Beckhoff KL3208 User manual

Documentation | EN
KL3208, KL3228/KS3228
Eight channel input terminals for PT1000, NI1000, NTC
2021-08-12 | Version: 3.3.0

Table of contents
KL3208, KL3228/KS3228 3Version: 3.3.0
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 Beckhoff Identification Code (BIC) ....................................................................................................9
2 Product overview.....................................................................................................................................11
2.1 KL3208-0010 - Introduction .............................................................................................................11
2.2 KL3228-0000 - Introduction .............................................................................................................12
2.3 Technical data .................................................................................................................................13
3 Mounting and wiring................................................................................................................................14
3.1 Instructions for ESD protection........................................................................................................14
3.2 Installation on mounting rails ...........................................................................................................14
3.3 Installation instructions for enhanced mechanical load capacity .....................................................18
3.4 Connection ......................................................................................................................................19
3.4.1 Connection system .......................................................................................................... 19
3.4.2 Wiring............................................................................................................................... 21
3.4.3 Shielding .......................................................................................................................... 22
3.4.4 KL3208-0010 - Contact assignment ................................................................................ 23
3.4.5 KL3228-0000/KS3228-0000 - Contact assignment ......................................................... 24
3.5 KL3228 - Positioning within the Bus Terminal Block .......................................................................25
3.6 ATEX - Special conditions (standard temperature range) ...............................................................27
3.7 ATEX - Special conditions (extended temperature range) ..............................................................28
3.8 Continuative documentation for ATEX and IECEx ..........................................................................29
3.9 Disposal...........................................................................................................................................29
4 Configuration Software KS2000.............................................................................................................30
4.1 KS2000 - Introduction......................................................................................................................30
4.2 Parameterization with KS2000 ........................................................................................................31
4.3 Settings for KL3208-0010................................................................................................................34
4.4 Settings for KL3228-0000................................................................................................................35
4.5 Sample program for KL register communication via EtherCAT on KL3314 exemplary...................35
5 Access from the user program ..............................................................................................................38
5.1 Process image.................................................................................................................................38
5.2 Control and status bytes..................................................................................................................39
5.2.1 Process data mode.......................................................................................................... 39
5.2.2 Register communication .................................................................................................. 40
5.3 Register overview ............................................................................................................................41
5.4 Register description.........................................................................................................................42
5.5 Examples of Register Communication ............................................................................................46
5.5.1 Example 1: reading the firmware version from Register 9............................................... 46
5.5.2 Example 2: Writing to an user register............................................................................. 46
6 TwinCAT ...................................................................................................................................................50
6.1 Programming ...................................................................................................................................51
6.2 KL3208, KL3228 - Configuration with Function blocks....................................................................52

Table of contents
KL3208, KL3228/KS32284 Version: 3.3.0
7 Appendix ..................................................................................................................................................53
7.1 Support and Service ........................................................................................................................53

Foreword
KL3208, KL3228/KS3228 5Version: 3.3.0
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
KL3208, KL3228/KS32286 Version: 3.3.0
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
KL3208, KL3228/KS3228 7Version: 3.3.0
1.3 Documentation issue status
Version Comment
3.3.0 • Product overview updated
• Technical data updated
• Ex markings added to technical data
• Register description updated
• Chapter Disposal added
• New title page
3.2.1 • Register description updated
3.2.0 • Chapter Instructions for ESD protection updated
• Chapter Beckhoff Identification Code (BIC) added
3.1.0 • Design of the safety instructions adapted to IEC 82079-1
• Chapter Instructions for ESD protection added
• Chapter Connection system/Connection updated
• Example program added to chapter KS2000 Configuration software
3.0.0 • Migration
• Technical data updated
• Installation instructions for enhanced mechanical load capacity added
• Chapter TwinCAT including Link to FB_KL3208Config and FB_KL3228Config added
• Chapter ATEX - Special conditions replaced with chapter ATEX - Special conditions
(standard temperature range) and ATEX - Special conditions (extended temperature range)
2.2.0 • Process data corrected
2.1.0 • KS2000 configuration mask for KL3208-0010 added
• Technical data updated
• Register description updated
• Information on basic function principles expanded
• Approvals extended
• ATEX notes added
2.0.1 • KS3228-0000 added
2.0.0 • KL3208-0010 added
• KS2000 configuration mask for KL3228-0000 corrected
1.1.0 • Notes on positioning in the Bus Terminal block expanded
• Sensor types corrected
1.0.0 • KS2000 configuration mask for KL3208-0000 added
• First release
0.5 Preliminary Version

