Beckhoff KL2819 Operator's manual

Documentation | EN
KL2819
HD Bus Terminal, 16-channel digital output 24 V DC, with diagnostics
2022-02-11 | Version: 1.1.0

Table of contents
KL2819 3Version: 1.1.0
Table of contents
1 Foreword ....................................................................................................................................................5
1.1 Notes on the documentation..............................................................................................................5
1.2 Safety instructions .............................................................................................................................6
1.3 Documentation Issue Status..............................................................................................................7
2 Product overview.......................................................................................................................................8
2.1 Introduction and contact assignment.................................................................................................8
2.2 Technical data .................................................................................................................................10
2.3 Overload protection .........................................................................................................................10
3 Interference-free Bus Terminals ............................................................................................................13
4 Mounting and wiring................................................................................................................................17
4.1 Instructions for ESD protection........................................................................................................17
4.2 Installation on mounting rails ...........................................................................................................18
4.3 Connection ......................................................................................................................................21
4.3.1 Connection system .......................................................................................................... 21
4.3.2 Wiring............................................................................................................................... 23
4.3.3 Shielding .......................................................................................................................... 24
4.4 Installation positions ........................................................................................................................24
4.5 Disposal...........................................................................................................................................26
5 KS2000 Configuration software .............................................................................................................27
5.1 KS2000 - Introduction......................................................................................................................27
5.2 Parameterization with KS2000 ........................................................................................................28
5.3 Register ...........................................................................................................................................30
6 Access from the user programm ...........................................................................................................31
6.1 Control and status bytes..................................................................................................................31
6.1.1 Process data mode.......................................................................................................... 31
6.1.2 Register communication .................................................................................................. 31
6.2 Register overview ............................................................................................................................32
6.3 Register description.........................................................................................................................33
6.4 Examples of Register Communication ............................................................................................35
6.4.1 Example 1: reading the firmware version from Register 9............................................... 35
6.4.2 Example 2: Writing to an user register............................................................................. 35
7 Appendix ..................................................................................................................................................39
7.1 Support and Service ........................................................................................................................39

Table of contents
KL28194 Version: 1.1.0

Foreword
KL2819 5Version: 1.1.0
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®, 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
KL28196 Version: 1.1.0
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.
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
KL2819 7Version: 1.1.0
1.3 Documentation Issue Status
Version Comment
1.1.0 • Chapter “Technical data” updated
• Document structure updated
• Chapter “Instruction for ESD protection” added
• Chapter “Disposal” added
• New title page
• Update revision status
1.0.0 • First published
Firmware and hardware versions
Documentation
Version
KL2819
Firmware Hardware
1.1.0 1B 02
1.0.0 1A 00
The firmware and hardware versions (delivery state) can be taken from the serial number printed on the side
of the terminal.
Syntax of the serial number
Structure of the serial number: WW YY FF HH
WW - week of production (calendar week)
YY - year of production
FF - firmware version
HH - hardware version
Example with serial number 40 15 1A 00:
40 - week of production 40
15 - year of production 2015
1A - firmware version 1A
00 - hardware version 00

Product overview
KL28198 Version: 1.1.0
2 Product overview
2.1 Introduction and contact assignment
Fig.1: KL2819
HD Bus Terminal, 16-channel digital output 24 VDC, 0.5 A, with diagnostics
The KL2819 Bus Terminal has 16 digital output channels for the switching of 24V loads up to 0.5A. The
integrated diagnostics can be evaluated by the controller and indicated by the LEDs. Overtemperature and
the lack of a voltage supply to the terminal are supplied as diagnostic information. Moreover, each of the
channels can signal e.g. a short circuit. The switching state and any error of the output are indicated by the
LED. Maintenance of the application is simplified by the diagnostic function. The power contacts are
connected through; reference ground of the outputs is the 0V power contact. The outputs are electrically
isolated from the fieldbus side.
LED displays
LED Color Meaning
OUTPUT 1- 16 green off No output signal
on Output signal 24V
DIAGNOSE 1- 16 red on ERROR: Overcurrent / Overtemperature

Product overview
KL2819 9Version: 1.1.0
Contact assignment
Terminal point Description
Name No.
Output 1 1 Output 1
Output 2 2 Output 2
Output 3 3 Output 3
Output 4 4 Output 4
Output 5 5 Output 5
Output 6 6 Output 6
Output 7 7 Output 7
Output 8 8 Output 8
Output 9 9 Output 9
Output 10 10 Output 10
Output 11 11 Output 11
Output 12 12 Output 12
Output 13 13 Output 13
Output 14 14 Output 14
Output 15 15 Output 15
Output 16 16 Output 16

