Beckhoff KL1859 Operator's manual

Documentation
KL1859
HD Bus Terminal, 8-channel digital input + 8-channel digital
output 24 V DC
1.0.0
2016-08-10
Version:
Date:

Table of contents
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 Introduction ....................................................................................................................................... 7
2.2 Technical data .................................................................................................................................. 8
3 Presentation KL1859 within TwinCAT .....................................................................................................9
4 Mounting and wiring ...............................................................................................................................10
4.1 Installation on mounting rails .......................................................................................................... 10
4.2 Connection system ......................................................................................................................... 12
4.3 ATEX - Special conditions .............................................................................................................. 15
4.4 ATEX Documentation ..................................................................................................................... 16
4.5 Connection and LED displays......................................................................................................... 17
5 Appendix ..................................................................................................................................................19
5.1 Support and Service ....................................................................................................................... 19
KL1859 3Version: 1.0.0

Foreword
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 following notes and explanations are followed when installing and commissioning
these components.
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. For that reason the documentation is not in every case checked for consistency with
performance data, standards or other characteristics. In the event that it contains technical or editorial errors,
we retain the right to make alterations at any time and without warning. 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.
KL18594 Version: 1.0.0

Foreword
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.
KL1859 5Version: 1.0.0

Foreword
1.3 Documentation Issue Status
Version Comment
1.0.0 • First published
Firmware and hardware versions
Documentation
Version
KL1859
Firmware Hardware
1.0.0 - 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 ser. no.: 40 15 1A 00:
40 - week of production 40
15 - year of production 2015
1A - firmware version 1A
00 - hardware version 00
KL18596 Version: 1.0.0

Product overview
2 Product overview
2.1 Introduction
Fig.1: KL1859
The digital KL1859 Bus Terminal combines eight digital inputs and eight digital outputs in one device. The
inputs have a filter of 3.0 ms. The outputs process load currents up to 0.5 A, are short-circuit-proof and
protected against polarity reversal. The signal states are displayed by LEDs.
The reference ground for all inputs is the 0 V power contact, the outputs are fed via the 24 V power contact.
The conductors can be connected without tools in the case of solid wires using a direct plug-in technique.
The HD Bus Terminals (High Density) with increased packing density feature 16 connection points in the
housing of a 12 mm terminal block.
KL1859 7Version: 1.0.0

Product overview
2.2 Technical data
KL1859 - Technical data
Technical data KL1859-0000
Connection technology 1-wire
Number of Inputs 8
Number of Outputs 8
Nominal voltage 24 V DC (-15%/+20%)
“0“ signal voltage -3…+5 V (EN 61131-2, type 1/3)
“1“ signal voltage 11…30 V (EN 61131-2, type 3)
Input filter typ. 3.0 ms
Input current typ. 3 mA (EN 61131-2, type 3)
Current consumpt. K-bus typ. 25 mA
Load type ohmic, inductive, lamp load
Max. output current 0.5 A (per channel)
Reverse voltage protection yes
Current consumption power contacts typ. 15 mA + load
Electrical isolation 500 V (K-bus/field potential)
Bit width in the process image 8 inputs + 8 outputs
Configuration no address or configuration setting
Dimensions (W x H x D) approx. 15 mm x 100 mm x 70 mm (width aligned: 12 mm)
Weight approx. 60 g
Mounting [}10] on 35mm mounting rail according to EN 60715
Operating temperature 0°C ... +55°C
Storage temperature -25°C ... +85°C
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 pos. variable
Protect. class IP20
Approvals CE, ATEX [}15], cULus, GL
KL18598 Version: 1.0.0

Presentation KL1859 within TwinCAT
3 Presentation KL1859 within TwinCAT
Fig.2: KL1859 within TwinCAT 2.11
KL1859 9Version: 1.0.0

Mounting and wiring
4 Mounting and wiring
4.1 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.3: 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
components 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).
KL185910 Version: 1.0.0

Mounting and wiring
Disassembly
Fig.4: 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.
KL1859 11Version: 1.0.0

Mounting and wiring
Fig.5: 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!
4.2 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 KLxxxx and ELxxxx series with standard wiring include electronics and connection
level in a single enclosure.
• The terminals of KSxxxx and ESxxxx 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.
KL185912 Version: 1.0.0

Mounting and wiring
Standard wiring
Fig.6: Standard wiring
The terminals of KLxxxx and ELxxxx series have been tried and tested for years.
They feature integrated screwless spring force technology for fast and simple assembly.
Pluggable wiring
Fig.7: Pluggable wiring
The terminals of KSxxxx and ESxxxx series feature a pluggable connection level.
The assembly and wiring procedure for the KS series is the same as for the KLxxxx and ELxxxx 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 KSxxxx and ESxxxx series has been retained as
known from KLxxxx and ELxxxx series.
High Density Terminals (HD Terminals)
Fig.8: High Density Terminals
The Bus Terminals from these series with 16 connection 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.
KL1859 13Version: 1.0.0

