Beckhoff KS2535, KL2545 User manual

Documentation | EN
KL2535/KS2535, KL2545/KS2545
Pulse width current terminals
2022-01-11 | Version: 2.1.0

Table of contents
KL2535/KS2535, KL2545/KS2545 3Version: 2.1.0
Table of contents
1 Foreword ....................................................................................................................................................5
1.1 Notes on the documentation..............................................................................................................5
1.2 Safety instructions .............................................................................................................................6
1.3 Documentation issue status ..............................................................................................................7
2 Product overview.......................................................................................................................................8
2.1 KL2535 - Introduction ........................................................................................................................8
2.2 KL2535 - Technical Data ...................................................................................................................9
2.3 KL2535 - LED displays ....................................................................................................................10
2.4 KL2545 - Introduction ......................................................................................................................11
2.5 KL2545 - Technical Data .................................................................................................................12
2.6 KL2545 - LED displays ....................................................................................................................13
2.7 Basic function principles ..................................................................................................................14
2.7.1 Pulse width modulation.................................................................................................... 14
2.7.2 Functions ......................................................................................................................... 15
3 Mounting and wiring................................................................................................................................19
3.1 Instructions for ESD protection........................................................................................................19
3.2 Installation on mounting rails ...........................................................................................................19
3.3 Prescribed installation position ........................................................................................................22
3.4 Connection system ..........................................................................................................................23
3.5 KL2535 - Contact assignment .........................................................................................................27
3.6 KL2545 - Contact assignment .........................................................................................................28
3.7 Disposal...........................................................................................................................................29
4 Configuration software KS2000 .............................................................................................................30
4.1 KS2000 - Introduction......................................................................................................................30
4.2 Parameterization with KS2000 ........................................................................................................31
4.3 Settings............................................................................................................................................33
4.4 Register ...........................................................................................................................................36
4.5 Process data....................................................................................................................................37
5 Access from the user program ..............................................................................................................39
5.1 Process image.................................................................................................................................39
5.2 Control and status bytes..................................................................................................................40
5.3 Register overview ............................................................................................................................42
5.4 Register description.........................................................................................................................43
5.5 Examples of Register Communication ............................................................................................47
5.5.1 Example 1: reading the firmware version from Register 9............................................... 47
5.5.2 Example 2: Writing to an user register............................................................................. 47
6 Appendix ..................................................................................................................................................51
6.1 Support and Service ........................................................................................................................51

Table of contents
KL2535/KS2535, KL2545/KS25454 Version: 2.1.0

Foreword
KL2535/KS2535, KL2545/KS2545 5Version: 2.1.0
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
KL2535/KS2535, KL2545/KS25456 Version: 2.1.0
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
KL2535/KS2535, KL2545/KS2545 7Version: 2.1.0
1.3 Documentation issue status
Version Comment
2.1.0 • Chapter “Technical data”
• Document structure updated
• Chapter “Instructions for ESD protection” added
• Chapter “Disposal” added
• New title page
• Update revision status
2.0.0 • Migration
1.5.0 • Technical data updated
1.4.0 • Product overview extended
1.3.0 • Mounting instructions updated
1.2.0 • Mounting instructions extended
• Technical data updated
• Register overview updated
1.1.0 • Connection description for the KL2535 corrected
• Basic function principles corrected
• Hardware version of the KL2535 corrected
1.0 First publication
0.1 Internal proof copy
Firmware and hardware versions
Documentation
version
KL2535-0000 / KS2535-0000 KL2545-0000 / KS2535-0000
Firmware Hardware Firmware Hardware
2.1.0 2A 08 3B 13
1.5.0 1B 04 2B 08
1.4.0 1B 01 1B 05
1.3.0 1B 01 1B 05
1.2.0 1B 01 1B 05
1.1.0 1B 00 1A 02
1.0 1B 00 1A 02
0.1 1B 00 1A 02
The firmware and hardware versions (delivery state) can be taken from the serial number printed on the side
of the terminal.
Syntax of the serial number
Structure of the serial number: WWYYFFHH
WW - week of production (calendar week)
YY - year of production
FF - firmware version
HH - hardware version
Example with serial number 12 06 1A 02:
12 - week of production 12
06 - year of production 2006
1A - firmware version 1A
02 - hardware version 02

Product overview
KL2535/KS2535, KL2545/KS25458 Version: 2.1.0
2 Product overview
2.1 KL2535 - Introduction
Fig.1: KL2535
The KL2535 two-channel pulse width current terminal regulates an output current by means of pulse width
control of the supply voltage. The current value (0A to 1A) is specified with 16-bit resolution by the
automation device.
The output stage is protected against overload and short-circuit and is electrically isolated from the K-bus.
Both channels indicate their state by LEDs, enabling fast on-the-spot diagnosis.
The Bus Terminal is available in the KL2535 version for standard wiring [}24] and the KS2535 for
permanent wiring [}23].

