxxx series feature integrated screwless spring force technology for fast and simple
assembly.
High Density Terminals (HD Terminals)
Fig.18: High Density Terminals
The Bus Terminals from these series with 16 connection points are distinguished by a particularly compact
design, as the packaging density is twice as large as that of the standard 12mm Bus Terminals. Massive
conductors and conductors with a wire end sleeve can be inserted directly into the spring loaded terminal
point without tools.
Ultrasonically "bonded" (ultrasonically welded) conductors
Ultrasonically “bonded" conductors
It is also possible to connect the Standard and High Density Terminals with ultrasonically
"bonded" (ultrasonically welded) conductors. In this case, please note the tables concerning the
wire-size width below!
3.6.2 Wiring
WARNING
Risk of electric shock and damage of device!
Bring the bus terminal system into a safe, powered down state before starting installation, disassembly or
wiring of the bus terminals!
ELX3152 and ELX315824 Version: 2.1.0
Terminals for standard wiring
Mounting and wiring
Fig.19: Connecting a cable on a terminal point
Up to eight terminal points enable the connection of solid or finely stranded cables to the Bus Terminal. The
terminal points are implemented in spring force technology. Connect the cables as follows:
1. Open a terminal point by pushing a screwdriver straight against the stop into the square opening
above the terminal point. Do not turn the screwdriver or move it alternately (don't toggle).
2. The wire can now be inserted into the round terminal opening without any force.
3. The terminal point closes automatically when the pressure is released, holding the wire securely and
permanently.
Observe the requirements for connecting cables and cross sections according to IEC 60079-7 and IEC
60079-11. See the following tables for the suitable wire size width.
Terminal housing Standard wiring ELX9560
Wire size width (single core wires) 0.08 ... 2.5mm
Wire size width (fine-wire conductors) 0.08 ... 2.5mm
Wire size width (conductors with a wire end sleeve) 0.14 ... 1.5mm
2
2
2
0.14 ... 1.5mm
0.14 ... 1.5mm
0.14 ... 1.0mm
2
2
2
Wire stripping length 8 ... 9mm 8 ... 9mm
NOTE
Maximum screwdriver width for ELX9560
Use a screwdriver with a maximum width of 2mm to wire the ELX9560 power supply terminal. Wider
screwdrivers can damage the terminal points.
High Density Terminals (HD Terminals) with 16 terminal points
The conductors of the HD Terminals are connected without tools for single-wire conductors using the direct
plug-in technique, i.e. after stripping the wire is simply plugged into the terminal point. The cables are
released, as usual, using the contact release with the aid of a screwdriver. See the following table for the
suitable wire size width.
ELX3152 and ELX3158 25Version: 2.1.0
Mounting and wiring
Terminal housing High Density Housing
Wire size width (single core wires) 0.08 ... 1.5mm
Wire size width (fine-wire conductors) 0.25 ... 1.5mm
Wire size width (conductors with a wire end sleeve) 0.14 ... 0.75mm
Wire size width (ultrasonically “bonded" conductors) only 1.5mm
2
2
2
2
Wire stripping length 8 ... 9mm
3.6.3 Proper line connection
Always connect only one wire per terminal point.
When using fine-wire conductors it is recommended to connect them with wire end sleeves in order to
establish a safe, conductive connection.
In addition, make sure that the pin assignment is correct to prevent damage to the ELX terminals and the
connected devices.
3.6.4 Shielding and potential separation
Shielding
Encoder, analog sensors and actors should always be connected with shielded, twisted paired
wires.
CAUTION
Observe installation requirements in areas of potentially explosive atmospheres!
During installation, observe the requirements for cables, shielding and earth potential equalization in areas
of potentially explosive atmospheres according to IEC60079-11, IEC60079-14 and IEC60079-25.
WARNING
Ensure potential separation of the 24V Ex busbar!
In any case, make sure that the galvanic isolation made by the ELX9560 between the 24V Ex busbar
(power contacts +24VEx and 0VEx) and other system potentials (if applicable also functional or protective earths) is not removed.
