Beckhoff KS2542 User manual

Documentation | EN
KL2542/KS2542
Two channel output stage terminals for DC motors
2022-01-14 | Version: 2.1.0

Table of contents
KL2542/KS2542 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 Introduction........................................................................................................................................8
2.2 Technical data ...................................................................................................................................9
2.3 LED displays....................................................................................................................................10
3 Mounting and wiring................................................................................................................................11
3.1 Instructions for ESD protection........................................................................................................11
3.2 Installation on mounting rails ...........................................................................................................12
3.3 Connection ......................................................................................................................................15
3.3.1 Connection system .......................................................................................................... 15
3.3.2 Wiring............................................................................................................................... 16
3.3.3 Contact assignment ......................................................................................................... 18
3.4 Disposal...........................................................................................................................................19
4 KS2000 Configuration Software ............................................................................................................20
4.1 KS2000 - Introduction......................................................................................................................20
4.2 Parameterization with KS2000 ........................................................................................................21
4.3 Settings............................................................................................................................................23
4.4 Register ...........................................................................................................................................26
4.5 Process data....................................................................................................................................27
5 Access from the user program ..............................................................................................................29
5.1 Process image.................................................................................................................................29
5.2 Control and status byte....................................................................................................................30
5.3 Register overview ............................................................................................................................32
5.4 Register description.........................................................................................................................34
5.5 Examples of Register Communication ............................................................................................39
5.5.1 Example 1: reading the firmware version from Register 9............................................... 39
5.5.2 Example 2: Writing to an user register............................................................................. 39
6 Appendix ..................................................................................................................................................43
6.1 Support and Service ........................................................................................................................43

Table of contents
KL2542/KS25424 Version: 2.1.0

Foreword
KL2542/KS2542 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
KL2542/KS25426 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
KL2542/KS2542 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
1.0.0 • Register description expanded
0.5 • KL2532 removed
0.4 • Description of control and status byte updated
• Register description corrected
0.3 • Connection description added
• LED descriptions updated
• Technical data updated
0.2 • Information on KL2532 added
• Description of parameterization using the KS2000 configuration software added
0.1 First provisional documentation for KL2542
Firmware and hardware versions
Documentation
Version
Firmware Hardware
2.1.0 3A 13
2.0.0 3A 10
1.0.0 1C 05
0.5 1C 05
0.4 1B 03
0.3 1B 03
0.2 1A 01
0.1 1A 01
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
Sample with serial number 49 05 1B 03:
49 - week of production 49
05 - year of production 2005
1B - firmware version 1B
03 - hardware version 03

Product overview
KL2542/KS25428 Version: 2.1.0
2 Product overview
2.1 Introduction
Fig.1: KL2542
The two-channel KL2542 DC motor output stage enables direct operation of two DC motors. The set speed
or the position is specified by the automation device through a 16-bit value. 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. A servo axis can easily be realized by connecting an
incremental encoder.

Product overview
KL2542/KS2542 9Version: 2.1.0
2.2 Technical data
Technical data KL2542 / KS2542
Number of DC motor output stages 2
Load type DC brush motors, inductive
Supply for the output stage via terminal points
Rated load voltage 8VDC to 48VDC
Output current per channel Rated current 3.5A, peak current 5A (short-circuit-proof,
common thermal overload warning for both output stages)
PWM clock frequency 36kHz, channels out of phase by 180° relative to each other
Duty factor 0...100% (voltage-controlled)
Resolution Current 12bit
Voltage (velocity) 16bit
Number of digital inputs 2 (for end positions)
Rated voltage of the inputs 24VDC (-15%/ +20%)
Signal voltage at digital input "0" -3V... 2V
Signal voltage at digital input "1" 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
Encoder frequency max. 250kHz
Electrical isolation 500V (K-bus/mains voltage)
Power supply for the electronics via the K-bus
Current consumption from K-bus typically: 100mA
Current consumption from power contacts typically: 20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. 100g
Permissible ambient temperature range
during operation
0°C ... + 55°C
Permissible ambient temperature range
during storage
-25°C ... + 85°C
Permissible relative air humidity 95%, no condensation
Dimensions (W x H x D) approx. 27mm x 100mm x 70mm (width aligned: 24mm)
Mounting on 35mm mounting rail conforms to EN
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
Installation position variable
Approvals/markings* CE, UKCA, EAC
*) Real applicable approvals/markings see type plate on the side (product marking).

Product overview
KL2542/KS254210 Version: 2.1.0
2.3 LED displays
Fig.2: KL2542 - 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
Motor power (green) off The motor supply voltage is not available (less than 7V).
on The motor supply voltage is available (greater 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

Mounting and wiring
KL2542/KS2542 11Version: 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.3: Spring contacts of the Beckhoff I/O components

Mounting and wiring
KL2542/KS254212 Version: 2.1.0
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!
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
KL2542/KS2542 13Version: 2.1.0
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
KL2542/KS254214 Version: 2.1.0
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!

