Beckhoff KL9540 Operator's manual

Documentation | EN
KL9540, KL9540-0010 and KL9550
Surge Filter Terminals
2020-07-21 | Version: 3.0.1

Table of contents
KL9540, KL9540-0010 and KL9550 3Version: 3.0.1
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 Overview............................................................................................................................................8
2.2 KL9540-0000 - introduction ...............................................................................................................9
2.3 KL9540-0010 - introduction .............................................................................................................10
2.4 KL9550-0000 - introduction .............................................................................................................11
2.5 Technical data .................................................................................................................................12
3 Mounting and wiring................................................................................................................................13
3.1 Installation on mounting rails ...........................................................................................................13
3.2 Connection system ..........................................................................................................................15
3.3 KL9540-0000 - connection ..............................................................................................................19
3.4 KL9540-0010 - connection ..............................................................................................................20
3.5 KL9550-0000 - connection ..............................................................................................................21
3.6 KL9540-0000, KL9550-0000 - application example ........................................................................22
3.7 KL9540-0010, KL9550-0000 - application example ........................................................................23
3.8 Installation instructions for enhanced mechanical load capacity .....................................................24
3.9 ATEX - Special conditions (standard temperature range) ...............................................................25
3.10 ATEX - Special conditions (extended temperature range) ..............................................................26
3.11 Continuative documentation about explosion protection .................................................................27
4 Appendix ..................................................................................................................................................28
4.1 Support and Service ........................................................................................................................28

Table of contents
KL9540, KL9540-0010 and KL95504 Version: 3.0.1

Foreword
KL9540, KL9540-0010 and KL9550 5Version: 3.0.1
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®, 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
KL9540, KL9540-0010 and KL95506 Version: 3.0.1
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
KL9540, KL9540-0010 and KL9550 7Version: 3.0.1
1.3 Documentation issue status
Version Comment
3.0.1 • Technical data updated
3.0.0 • Migration
2.1.0 • Technical data updated
• ATEX notes added
• KL9540-0010 updated
2.0.0 • Permitted ambient temperature range extended
• KL9540-0010 added
1.0 First public issue (describes KL9540-0000 and KL9550-0000)

Product overview
KL9540, KL9540-0010 and KL95508 Version: 3.0.1
2 Product overview
2.1 Overview
Surge filter terminals for the field supply and K-bus supply
The surge filter terminals include overvoltage filters for the K-bus (Bus Coupler) and/or field supply (power
contacts).
The filters protect the components from line-bound surge voltages that can occur due to high-energy
disturbance variables such as switching surges at inductive consumers or lightning strikes at the supply
lines. The surge filter terminals can be used to protect the Bus Terminal station from damage in particularly
hostile environments. The ship classification organizations stipulate the use of surge filters in shipbuilding
applications and in the onshore / offshore sector.
The following types are available:
•KL9540-0000 / KS9540-0000 [}9]: Surge filter terminals for field supply
•KL9540-0010 / KS9540-0010: [}10] Surge filter terminals for field supply of analog Bus Terminals
•KL9550-0000 / KS9550-0000 [}11]: Surge filter terminals for field supply and K-Bus supply
Features
Surge filter terminal KL9540-0000
KS9540-0000
KL9540-0010
KS9540-0010
KL9550-0000
KS9550-0000
Surge filter for system supply (Us) no no yes
Surge filter for field supply (Up) yes yes yes
Buffers the field supply (Up) no yes no

Product overview
KL9540, KL9540-0010 and KL9550 9Version: 3.0.1
2.2 KL9540-0000 - introduction
Fig.1: KL9540
Surge filter terminals for field supply
The KL9540-0000 surge filter terminal contains an overvoltage filter for the field supply. The filter protects the
components from line-bound surge voltages that can occur due to high-energy disturbance variables such as
switching surges at inductive consumers or lightning strikes at the supply lines.
LED displays
LED Meaning
Power (green) on Field supply voltage present

Product overview
KL9540, KL9540-0010 and KL955010 Version: 3.0.1
2.3 KL9540-0010 - introduction
Fig.2: KL9540-0010
Surge filter terminals for field supply of analog Bus Terminals
The KL9540-0010 system terminal includes an overvoltage filter for the 24 V field supply.
The filter protects the Bus Terminal from line-bound surge voltages that can occur due to high-energy
disturbance variables such as switching overvoltages at inductive consumers or lightning strikes at the
supply lines.
The KL9540-0010 can protect Bus Terminal stations in particularly harsh environments from damage.
The use of such overvoltage filters is stipulated by the ship classification organizations in shipbuilding and
on/offshore applications in which GL certification is required.
The KL9540-0010 is intended in particular for the protection of analog terminals; the standard variant
KL9540 for digital terminals.
The LED indicates the 24 V rated voltage. The terminal does not transfer process data to the higher-level
control system.
LED displays
LED Meaning
Power (green) on Field supply voltage present

