Beckhoff KM2002 Operator's manual

Documentation
KM2002, KM2004, KM2008
Terminal modules with digital outputs, 24 V, 0.5 A
3.2.0
2017-01-23
Version:
Date:

Table of contents
KM2002, KM2004, KM2008 3Version: 3.2.0
Table of contents
1 Foreword ....................................................................................................................................................4
1.1 Notes on the documentation........................................................................................................... 4
1.2 Safety instructions .......................................................................................................................... 5
1.3 Documentation Issue Status........................................................................................................... 6
2 Product overview.......................................................................................................................................7
2.1 Terminal Modules - System Overview ............................................................................................ 7
2.2 KM2002 ........................................................................................................................................ 10
2.2.1 Introduction ......................................................................................................................10
2.2.2 Technical data..................................................................................................................11
2.3 KM2004 ........................................................................................................................................ 12
2.3.1 Introduction ......................................................................................................................12
2.3.2 Technical data..................................................................................................................13
2.4 KM2008 ........................................................................................................................................ 14
2.4.1 Introduction ......................................................................................................................14
2.4.2 Technical data..................................................................................................................15
2.5 KM plug-in connectors .................................................................................................................. 15
2.5.1 Ordering information for KM plug-in connector ................................................................15
2.5.2 Technical Data .................................................................................................................16
3 Mounting and Wiring...............................................................................................................................17
3.1 Recommended mounting rails ...................................................................................................... 17
3.2 Dimensions ................................................................................................................................... 17
3.3 Mounting and demounting - terminals with traction lever unlocking ............................................. 19
3.4 Mounting and demounting - terminals with front unlocking........................................................... 21
3.5 Wiring............................................................................................................................................ 23
3.6 Connection.................................................................................................................................... 25
4 Access from the user programm ...........................................................................................................26
4.1 Process Image.............................................................................................................................. 26
5 Appendix ..................................................................................................................................................27
5.1 Support and Service ..................................................................................................................... 27

Foreword
KM2002, KM2004, KM20084 Version: 3.2.0
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
KM2002, KM2004, KM2008 5Version: 3.2.0
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 symbols
In this documentation the following symbols are used with an accompanying safety instruction or note. The
safety instructions must be read carefully and followed without fail!
DANGER
Serious risk of injury!
Failure to follow the safety instructions associated with this symbol directly endangers the
life and health of persons.
WARNING
Risk of injury!
Failure to follow the safety instructions associated with this symbol endangers the life and
health of persons.
CAUTION
Personal injuries!
Failure to follow the safety instructions associated with this symbol can lead to injuries to
persons.
Attention
Damage to the environment or devices
Failure to follow the instructions associated with this symbol can lead to damage to the en-
vironment or equipment.
Note
Tip or pointer
This symbol indicates information that contributes to better understanding.

Foreword
KM2002, KM2004, KM20086 Version: 3.2.0
1.3 Documentation Issue Status
Version Comment
3.2.0 • Technical data for KM plug-in connectors updated
3.1.0 • Technical data for KM plug-in connectors extended
• Update structure
3.0.0 • Migration
• Update structure
• Technical data updated
2.0.0 • Notes about wiring and mounting updated
• Technical data updated
1.0.2 • Technical data updated
• Pinning of terminal block X1 corrected
1.0.1 • Notes about wiring and mounting updated
• Notes about wiring technique corrected
• Technical data updated
1.0.0 • KM2004 and KM2008 added
• Mounting and demounting added
• Dimension drawings added
0.1 • first preliminary documentation for KM2002
Firm and hardware versions
Documentation
version
Hardware version
KM2002 KM2004 KM2008
3.2.0 06 05 04
3.1.0 06 05 04
3.0.0 06 05 04
2.0.0 05 03 02
1.0.2 02 02 00
1.0.1 01 00 00
1.0.0 01 00 00
0.1 00 - -
The hardware version can be found in the serial number printed at the top of the terminal module.
Syntax of the serial number
Structure of the serial number: WW YY FF HH
WW - week of production (CW, calendar week)
YY - year of production
FF - firmware version (n/a for digital modules)
HH - hardware version
Example with Ser. No.: 35 05 00 01
35 - week of production 35
05 - year of production 2005
00 - firmware version 00
01 - hardware version 01