Product overview
KL281910 Version: 1.1.0
2.2 Technical data
Technical data KL2819
Connection technology 1-wire
Number of Outputs 16
Rated load voltage 24VDC (-15 %/+20 %)
Current consumption from K-bus typ. 30mA
Load type ohmic, inductive, lamp load
Max. output current 0.5A (short-circuit-proof) per channel
Short circuit current < typ. 1.1A
Breaking energy < 300 mJ/channel
Reverse voltage protection yes
Current consumption power contacts typ. 50mA + load
Electrical isolation 500V (K-bus/field potential)
Output stage push (high-side switch)
Bit width in the process image 16bit output and diagnostics (2 x 8Bit-control/status
optional)
Dimensions (W x H x D) approx. 15 mm x 100 mm x 70 mm (width aligned: 12 mm)
Weight approx. 70g
Mounting on 35mm mounting rail according to EN60715
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
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
Installation position variable, see section Installation positions [}24] of
chapter Mounting and wiring
Protection class IP20
Approvals/markings* CE, UKCA, EAC
*) Real applicable approvals/markings see type plate on the side (product marking).
2.3 Overload protection
The maximum continuous output current per output is around 0.5 A.
When switching on lamp loads, high starting currents occur that are limited by the output circuit of the
terminals. This ensures that the upstream circuit breaker does not trip (see fig. Overload current limitation).

Product overview
KL2819 11Version: 1.1.0
Fig.2: Overload current limitation
Fig.3: Schematic illustration of the thermal switch-off in case of overload
In case of a long-term overload and/or short-circuit, the output is protected by the thermal switch-off of the
channel.
The output circuit of the terminal limits the current. The terminal maintains this current until important self-
heating of the channel occurs.
On exceeding the upper temperature limit, the terminal switches the channel off.
The channel is switched on again after it has cooled down to below the lower temperature limit.
The output signal is clocked until the output is switched off by the controller or the short-circuit is eliminated
(see fig. Schematic illustration of the thermal switch-off in case of overload). The clock frequency depends
on the ambient temperature and the load of the other terminal channels. This overload cause the device
temperature to rise further.
If several channels are overloaded, this leads to a rapid increase in the device temperature. The overloaded
channels are switched off when the upper limit for the device temperature is exceeded. The channels are
only switched on again if the temperature falls below the lower limit values for both the device and the
channel. The non-overloaded channels continue operating properly.
When switching off inductive loads, high induction voltages result from interrupting the current too quickly.
These are limited by an integrated freewheeling diode to approx. -35 V. Since the current reduces only
slowly, a delayed switch-off can occur in many control applications. For example, a valve remains open for
many milliseconds. Switch-off times are realized that correspond, for instance, to the switch-on time of the
coil.

Product overview
KL281912 Version: 1.1.0
Fig.4: Switch-off of inductive loads

Interference-free Bus Terminals
KL2819 13Version: 1.1.0
3 Interference-free Bus Terminals
Use of interference-free Bus or EtherCAT Terminals in safety applications
If a Bus or EtherCAT Terminal is described as interference-free, this means that the consecutive
terminal behaves passively in a safety application (e.g. in the case of the all-pole switch-off of a po-
tential group).
In this case the terminals do not represent an active part of the safety controller and do not affect
the Safety Integrity Level (SIL) or Performance Level (PL) attained in the safety application.
For details, please refer to chapter 2.17f in the TwinSAFE application manual.
NOTE
Pay attention to the hardware version
Please pay attention to the information about the hardware version and non-reactivity of the respective Bus
Terminal in the chapters "Technical Data" or "Firmware Compatibility"!
Only terminals with the appropriate hardware version may be used without the attained SIL/PL being af-
fected!
The Bus or EtherCAT Terminals regarded as interference-free at the time of preparing this document are
listed in the following tables together with their respective hardware versions.
Terminal name
Bus Terminal
from hardware version
KL2408 05
KL2809 02
KL2134 09
KL2424 05
KL9110 07
Terminal name
EL/ELX terminal
from hardware version
EL2004 15
EL2008 07
EL2022 09
EL2024 06
EL2034 06
EL2809 01
EL2828 00
EL2872 01
EL2878-0005 00
EL9110 13
EL9410 16
ELX1052 00
ELX1054 00
ELX1058 00
ELX2002 00
ELX2008 00
ELX3152 00
ELX3181 00
ELX3202 00
ELX3204 00
ELX3252 00
ELX3312 00
ELX3314 00
ELX3351 00
ELX4181 00
ELX5151 00
ELX9560 03

Interference-free Bus Terminals
KL281914 Version: 1.1.0
External wiring
The following requirements are to be ensured by the system manufacturer and must be incorporated into the
user documentation.
•Protection class IP54
The terminals must be installed in IP54 control cabinets to ensure the necessary protection class IP54.
•Power supply unit
The standard terminals must be supplied with 24V by an SELV/PELV power supply unit with an output
voltage limit Umax of 60V in the event of a fault.
•Prevention of feedback
Feedback can be prevented through different measures. These are described below. In addition to
mandatory requirements there are also optional requirements, of which only one needs to be selected.
◦No switching of loads with a separate power supply
Loads that have their own power supply must not be switched by standard terminals, since in this
case feedback via the load cannot be ruled out.
Fig.5: Negative example – active load
◦ The control of an STO input of a frequency converter could serve here as a negative example.
Exceptions to the general requirement are allowed only if the manufacturer of the connected load
guarantees that feedback to the control input cannot occur. This can be achieved, for example,
through adherence to load-specific standards.
◦Option 1: Ground feedback and all-pole disconnection
The ground connection of the connected load must be fed back to the safely switched ground.

