Beckhoff KL9570 Operator's manual

Documentation
KL9570
Buffer capacitor terminal
2.0
2017-10-20
Version:
Date:

Table of contents
KL9570 3Version: 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
2 Product overview.......................................................................................................................................8
2.1 Introduction ..................................................................................................................................... 8
2.2 Technical data ................................................................................................................................ 9
3 Mounting and wiring ...............................................................................................................................10
3.1 Installation on mounting rails ........................................................................................................ 10
3.2 Installation instructions for enhanced mechanical load capacity .................................................. 12
3.3 Connection.................................................................................................................................... 13
3.3.1 Connection system...........................................................................................................13
3.3.2 Wiring...............................................................................................................................15
3.3.3 Connection.......................................................................................................................16
3.4 Application example...................................................................................................................... 17
3.5 ATEX - Special conditions (standard temperature range) ............................................................ 18
3.6 ATEX Documentation ................................................................................................................... 19
4 Appendix ..................................................................................................................................................20
4.1 Support and Service ..................................................................................................................... 20

Table of contents
KL95704 Version: 2.0

Foreword
KL9570 5Version: 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
KL95706 Version: 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
KL9570 7Version: 2.0
1.3 Documentation issue status
Version Comment
2.0 • Migration
1.0 • First release
0.1 • Preliminary version for internal use
Firmware and hardware versions
Documentation
Version
KL2531
Firmware Hardware
2.0 - 01
1.0 - 00
0.1 - 00
The firmware and hardware versions (delivery state) can be found in 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 ser. no.: 39 04 1B 01:
39 - week of production 39
4 - year of production 2004
1B - firmware version 1B
01 - hardware version 01

Product overview
KL95708 Version: 2.0
2 Product overview
2.1 Introduction
Fig.1: KL9570
The KL9570 Bus Terminal contains high-performance capacitors for stabilizing supply voltages. It can be
used in conjunction with the stepper motor terminals KL2531 and KL2541 and the DC motor terminals
KL2532 and KL2552.
Low internal resistance and high pulse current capability enable good buffering in parallel with a power
supply unit. Return currents are stored, particularly in the context of drive applications, thereby preventing
overvoltages. If the recovery energy exceeds the capacity of the capacitors, energy can be dissipated via an
external ballast resistor.
Functioning
• The KL9570 monitors the voltage between terminal points 2(+UIN) and 6(-UIN).
• When this voltage reaches 55V, the KL9570 establishes a connection between terminal points 5 and
6.
• If the voltage between terminal points 2 and 6 falls below 52V, the KL9570 disconnects terminal points
5 and 6 from each other again.
The switch-on threshold of 55V in conjunction with the switch-off threshold results in a hysteresis of 3V.
If you connect a brake resistor (typically10Ω) between terminal points 1(+Rext) and 5(-Rext),
it dissipates the surplus energy when the KL9570 connects terminal points 5 and 6.

Product overview
KL9570 9Version: 2.0
LED display
The Overload LED is lit as soon as terminal points 5 and 6 are connected.
2.2 Technical data
Technical data KL9570/KS9570
Rated voltage 50V
Capacity 500µF
Switch-on threshold 55V
Switch-off threshold 52V
Ripple current 10 A in continuous operation
Internal resistance <10mΩ
Overvoltage protection >53V
Recommended ballast resistor 10Ω, typically10W
Overvoltage control range ±2V
Ballast resistor clock rate load-dependent, 2-point control
Electrical isolation 1.500V (connection terminal point/K-bus)
Dimensions (W x H x D) approx. 15mmx100mmx70mm (width aligned:
12mm)
Weight approx. 65g
Permissible ambient temperature range during
operation
0°C ... + 55°C
Permissible ambient temperature range during
storage
-25°C ... + 85°C
Permissible relative air humidity 95%, no condensation
Mounting on 35mm mounting rail conforms to EN60715
Vibration/shock resistance conforms to EN60068-2-6/EN60068-2-27, see also
Installation instructions for enhanced mechanical load
capacity
EMC immunity/emission conforms to EN61000-6-2/ EN61000-6-4
Protection class IP20
Installation position variable
Approval CE, ATEX

