Beckhoff EPP3204-0002 Operator's manual

Documentation | EN
EPP3204-0002
4-channel analog input Pt100 (RTD)
2023-01-30 | Version: 1.4

Table of contents
EPP3204-0002 3Version: 1.4
Table of contents
1 Foreword....................................................................................................................................................5
1.1 Notes on the documentation .............................................................................................................5
1.2 Safety instructions.............................................................................................................................6
1.3 Documentation issue status ..............................................................................................................7
2 Product group: EtherCATPBox modules..............................................................................................8
3 Product overview ......................................................................................................................................9
3.1 Introduction .......................................................................................................................................9
3.2 Technical data.................................................................................................................................10
3.3 Scope of supply...............................................................................................................................11
3.4 Process image ................................................................................................................................12
4 Mounting and connection.......................................................................................................................14
4.1 Dimensions .....................................................................................................................................14
4.2 Fixing...............................................................................................................................................15
4.3 Functional earth (FE) ......................................................................................................................15
4.4 EtherCATP .....................................................................................................................................16
4.4.1 Connectors....................................................................................................................... 17
4.4.2 Status LEDs ..................................................................................................................... 18
4.4.3 Conductor losses ............................................................................................................. 19
4.5 RTD inputs ......................................................................................................................................20
4.5.1 Connector......................................................................................................................... 20
4.5.2 Cabling .............................................................................................................................20
4.5.3 Status LEDs ..................................................................................................................... 21
4.6 UL Requirements ............................................................................................................................22
4.7 Disposal ..........................................................................................................................................23
5 Commissioning/Configuration...............................................................................................................24
5.1 Integrating into a TwinCAT project..................................................................................................24
5.2 Measured value processing ............................................................................................................24
5.2.1 Vendor calibration ............................................................................................................ 25
5.2.2 User calibration and linearization ..................................................................................... 29
5.2.3 Scaling, limits and formatting ........................................................................................... 30
5.2.4 Summary.......................................................................................................................... 31
5.3 Two-point user calibration ...............................................................................................................32
5.3.1 Example ...........................................................................................................................33
5.4 Limit value monitoring .....................................................................................................................34
5.5 CoE objects.....................................................................................................................................35
5.5.1 Object overview................................................................................................................ 35
5.5.2 Object description and parameterization.......................................................................... 41
5.6 Restoring the delivery state.............................................................................................................55
5.7 Decommissioning............................................................................................................................56
6 Appendix..................................................................................................................................................57
6.1 General operating conditions ..........................................................................................................57
6.2 Accessories.....................................................................................................................................58
6.3 Version identification of EtherCAT devices .....................................................................................59

Table of contents
EPP3204-00024 Version: 1.4
6.3.1 General notes on marking................................................................................................ 59
6.3.2 Version identification of EP/EPI/EPP/ER/ERI boxes........................................................ 60
6.3.3 Beckhoff Identification Code (BIC) ................................................................................... 61
6.3.4 Electronic access to the BIC (eBIC)................................................................................. 63
6.4 Support and Service........................................................................................................................65

Foreword
EPP3204-0002 5Version: 1.4
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®, TwinCAT/BSD®, TC/BSD®, 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.

Foreword
EPP3204-00026 Version: 1.4
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.

Foreword
EPP3204-0002 7Version: 1.4
1.3 Documentation issue status
Version Comment
1.4 • EtherCATP status LEDs updated
1.3 • Dimensions updated
• UL requirements updated
1.2 • Terminology update
• Structure update
1.1 • Front page updated
• Structure update
1.0 • First release
Firmware and hardware versions
This documentation refers to the firmware and hardware version that was applicable at the time the
documentation was written.
The module features are continuously improved and developed further. Modules having earlier production
statuses cannot have the same properties as modules with the latest status. However, existing properties
are retained and are not changed, so that older modules can always be replaced with new ones.
The firmware and hardware version (delivery state) can be found in the batch number (D-number) printed on
the side of the EtherCAT Box.
Syntax of the batch number (D-number)
D: WW YY FF HH
WW - week of production (calendar week)
YY - year of production
FF - firmware version
HH - hardware version
Example with D no. 29 10 02 01:
29 - week of production 29
10 - year of production 2010
02 - firmware version 02
01 - hardware version 01
Further information on this topic: Version identification of EtherCAT devices [}59].