Product overview
KM2002, KM2004, KM2008 7Version: 3.2.0
2 Product overview
2.1 Terminal Modules - System Overview
Fig.1: Bus Terminal Block
Better sensor and actuator functionality makes machines and systems more and more powerful. The Bus
Terminal reliably meets increased requirements for I/O signals through its modularity and compact design.
The existing Beckhoff Bus Terminal system is complemented by the new version of the EMxxxx / KMxxxx
Terminal Module with increased packing density. In many areas of application, cost benefits can be realized
through lower overall installed size and application-specific signal mix.
The new Terminal Modules are fully system-compatible. Like the Bus Terminals, they are bus-neutral and
can therefore be operated with any Beckhoff Bus Coupler and Bus Terminal Controller. Like the standard
Bus Terminals, the EM / KM modules are integrated in the I/O system and connected with the internal
terminal bus (E-bus / K-bus). Bus Terminals and terminal modules can be combined without restriction.
Plug connector
Like for the Bus Terminals, no tools are required for the wiring. Spring-loaded technology is used, however
the connection layer is pluggable (fixed wiring).
Fig.2: Pluggable connection (fixed wiring)

Product overview
KM2002, KM2004, KM20088 Version: 3.2.0
Connection
Plug connectors are available for single and triple conductor connection methods.
Fig.3: Terminal module with plug connector for single conductor connection method (ZS2001-0002)
Fig.4: Terminal module with plug connector for triple-conductor connection method (ZS2001-0004)
Packing density
The Terminal Modules combine 16, 32 or 64 digital inputs or outputs on a very small area. This compact and
slimline design enables very high packing densities, leading to smaller control cabinets and terminal boxes.

Product overview
KM2002, KM2004, KM2008 9Version: 3.2.0
Fig.5: Terminal module with 16 channels
Fig.6: Terminal module with 32 channels
Fig.7: Terminal module with 64 channels

Product overview
KM2002, KM2004, KM200810 Version: 3.2.0
2.2 KM2002
2.2.1 Introduction
Fig.8: Digital Terminal Module with 16 output channels
Digital Terminal Module with 16 output channels (24VDC)
The terminal module KM2002 combines 16 digital outputs with 8 channels per plug connector in a compact
design with high packing density. The binary control signals are transferred (electrically isolated) to the
actuators at the process level. Like the standard Bus Terminals, the terminal modules are integrated in the
Beckhoff I/O system. Plug connectors with spring connections enable plug-in wiring and are available with 1
or 3 pins. LEDs integrated in the connector indicate the signal state for each channel directly at the wire. The
outputs are protected against overload and short circuit.
Table1: Ordering information for terminal modules with 16 digital inputs
Ordering name Scope of supply
KM2002-0000 digital output module, 16 channels (0.5A), without connectors
KM2002-0001 digital output module, 16 channels (0.5A), with 2 connectors ZS2001-0001
KM2002-0002 digital output module, 16 channels (0.5A), with 2 connectors ZS2001-0002
KM2002-0004 digital output module, 16 channels (0.5A), with 2 connectors ZS2001-0004
See also chapter ordering information for KM plug-in connectors [}15].

Product overview
KM2002, KM2004, KM2008 11Version: 3.2.0
2.2.2 Technical data
Technical data KM2002
Number of outputs 16 (2 x 8)
Nominal voltage 24VDC (-15%/+20%)
Load type ohmic, inductive, lamp load
Output current per channel max. 0.5A
Short circuit current 0.6 ... 1.0A
Breaking energy (inductive) < 150 mJ/channel
Power supply for the electronics via the K-Bus
Current consumption from K-bus typically 5mA
Current consumption from the load voltage (24 V) typically 15mA
With of an Bus Terminal block max. [}18] 64 standard bus terminals or 80cm
(for this a KM2002 is equivalent to 2 standard bus
terminals)
Electrical isolation 500V (K-Bus/ signal voltage)
Bit width in the output process image 16bit
Dimensions with connector (W x H x D) approx. 26.5mm x 100 mm x 71mm (aligned
width: 24mm), see dimensional drawing [}17]
Weight (without connector) approx. 70g
Permissible ambient temperature range during operation 0°C...+55°C
Permissible ambient temperature range during storage -25°C...+85°C
Permissible relative humidity 95%, no condensation
Mounting [}21] on 35mm mounting rail according to EN60715
Vibration / shock resistance conforms to EN 60068-2-6/ EN60068-2-27
EMC resistance burst / ESD conforms to EN 61000-6-2/ EN61000-6-4
Protection class IP20
Installation position variable
Approval CE

Product overview
KM2002, KM2004, KM200812 Version: 3.2.0
2.3 KM2004
2.3.1 Introduction
Fig.9: Digital Terminal Modules with 32 output channels
Digital Terminal Modules with 32 output channels (24VDC)
The terminal module KM2004 combines 32 digital outputs with 8 channels per plug connector in a compact
design with high packing density. The binary control signals are transferred (electrically isolated) to the
actuators at the process level. Like the standard Bus Terminals, the terminal modules are integrated in the
Beckhoff I/O system. Plug connectors with spring connections enable plug-in wiring and are available with 1
or 3 pins. LEDs integrated in the connector indicate the signal state for each channel directly at the wire. The
outputs are protected against overload and short circuit.
Table2: Ordering information for terminal modules with 32 digital inputs
Ordering name Scope of supply
KM2004-0000 digital output module, 32 channels (0.5A), without connectors
KM2004-0001 digital output module, 32 channels (0.5A), with 4 connectors ZS2001-0001
KM2004-0002 digital output module, 32 channels (0.5A), with 4 connectors ZS2001-0002
KM2004-0004 digital output module, 32 channels (0.5 A), with 4 connectors ZS2001-0004
See also chapter ordering information for KM plug-in connectors [}15].