Mounting and wiring
KL957010 Version: 2.0
3 Mounting and wiring
3.1 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.2: 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.
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 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
KL9570 11Version: 2.0
Disassembly
Fig.3: 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.
Note
Power Contacts
During the design of a bus terminal block, the pin assignment of the individual Bus Termi-
nals must be taken account of, since some types (e.g. analog Bus Terminals or digital 4-
channel Bus Terminals) do not or not fully loop through the power contacts. Power Feed
Terminals (KL91xx, KL92xx or EL91xx, EL92xx) interrupt the power contacts and thus rep-
resent 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
KL957012 Version: 2.0
Fig.4: Power contact on left side
Attention
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 order 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!
3.2 Installation instructions for enhanced mechanical load
capacity
WARNING
Risk of injury through electric shock and damage to the device!
Bring the Bus Terminal system into a safe, de-energized state before starting mounting,
disassembly or wiring of the Bus Terminals!
Additional checks
The terminals have undergone the following additional tests:
Verification Explanation
Vibration 10 frequency runs in 3 axes
6 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
25 g, 6 ms

Mounting and wiring
KL9570 13Version: 2.0
Additional installation instructions
For terminals with enhanced mechanical load capacity, the following additional installation instructions apply:
• The enhanced mechanical load capacity is valid for all permissible installation positions
• Use a mounting rail according to EN 60715 TH35-15
• Fix the terminal segment on both sides of the mounting rail with a mechanical fixture, e.g. an earth
terminal or reinforced end clamp
• The maximum total extension of the terminal segment (without coupler) is:
64 terminals (12 mm mounting with) or 32 terminals (24 mm mounting with)
• Avoid deformation, twisting, crushing and bending of the mounting rail during edging and installation of
the rail
• The mounting points of the mounting rail must be set at 5 cm intervals
• Use countersunk head screws to fasten the mounting rail
• The free length between the strain relief and the wire connection should be kept as short as possible. A
distance of approx. 10 cm should be maintained to the cable duct.
3.3 Connection
3.3.1 Connection system
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!
Overview
The Bus Terminal system offers different connection options for optimum adaptation to the respective
application:
• The terminals of ELxxxx and KLxxxx series with standard wiring include electronics and connection
level in a single enclosure.
• The terminals of ESxxxx and KSxxxx series feature a pluggable connection level and enable steady
wiring while replacing.
• The High Density Terminals (HD Terminals) include electronics and connection level in a single
enclosure and have advanced packaging density.
Standard wiring (ELxxxx / KLxxxx)
Fig.5: Standard wiring
The terminals of ELxxxx and KLxxxx series have been tried and tested for years.
They feature integrated screwless spring force technology for fast and simple assembly.

