Beckhoff KL28 Series User manual

Documentation | EN
KL28xx
HD Bus Terminals with digital outputs, 24 V DC
2021-06-11 | Version: 1.1.0

Table of contents
KL28xx 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
1.4 Interference-free Bus Terminals ........................................................................................................8
2 Product overview.....................................................................................................................................12
2.1 KL2808 ............................................................................................................................................12
2.1.1 Introduction and contact assignment ............................................................................... 12
2.1.2 Technical data ................................................................................................................. 14
2.2 KL2828 ............................................................................................................................................15
2.2.1 Introduction and contact assignment ............................................................................... 15
2.2.2 Technical data ................................................................................................................. 17
2.3 KL2809, KL2889..............................................................................................................................18
2.3.1 Introduction and contact assignment ............................................................................... 18
2.3.2 Technical data ................................................................................................................. 20
2.4 KL2872-0000, KL2872-0010 ...........................................................................................................21
2.4.1 Introduction and contact assignment ............................................................................... 21
2.4.2 Technical data ................................................................................................................. 23
3 Mounting and wiring................................................................................................................................24
3.1 Instructions for ESD protection........................................................................................................24
3.2 Installation on mounting rails ...........................................................................................................25
3.3 Installation instructions for enhanced mechanical load capacity .....................................................27
3.4 Connection system ..........................................................................................................................28
3.5 Installation positions ........................................................................................................................31
3.6 ATEX - Special conditions (standard temperature range) ...............................................................33
3.7 ATEX - Special conditions (extended temperature range) ..............................................................34
3.8 Continuative documentation for ATEX and IECEx ..........................................................................35
4 Appendix ..................................................................................................................................................36
4.1 Support and Service ........................................................................................................................36

Table of contents
KL28xx4 Version: 1.1.0

Foreword
KL28xx 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
KL28xx6 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
KL28xx 7Version: 1.1.0
1.3 Documentation Issue Status
Version Comment
1.1.0 • Technical data updated
• Chapter Instructions for ESD protection added
• Design of the safety instructions adapted to IEC82079-1
• New title page
1.0.0 • First release
Hardware versions
The 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

Foreword
KL28xx8 Version: 1.1.0
1.4 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

Foreword
KL28xx 9Version: 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.1: 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.

Foreword
KL28xx10 Version: 1.1.0
Fig.2: 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.

Foreword
KL28xx 11Version: 1.1.0
Fig.3: 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

Product overview
KL28xx12 Version: 1.1.0
2 Product overview
Terminal Outputs Voltage Current Comment
KL2808 [}12] 8 24VDC 0,5A
KL2828 [}15] 8 24VDC 2A
KL2809 [}18] 16 24VDC 0,5A
KL2872-0000 [}21] 16 24VDC 0,5A ribbon cable connection
KL2872-0010 [}21] 16 24VDC 0,5A ribbon cable connection, ground switching
KL2889 [}18] 16 24VDC 0,5A ground switching
2.1 KL2808
2.1.1 Introduction and contact assignment
Fig.4: KL2808
HD Bus Terminal, 8-channel digital output 24 VDC, 0.5 A
The KL2808 digital output terminal connects the binary control signals from the automation device on to the
actuators at the process level with electrical isolation. The KL2808 is protected against polarity reversal and
processes load currents with outputs protected against overload and short-circuit. The Bus Terminal contains
eight channels, consisting of a signal output and 0VDC. The signal states are displayed by LEDs. The power
contacts are looped through.
The outputs are fed via the 24V power contact in the KL2808. 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.

