Beckhoff ELX3202 User manual

Operating manual
ELX3202 and ELX3204
2- and 4-channel analog input terminals, RTD, 16 bit, Ex i
1.2.0
2018-08-08
Version:
Date:

Table of contents
ELX3202 and ELX3204 3Version: 1.2.0
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.....................................................................................................................................11
2.1 ELX3202 - Introduction ................................................................................................................. 11
2.2 ELX3204 - Introduction ................................................................................................................. 12
2.3 Technical data .............................................................................................................................. 13
2.4 Intended use ................................................................................................................................. 14
3 Mounting and wiring ...............................................................................................................................15
3.1 Special conditions of use for ELX terminals ................................................................................. 15
3.2 Installation notes for ELX terminals .............................................................................................. 15
3.3 Arrangement of ELX terminals within a bus terminal block .......................................................... 17
3.4 Installation position and minimum distances ................................................................................ 20
3.5 Installation of ELX terminals on mounting rails............................................................................. 21
3.6 Connection.................................................................................................................................... 22
3.6.1 Connection system...........................................................................................................22
3.6.2 Wiring...............................................................................................................................23
3.6.3 Proper line connection .....................................................................................................24
3.6.4 Shielding and potential separation...................................................................................24
3.6.5 ELX3202 - Contact assignment .......................................................................................25
3.6.6 ELX3204 - Contact assignment .......................................................................................27
4 Appendix ..................................................................................................................................................29
4.1 EtherCAT AL Status Codes .......................................................................................................... 29
4.2 UL notice....................................................................................................................................... 29
4.3 Support and Service ..................................................................................................................... 30

Table of contents
ELX3202 and ELX32044 Version: 1.2.0

Foreword
ELX3202 and ELX3204 5Version: 1.2.0
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®, Safety over EtherCAT®, TwinSAFE®, XFC® and XTS® 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, DE102004044764, DE102007017835 with corresponding applications or
registrations in various other countries.
The TwinCAT Technology is covered, including but not limited to the following patent applications and
patents: EP0851348, US6167425 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
ELX3202 and ELX32046 Version: 1.2.0
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.
Attention
Damage to environment/equipment or data loss
Failure to follow this instruction can lead to environmental damage, equipment damage or
data loss.
Note
Tip or pointer
This symbol indicates information that contributes to better understanding.

Foreword
ELX3202 and ELX3204 7Version: 1.2.0
1.3 Documentation Issue Status
Version Comment
1.2.0 • 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
1.1.0 • Chapter Arrangement of ELX terminals at the bus terminal updated
1.0.1 • Layout updated
1.0 • Chapter Mounting and wiring updated
0.3 • Technical data updated
• Chapter Mounting and wiring updated
0.2 • Chapter Intended use added
0.1 • First preliminary version

Foreword
ELX3202 and ELX32048 Version: 1.2.0
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
ELX1052-0000-0000 ELX terminal 1052: two-channel digital input terminal
for NAMUR sensors, Ex i
0000: basic type 0001
ELX9650-0000-0000 ELX terminal 9650: 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 0000
• The type, software version and revision are read as decimal numbers, even if they are technically
saved in hexadecimal.
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)
Datecode
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: WWYYFFHH
WW - week of production (calendar week)
YY - year of production
FF - firmware version
HH - hardware version

Foreword
ELX3202 and ELX3204 9Version: 1.2.0
Example with date code: 02180100:
02 - week of production 02
18 - year of production 2018
01 - firmware version 01
00 - hardware version 00
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
Fig.1: ELX1052-0000 with date code 3218FMFM, BTN 10000100 and Ex marking

Foreword
ELX3202 and ELX320410 Version: 1.2.0
Fig.2: ELX9012 with date code 32180005 and Ex marking

Product overview
ELX3202 and ELX3204 11Version: 1.2.0
2 Product overview
2.1 ELX3202 - Introduction
Fig.3: ELX3202 - 2-channel analog input terminal RTD for 2, 3 and 4-wire connection, 16 bit, Exi
The ELX3202 analog input terminal allows the direct connection of RTDs located in hazardous areas
classified Zone 0/20 or 1/21. The circuitry of the ELX3202 can operate sensors with 2, 3 and 4-wire
technology. Linearization is carried out over the entire freely selectable temperature range. By default the
terminal is set to PT100 sensors with 2-wire technology. The ELX3202 terminal indicates signal state and
sensor malfunctions (e.g. wire breakage) by means of LEDs.

Product overview
ELX3202 and ELX320412 Version: 1.2.0
2.2 ELX3204 - Introduction
Fig.4: ELX3204 - 4-channel analog input terminal RTD, 2-wire connection, 16bit, Exi
The ELX3204 analog input terminal allows the direct connection of RTDs located in hazardous areas
classified Zone 0/20 or 1/21. The circuitry of the ELX3204 can operate sensors with 2-wire technology.
Linearization is carried out over the entire freely selectable temperature range. By default the terminal is set
to PT100 sensors with 2-wire technology. The ELX3204 terminal indicates signal state and sensor
malfunctions (e.g. wire breakage) by means of LEDs.

