Documentation
KL2535, KL2545
Pulse width current terminals
Version:
Date:
2.0.0
2016-02-29
Table of contents
Table of contents
1 Foreword ....................................................................................................................................................4
1.1 Notes on the documentation............................................................................................................. 4
1.2 Safety instructions ............................................................................................................................ 5
1.3 Documentation issue status.............................................................................................................. 6
2 Product overview.......................................................................................................................................7
2.1 KL2535 - Introduction ....................................................................................................................... 7
2.2 KL2535 - Technical Data .................................................................................................................. 8
2.3 KL2535 - LED displays ..................................................................................................................... 9
2.4 KL2545 - Introduction ..................................................................................................................... 10
2.5 KL2545 - Technical Data ................................................................................................................ 11
2.6 KL2545 - LED displays ................................................................................................................... 12
2.7 Pulse width modulation................................................................................................................... 13
2.8 Functions ........................................................................................................................................ 14
3 Mounting and wiring ...............................................................................................................................18
3.1 Installation on mounting rails .......................................................................................................... 18
3.2 Prescribed installation position ....................................................................................................... 20
3.3 Connection system ......................................................................................................................... 21
3.4 KL2535 - Connection ...................................................................................................................... 25
3.5 KL2545 - Connection ...................................................................................................................... 26
4 Configuration software KS2000 .............................................................................................................28
4.1 KS2000 - Introduction ..................................................................................................................... 28
4.2 Parameterization with KS2000 ....................................................................................................... 29
4.3 Settings........................................................................................................................................... 31
4.4 Register .......................................................................................................................................... 34
4.5 Process data................................................................................................................................... 35
5 Access from the user program ..............................................................................................................37
5.1 Process image ................................................................................................................................ 37
5.2 Control and status bytes ................................................................................................................. 38
5.3 Register overview ........................................................................................................................... 40
5.4 Register description ........................................................................................................................ 41
5.5 Examples of Register Communication............................................................................................ 45
5.5.1 Example 1: reading the firmware version from Register 9 of a terminal .............................45
5.5.2 Example 2: Writing to a user register..................................................................................45
6 Appendix ..................................................................................................................................................48
6.1 Support and Service ....................................................................................................................... 48
KL2535, KL2545 3Version: 2.0.0
Foreword
1 Foreword
1.1 Notes on the documentation
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 following notes and explanations are followed when installing and commissioning
these components.
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. For that reason the documentation is not in every case checked for consistency with
performance data, standards or other characteristics. In the event that it contains technical or editorial errors,
we retain the right to make alterations at any time and without warning. 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 & Co. KG.
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.
KL2535, KL25454 Version: 2.0.0
Foreword
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!
Serious risk of injury!
Failure to follow the safety instructions associated with this symbol directly endangers the
DANGER
life and health of persons.
Risk of injury!
Failure to follow the safety instructions associated with this symbol endangers the life and
WARNING
health of persons.
Personal injuries!
Failure to follow the safety instructions associated with this symbol can lead to injuries to
CAUTION
persons.
Damage to the environment or devices
Failure to follow the instructions associated with this symbol can lead to damage to the en-
Attention
vironment or equipment.
Tip or pointer
This symbol indicates information that contributes to better understanding.
Note
KL2535, KL2545 5Version: 2.0.0
Foreword
1.3 Documentation issue status
Version Comment
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
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.
KL2535 KL2545
Firmware Hardware Firmware Hardware
Syntax of the serial number
Structure of the serial number: WWYYFFHH
WW - week of production (calendar week)
YY - year of production
FF - firmware version
HH - hardware version
Example with ser. no.: 12 06 1A 02:
12 - week of production 12
06 - year of production 2006
1A - firmware version 1A
02 - hardware version 02
KL2535, KL25456 Version: 2.0.0
2 Product overview
2.1 KL2535 - Introduction
Product overview
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 (0A to 1A) 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 [}22] and the KS2535 for
permanent wiring [}21].