Product group: EtherCATPBox modules
EPP3204-00028 Version: 1.4
2 Product group: EtherCATPBox modules
EtherCATP
EtherCATP supplements the EtherCAT technology with a process in which communication and supply
voltages are transmitted on a common line. All EtherCAT properties are retained with this process.
Two supply voltages are transmitted per EtherCATP line. The supply voltages are electrically isolated from
each other and can therefore be switched individually. The nominal supply voltage for both is 24VDC.
EtherCATP uses the same cable structure as EtherCAT: a 4-core Ethernet cable with M8 connectors. The
connectors are mechanically coded so that EtherCAT connectors and EtherCATP connectors cannot be
interchanged.
EtherCATP Box modules
EtherCATP Box modules are EtherCATP slaves with degree of protection IP67. They are designed for
operation in wet, dirty or dusty industrial environments.
EtherCAT basics
A detailed description of the EtherCAT system can be found in the EtherCAT system documentation.

Product overview
EPP3204-0002 9Version: 1.4
3 Product overview
3.1 Introduction
EPP3204-0002 | 4-channel analog input Pt100 (RTD)
The EPP3204 EtherCAT P Box with analog inputs allows resistance sensors to be connected directly. The
module’s circuitry can operate the sensors using 2-, 3- or 4-wire connection techniques. Linearisation over
the full temperature range is realised with the aid of a microprocessor. The temperature range can be
selected freely. The module can also be used for simple resistance measurement with the output in ohms.
The module’s standard settings are: resolution 0.1°C in the temperature range of Pt100 sensors in 2-wire
connection. Sensor malfunctions such as broken wires are indicated by error LEDs. The module is quite
versatile, but the default values are selected in such a way that in most cases it is not necessary to perform
configuration. The input filter and associated conversion times can be set within a wide range; several data
output formats may be chosen. If required, the inputs can be scaled differently. Automatic limit monitoring is
also available. Parameterisation is carried out via EtherCAT.
Quick links
Technical data [}10]
Process image [}12]
Signal connection [}20]
Commissioning [}24]

Product overview
EPP3204-000210 Version: 1.4
3.2 Technical data
All values are typical values over the entire temperature range, unless stated otherwise.
EtherCATP
Connection 2xM8 socket, 4-pin, P-coded, red
Supply voltages
Connection See EtherCATP connection
US nominal voltage 24VDC (-15%/ +20%)
US sum current: IS,sum max. 3A
Current consumption from US100mA
Rated voltage UP24VDC (-15%/ +20%)
UP sum current: IP,sum max. 3A
Current consumption from UPNone. UP is only forwarded.
RTD inputs
Number 4
Connectors 4x M12socket
Sensor types • Platinum RTD: Pt100, Pt200, Pt500, Pt1000
• Nickel RTD: Ni100, Ni120, Ni1000
• Resistance/potentiometer up to 4095Ω
Connection technology • 2-wire connection
• 3-wire connection
• 4-wire connection
Electrical isolation The measuring channels have a common isolated ground
potential.
Measuring current RL+, RL- Max. 0.5 mA, load-dependent
Measuring range Platinum RTD: -200…+850°C
Nickel RTD: -60…+250°C (Ni120: -60…+320°C)
Resistance: 0…4095Ω
Measuring error max. ±0.5K (Pt sensors in 4-wire connection)
Digital resolution 16 Bit
Value of an LSB Temperature measurement:
Standard: 0.1°C
High-precision: 0.01°C
Resistance measurement:
Measuring range 1023Ω: 1/64Ω
Measuring range 4095Ω: 1/16Ω
Filter Digital filter. Cut-off frequency parameterizable: 5Hz …
30kHz..
Conversion time 2…800ms, depending on the parameterization
Default: approx. 85 ms
Diagnostics • Open-circuit recognition
• Limit value monitoring

Product overview
EPP3204-0002 11Version: 1.4
Environmental conditions
Ambient temperature during operation -25 … +60°C
-25 … +55°C according to cULus
Ambient temperature during storage -40 … +85°C
Vibration resistance, shock resistance conforms to EN60068-2-6/ EN60068-2-27
Additional checks [}11]
EMC immunity / emission conforms to EN61000-6-2/ EN61000-6-4
Protection class IP65, IP66, IP67 (conforms to EN60529)
Housing data
Dimensions WxHxD 30mmx 126mmx 26.5mm (without connectors)
Weight approx. 165 g
Installation position variable
Material PA6 (polyamide)
Approvals/ markings
Approvals/ markings*) CE, cULus [}22]
*) Real applicable approvals/markings see type plate on the side (product marking).
Additional tests
The devices have undergone the following additional tests:
Test Explanation
Vibration 10 frequency sweeps in 3 axes
5Hz<f<60Hz displacement 0.35mm, constant amplitude
60.1Hz<f<500Hz acceleration 5g, constant amplitude
Shocks 1000 shocks in each direction, in 3 axes
35g, 11ms
3.3 Scope of supply
Make sure that the following components are included in the scope of delivery:
• 1x EPP3204-0002
• 2x protective cap for EtherCATP socket, M8, red (pre-assembled)
• 10x labels, blank (1 strip of 10)
Pre-assembled protective caps do not ensure IP67 protection
Protective caps are pre-assembled at the factory to protect connectors during transport. They may
not be tight enough to ensure IP67 protection.
Ensure that the protective caps are correctly seated to ensure IP67 protection.

