Beckhoff KL400 Series Operator's manual

Documentation
KL400x
Single-, Dual and Four-Channel Analog Output Terminals,
(0V...10V)
4.0
2017-10-20
Version:
Date:

Table of contents
KL400x 3Version: 4.0
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 KL400x - introduction...................................................................................................................... 8
2.2 KL400x - technical data .................................................................................................................. 9
2.3 Basic function principles ............................................................................................................... 10
3 Mounting and wiring ...............................................................................................................................11
3.1 Instructions for ESD protection ..................................................................................................... 11
3.2 Installation on mounting rails ........................................................................................................ 11
3.3 Installation instructions for enhanced mechanical load capacity .................................................. 15
3.4 Connection.................................................................................................................................... 15
3.4.1 Connection system...........................................................................................................15
3.4.2 Wiring...............................................................................................................................17
3.4.3 Shielding ..........................................................................................................................18
3.5 KL4001, KL4002 - connection and LED description ..................................................................... 19
3.6 KL4004 - connection and LED description ................................................................................... 20
3.7 ATEX - Special conditions (standard temperature range) ............................................................ 21
3.8 ATEX - Special conditions (extended temperature range) ........................................................... 22
3.9 ATEX Documentation ................................................................................................................... 23
4 Configuration Software KS2000.............................................................................................................24
4.1 KS2000 - Introduction ................................................................................................................... 24
5 Access from the user program ..............................................................................................................26
5.1 KL400x - terminal configuration .................................................................................................... 26
5.2 Mapping in the Bus Coupler ......................................................................................................... 28
5.2.1 KL4001.............................................................................................................................29
5.2.2 KL4002.............................................................................................................................30
5.2.3 KL4004.............................................................................................................................31
5.3 Register overview ......................................................................................................................... 32
5.4 Register description ...................................................................................................................... 32
5.5 Control and status byte................................................................................................................. 35
5.5.1 Process data exchange ...................................................................................................35
5.5.2 Register communication...................................................................................................36
5.6 Examples of Register Communication.......................................................................................... 37
5.6.1 Example 1: reading the firmware version from Register 9 ...............................................37
5.6.2 Example 2: Writing to an user register.............................................................................38
6 Appendix ..................................................................................................................................................41
6.1 Support and Service ..................................................................................................................... 41

Table of contents
KL400x4 Version: 4.0

Foreword
KL400x 5Version: 4.0
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
KL400x6 Version: 4.0
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
KL400x 7Version: 4.0
1.3 Documentation issue status
Version Comment
4.0 • Migration
• Update Technical data
• Structure update
• Chapters KS2000 configuration software and Access from the user program added
Firmware (FW) and hardware (HW) versions
Documen-
tation,
Version
KL4001 KL4002 KL4004
FW HW FW HW FW HW
4.0 3D 08 3D 08 3D 04
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.: 35 04 1B 01:
35 - week of production 35
4 - year of production 2004
1B - firmware version 1B
1 - hardware version 1

Product overview
KL400x8 Version: 4.0
2 Product overview
2.1 KL400x - introduction
Fig.1: KL4001, KL4002, KL4004
The analog KL400x output terminals generate signals in the range 0 V to 10 V. The voltage is supplied to the
process level with a resolution of 12bits, and is electrically isolated. The output channels of the Bus
Terminals have a common ground potential. Run LEDs indicate the data exchange with the Bus Coupler.

Product overview
KL400x 9Version: 4.0
2.2 KL400x - technical data
Technical data KL4001 KL4002 KL4004
Number of outputs 1 2 4
Power supply for the electronics via the K-Bus
Signal voltage 0V…10V
Load >5kΩ (short-circuit-proof)
Accuracy ± 0.5 LSB linearity error, ± 0.5 LSB offset error
Output error <±0.10% (at 0°C to +55°C)
<±0.75% (when the extended temperature range is used)
<±0.1% of the end value
Resolution 12bit
Electrical isolation 500V (K-Bus / signal voltage)
Conversion time ~1.5ms ~2ms
Current consumption from the K-bus typically 75mA typically 85mA
Bit width in the K-bus I/O Output: 1 x 16bits of data (1 x
8bit control/status optional)
Output: 2 x 16bits of data (2
x 8bit control/status optional)
Output: 4 x 16bits of data (4 x
8bit control/status optional)
Configuration No address or configuration settings
Weight approx. 85g
Dimensions (W x H x D) approx. 15mmx100mmx70mm (width aligned: 12mm)
Mounting [}11] on 35mm mounting rail conforms to EN60715
Permissible ambient temperature range
during operation
-25°C to +60°C (extended temperature range) 0°C to + 55°C
Permissible ambient temperature range
during storage
-40°C to +85°C -25°C to +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 me-
chanical load capacity [}15]
EMC immunity/emission conforms to EN61000-6-2/ EN61000-6-4
Protection class IP20
Installation position variable
Approval CE, cULus, ATEX [}22] CE, cULus, ATEX [}21]