KL2535, KL2545 7Version: 2.0.0
Product overview
2.2 KL2535 - Technical Data
Technical data KL2535/KS2535
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 24VDC (-15%/+20%)
Signal voltage “0” -3 V... 2 V
Signal voltage “1” 15 V... 30 V
Input filter 0.2ms
Input current typically 5 mA
Electrical isolation 500 V (K-bus/mains voltage)
Supply voltage for internal E-bus circuit 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
Permissible ambient temperature range during
storage
Permissible relative humidity 95%, no condensation
Dimensions (W x H x D) approx. 15 mm x 100 mm x 70 mm (width aligned: 12
Mounting [}18]
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
Approval CE
0°C ... + 55°C
-25°C ... + 85°C
mm)
on 35 mm mounting rail conforms to EN 60715
see section Installation position [}20]
KL2535, KL25458 Version: 2.0.0
2.3 KL2535 - LED displays
LED indicators
Product overview
Fig.2: KL2535 - LEDs
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
KL2535, KL2545 9Version: 2.0.0
Product overview
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 (0A 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 [}22] and the KS2545 for
permanent wiring [}21].
KL2535, KL254510 Version: 2.0.0
Product overview
2.5 KL2545 - Technical Data
Technical data KL2545/KS2545
Number of output stages 2
Load type ohmic/inductive > 1 mH
Supply for the output stage 8 VDC to 50 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 24VDC (-15%/+20%)
Signal voltage “0” at digital inputs -3V... 2V
Signal voltage “1” at digital inputs 15V... 30V
Input filter 0.2ms
Input current typically 5 mA
Number of encoder inputs 4 (for an encoder system)
Encoder voltage "0" -3V ... 1.5V
Encoder voltage "1" 2.5 V ... 24 V
Electrical isolation 500 V (K-bus/mains voltage)
Supply voltage for internal E-bus circuit 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
Permissible ambient temperature range during
storage
Permissible relative humidity 95%, no condensation
Dimensions (W x H x D) approx. 27 mm x 100 mm x 70 mm (width aligned: 24
Mounting [}18]
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
Approval CE
0°C ... + 55°C
-25°C ... + 85°C
mm)
on 35 mm mounting rail conforms to EN 60715
see section Installation position [}20]
KL2535, KL2545 11Version: 2.0.0
Product overview
2.6 KL2545 - LED displays
Fig.4: KL2545 - LEDs
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.
Input1 (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.
Input2 (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
Error B (red) on There is an error at channel 2
dropped.
KL2535, KL254512 Version: 2.0.0
Product overview
2.7 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
Note
width current terminals at loads with an inductance of less than 1 mH is not recommended,
since the intermittent current flow prevents reference between the set value and the arithmetic mean of the current.
KL2535, KL2545 13Version: 2.0.0
Product overview
2.8 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 [}38] 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
[}38], 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 [}41] is the
reference for this. A rising edge at bit CB1.1 [}38] sets the current position, and the acknowledgement is
provided through status bit SB1.1 [}38].
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 [}38] activates the rising edge at the digital input (highest priority)
• Setting the control bit CB1.3 [}38] 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 [}38]. Reading out the latch value must be started by
setting CB1.4 [}38]; this will map the latch value into the DataIN process data (the terminal indicates this
through status bit SB1.3 [}38]).
Enable for latch values
The enable that was set previously must be retained while reading out the latch value. The
Note
latch values are lost if the enable is removed!
Digital inputs
The digital inputs are mapped into the status byte in bit SB1.0 [}38].
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 [}38] (Warning) is set in the status byte.
• OverTemperature R0.8 [}41]
(If the temperature inside the terminal reaches 80°C, bit SB1.5 [}38] (Warning) is set. The bit is
automatically reset if the temperature falls below 60°C.
• LowVoltage R0.9 [}41]
KL2535, KL254514 Version: 2.0.0
Product overview
Hardware error
If one of the following errors occurs, the load is de-energized and bit SB1.6 [}38] (Error) is set in the Status
byte.
• UnderVoltage R0.11 [}41]
• OverCurrent, R0.12 [}41]
• Open load / broken wire (OpenLoad, R0.13 [}41])
• Failure of the 24 V control supply (NoControlPower, R0.14 [}41])
(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 [}38] in the control byte.
Dithering
Feature bit R32.5 [}43] and control bit CB1.0 [}38] 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
Amplitude - i
Switch-off ramp t
R37
[}44]
R38
[}44]
R39
[}44]
10 Hz to 500 Hz The frequency of the rectangular signal; the resolution of the
setting is 1 Hz.
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 [}43])
0ms to
32767ms
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
KL2535, KL2545 15Version: 2.0.0
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