Mounting and wiring
Note
Wiring HD Terminals
The High Density (HD) Terminals of the KLx8xx and ELx8xx series doesn't support steady
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 [}14] below!
Wiring
Terminals for standard wiring ELxxxx / KLxxxx and terminals for steady wiring
ESxxxx / KSxxxx
Fig.9: Mounting a cable on a terminal connection
Up to eight connections enable the connection of solid or finely stranded cables to the Bus Terminals. The
terminals are implemented in spring force technology. Connect the cables as follows:
1. Open a spring-loaded terminal by slightly pushing with a screwdriver or a rod into the square opening
above the terminal.
2. The wire can now be inserted into the round terminal opening without any force.
3. The terminal closes automatically when the pressure is released, holding the wire securely and
permanently.
Terminal housing ELxxxx, KLxxxx ESxxxx, KSxxxx
Wire size width 0.08 ... 2,5mm20.08 ... 2.5mm2
Wire stripping length 8 ... 9mm 9 ... 10mm
KL185914 Version: 1.0.0

Mounting and wiring
High Density Terminals ELx8xx, KLx8xx (HD)
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 contact 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.
Terminal housing High Density Housing
Wire size width (conductors with a wire end sleeve) 0.14... 0.75mm2
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 (ultrasonically “bonded" conductors) only 1.5mm2 (see notice
[}14]!)
Wire stripping length 8 ... 9mm
Shielding
Note
Shielding
Analog sensors and actors should always be connected with shielded, twisted paired wires.
4.3 ATEX - Special conditions
WARNING
Observe the special conditions for the intended use of Beckhoff fieldbus
components in potentially explosive areas (directive 94/9/EU)!
üConditions
a) 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!
b) 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!
c) Observe the permissible ambient temperature range of 0 - 55°C for the use of Beckhoff
fieldbus components in potentially explosive areas!
d) Measures must be taken to protect against the rated operating voltage being exceeded
by more than 40% due to short-term interference voltages!
e) 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!
f) 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!
g) 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!
h) 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: 2006
• EN 60079-15: 2005
KL1859 15Version: 1.0.0

Mounting and wiring
Marking
The Beckhoff fieldbus components certified for potentially explosive areas bear one of the following
markings:
II 3 G Ex nA II T4 KEMA 10ATEX0075 X Ta: 0 - 55°C
or
II 3 G Ex nA nC IIC T4 KEMA 10ATEX0075 X Ta: 0 - 55°C
4.4 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!
KL185916 Version: 1.0.0

Mounting and wiring
4.5 Connection and LED displays
Fig.10: KL1859 - terminal points and LEDs
Terminal point Description
Name No.
Input 1 1 Input 1
Input 2 2 Input 2
Input 3 3 Input 3
Input 4 4 Input 4
Input 5 5 Input 5
Input 6 6 Input 6
Input 7 7 Input 7
Input 8 8 Input 8
Output 1 9 Output 1
Output 2 10 Output 2
Output 3 11 Output 3
Output 4 12 Output 4
Output 5 13 Output 5
Output 6 14 Output 6
Output 7 15 Output 7
Output 8 16 Output 8
KL1859 17Version: 1.0.0

Mounting and wiring
LED indicators
LED Color Meaning
INPUT 1- 8 green off signal "0" voltage (-3 V ... 5 V)
on signal "1" voltage (15 V ... 30 V)
OUTPUT 1- 8 green off no output voltage
on +24VDC output voltage
KL185918 Version: 1.0.0

Appendix
5 Appendix
5.1 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]
KL1859 19Version: 1.0.0

List of illustrations
List of illustrations
Fig. 1 KL1859 ...................................................................................................................................... 7
Fig. 2 KL1859 within TwinCAT 2.11 .................................................................................................... 9
Fig. 3 Attaching on mounting rail ......................................................................................................... 10
Fig. 4 Disassembling of terminal.......................................................................................................... 11
Fig. 5 Power contact on left side.......................................................................................................... 12
Fig. 6 Standard wiring.......................................................................................................................... 13
Fig. 7 Pluggable wiring ........................................................................................................................ 13
Fig. 8 High Density Terminals.............................................................................................................. 13
Fig. 9 Mounting a cable on a terminal connection ............................................................................... 14
Fig. 10 KL1859 - terminal points and LEDs .......................................................................................... 17
KL185920 Version: 1.0.0