ELX3152 and ELX315826 Version: 2.1.0
3.6.5 ELX3152 - Contact assignment
Mounting and wiring
Fig.20: ELX3152 - Contact assignment
Terminal point Description
Name No.
Uv1 1 Supply voltage for channel 1
GND 2 Ground for channel 1 (for using a 3-wire connection)
Input 1 3 Signal input channel 1
4 not implemented
Uv2 5 Supply voltage for channel 2
GND 6 Ground for channel 2 (for using a 3-wire connection)
Input 2 7 Signal input channel 2
8 not implemented
ELX3152 and ELX3158 27Version: 2.1.0
Mounting and wiring
LED display
LED Color Meaning
Run green This LED indicates the terminal's operating state:
off State of the EtherCAT State Machine: INIT = initialization of the terminal or
BOOTSTRAP = function for firmware updates of the terminal
flashing State of the EtherCAT State Machine: PREOP = function for mailbox
communication and different standard-settings set
single
flash
on State of the EtherCAT State Machine: OP = normal operating state; mailbox and
Error red General error of the A/D converter
Error Ch 1 red Fault indication in the event of broken wire or undershooting or overshooting of the
measuring range for channel1
Error Ch 2 red Fault indication in the event of broken wire or undershooting or overshooting of the
measuring range for channel2
State of the EtherCAT State Machine: SAFEOP = verification of the Sync
Manager [}91] channels and the distributed clocks.
Outputs remain in safe state
process data communication is possible
ELX3152 and ELX315828 Version: 2.1.0
3.6.6 ELX3158 - Contact assignment
Mounting and wiring
Fig.21: ELX3158 - Contact assignment
Terminal point Description
Name No.
Input 1 1 Signal input channel 1
Input 3 2 Signal input channel 3
Input 5 3 Signal input channel 5
Input 7 4 Signal input channel 7
Input 2 5 Signal input channel 2
Input 4 6 Signal input channel 4
Input 6 7 Signal input channel 6
Input 8 8 Signal input channel 8
Uv1 9 Supply voltage for channel 1
Uv3 10 Supply voltage for channel 3
Uv5 11 Supply voltage for channel 5
Uv7 12 Supply voltage for channel 7
Uv2 13 Supply voltage for channel 2
Uv4 14 Supply voltage for channel 4
Uv6 15 Supply voltage for channel 6
Uv8 16 Supply voltage for channel 8
ELX3152 and ELX3158 29Version: 2.1.0
Mounting and wiring
LED display
LED Color Meaning
Run green This LED indicates the terminal's operating state:
off State of the EtherCAT State Machine: INIT = initialization of the terminal or
BOOTSTRAP = function for firmware updates of the terminal
flashing State of the EtherCAT State Machine: PREOP = function for mailbox
communication and different standard-settings set
single
flash
on State of the EtherCAT State Machine: OP = normal operating state; mailbox and
Error red General error of the A/D converter
Error Ch 1 red Fault indication in the event of broken wire or undershooting or overshooting of the
measuring range for channel1
Error Ch 2 red Fault indication in the event of broken wire or undershooting or overshooting of the
measuring range for channel2
Error Ch 3 red Fault indication in the event of broken wire or undershooting or overshooting of the
measuring range for channel3
Error Ch 4 red Fault indication in the event of broken wire or undershooting or overshooting of the
measuring range for channel4
Error Ch 5 red Fault indication in the event of broken wire or undershooting or overshooting of the
measuring range for channel5
Error Ch 6 red Fault indication in the event of broken wire or undershooting or overshooting of the
measuring range for channel6
Error Ch 7 red Fault indication in the event of broken wire or undershooting or overshooting of the
measuring range for channel7
Error Ch 8 red Fault indication in the event of broken wire or undershooting or overshooting of the
measuring range for channel8
State of the EtherCAT State Machine: SAFEOP = verification of the Sync
Manager [}91] channels and the distributed clocks.
Outputs remain in safe state
process data communication is possible
ELX3152 and ELX315830 Version: 2.1.0
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