Mounting and wiring
KL957014 Version: 2.0
Pluggable wiring (ESxxxx / KSxxxx)
Fig.6: Pluggable wiring
The terminals of ESxxxx and KSxxxx series feature a pluggable connection level.
The assembly and wiring procedure for the KS series is the same as for the ELxxxx and KLxxxx series.
The KS/ES series terminals enable the complete wiring to be removed as a plug connector from the top of
the housing for servicing.
The lower section can be removed from the terminal block by pulling the unlocking tab.
Insert the new component and plug in the connector with the wiring. This reduces the installation time and
eliminates the risk of wires being mixed up.
The familiar dimensions of the terminal only had to be changed slightly. The new connector adds about 3
mm. The maximum height of the terminal remains unchanged.
A tab for strain relief of the cable simplifies assembly in many applications and prevents tangling of individual
connection wires when the connector is removed.
Conductor cross sections between 0.08mm2 and 2.5mm2 can continue to be used with the proven spring
force technology.
The overview and nomenclature of the product names for ESxxxx and KSxxxx series has been retained as
known from ELxxxx and KLxxxx series.
High Density Terminals (HD Terminals)
Fig.7: High Density Terminals
The Bus Terminals from these series with 16 terminal points are distinguished by a particularly compact
design, as the packaging density is twice as large as that of the standard 12mm Bus Terminals. Massive
conductors and conductors with a wire end sleeve can be inserted directly into the spring loaded terminal
point without tools.
Note
Wiring HD Terminals
The High Density (HD) Terminals of the ELx8xx and KLx8xx series doesn't support plug-
gable wiring.
Ultrasonically "bonded" (ultrasonically welded) conductors
Note
Ultrasonically “bonded" conductors
It is also possible to connect the Standard and High Density Terminals with ultrasonically
"bonded" (ultrasonically welded) conductors. In this case, please note the tables concern-
ing the wire-size width below!

Mounting and wiring
KL9570 15Version: 2.0
3.3.2 Wiring
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!
Terminals for standard wiring ELxxxx/KLxxxx and for pluggable wiring ESxxxx/KSxxxx
Fig.8: Connecting a cable on a terminal point
Up to eight terminal points enable the connection of solid or finely stranded cables to the Bus Terminal. The
terminal points are implemented in spring force technology. Connect the cables as follows:
1. Open a terminal point by pushing a screwdriver straight against the stop into the square opening
above the terminal point. Do not turn the screwdriver or move it alternately (don't toggle).
2. The wire can now be inserted into the round terminal opening without any force.
3. The terminal point closes automatically when the pressure is released, holding the wire securely and
permanently.
See the following table for the suitable wire size width.
Terminal housing ELxxxx, KLxxxx ESxxxx, KSxxxx
Wire size width (single core wires) 0.08 ... 2.5mm20.08 ... 2.5mm2
Wire size width (fine-wire conductors) 0.08 ... 2.5mm20,08 ... 2.5mm2
Wire size width (conductors with a wire end sleeve) 0.14 ... 1.5mm20.14 ... 1.5mm2
Wire stripping length 8 ... 9mm 9 ... 10mm
High Density Terminals (HD Terminals [}14]) with 16 terminal points
The conductors of the HD Terminals are connected without tools for single-wire conductors using the direct
plug-in technique, i.e. after stripping the wire is simply plugged into the terminal point. The cables are
released, as usual, using the contact release with the aid of a screwdriver. See the following table for the
suitable wire size width.

Mounting and wiring
KL957016 Version: 2.0
Terminal housing High Density Housing
Wire size width (single core wires) 0.08 ... 1.5mm2
Wire size width (fine-wire conductors) 0.25 ... 1.5mm2
Wire size width (conductors with a wire end sleeve) 0.14 ... 0.75mm2
Wire size width (ultrasonically “bonded" conductors) only 1.5mm2
Wire stripping length 8 ... 9mm
3.3.3 Connection
WARNING
Risk of injury through electric shock and damage to the device!
Bring the Bus Terminals system into a safe, de-energized state before starting mounting,
disassembly or wiring of the Bus Terminals!
Fig.9: KL9570 - pin assignment
Terminal point No. Comment
+Rext 1 for connecting the external brake resistor
+UIN 2 for connection with stepper motor or DC motor terminal
+UIN 3
+UIN 4
-Rext 5 for connecting the external brake resistor
-UIN 6 for connection with stepper motor or DC motor terminal
-UIN 7
-UIN 8

Mounting and wiring
KL9570 17Version: 2.0
3.4 Application example
WARNING
Risk of injury through electric shock and damage to the device!
Bring the Bus Terminals system into a safe, de-energized state before starting mounting,
disassembly or wiring of the Bus Terminals!
Function
• The capacitor in the KL9570 compensates peaks in the supply voltage for the stepper motor/DC motor.
• As soon as this supply voltage exceeds 55V, the KL9570 activates the brake resistor Rchopper, which
then uses up the braking energy fed back from the stepper motor/DC motor connected to the KL2541.
Fig.10: Application example
Note
Several motors
A KL9570 Capacitor Terminal can condition the supply voltage for several motors.