Product overview
ELX3202 and ELX3204 13Version: 1.2.0
2.3 Technical data
Technical data ELX3202-0000 ELX3204-0000
Technology temperature measurement
Sensor types Pt100, Pt200, Pt500, Pt1000, Ni100, Ni120, Ni1000
resistance measurement (10Ω…4kΩ), KT(Y)
sensors
Number of inputs 2 (differential) 4 (differential)
Connection method 2-, 3-, 4-wire,
default: 2-wire
2-wire
Measuring range Pt sensors: -200…+850°C
Ni sensors: -60…+250°C
Resolution 0.1°C per digit
Measuring current < 1 mA (depending on sensor and measuring range)
Measuring error < ±0,3 % (relative to the respective full-scale value)
Internal resistance ≥ 10kΩ typ. (differential)
Input filter limit frequency typical 1kHz
Conversion time adjustable: 10…3300ms
(default: 170ms)
adjustable: 10…3300ms
(default: 270ms)
Supply voltage electronics via E-Bus (5VDC) and Power Contacts (24VDCEx,
feeding by ELX9560)
Current consumption from the E-Bus typically 70mA
Current consumption from Power Contacts typically 10 mA + load (ELX9560 power supply)
Special features limit value monitoring, digital filter and characteristic
curve linearization integrated, connection method
freely configurable
Bit width in the process image 2 x 32 bit RTD input 4 x 32 bit RTD input
Electrical isolation 1500V (E-Bus/ field voltage)
Weight ca. 60g
Permissible ambient temperature range during
operation
-25°C ... + 60°C
Permissible ambient temperature range during
storage
-40°C ... + 85°C
Permissible relative humidity 95%, no condensation
Permissible air pressure
(operation, storage, transport)
800hPa to 1100hPa
(this corresponds to a height of approx. -690m to
2000m over sea level assuming an international
standard atmosphere)
Dimensions (W x H x D) app. 15mm x 100mm x 70mm (width aligned:
12mm)
Mounting on 35mm mounting rail conforms to EN 60715
Vibration/ shock resistance conforms to EN60068-2-6/ EN60068-2-27
EMC immunity/ emission conforms to EN61000-6-2/ EN61000-6-4
Protect. class IP20
Permissible installation position See chapter Installation position and minimum
distances [}20]
Approvals CE, ATEX, IECEx

Product overview
ELX3202 and ELX320414 Version: 1.2.0
Technical data for explosion protection ELX3202-0000, ELX3204-0000
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 = 4.94V
IO = 12mA
PO = 15mW
Characteristic curve: linear
Reactance (without consideration of the
simultaneousness)
L0C0
Ex ia I 100mH 1000µF
Ex ia IIA 100mH 1000µF
Ex ia IIB 100mH 1000µF
Ex ia IIC 100mH 100µF
Ex ia IIIC 100mH 1000µF
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" (Exe) according to
IEC60079-7 and must only be operated in hazardous areas of Zone2 or in non-hazardous areas.
The field interfaces of the ELX terminals achieve explosion protection through the type of protection "intrinsic
safety" (Exi) according to IEC60079-11. 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) [}9].

Mounting and wiring
ELX3202 and ELX3204 15Version: 1.2.0
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 EN60079-0 and EN60529! 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 per-
missible.
• 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 tempera-
ture 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 categoryII according
to EN60664-1
• The individual terminals may only be unplugged or removed from the bus terminal sys-
tem 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 dis-
connected if all supply voltages have been switched off or if a non-explosive atmos-
phere is ensured!
• The fuses of the EL92xx power feed terminals may only be exchanged if all supply volt-
ages 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
Attention
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 car-
ton. 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 regula-
tions, accident prevention regulations and general technical rules applicable to your de-
vices, machines and plants.

Mounting and wiring
ELX3202 and ELX320416 Version: 1.2.0
CAUTION
Observe the erection regulations
Observe the applicable erection regulations.
Attention
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 surround-
ings are suitably earthed.
Attention
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 E-bus contacts can be negatively affected by damage caused by this, e.g.
scratches.
Attention
Protect the terminals against dirt
To ensure the functionality of the ELX terminals they must be protected against dirt, espe-
cially on the contact points. For this reason use only clean tools and materials.
Attention
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 [}23].
• 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.
Attention
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!

Mounting and wiring
ELX3202 and ELX3204 17Version: 1.2.0
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 termi-
nal, 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 con-
tinuing the same terminal segment with standard Beckhoff EtherCAT terminals (e.g. EL/
ES/EK)!
Examples for the arrangement of ELX terminals
Fig.5: Valid arrangement of the ELX terminals (right terminal block).
Fig.6: 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.7: Valid arrangement - multiple power supplies by ELX9560, each with an upstream ELX9410.

Mounting and wiring
ELX3202 and ELX320418 Version: 1.2.0
Fig.8: Valid arrangement - ELX9410 in front of an ELX9560 power supply terminal.
Fig.9: Invalid arrangement - missing ELX9560 power supply terminal.
Fig.10: Invalid arrangement - terminal that does not belong to the ELX series within the ELX terminal
segment.
Fig.11: Invalid arrangement - second ELX9560 power supply terminal within the ELX terminal segment
without an upstream ELX9410.

Mounting and wiring
ELX3202 and ELX3204 19Version: 1.2.0
Fig.12: Invalid arrangement - missing ELX9012 bus end cover.
Attention
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 con-
nected (see mounting examples) must be installed or a completely new terminal block must
be assembled.

Mounting and wiring
ELX3202 and ELX320420 Version: 1.2.0
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: 35mm (required!)
• besides the bus terminal block: 20mm (recommended)
Fig.13: 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.