Product overview
EPP3204-000212 Version: 1.4
3.4 Process image
3.4.1 Assignment of connectors to the process data objects
Process image in TwinCAT Connector Process data object
X01 RTD RTDInputs Channel 1
X02 RTD RTDInputs Channel 2
X03 RTD RTDInputs Channel 3
X04 RTD RTDInputs Channel 4

Product overview
EPP3204-0002 13Version: 1.4
3.4.2 Contents of the process data objects
The structure of the content of all process data objects is the same. The content of the process data object of
channel 1 is described here by way of example.
Status
Variable Description
Underrange TRUE if the measured value falls below the measuring range.
Overrange TRUE if the measured value exceeds the measuring range.
Limit 1 Limit value monitoring [}34]
Limit 2 Limit value monitoring [}34]
Error TRUE if the measured value is invalid. Possible reasons:
• open circuit
• Measured value outside of the measuring range
TxPDO State TRUE if an internal error occurs.
TxPDO Toggle This bit is inverted on each update of the measured value.
You can determine the present conversion time from the time between
two edges of this bit.
Value
The measured value.

Mounting and connection
EPP3204-000214 Version: 1.4
4 Mounting and connection
4.1 Dimensions
30
126
119
26.52314
Ø 3.5 13.5
All dimensions are given in millimeters.
The drawing is not true to scale.
Housing features
Housing material PA6 (polyamide)
Sealing compound polyurethane
Mounting two mounting holes Ø 3.5 mm for M3
Metal parts brass, nickel-plated
Contacts CuZn, gold-plated
Installation position variable
Protection class IP65, IP66, IP67 (conforms to EN 60529) when screwed together
Dimensions (H x W x D) approx. 126 x 30 x 26.5 mm (without connectors)

Mounting and connection
EPP3204-0002 15Version: 1.4
4.2 Fixing
NOTE
Dirt during assembly
Dirty connectors can lead to malfunctions. Protection class IP67 can only be guaranteed if all cables and
connectors are connected.
• Protect the plug connectors against dirt during the assembly.
Mount the module with two M3 screws on the mounting holes in the corners of the module. The mounting
holes have no thread.
4.3 Functional earth (FE)
The upper mounting holes also serves as a connection for functional earth (FE).
Make sure that the box is grounded to low impedance via the functional earth (FE) connection. You can
achieve this, for example, by mounting the box on a grounded machine bed.
FE
Fig.1: Connection for functional earth (FE)

Mounting and connection
EPP3204-000216 Version: 1.4
4.4 EtherCATP
WARNING
Power supply from SELV/PELV power supply unit!
SELV/PELV circuits (Safety Extra Low Voltage, Protective Extra Low Voltage) according to
IEC61010-2-201 must be used to supply the EtherCATP Power Sourcing Device (PSD).
Notes:
• SELV/PELV circuits may give rise to further requirements from standards such as IEC60204-1etal, for
example with regard to cable spacing and insulation.
• A SELV (Safety Extra Low Voltage) supply provides safe electrical isolation and limitation of the voltage
without a connection to the protective conductor,
a PELV (Protective Extra Low Voltage) supply also requires a safe connection to the protective conduc-
tor.
CAUTION
Observe the UL requirements
• When operating under UL conditions, observe the warnings in the chapter UL Requirements [}22].
EtherCATP transmits two supply voltages:
•Control voltage US
The following sub-functions are supplied from the control voltage US:
◦ the fieldbus
◦ the processor logic
◦ typically the inputs and the sensors if the EtherCATPBox has inputs.
•Peripheral voltage UP
The digital outputs are typically supplied from the peripheral voltage UP for EtherCATPBox modules
with digital outputs. UP can be supplied separately. If UP is switched off, the fieldbus function, the
function of the inputs and the supply of the sensors are maintained.
The exact assignment of US and UP can be found in the pin assignment of the I/O connections.
Redirection of the supply voltages
The supply voltages are passed on internally from the "IN" connection to the "OUT" connection. Hence, the
supply voltages US and UP can be passed from one EtherCATPBox to the next EtherCATPBox in a simple
manner.
NOTE
Note the maximum current.
Ensure that the maximum permitted current of 3A for the M8 connectors is not exceeded when redirecting
EtherCATP.