Product overview
KL9540, KL9540-0010 and KL9550 11Version: 3.0.1
2.4 KL9550-0000 - introduction
Fig.3: KL9550
Surge filter terminals for field supply and K-Bus supply
The KL9550-0000 surge filter terminal contains overvoltage filters for the field supply (power contacts) and
the K-Bus supply (Bus Coupler). The filters protect the components from line-bound surge voltages that can
occur due to high-energy disturbance variables such as switching surges at inductive consumers or lightning
strikes at the supply lines.
LED displays
LED Meaning
Power system (green) on K-Bus supply voltage present
Power field (green) on Field supply voltage present

Product overview
KL9540, KL9540-0010 and KL955012 Version: 3.0.1
2.5 Technical data
Technical data KL9540-0000
KS9540-0000
KL9550-0000
KS9550-0000
KL9540-0010
KS9540-0010
Rated voltage 24 V (-15%, +20%)
Surge filter for field supply (Up) yes yes yes
Surge filter for system supply (Us) no yes no
Buffers the field supply (Up) no no yes
Terminal point for PE yes no no
Current carrying capacity of the field
supply
10A max. 5A max.
Current carrying capacity of the system
supply
- 0.5A max. -
Current consumption from the K-bus -
Bit width in the input process image -
Bit width in the output process image -
Dimensions (W x H x D) approx. 12mmx100mmx70mm
Weight approx. 40g approx. 50g approx. 65g
Permissible ambient temperature range
during operation
-25°C ... +60 °C (extended temperature
range [}26])
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
Mounting [}13] on 35mm mounting rail conforms to EN60715
Pluggable wiring [}15] at all KSxxxx series terminals
Vibration/shock resistance conforms to EN60068-2-6/EN60068-2-27, see also Installation
instructions [}24] for terminals with enhanced mechanical load
capacity
EMC immunity/emission conforms to EN61000-6-2/ EN61000-6-4
Protection class IP20
Installation position variable
Approval CE, cULus, ATEX, GL CE, cULus, GL

Mounting and wiring
KL9540, KL9540-0010 and KL9550 13Version: 3.0.1
3 Mounting and wiring
3.1 Installation on mounting rails
WARNING
Risk of electric shock and damage of device!
Bring the bus terminal system into a safe, powered down state before starting installation, disassembly or
wiring of the bus terminals!
Assembly
Fig.4: 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
KL9540, KL9540-0010 and KL955014 Version: 3.0.1
Disassembly
Fig.5: 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
KL9540, KL9540-0010 and KL9550 15Version: 3.0.1
Fig.6: 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!
3.2 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.

Mounting and wiring
KL9540, KL9540-0010 and KL955016 Version: 3.0.1
Standard wiring
Fig.7: 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.8: 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.9: 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.

Mounting and wiring
KL9540, KL9540-0010 and KL9550 17Version: 3.0.1
Wiring HD Terminals
The High Density Terminals of the KLx8xx and ELx8xx series doesn't support steady 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 [}17] below!
Wiring
Terminals for standard wiring ELxxxx/KLxxxx and for pluggable wiring ESxxxx/KSxxxx
Fig.10: 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 per-
manently.
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
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.

Mounting and wiring
KL9540, KL9540-0010 and KL955018 Version: 3.0.1
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 [}17]!)
Wire stripping length 8 ... 9mm
Shielding
Shielding
Analog sensors and actors should always be connected with shielded, twisted paired wires.

Mounting and wiring
KL9540, KL9540-0010 and KL9550 19Version: 3.0.1
3.3 KL9540-0000 - connection
Fig.11: KL9540 connection
Terminal point No. Function
- 1 not used
- 5 not used
+24V 2 Field supply feed for the power contacts (internally connected to
terminal point 6)
+24V 6 Field supply feed for the power contacts (internally connected to
terminal point 2)
0V 3 Field supply feed for the power contacts (internally connected to
terminal point 7)
0V 7 Field supply feed for the power contacts (internally connected to
terminal point 3)
PE 4 PE connection (internally connected to terminal point 8)
PE 8 PE connection (internally connected to terminal point 4)

Mounting and wiring
KL9540, KL9540-0010 and KL955020 Version: 3.0.1
3.4 KL9540-0010 - connection
Fig.12: KL9540-0010 connection
Terminal point No. Function
- 1 not used
- 5 not used
+24V input 2 Field supply feed for the power contacts
+24V output 6 internally connected to positive power contact
0V input 3 Field supply feed for the power contacts
0V output 7 internally connected to negative power contact
- 4 not used
- 8 not used