Interference-free Bus Terminals
KL2819 15Version: 1.1.0
Fig.6: Ground connection of the load: correct (K1) and incorrect (K2)
◦ If either
a) the ground of the load is not fed back to the terminal or
b) the ground is not safely switched but connected permanently
then fault exclusions are necessary with regard to a short-circuit with external potential in order to
be able to achieve Cat. 4 PLe according to EN ISO 13849-1:2007 or SIL3 according to IEC
61508:2010 (refer here to the overview in the chapter "Effect of options on the safety level").
◦Option 2: Cable short-circuit fault exclusion
If solution option 1 is not feasible, the ground feedback and all-pole disconnection can be
dispensed with if the danger of feedback due to a cable short-circuit can be excluded by other
measures. These measures, which can be implemented alternatively, are described in the
following sections.

Interference-free Bus Terminals
KL281916 Version: 1.1.0
Fig.7: Short circuit fault exclusion through protected cable laying
◦a) Possibility 1: Load connection via separate sheathed cables
The non-safely switched potential of the standard terminal may not be conducted together with
other potential-conducting cores inside the same sheathed cable. (Fault exclusion, see EN ISO
13849-2:2013, Table D.4)
◦b) Possibility 2: Wiring only inside the control cabinet
All loads connected to the non-safe standard terminals must be located in the same control
cabinet as the terminals. The cables are routed entirely inside the control cabinet. (Fault exclusion,
see EN ISO 13849-2:2013, Table D.4)
◦c) Possibility 3: Dedicated earth connection per conductor
All conductors connected to the non-safe standard terminals are protected by their own earth
connection. (Fault exclusion, see EN ISO 13849-2:2013, Table D.4)
◦d) Possibility 4: Cable permanently (fixed) installed and protected against external damage
All conductors connected to the non-safe standard terminals are permanently fixed and, e.g.
protected against external damage by a cable duct or armored pipe.
•Effect of the options on the safety level
In principle, standard terminals in safely switched potential groups are not an active part of the safety
controller. Accordingly, the safety level attained is defined only by the higher-level safety
controller, i.e. the standard terminals are not included in the calculation! However, the wiring of the
standard terminals can lead to limitations in the maximum attainable safety level.
Depending on the solution selected for the avoidance of feedback and the safety standard considered
(see Option 1 and Option 2), different maximum attainable safety levels result, which are summarized
in the following table:
Summary of safety classifications
Feedback avoidance measures DIN EN ISO 13849-1 IEC 61508 EN 62061
Fault exclusion
Cable short-circuit
max.
Cat. 4
PLe
max. SIL3 max. SIL2 *
Ground feedback and all-pole
disconnection
max. SIL3

Mounting and wiring
KL2819 17Version: 1.1.0
4 Mounting and wiring
4.1 Instructions for ESD protection
NOTE
Destruction of the devices by electrostatic discharge possible!
The devices contain components at risk from electrostatic discharge caused by improper handling.
• Please ensure you are electrostatically discharged and avoid touching the contacts of the device directly.
• Avoid contact with highly insulating materials (synthetic fibers, plastic film etc.).
• Surroundings (working place, packaging and personnel) should by grounded probably, when handling
with the devices.
• Each assembly must be terminated at the right hand end with a KL9010 bus end terminal, to ensure the
protection class and ESD protection.
Fig.8: Spring contacts of the Beckhoff I/O components

Mounting and wiring
KL281918 Version: 1.1.0
4.2 Installation 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!
Assembly
Fig.9: Attaching on mounting rail
The bus coupler and bus terminals are attached to commercially available 35mm mounting rails (DIN rails
according to EN60715) 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 compo-
nents 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 7.5mm under the terminals
and couplers, you should use flat mounting connections (e.g. countersunk screws or blind rivets).

Mounting and wiring
KL2819 19Version: 1.1.0
Disassembly
Fig.10: 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 1cm 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 K-Bus/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 are supplied via terminals on the Bus Coupler (up to 24V)
or for higher voltages via power feed terminals.
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 Termi-
nals) do not or not fully loop through the power contacts. Power Feed Terminals (KL91xx, KL92xx
or EL91xx, EL92xx) interrupt the power contacts and thus represent the start of a new supply rail.
PE power contact
The power contact labeled PE can be used as a protective earth. For safety reasons this contact mates first
when plugging together, and can ground short-circuit currents of up to 125A.

Mounting and wiring
KL281920 Version: 1.1.0
Fig.11: Power contact on left side
NOTE
Possible damage of the device
Note that, for reasons of electromagnetic compatibility, the PE contacts are capacitatively coupled to the
mounting rail. This may lead to incorrect results during insulation testing or to damage on the terminal (e.g.
disruptive discharge to the PE line during insulation testing of a consumer with a nominal voltage of 230V).
For insulation testing, disconnect the PE supply line at the Bus Coupler or the Power Feed Terminal! In or-
der to decouple further feed points for testing, these Power Feed Terminals can be released and pulled at
least 10mm from the group of terminals.
WARNING
Risk of electric shock!
The PE power contact must not be used for other potentials!