Product overview
KL28xx 13Version: 1.1.0
KL2808 - LEDs
LED Color Meaning
OUTPUT 1- 8 green off No output signal
on 24 VDC output signal at the respective output
KL2808 – 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
0V 9 0 V (internally connected to terminal point 10, 11, 12, 13, 14, 15, 16 and
negative power contact)
0V 10 0 V (internally connected to terminal point 9, 11, 12, 13, 14, 15, 16 and
negative power contact)
0V 11 0 V (internally connected to terminal point 9, 10, 12, 13, 14, 15, 16 and
negative power contact)
0V 12 0 V (internally connected to terminal point 9, 10, 11, 13, 14, 15, 16 and
negative power contact)
0V 13 0 V (internally connected to terminal point 9, 10, 11, 12, 14, 15, 16 and
negative power contact)
0V 14 0 V (internally connected to terminal point 9, 10, 11, 12, 13, 15, 16 and
negative power contact)
0V 15 0 V (internally connected to terminal point 9, 10, 11, 12, 13, 14, 16 and
negative power contact)
0V 16 0 V (internally connected to terminal point 9, 10, 11, 12, 13, 14, 15 and
negative power contact)

Product overview
KL28xx14 Version: 1.1.0
2.1.2 Technical data
Technical data KL2808
Connection technology 2-wire
Number of Outputs 8
Rated load voltage 24VDC (-15%/ +20%)
Load type ohmic, inductive, lamp load
Output current max. 0.5A (short-circuit-proof) per channel
Short circuit current < 2A
Breaking energy < 150mJ/channel
Reverse voltage protection yes
Current consumption K-bus typ. 20mA
Current consumption power contacts typ. 15mA + load
Electrical isolation 500 V (K-bus/field potential)
Bit width in the process image 8 output bits
Configuration no address or configuration setting
Dimensions (W x H x D) app. 15mm x 100mm x 70mm (aligned width 12mm)
Weight app. 65g
Mounting [}24] 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, see also Installation
instructions for enhanced mechanical load capacity [}27]
EMC immunity/ emission conforms to EN61000-6-2/ EN 61000-6-4
Installation position variable, see chapter Installation positions [}31]
Protection class IP20
Approvals/ markings CE, cULus, GL, ATEX [}33]
Ex marking
Standard Marking
ATEX II 3 G Ex nA IIC T4 Gc

Product overview
KL28xx 15Version: 1.1.0
2.2 KL2828
2.2.1 Introduction and contact assignment
Fig.5: KL2828
HD Bus Terminal, 8-channel digital output 24 VDC, 2 A
The 8-channel KL2828 digital output terminal connects the binary control signals from the electrically isolated
automation device on to the actuators at the process level. The KL2828 is protected against polarity reversal
and processes load currents with outputs protected against overload and short-circuit. The HD Bus Terminal
contains eight 2A channels, consisting of signal output and 0V, whose signal state are indicated by light
emitting diodes. The power contacts are looped through. In the KL2828 the outputs are fed via the 24V
power contact. The conductors can be connected without tools in the case of single-wire conductors using a
direct plug-in technique. The maximum total output current of the terminal is 10A.
KL2828 - LEDs
LED Color Meaning
OUTPUT 1- 8 green off No output signal
on 24 VDC output signal at the respective output

Product overview
KL28xx16 Version: 1.1.0
KL2828 - 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
0V 9 0 V (internally connected to terminal point 10, 11, 12, 13, 14, 15, 16 and
negative power contact)
0V 10 0 V (internally connected to terminal point 9, 11, 12, 13, 14, 15, 16 and
negative power contact)
0V 11 0 V (internally connected to terminal point 9, 10, 12, 13, 14, 15, 16 and
negative power contact)
0V 12 0 V (internally connected to terminal point 9, 10, 11, 13, 14, 15, 16 and
negative power contact)
0V 13 0 V (internally connected to terminal point 9, 10, 11, 12, 14, 15, 16 and
negative power contact)
0V 14 0 V (internally connected to terminal point 9, 10, 11, 12, 13, 15, 16 and
negative power contact)
0V 15 0 V (internally connected to terminal point 9, 10, 11, 12, 13, 14, 16 and
negative power contact)
0V 16 0 V (internally connected to terminal point 9, 10, 11, 12, 13, 14, 15 and
negative power contact)