Mounting and connection
EPP3204-0002 17Version: 1.4
4.4.1 Connectors
NOTE
Risk of damage to the device!
Bring the EtherCAT/EtherCATP system into a safe, powered down state before starting installation, disas-
sembly or wiring of the modules!
Two M8 sockets at the upper end of the modules are provided for supply and downstream connection of
EtherCATP:
• IN: left M8 socket for EtherCATP supply
• OUT: right M8 socket for downstream connection of EtherCATP
The metal threads of the M8 EtherCAT P sockets are internally linked to the FE connection via high
impedance RC combination. See chapter Functional earth (FE) [}15].
Fig.2: Connectors for EtherCATP
1
2
3
4
Fig.3: M8 socket, p-coded
Contact Signal Voltage Core color1)
1 Tx + GNDSyellow
2 Rx + GNDPwhite
3 Rx - UP: peripheral voltage, +24VDC blue
4 Tx - US: control voltage, +24VDC orange
Housing Shield Shield Shield
1) The core colors apply to EtherCATP cables and ECP cables from Beckhoff.

Mounting and connection
EPP3204-000218 Version: 1.4
4.4.2 Status LEDs
4.4.2.1 Supply voltages
EtherCATPBox modules indicate the status of the supply voltages via two status LEDs. The status LEDs
are labeled with the designations of the supply voltages: Us and Up.
LED Display Meaning
US
(control voltage)
off The supply voltage US is not available.
green illuminated The supply voltage US is available.
UP
(peripheral voltage)
off The supply voltage UP is not available.
green illuminated The supply voltage UP is available.
4.4.2.2 EtherCAT
L/A (Link/Act)
A green LED labeled "L/A" or "Link/Act" is located next to each EtherCAT/EtherCATP socket. The LED
indicates the communication state of the respective socket:
LED Meaning
off no connection to the connected EtherCAT device
lit LINK: connection to the connected EtherCAT device
flashes ACT: communication with the connected EtherCAT device
Run
Each EtherCAT slave has a green LED labelled "Run". The LED signals the status of the slave in the
EtherCAT network:
LED Meaning
off Slave is in "Init" state
flashes uniformly Slave is in "Pre-Operational“ state
flashes sporadically Slave is in "Safe-Operational" state
lit Slave is in "Operational" state
Description of the EtherCAT slave states

Mounting and connection
EPP3204-0002 19Version: 1.4
4.4.3 Conductor losses
Take into account the voltage drop on the supply line when planning a system. Avoid the voltage drop being
so high that the supply voltage at the box lies below the minimum nominal voltage.
Variations in the voltage of the power supply unit must also be taken into account.
Planning tool for EtherCATP
You can plan cable lengths, voltages and currents of your EtherCATP system using TwinCAT3.
The requirement for this is TwinCAT3 Build4020 or higher.
Further information can be found in the quick start guide IO configuration in TwinCAT in chapter
"Configuration of EtherCATP via TwinCAT".
Voltage drop on the supply line
I = 3 A
10 20
5
10
15
20
300
0
25
40
Vert. Faktor: 0,22 cm / V
Voltage drop (V)
Cable length (m)
0.14 mm²
0.22 mm²
0.34 mm²

Mounting and connection
EPP3204-000220 Version: 1.4
4.5 RTD inputs
4.5.1 Connector
M12 sockets
1
2
3
45
Fig.4: M12 socket
Contact Core color 1) 4-wire 3-wire 2-wire
1 brown RL+ Measuring
current +

RL+ Measuring
current +

RL+
R+
Measuring
current +
Measurement
input +
2 white R+ Measurement
input +
R+ Measurement
input +
- -
3 blue RL- Measuring
current -

RL-
R-
Measuring
current –
Measurement
input -
RL-
R-
Measuring
current -
Measurement
input -
4 black R- Measurement
input -
- - - -
5 - Shield Shield Shield
1) The core colors apply to shielded M12 sensor cables from Beckhoff: ZK2000-7xxx
Fig.5: Connection technology
4.5.2 Cabling
• Connect each sensor with a shielded, sheathed cable in which the cable shield is connected to contact
5 of the M12 plug. e.g. Beckhoff ZK2000-7xxx.
• Two-conductor measurement: use cables with the lowest possible resistance.
• Three-conductor measurement: Make sure that the resistances of the conductors for RL+ and RL- are
as equal as possible.