Product overview
KL2535/KS2535, KL2545/KS2545 9Version: 2.1.0
2.2 KL2535 - Technical Data
Technical data KL2535-0000 / KS2535-0000
Number of output stages 2
Load type ohmic/inductive > 1 mH
Supply for the output stage 24 VDC via power contacts
Output current per channel 1 A (short-circuit-proof, common thermal overload
warning for both output stages)
PWM clock frequency 36 kHz
Resolution max. 12 bit
Number of digital inputs 2 digital inputs (24 V)
Nominal voltage of the inputs 24VDC (-15%/+20%)
Signal voltage “0” -3 V... 2 V
Signal voltage “1” 15 V... 30 V
Input filter 0.2ms
Input current typically 5 mA
Electrical isolation 500 V (K-Bus/mains voltage)
Power supply for electronic via the K-Bus
Current consumption from K-bus typically: 60 mA
Current consumption from the power contacts typically: 10 mA
Bit width in the input process image 2 x 16 bit data, 2 x 8 bit status
Bit width in the output process image 2 x 16 bit data, 2 x 8 bit control
Configuration via the Bus Coupler or the controller
Weight approx. 55 g
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
Dimensions (W x H x D) approx. 15 mm x 100 mm x 70 mm (width aligned: 12
mm)
Mounting [}19] on 35 mm mounting rail conforms to EN 60715
Vibration/shock resistance conforms to EN 60068-2-6 / EN 60068-2-27
EMC immunity/emission conforms to EN 61000-6-2 / EN 61000-6-4
Protection class IP20
Correct installation position see section Installation position [}22]
Approvals/markings CE, UKCA, EAC
*) Real applicable approvals/markings see type plate on the side (product marking).

Product overview
KL2535/KS2535, KL2545/KS254510 Version: 2.1.0
2.3 KL2535 - LED displays
Fig.2: KL2535 - LED displays
LED Display
Run (green) reserved Data transmission on the K-bus is active
Enable A (green) off Channel 1 is either not enabled or not ready to operate.
on Channel 1 is enabled and is ready to operate.
- reserved
Error A (red) on There is an error at channel 1
Power (green) off The power supply voltage is absent (less than 7 V).
on The power supply voltage is present (more than 8 V).
Enable B (green) off Channel 2 is either not enabled or not ready to operate.
on Channel 2 is enabled and is ready to operate.
Warning (yellow) on The internal temperature has risen to more than 80°C, or the power supply
voltage has dropped.
Error B (red) on There is an error at channel 2

Product overview
KL2535/KS2535, KL2545/KS2545 11Version: 2.1.0
2.4 KL2545 - Introduction
Fig.3: KL2545
The KL2545 two-channel pulse width current terminal regulates an output current by means of pulse width
control of the supply voltage. The current value (0A to 3.5 A) is specified with 16-bit resolution by the
automation device.
The output stage is protected against overload and short-circuit and is electrically isolated from the K-bus.
Both channels indicate their state by LEDs, enabling fast on-the-spot diagnosis. An incremental encoder can
be connected to each channel for the implementation of the position feedback directly in the terminal.
The Bus Terminal is available in the KL2545 version for standard wiring [}24] and the KS2545 for
permanent wiring [}23].

Product overview
KL2535/KS2535, KL2545/KS254512 Version: 2.1.0
2.5 KL2545 - Technical Data
Technical data KL2545-0000 / KS2545-0000
Number of output stages 2
Load type ohmic/inductive > 1 mH
Supply for the output stage 8 VDC to 48 VDC, via terminal locations
Output current per channel 3.5 A (short-circuit-proof, common thermal overload
warning for both output stages)
PWM clock frequency 36 kHz
Resolution max. 12 bit
Number of digital inputs 2 (for end positions)
Rated voltage of the digital inputs 24VDC (-15%/+20%)
Signal voltage “0” at digital inputs -3V... 2V
Signal voltage “1” at digital inputs 15V... 30V
Input filter 0.2ms
Input current typically 5 mA
Number of encoder inputs 4 (for an encoder system)
Encoder voltage "0" -3V ... 1.5V
Encoder voltage "1" 2.5 V ... 24 V
Electrical isolation 500 V (K-Bus/mains voltage)
Power supply for electronic via the K-Bus
Current consumption from K-bus typically: 100 mA
Current consumption from the power contacts typically: 20 mA
Power loss typically: 4 W
Bit width in the input process image 2 x 16 bit data, 2 x 8 bit status
Bit width in the output process image 2 x 16 bit data, 2 x 8 bit control
Configuration via the Bus Coupler or the controller
Weight approx. 100 g
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
Dimensions (W x H x D) approx. 27 mm x 100 mm x 70 mm (width aligned: 24
mm)
Mounting [}19] on 35 mm mounting rail conforms to EN 60715
Vibration/shock resistance conforms to EN 60068-2-6 / EN 60068-2-27
EMC immunity/emission conforms to EN 61000-6-2 / EN 61000-6-4
Protection class IP20
Correct installation position see section Installation position [}22]
Approvals/markings* CE, UKCA, EAC
*) Real applicable approvals/markings see type plate on the side (product marking).