Product overview
KL28xx 17Version: 1.1.0
2.2.2 Technical data
Technical data KL2828
Connection technology 2 wire
Number of outputs 8
Rated load voltage 24VDC (-15%/ +20%)
Load type ohmic, inductive, capacitive
Output current max. 2A per channel (∑ max. 10A)
Short circuit current < 40A typ.
Breaking energy < 1.2 J/channel
Reverse voltage protection yes
Current consumption K-bus typ. 18mA
Current consumption of power contacts typ. 15mA + load
Electrical isolation 500V (K-bus/field potential)
Bit width in process image 8 output bits
Configuration no address or configuration settings required
Dimensions (W x H x D) app. 15 mm x 100 mm x 70 mm (aligned width 12mm)
Weight app. 70g
Mounting [}24] on 35mm mounting rail according to EN60715
Permissible ambient temperature range
during operation
-25°C … +60°C (extended temperature range)
Permissible ambient temperature range
during storage
-40°C ... +85°C
Permissible relative humidity 95%, no condensation
Vibration/ shock resistance conforms to EN60068-2-6/ EN60068-2-27, see also Installation
instructions for enhanced mechanical load capacity [}27]
EMC immunity/ emission conforms to EN61000-6-2/ EN61000-6-4
Installation position variable, see chapter Installation positions [}31]
Protection class IP20
Approvals/ markings CE, cULus

Product overview
KL28xx18 Version: 1.1.0
2.3 KL2809, KL2889
2.3.1 Introduction and contact assignment
Fig.6: KL2809
Fig.7: KL2889

Product overview
KL28xx 19Version: 1.1.0
HD Bus Terminals, 16-channel digital output 24 VDC, 0.5 A
The KL2809 digital output terminal connects the binary control signals from the automation device on to the
actuators at the process level with electrical isolation. The KL2809 is protected against polarity reversal and
processes load currents with outputs protected against overload and short-circuit. The Bus Terminal contains
16 channels, whose signal states are displayed by LEDs. The connection technology is particularly suitable
for single-ended inputs. All components have to use the same reference point as the KL2809 or KL2889.
The power contacts are looped through.
The outputs of the KL2809 are fed via the 24V power contact and the outputs of the KL2889 via the 0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. They are particularly suitable for space-saving use in control cabinets.
KL2809, KL2889 – LEDs
LED Color Meaning
OUTPUT 1- 16 green off No output signal
on - Output signal 24VDC (KL2809)
- Output signal 0 V (KL2889)
KL2809, KL2889 – 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
KL28xx20 Version: 1.1.0
2.3.2 Technical data
Technical data KL2809 KL2889
Connection technology 1-wire
Number of Outputs 16
Rated load voltage 24VDC (-15%/ +20%)
Load type ohmic, inductive, lamp load
Output current max. 0.5A (short-circuit-proof) per channel
Short circuit current < 2A < 7A
Breaking energy < 150mJ/channel < 100mJ/channel
Reverse voltage protection yes
Reference potential Ground (switching to +24V
potential)
+24V (switching to ground
potential)
Current consumption K-bus typ. 35mA typ. 45mA
Current consumption power contacts typ. 35mA + load
Electrical isolation 500V (K-bus/ field potential)
Bit width in the process image 16 output bits
Configuration no address or configuration setting
Dimensions (W x H x D) app. 15 mm x 100 mm x 70 mm (aligned width 12mm)
Weight app. 70g
Mounting [}24] on 35mm mounting rail according to EN 60715
Permissible ambient temperature range
during operation
-25°C ... +60°C
Permissible ambient temperature range
during storage
-40°C ... +85°C
Permissible relative humidity 95 %, no condensation
Vibration/ shock resistance conforms to EN60068-2-6/EN60068-2-27, see also Installation
instructions for enhanced mechanical load capacity [}27]
EMC immunity/ emission conforms to EN61000-6-2/EN61000-6-4
Installation position variable, see chapter Installation positions [}31]
Protection class IP20
Approvals/ markings CE, cULus, GL, ATEX [}34]
Ex marking
Standard Marking
ATEX II 3 G Ex nA IIC T4 Gc