BECKHOFF ELX3202-0090 ELX Series EtherCAT Terminal

Description

The BECKHOFF ELX3202-0090 is an intrinsically safe (Ex i) 2-channel analog input EtherCAT Terminal designed for direct connection of resistance thermometers (RTD) located in hazardous areas. Operating with 16-bit resolution, this terminal provides highly accurate temperature measurements from explosive gas or dust environments. It features integrated TwinSAFE SC (Single Channel) technology, which permits the use of standard analog signal values for safety-directed tasks within a TwinSAFE system architecture.

Housed in a compact 12 mm terminal enclosure, the BECKHOFF ELX3202-0090 accommodates various platinum and nickel-based temperature sensors (such as Pt100 and Ni100) as well as resistance measurements. The terminal supports 2-, 3-, and 4-wire connection configurations, with the default connection method software-configurable to suit specific field requirements. It is designed for installation on a standard 35 mm DIN rail, integrating into the EtherCAT I/O system alongside an appropriate power supply terminal.

Features

• Two differential analog input channels dedicated to temperature and RTD sensor measurements.
• Intrinsically safe (Ex i) design for direct interface with field devices in hazardous locations.
• TwinSAFE SC technology enables the deployment of standard analog signals in safety-related process applications.
• Supports a wide range of sensor types including Pt100, Pt200, Pt500, Pt1000, Ni100, Ni120, Ni1000, and KT(Y) sensors.
• Configurable 2-wire, 3-wire, or 4-wire connection modes (2-wire by default).
• Onboard digital filtering, limit value monitoring, and integrated sensor characteristic curve linearization.
• Compact 12 mm housing width optimized for high-density DIN rail mounting.

Applications

• Intrinsically safe temperature monitoring in hazardous chemical and petrochemical facilities (Zone 0/20 and Division 1).
• Process temperature control utilizing RTD sensors in oil and gas refineries.
• Safety-related temperature tracking and limit monitoring in automated industrial systems using TwinSAFE SC.
• High-density temperature data acquisition for process machinery and critical infrastructure.

Technical Specifications

Installation Guidelines

1. Verify System Power: Prior to mounting or wiring, ensure that all electrical power to the DIN rail, E-bus, and field-side power contacts is fully disconnected.
2. DIN Rail Mounting: Securely snap the terminal onto a standard 35 mm DIN rail (conforming to EN 60715). Use the double slot and key connection system to slide adjacent terminals together.
3. Intrinsically Safe Separation: Ensure that the terminal is installed in accordance with standard Ex i installation rules, using an ELX9560 power supply terminal to isolate Ex i circuits from standard I/O lines.
4. Conductor Connection: Connect the sensor wiring using solid or flexible conductors (0.08 to 2.5 mm² for solid/stranded, 0.14 to 1.5 mm² with ferrule). Depress the spring mechanism using a small screwdriver to insert the wires. Strip wires to a length of 8 to 9 mm.
5. Shielding and Grounding: Employ appropriate shielding practices for analog RTD signals to minimize noise and maintain safety parameters required for explosive environments.
6. Commissioning: Apply E-bus power and configure the appropriate sensor type, filtering parameters, and connection method (2-, 3-, or 4-wire) in TwinCAT before operating.

Replacement Recommendations

When replacing a BECKHOFF ELX3202-0090 terminal, document the existing wiring connections, channel layout, and configuration parameters in TwinCAT. Power down the entire node, release the safety lock, and slide the module out from the assembly. Ensure the replacement unit has the same hardware and TwinSAFE SC revision levels before restoring the system configuration and recommissioning the safety function.

Compliance and Certifications

The BECKHOFF ELX3202-0090 is certified under ATEX, IECEx, and cFMus regulations for use in hazardous areas. It carries Ex ec [ia Ga] IIC T4 Gc, [Ex ia Da] IIIC, and [Ex ia Ma] I ratings, and supports TwinSAFE SC single-channel functional capabilities when integrated within approved TwinSAFE control environments.