Product overview
KL400x10 Version: 4.0
2.3 Basic function principles
The analog KL400x output terminals generate signals in the range 0V to 10V with a resolution of 12bits
(4095 steps). The output voltage is electrically isolated from the K-bus.
The LEDs indicate the operating state of the associated terminal channels.
• green Run LED:
◦ On: Normal operation
◦ Off: Watchdog timer overflow has occurred. If no process data are transmitted by the Bus
Coupler for 100ms, the green LEDs go out. The output assumes a user-specified voltage (see
Feature register [}34]).
Process data input format
In the delivery state the process data are shown in two's complement form (integer -1 corresponds to
0xFFFF). Alternative presentation types can be selected via the feature register (R32 [}34]).
Output voltage Process data
dec hex
0V 0 0x0000
5V 16383 0x3FFF
10V 32767 0x7FFF
Process data
The process data arriving from the Bus Coupler are output to the process:
Y_dac = X (1.0) Neither user nor manufacturer scaling is active.
Y_1 = B_h + A_h * X
Y_dac = Y_1
(1.1) Manufacturer scaling active
Y_2 = B_w + A_w * X
Y_dac = Y_2
(1.2) User scaling active
Y_1 = B_h + A_h * X
Y_dac = B_w + A_w * Y_1
(1.3)
(1.4)
Manufacturer and user scaling active
Key
Name Name Register
X PLC process data -
B_h Manufacturer scaling: Offset R19 [}34]
A_h Manufacturer scaling: Gain R20 [}34]
B_w User scaling: Offset R33 [}34]
A_w User scaling: Gain R34 [}35]
Y_dac Output value for the D/A converter -
The equations of the straight line are enabled via register R32 [}34].

Mounting and wiring
KL400x 11Version: 4.0
3 Mounting and wiring
3.1 Instructions for ESD protection
Attention
Destruction of the devices by electrostatic discharge possible!
The devices contain components at risk from electrostatic discharge caused by improper
handling.
üPlease ensure you are electrostatically discharged and avoid touching the contacts of
the device directly.
a) Avoid contact with highly insulating materials (synthetic fibers, plastic film etc.).
b) Surroundings (working place, packaging and personnel) should by grounded probably,
when handling with the devices.
c) Each assembly must be terminated at the right hand end with an EL9011 bus end cap,
to ensure the protection class and ESD protection.
Fig.2: 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
KL400x12 Version: 4.0
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 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
KL400x 13Version: 4.0
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.

Mounting and wiring
KL400x14 Version: 4.0
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!

Mounting and wiring
KL400x 15Version: 4.0
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.
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.

Mounting and wiring
KL400x16 Version: 4.0
• 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.6: 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.7: 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.8: High Density Terminals

Mounting and wiring
KL400x 17Version: 4.0
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!
3.4.2 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.9: 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.

Mounting and wiring
KL400x18 Version: 4.0
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 [}16]) 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.
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
3.4.3 Shielding
Note
Shielding
Encoder, analog sensors and actors should always be connected with shielded, twisted
paired wires.

Mounting and wiring
KL400x 19Version: 4.0
3.5 KL4001, KL4002 - connection and LED description
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.10: KL4001, KL4002 - connection and LEDs
KL4001 connection
Terminal point No. Comment
Output 1 + Output 1
n.c. 2 not used
GND 3 Internal ground (internally connected to terminal point 7)
Shield 4 PE contact (internally connected to terminal point 8)
n.c. 5 not used
n.c. 6 not used
GND 7 Internal ground (internally connected to terminal point 3)
Shield 8 PE contact (internally connected to terminal point 4)
KL4002 connection
Terminal point No. Comment
Output 1 1 + Output 1
n.c. 2 not used
GND 3 Internal ground (internally connected to terminal point 7)
Shield 4 PE contact (internally connected to terminal point 8)
Output 2 5 + Output 2
n.c. 6 not used
GND 7 Internal ground (internally connected to terminal point 3)
Shield 8 PE contact (internally connected to terminal point 4)
LED description KL4001, KL4002
LED Color Description
Run1 LED
LED Run2 (KL4002 only)
green On: Normal operation
Off: Watchdog timer overflow has occurred. If no process data is transmitted to the bus cou-
pler for 100ms, the green LEDs go out. The output assumes a user-specified voltage
(see Feature register [}34]).

Mounting and wiring
KL400x20 Version: 4.0
3.6 KL4004 - connection and LED description
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.11: KL4004 - connection and LEDs
KL4004 connection
Terminal point No. Comment
Output 1 1 + Output 1
GND 2 Internal ground (internally connected to terminal point 6)
Output 3 3 + Output 3
GND 4 Internal ground (internally connected to terminal point 8)
Output 2 5 + Output 2
GND 6 Internal ground (internally connected to terminal point 2)
Output 4 7 + Output 4
GND 8 Internal ground (internally connected to terminal point 4)
LED description KL4004
LED Color Description
Run1 LED
Run2 LED
Run3 LED
Run4 LED
green On: Normal operation
Off: Watchdog timer overflow has occurred. If no process data is transmitted to the bus coupler for
100ms, the green LEDs go out. The output assumes a user-specified voltage (see Feature reg-
ister [}34]).