Foreword
KL3208, KL3228/KS32288 Version: 3.3.0
Firmware and hardware versions
Documentation
Version
KL3208-0010 KL3228-0000, KS3228-0000
Firmware Hardware Firmware Hardware
3.3.0 1D 03 3C 02
3.2.1 1D 02 3C 01
3.2.0 1D 02 3C 01
3.1.0 1D 02 3C 01
3.0.0 1C 02 3C 01
2.2.0 1C 02 3C 01
2.1.0 1C 02 3C 01
2.0.1 1A 00 3C 00
2.0.0 1A 00 3C 00
1.1.0 - - 3B 00
1.0.0 - - 3B 00
0.5 - - 3A 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
FF - firmware version
HH - hardware version
Sample with serial number 20 09 3A 00:
20 - week of production 20
09 - year of production 2009
3A - firmware version 3A
00 - hardware version 00

Foreword
KL3208, KL3228/KS3228 9Version: 3.3.0
1.4 Beckhoff Identification Code (BIC)
The Beckhoff Identification Code (BIC) is increasingly being applied to Beckhoff products to uniquely identify
the product. The BIC is represented as a Data Matrix Code (DMC, code scheme ECC200), the content is
based on the ANSI standard MH10.8.2-2016.
Fig.1: BIC as data matrix code (DMC, code scheme ECC200)
The BIC will be introduced step by step across all product groups.
Depending on the product, it can be found in the following places:
• on the packaging unit
• directly on the product (if space suffices)
• on the packaging unit and the product
The BIC is machine-readable and contains information that can also be used by the customer for handling
and product management.
Each piece of information can be uniquely identified using the so-called data identifier
(ANSIMH10.8.2-2016). The data identifier is followed by a character string. Both together have a maximum
length according to the table below. If the information is shorter, spaces are added to it. The data under
positions 1 to 4 are always available.
The following information is contained:

Foreword
KL3208, KL3228/KS322810 Version: 3.3.0
Item
no.
Type of
information
Explanation Data
identifier
Number of digits
incl. data identifier
Example
1 Beckhoff order
number
Beckhoff order number 1P 8 1P072222
2 Beckhoff Traceability
Number (BTN)
Unique serial number,
see note below
S 12 SBTNk4p562d7
3 Article description Beckhoff article
description, e.g.
EL1008
1K 32 1KEL1809
4 Quantity Quantity in packaging
unit, e.g. 1, 10, etc.
Q 6 Q1
5 Batch number Optional: Year and week
of production
2P 14 2P401503180016
6 ID/serial number Optional: Present-day
serial number system,
e.g. with safety products
or calibrated terminals
51S 12 51S678294104
7 Variant number Optional: Product variant
number on the basis of
standard products
30P 32 30PF971, 2*K183
...
Further types of information and data identifiers are used by Beckhoff and serve internal processes.
Structure of the BIC
Example of composite information from item 1 to 4 and 6. The data identifiers are marked in red for better
display:
BTN
An important component of the BIC is the Beckhoff Traceability Number (BTN, item no.2). The BTN is a
unique serial number consisting of eight characters that will replace all other serial number systems at
Beckhoff in the long term (e.g. batch designations on IO components, previous serial number range for
safety products, etc.). The BTN will also be introduced step by step, so it may happen that the BTN is not yet
coded in the BIC.
NOTE
This information has been carefully prepared. However, the procedure described is constantly being further
developed. We reserve the right to revise and change procedures and documentation at any time and with-
out prior notice. No claims for changes can be made from the information, illustrations and descriptions in
this information.