Product overview
KL2535/KS2535, KL2545/KS2545 13Version: 2.1.0
2.6 KL2545 - LED displays
Fig.4: KL2545 - LED displays
Left LED prism
LED Display
Run (green) on Data transmission on the K-bus is active
Enc. A: A (green) on There is a signal at input A for encoder A.
Enc. B: A (green) on There is a signal at input A for encoder B.
Input1 (green) on There is a signal at input 1.
- reserved
Enc. A: B (green) on There is a signal at input B for encoder A.
Enc. B: B (green) on There is a signal at input B for encoder B.
Input2 (green) on There is a signal at input 2.
Right LED prism
LED Display
- reserved
Enable A (green) off Channel 1 is either not enabled or not ready to operate.
on Channel 1 is enabled and is ready to operate.
- reserved
Error A (red) on There is an error at channel 1
Load Power (green) off The power supply voltage for the load is absent (less than 7 V).
on The power supply voltage for the load is present (more than 8 V).
Enable B (green) off Channel 2 is either not enabled or not ready to operate.
on Channel 2 is enabled and is ready to operate.
Warning (yellow) on The internal temperature has risen to more than 80°C, or the power supply voltage has dropped.
Error B (red) on There is an error at channel 2

Product overview
KL2535/KS2535, KL2545/KS254514 Version: 2.1.0
2.7 Basic function principles
2.7.1 Pulse width modulation
The KL2535 and KL2545 pulse-width current terminals include an integrated PWM output stage (up to 175
W) in a very compact design.
By means of the PWM output stage the pulse width modulation (PWM) of the supply voltage is used to
regulate the output current of a connected ohmic/inductive load. The full supply voltage, pulsating with a
certain frequency, is thereby fed to the output. A load current only develops at the inductance at the high
level. The load current is not changed by changing the voltage level, but by the duration of the switch-off
(pulse width) in relation to the period duration. This results in a duty factor corresponding to the pulse width
divided by the period duration of between 0 and 100% and is proportional to the load current.
Fig.5: Operation at load with adequate inductance
Fig.6: Operation at load inadequate inductance (near ohmic)
The figure "Operation at load with inadequate inductance" illustrates operation with an inadequate
inductance. Continuous current flow is not reached. The current has "gaps". This mode of operation is not
permitted.
Pulse width current terminals require inductive loads
The load inductance should have a minimum inductance of 1 mH. Operation of the pulse width cur-
rent terminals at loads with an inductance of less than 1 mH is not recommended, since the inter-
mittent current flow prevents reference between the set value and the arithmetic mean of the cur-
rent.

Product overview
KL2535/KS2535, KL2545/KS2545 15Version: 2.1.0
2.7.2 Functions
The KL2535 and KL2545 pulse-width current terminals include an integrated PWM output stage (up to 175
W) in a very compact design.
General functions
Enable/Readiness for operation
The enable bit CB1.5 [}40] in the control byte must be set in order to activate the output stage. If the
terminal is not subject to an error at this time, it acknowledges the command by setting the ready bit, SB1.4
[}40], in the status byte
Setting/deleting the position (KL2545 only)
The current position value of the encoder can be set or deleted by the user. Register R1 [}43] is the
reference for this. A rising edge at bit CB1.1 [}40] sets the current position, and the acknowledgement is
provided through status bit SB1.1 [}40].
Latch functions
The internal encoder offers the option of registering a latch event. A latch event can be generated via the
digital input signals.
The terminal response to the latch events is activated as follows:
• Setting the control bit CB1.2 [}40] activates the rising edge at the digital input (highest priority)
• Setting the control bit CB1.3 [}40] activates the falling edge at the digital input (second-highest
priority)
Once the user has enabled the function, during the next latch event, the terminal saves the current position
value and indicates this by setting status bit SB1.2 [}40]. Reading out the latch value must be started by
setting CB1.4 [}40]; this will map the latch value into the DataIN process data (the terminal indicates this
through status bit SB1.3 [}40]).
Enable for latch values
The enable that was set previously must be retained while reading out the latch value. The latch
values are lost if the enable is removed!
Digital inputs
The digital inputs are mapped into the status byte in bit SB1.0 [}40].
Error indication
The terminal offers the user a variety of diagnostic options. These messages are divided into hardware
warnings and hardware errors.
Hardware warnings
When one of the following warning occurs, bit SB1.5 [}40] (Warning) is set in the status byte.
• OverTemperature R0.8 [}43]
(If the temperature inside the terminal reaches 80°C, bit SB1.5 [}40] (Warning) is set. The bit is
automatically reset if the temperature falls below 60°C.
• LowVoltage R0.9 [}43]