Product overview
KM2002, KM2004, KM2008 13Version: 3.2.0
2.3.2 Technical data
Technical data KM2004
Number of outputs 32 (4 x 8)
Nominal voltage 24VDC (-15%/+20%)
Load type ohmic, inductive, lamp load
Output current per channel max. 0.5A
Short circuit current 0.6 ... 1.0A
Breaking energy (inductive) < 150 mJ/channel
Power supply for the electronics via the K-Bus
Current consumption from K-bus typically 5mA
Current consumption from the load voltage (24 V) typically 15mA
With of an Bus Terminal block max. [}18] 64 standard bus terminals or 80cm
(for this a KM2004 is equivalent to 4 standard bus
terminals)
Electrical isolation 500V (K-Bus/ signal voltage)
Bit width in the output process image 32bit
Dimensions with connector (W x H x D) approx. 75mm x 100 mm x 55mm (aligned width:
73mm), see dimensional drawing [}18]
Weight (without connector) approx. 150g
Permissible ambient temperature range during operation 0°C...+55°C
Permissible ambient temperature range during storage -25°C...+85°C
Permissible relative humidity 95%, no condensation
Mounting [}19] on 35mm mounting rail according to EN60715
Vibration / shock resistance conforms to EN 60068-2-6/ EN60068-2-27
EMC resistance burst / ESD conforms to EN 61000-6-2/ EN61000-6-4
Protection class IP20
Installation position variable
Approval CE

Product overview
KM2002, KM2004, KM200814 Version: 3.2.0
2.4 KM2008
2.4.1 Introduction
Fig.10: Digital Terminal Modules with 64 output channels
Digital Terminal Modules with 64 output channels (24VDC)
The terminal module KM2008 combines 64 digital outputs with 8 channels per plug connector in a compact
design with high packing density. The binary control signals are transferred (electrically isolated) to the
actuators at the process level. Like the standard Bus Terminals, the terminal modules are integrated in the I/
O system. Plug connectors with spring connections enable plug-in wiring and are available with 1 or 3 pins.
LEDs integrated in the connector indicate the signal state for each channel directly at the wire. The outputs
are protected against overload and short circuit.
Table3: Ordering information for terminal modules with 64 digital inputs
Ordering name Scope of supply
KM2008-0000 digital output module, 64 channels (0.5A), without connectors
KM2008-0001 digital output module, 64 channels (0.5A), with 8 connectors ZS2001-0001
KM2008-0002 digital output module, 64 channels (0.5A), with 8 connectors ZS2001-0002
KM2008-0004 digital output module, 64 channels (0.5A), with 8 connectors ZS2001-0004
See also chapter ordering information for KM plug-in connectors [}15].

Product overview
KM2002, KM2004, KM2008 15Version: 3.2.0
2.4.2 Technical data
Technical data KM2008
Number of outputs 64 (8 x 8)
Nominal voltage 24VDC (-15%/+20%)
Load type ohmic, inductive, lamp load
Output current per channel max. 0.5A
Short circuit current 0.6 ... 1.0A
Breaking energy (inductive) < 150 mJ/channel
Power supply for the electronics via the K-Bus
Current consumption from K-bus typically 5mA
Current consumption from the load voltage (24 V) typically 15mA
With of an Bus Terminal block max. [}18] 64 standard bus terminals or 80cm
(for this a KM2008 is equivalent to 8 standard bus
terminals)
Electrical isolation 500 V (K-Bus/ signal voltage)
Bit width in the output process image 64bit
Dimensions with connector (W x H x D) approx. 123mm x 100 mm x 55mm (aligned
width: 121mm), see dimensional drawing [}18]
Weight (without connector) approx. 225g
Permissible ambient temperature range during operation 0°C...+55°C
Permissible ambient temperature range during storage -25°C...+85°C
Permissible relative humidity 95%, no condensation
Mounting [}19] on 35mm mounting rail according to EN60715
Vibration / shock resistance conforms to EN 60068-2-6/ EN60068-2-27
EMC resistance burst / ESD conforms to EN 61000-6-2/ EN61000-6-4
Protection class IP20
Installation position variable
Approval CE
2.5 KM plug-in connectors
2.5.1 Ordering information for KM plug-in connector
Fig.11: KM plug-in connector for single-wire connection (ZS2001-0001, ZS2001-0002)