Mounting and wiring
KL957018 Version: 2.0
Attention
Dimensioning of the brake resistor
The brake resistor Rchopper (typically10Ω) should be dimensioned such that it can handle
the expected heat generation without damage!
3.5 ATEX - Special conditions (standard temperature
range)
WARNING
Observe the special conditions for the intended use of Beckhoff fieldbus
components with standard temperature range in potentially explosive areas
(directive 94/9/EU)!
• The certified components are to be installed in a suitable housing that guarantees a
protection class of at least IP54 in accordance with EN 60529! The environmental con-
ditions during use are thereby to be taken into account!
• 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 0 to 55°C for the use of Beck-
hoff fieldbus components standard temperature range in potentially explosive areas!
• Measures must be taken to protect against the rated operating voltage being exceeded
by more than 40% due to short-term interference voltages!
• The individual terminals may only be unplugged or removed from the Bus Terminal sys-
tem if the supply voltage has been switched off or if a non-explosive atmosphere is en-
sured!
• The connections of the certified components may only be connected or disconnected if
the supply voltage has been switched off or if a non-explosive atmosphere is ensured!
• The fuses of the KL92xx/EL92xx power feed terminals may only be exchanged if the
supply voltage has been switched off or if a non-explosive atmosphere is ensured!
• Address selectors and ID switches may only be adjusted if the supply voltage has been
switched off or if a non-explosive atmosphere is ensured!
Standards
The fundamental health and safety requirements are fulfilled by compliance with the following standards:
• EN 60079-0:2012+A11:2013
• EN 60079-15:2010
Marking
The Beckhoff fieldbus components with standard temperature range certified for potentially explosive areas
bear one of the following markings:
II 3GKEMA 10ATEX0075 X Ex nA IIC T4 GcTa: 0…55°C
or
II 3GKEMA 10ATEX0075 X Ex nC IIC T4 GcTa: 0…55°C

Mounting and wiring
KL9570 19Version: 2.0
3.6 ATEX Documentation
Note
Notes about operation of the Beckhoff terminal systems in potentially explo-
sive areas (ATEX)
Pay also attention to the continuative documentation
Notes about operation of the Beckhoff terminal systems in potentially explosive areas
(ATEX)
that is available in the download area of the Beckhoff homepage http:\\www.beckhoff.com!

Appendix
KL957020 Version: 2.0
4 Appendix
4.1 Support and Service
Beckhoff and their partners around the world offer comprehensive support and service, making available fast
and competent assistance with all questions related to Beckhoff products and system solutions.
Beckhoff's branch offices and representatives
Please contact your Beckhoff branch office or representative for local support and service on Beckhoff
products!
The addresses of Beckhoff's branch offices and representatives round the world can be found on her internet
pages:
http://www.beckhoff.com
You will also find further documentation for Beckhoff components there.
Beckhoff Headquarters
Beckhoff Automation GmbH & Co. KG
Huelshorstweg 20
33415 Verl
Germany
Phone: [phone]
Fax: [phone]
e-mail: [email protected]
Beckhoff Support
Support offers you comprehensive technical assistance, helping you not only with the application of
individual Beckhoff products, but also with other, wide-ranging services:
• support
• design, programming and commissioning of complex automation systems
• and extensive training program for Beckhoff system components
Hotline: [phone]
Fax: [phone]
e-mail: [email protected]
Beckhoff Service
The Beckhoff Service Center supports you in all matters of after-sales service:
• on-site service
• repair service
• spare parts service
• hotline service
Hotline: [phone]
Fax: [phone]
e-mail: [email protected]