Mounting and wiring
KL2542/KS2542 15Version: 2.1.0
3.3 Connection
3.3.1 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.7: 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.8: 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
KL2542/KS254216 Version: 2.1.0
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.9: 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 [}17]!
3.3.2 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!

Mounting and wiring
KL2542/KS2542 17Version: 2.1.0
Terminals for standard wiring ELxxxx/KLxxxx and for pluggable wiring ESxxxx/KSxxxx
Fig.10: 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.
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 (see notice [}16])
Wire stripping length 8 ... 9mm

Mounting and wiring
KL2542/KS254218 Version: 2.1.0
3.3.3 Contact assignment
WARNING
Risk of injury from 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: KL2542 - Contact assignment
Left-hand section of the housing
Terminal point No. Connection for
EncoderA, A 1 EncoderA, connectionA
Encoder B, A 2 EncoderB, connectionA
Encoder power +24V 3 Encoder supply (from positive power contact)
Input1 4 Digital input 1 (24VDC).
The current counter value is saved as a reference mark in the latch register if
bit CB.1 [}30] is set in the control byte and a rising edge occurs at digital
input 1.
Encoder A, B 5 EncoderA, connectionB
Encoder B, B 6 EncoderB, connectionB
Encoder Power 0V 7 Encoder supply (from negative power contact)
Input2 8 Digital input 2 (24VDC).
The current counter value is saved as a reference mark in the latch register if
bit CB.2 [}30] is set in the control byte and a rising edge occurs at digital
input 2.

Mounting and wiring
KL2542/KS2542 19Version: 2.1.0
Right-hand section of the housing
Terminal point No. Connection for
Motor A, A1 1' Motor A, connection A1
Motor B, B1 2' Motor B, connection B1
n.c. 3' reserved
Power Motor48 V 4' Motor supply feed (maximum +48VDC)
Motor A, A2 5' Motor A, connection A2
Motor B, B2 6' Motor B, connection B2
n.c. 7' reserved
Power Motor0 V 8' Motor supply feed (0VDC)
CAUTION
Danger for persons, the environment or devices!
If the K-bus voltage (5V, supplied via the Bus Coupler supply voltage Us) fails, the output drivers are not
reset. This means that the motors are not stopped if they are in motion!
Power contacts
The voltage Up of the power contacts (+24VDC) supplies the following consumers:
• Incremental encoder (terminal points 3 and 7)
• Digital inputs (terminal points 4 and 8)
• Output driver of the DC motor output stage
CAUTION
Please note the order of the supply voltages.
The voltage Up must already be present at the power contacts when the K-bus voltage is switched on so
that the internal circuits (output stage drivers) can be initialized. If this is not possible due to the application
(supply is switched, for example, via emergency stop circuit), the terminal performs a software reset after
the system starts up. If the voltage Up at the power contacts fails, this is indicated in register0 through bit
R0.14 [}34]. The return of the voltage is automatically detected and an initialization is performed.
3.4 Disposal
Products marked with a crossed-out wheeled bin shall not be discarded
with the normal waste stream. The device is considered as waste
electrical and electronic equipment. The national regulations for the
disposal of waste electrical and electronic equipment must be observed.

KS2000 Configuration Software
KL2542/KS254220 Version: 2.1.0
4 KS2000 Configuration Software
4.1 KS2000 - Introduction
The KS2000 configuration software permits configuration, commissioning and parameterization of bus
couplers, of the affiliated bus terminals and of Fieldbus Box Modules. The connection between bus coupler/
Fieldbus Box Module and the PC is established by means of the serial configuration cable or the fieldbus.
Fig.12: KS2000 configuration software
Configuration
You can configure the Fieldbus stations with the Configuration Software KS2000 offline. That means, setting
up a terminal station with all settings on the couplers and terminals resp. the Fieldbus Box Modules can be
prepared before the commissioning phase. Later on, this configuration can be transferred to the terminal
station in the commissioning phase by means of a download. For documentation purposes, you are provided
with the breakdown of the terminal station, a parts list of modules used and a list of the parameters you have
modified. After an upload, existing fieldbus stations are at your disposal for further editing.
Parameterization
KS2000 offers simple access to the parameters of a fieldbus station: specific high-level dialogs are available
for all bus couplers, all intelligent bus terminals and Fieldbus Box modules with the aid of which settings can
be modified easily. Alternatively, you have full access to all internal registers of the bus couplers and
intelligent terminals. Refer to the register description for the meanings of the registers.