Product overview
KM2002, KM2004, KM200816 Version: 3.2.0
Fig.12: KM plug-in connector for tree-wire connection (ZS2001-0004)
Ordering name Signal LEDs Wiring technique
single-wire two-wire three-wire
ZS2001-0001 no yes no no
ZS2001-0002 yes yes no no
ZS2001-0004 yes yes yes yes
2.5.2 Technical Data
Technical Data ZS2001-0001 ZS2001-0002 ZS2001-0004
Number of terminal points 10 10 30
Signal LEDs no yes yes
Nominal voltage 24VDC
Nominal current 2A
Cycle of connector operation 25
Wire size width
Solid:
stranded:
with ferrule:
0.2mm2 ... 1.0mm2 (H05V-U, H07V-U)
0.2mm2 ... 1.5mm (H05V-K, H07V-K)
0.2mm2 ... 1.0mm2 (ferrule to DIN46228pt1)
0.2mm2 ... 0.75mm2 (ferrule with plastic collar to DIN46228pt4)
Maximum outer diameter of the
conductor
2.9mm
Wire stripping length 8mm, 10mm for use with ferrule
Dimensions (w x h x d) app. 42mm x 10.3mm
x 26.9mm
app. 42mm x 12.7mm
x 26.9mm
app. 42mm x 20.8mm
x 26.9mm
Weight app. 11g app. 13g app. 23g
Permissible ambient temperature
range during operation
0°C ... +55°C
Permissible ambient temperature
range during storage
-25°C ... +55°C
Permissible relative humidity 80%, no condensation
Vibration / shock resistance conforms to EN60068-2-6/ EN60068-2-27
EMC resistance burst / ESD conforms to EN61000-6-2/ EN61000-6-4
Protection class IP20
Installation position variable

Mounting and Wiring
KM2002, KM2004, KM2008 17Version: 3.2.0
3 Mounting and Wiring
3.1 Recommended mounting rails
Terminal Modules und EtherCAT Modules of KMxxxx and EMxxxx series, same as the terminals of the
EL66xx and EL67xx series can be snapped onto the following recommended mounting rails:
• DIN Rail TH35-7.5 with 1mm material thickness (according to EN60715)
• DIN Rail TH35-15 with 1,5mm material thickness
Note
Pay attention to the material thickness of the DIN Rail
Terminal Modules und EtherCAT Modules of KMxxxx and EMxxxx series, same as the ter-
minals of the EL66xx and EL67xx seriesdoes not fit to the DIN Rail TH35-15 with 2,2 to
2,5mm material thickness (according to EN60715)!
3.2 Dimensions
KM10x2, KM20x2
Fig.13: Dimensions KM10x2, KM20x2

Mounting and Wiring
KM2002, KM2004, KM200818 Version: 3.2.0
KM10x4, KM20x4
Fig.14: Dimensions KM10x4, KM20x4
KM10x8, KM20x8
Fig.15: Dimensions KM10x8, KM20x8
Width of a Bus Terminal block
Attention
Pay attention to the maximum with and the current consumption
A maximum of 64 Bus Terminals or Bus Terminal Modules may be aligned to a Bus Cou-
pler! An overall with of 80 cm must not be exceeded! Also take care that the current con-
sumption of the Bus Terminals / Bus Terminal Modules does not overstrain the K-Bus
power supply of the Bus Coupler!

Mounting and Wiring
KM2002, KM2004, KM2008 19Version: 3.2.0
3.3 Mounting and demounting - terminals with traction
lever unlocking
The terminal modules are fastened to the assembly surface with the aid of a 35 mm mounting rail (e.g.
mounting rail TH 35-15).
Note
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 con-
flict with the fixing bolts of the mounting rail. To mount the recommended mounting rails un-
der the terminals and couplers, you should use flat mounting connections (e.g. countersunk
screws or blind rivets).
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!
Mounting
• Fit the mounting rail to the planned assembly location.
and press (1) the terminal module against the mounting rail until it latches in place on the mounting
rail (2).
• Attach the cables.
Demounting
• Remove all the cables. Thanks to the KM/EM connector, it is not necessary to remove all the cables
separately for this, but for each KM/EM connector simply undo 2 screws so that you can pull them off
(fixed wiring)!
• Lever the unlatching hook on the left-hand side of the terminal module upwards with a screwdriver (3).
As you do this
◦ an internal mechanism pulls the two latching lugs (3a) from the top hat rail back into the
terminal module,
◦ the unlatching hook moves forwards (3b) and engages

Mounting and Wiring
KM2002, KM2004, KM200820 Version: 3.2.0
• In the case 32 and 64 channel terminal modules (KMxxx4 and KMxxx8 or EMxxx4 and EMxxx8) you
now lever the second unlatching hook on the right-hand side of the terminal module upwards in the
same way.
• Pull (4) the terminal module away from the mounting surface.