Product overview
KL2535/KS2535, KL2545/KS254516 Version: 2.1.0
Hardware error
If one of the following errors occurs, the load is de-energized and bit SB1.6 [}40] (Error) is set in the Status
byte.
• UnderVoltage R0.11 [}43]
• OverCurrent, R0.12 [}43]
• Open load / broken wire (OpenLoad, R0.13 [}43])
• Failure of the 24 V control supply (NoControlPower, R0.14 [}43])
(The terminal is automatically reinitialized when the control voltage returns)
If an error occurs, it first has to be rectified and subsequently acknowledged and thus cancelled by setting bit
CB1.6 [}40] in the control byte.
Dithering
Feature bit R32.5 [}45] and control bit CB1.0 [}40] must be set to activate the dither.
The purpose of this function is to eliminate magnetization effects. Dithering involves modulating a
rectangular signal on top of the actual output value. The configuration required for this depends a lot on the
particular application. It must be determined with the aid of the characteristic data of whatever actuator is
connected.
The following parameters can be set:
Name Register Value range Description
Frequency - f R37
[}46]
10 Hz to 500 Hz The frequency of the rectangular signal; the resolution of the
setting is 1 Hz.
Amplitude - i R38
[}46]
0% to 100% The amplitude of the rectangular signal; the resolution is 1%
(with reference to the output current that has been set in
register R36 [}45])
Switch-off ramp -
t
R39
[}46]
0ms to
32767ms
When switched on, the dither signal jumps immediately to the
amplitude set in R38. When switched off, the signal is
attenuated linearly over the time configured here; the
resolution is 1 ms.
Fig.7: Frequency - f / Amplitude - i

Product overview
KL2535/KS2535, KL2545/KS2545 17Version: 2.1.0
Fig.8: Switch-off ramp - t
Valve curve
Feature bit R32.4 [}45] must be set in order to activate the valve curve.
The following parameters can be set:
Name Regis-
ter
Value range Description
Overlap threshold value - x1R40
[}46]
0 to 1000 The overlap range ends at this process data
value; the resolution is 0.1% (as a fraction of
32767)
Overlap output value - y1R41
[}46]
0 to 1000 The maximum output current in the overlap
region; the resolution is 0.1% (with reference
to the output current that has been set in
register R36 [}45])
Bend compensation -threshold
value- x2
R42
[}46]
0 to 1000 The bend compensation range ends at this
process data value; the resolution is 0.1% (as
a fraction of 32767)
Bend compensation - output value -
y2
R43
[}46]
0 to 1000 The maximum output current in the bend
compensation region; the resolution is 0.1%
(with reference to the output current that has
been set in register R36 [}45])
Area compensation - threshold
value - x3
R44
[}46]
0 to 1000 The area compensation region ends at this
process data value; the resolution is 0.1% (as
a fraction of 32767)
The characteristic curve is divided into four regions:
I Overlapping
II Bend compensation
III, III' Area compensation
IV End region

Product overview
KL2535/KS2535, KL2545/KS254518 Version: 2.1.0
Fig.9: Valve curve
Process data ramps
Feature bit R32.6 [}45] must be set in order to activate the process data ramps.
This function offers the facility for automatically changing the output current from the current process data
value to the new one up or down along a linear ramp. The values of registers R45 and R46 here are related
to the entire process data range, i.e. from 0 to 32767.
The following parameters can be set:
Name Register Value range Description
Rising ramp - t1R45
[}46]
0 to 32767 ms The time, t1, required for the process data value to rise from 0
to 32767 (resolution: 1 ms).
Falling ramp - t2R46
[}47]
0 to 32767 ms The time, t2, required for the process data value to fall from
32767 to 0 (resolution: 1ms).
Fig.10: Process data ramps

Mounting and wiring
KL2535/KS2535, KL2545/KS2545 19Version: 2.1.0
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.11: 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
KL2535/KS2535, KL2545/KS254520 Version: 2.1.0
Assembly
Fig.12: 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).