Product overview
KL3208, KL3228/KS3228 11Version: 3.3.0
2 Product overview
2.1 KL3208-0010 - Introduction
Fig.2: KL3208-0010
The KL3228-0010 analog input terminal enables connection of eight resistance sensors up to 650kΩ. The
Bus Terminal's circuitry can handle sensors using the 2-wire technique.
Linearization over the entire, freely selectable temperature range is realized with the aid of a microprocessor.
The bus terminals standard setting is: Resolution 0,01°C within the temperature range of Ni1000 sensors.
The signal LEDs indicate that the channel is communicating over the K-bus.
The error LEDs indicate sensor faults (e.g. a broken wire) in the respective channel.
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
KL3208, KL3228/KS322812 Version: 3.3.0
2.2 KL3228-0000 - Introduction
Fig.3: KL3228
The KL3228 analog input terminal enables connection of eight resistance sensors. The Bus Terminal's
circuitry can handle sensors using the 1-wire technique. Linearization over the entire, freely selectable
temperature range is realized with the aid of a microprocessor. The terminal has a resolution of 0.1 °C; the
standard setting is the sensor type PT1000. The error LEDs indicate sensor faults (e.g. a broken wire).

Product overview
KL3208, KL3228/KS3228 13Version: 3.3.0
2.3 Technical data
Technical data KL3208-0010 KL3228-0000/ KS3228-0000
Inputs 8
Sensor types PT1000 (default)
Ni1000
NTC: 1.8k, 2.2k, 3k, 5k, 10k, 20k, 100k
Poti/Resistor: 6kΩ, 65kΩ, 655kΩ
PT1000 (default)
Ni1000
Wiring 2-wire 1-wire
Terminal points High Density (HD) standard (KL), pluggable (KS)
Temperature range Pt sensors -50°C…+150°C
Ni sensors -50°C…+150°C
Conversion time app.1s
Measuring current typically 0.5mA
Resolution 0.01°C per digit 0.1°C per digit
Measuring error (full measuring
range)
-20°C … +60°C: ±0.25°C
(at 25°C ambient temperature)
-50°C … +150°C: ±1.5°C
±1.0°C, depending on wiring
Bit width in the input process image 8 status bytes (optional), 8 data words
Bit width in the output process
image
8 control bytes (optional), 8 data words (optional)
Power supply for the electronics via the K-bus
Current consumption from K-bus typically 85mA
Electrical isolation 500V (K-Bus/signal voltage)
Weight app. 75g app. 75g
Dimensions (W x H x D) app. 15mm x 100mm x 70mm (aligned with: 12mm)
Assembly [}14] on 35mm mounting rail conforming to EN60715
Pluggable wiring - for all KSxxxx terminals
Permissible ambient temperature
range during operation
-25 °C ... +60 °C (extended
temperature range)
0°C ... + 55°C
Permissible ambient temperature
range during storage
-40°C ... + 85°C -25°C ... + 85°C
Permissible relative air 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 [}18]
EMC immunity/ emission conforms to EN61000-6-2/ EN61000-6-4
Protection class IP20
Installation position variable
Approvals/ markings CE, UKCA, cULus, EAC,
ATEX [}28]
CE, UKCA, cULus, EAC,
ATEX [}27]
Ex marking
Standard Marking
ATEX II 3 G Ex nA IIC T4 Gc

Mounting and wiring
KL3208, KL3228/KS322814 Version: 3.3.0
3 Mounting and wiring
3.1 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.4: Spring contacts of the Beckhoff I/O components
3.2 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!

Mounting and wiring
KL3208, KL3228/KS3228 15Version: 3.3.0
Assembly
Fig.5: 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
KL3208, KL3228/KS322816 Version: 3.3.0
Disassembly
Fig.6: 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
KL3208, KL3228/KS3228 17Version: 3.3.0
Fig.7: 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!

Mounting and wiring
KL3208, KL3228/KS322818 Version: 3.3.0
3.3 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
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.

Mounting and wiring
KL3208, KL3228/KS3228 19Version: 3.3.0
3.4 Connection
3.4.1 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.8: 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.
Pluggable wiring (ESxxxx / KSxxxx)
Fig.9: Pluggable wiring
The terminals of ESxxxx and KSxxxx series feature a pluggable connection level.
The assembly and wiring procedure is the same as for the ELxxxx and KLxxxx series.
The pluggable connection level enables 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.

Mounting and wiring
KL3208, KL3228/KS322820 Version: 3.3.0
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.10: High Density Terminals
The 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.
Wiring HD Terminals
The High Density Terminals of the ELx8xx and KLx8xx series doesn't support pluggable wiring.
Ultrasonically “bonded” (ultrasonically welded) conductors
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 concerning the
wire-size width!