Documentation
KL2542
Two channel output stage terminal for DC motors
2.0.0
2017-08-02
Version:
Date:
Table of contents
KL2542 3Version: 2.0.0
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 LEDs ............................................................................................................................................. 10
3 Mounting and wiring ...............................................................................................................................11
3.1 Installation on mounting rails ........................................................................................................ 11
3.2 Connection.................................................................................................................................... 14
3.2.1 Connection system...........................................................................................................14
3.2.2 Wiring...............................................................................................................................15
3.2.3 Connection.......................................................................................................................17
4 KS2000 Configuration Software ............................................................................................................19
4.1 KS2000 - Introduction ................................................................................................................... 19
4.2 Parameterization with KS2000 ..................................................................................................... 20
4.3 Settings......................................................................................................................................... 22
4.4 Register ........................................................................................................................................ 25
4.5 Process data................................................................................................................................. 26
5 Access from the user program ..............................................................................................................28
5.1 Process image .............................................................................................................................. 28
5.2 Control and status byte................................................................................................................. 29
5.3 Register overview ......................................................................................................................... 31
5.4 Register description ...................................................................................................................... 33
5.5 Examples of Register Communication.......................................................................................... 38
5.5.1 Example 1: reading the firmware version from Register 9 ...............................................38
5.5.2 Example 2: Writing to an user register.............................................................................38
6 Appendix ..................................................................................................................................................41
6.1 Support and Service ..................................................................................................................... 41
Table of contents
KL25424 Version: 2.0.0
Foreword
KL2542 5Version: 2.0.0
1 Foreword
1.1 Notes on the documentation
Intended audience
This description is only intended for the use of trained specialists in control and automation engineering who
are familiar with the applicable national standards.
It is essential that the documentation and the following notes and explanations are followed when installing
and commissioning these components.
It is the duty of the technical personnel to use the documentation published at the respective time of each
installation and commissioning.
The responsible staff must ensure that the application or use of the products described satisfy all the
requirements for safety, including all the relevant laws, regulations, guidelines and standards.
Disclaimer
The documentation has been prepared with care. The products described are, however, constantly under
development.
We reserve the right to revise and change the documentation at any time and without prior announcement.
No claims for the modification of products that have already been supplied may be made on the basis of the
data, diagrams and descriptions in this documentation.
Trademarks
Beckhoff®, TwinCAT®, EtherCAT®, Safety over EtherCAT®, TwinSAFE®, XFC® and XTS® are registered
trademarks of and licensed by Beckhoff Automation GmbH.
Other designations used in this publication may be trademarks whose use by third parties for their own
purposes could violate the rights of the owners.
Patent Pending
The EtherCAT Technology is covered, including but not limited to the following patent applications and
patents: EP1590927, EP1789857, DE102004044764, DE102007017835 with corresponding applications or
registrations in various other countries.
The TwinCAT Technology is covered, including but not limited to the following patent applications and
patents: EP0851348, US6167425 with corresponding applications or registrations in various other countries.
EtherCAT® is registered trademark and patented technology, licensed by Beckhoff Automation GmbH,
Germany
Copyright
© Beckhoff Automation GmbH & Co. KG, Germany.
The reproduction, distribution and utilization of this document as well as the communication of its contents to
others without express authorization are prohibited.
Offenders will be held liable for the payment of damages. All rights reserved in the event of the grant of a
patent, utility model or design.
Foreword
KL25426 Version: 2.0.0
1.2 Safety instructions
Safety regulations
Please note the following safety instructions and explanations!
Product-specific safety instructions can be found on following pages or in the areas mounting, wiring,
commissioning etc.
Exclusion of liability
All the components are supplied in particular hardware and software configurations appropriate for the
application. Modifications to hardware or software configurations other than those described in the
documentation are not permitted, and nullify the liability of Beckhoff Automation GmbH & Co. KG.
Personnel qualification
This description is only intended for trained specialists in control, automation and drive engineering who are
familiar with the applicable national standards.
Description of symbols
In this documentation the following symbols are used with an accompanying safety instruction or note. The
safety instructions must be read carefully and followed without fail!
DANGER
Serious risk of injury!
Failure to follow the safety instructions associated with this symbol directly endangers the
life and health of persons.
WARNING
Risk of injury!
Failure to follow the safety instructions associated with this symbol endangers the life and
health of persons.
CAUTION
Personal injuries!
Failure to follow the safety instructions associated with this symbol can lead to injuries to
persons.
Attention
Damage to the environment or devices
Failure to follow the instructions associated with this symbol can lead to damage to the environment or equipment.
Note
Tip or pointer
This symbol indicates information that contributes to better understanding.
Foreword
KL2542 7Version: 2.0.0
1.3 Documentation issue status
Version Comment
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
2.0.0 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: WWYYFFHH
WW - week of production (calendar week)
YY - year of production
FF - firmware version
HH - hardware version
Sample with ser. no.: 49 05 1B 03:
49 - week of production 49
05 - year of production 2005
1B - firmware version 1B
03 - hardware version 03
Product overview
KL25428 Version: 2.0.0
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 9Version: 2.0.0
2.2 Technical data
Technical data KL2542
Number of DC motor output stages 2
Load type DC brush motors, inductive
Supply for the output stage via terminal points
Rated load voltage 8VDC to 50V
DC
Output current per channel Rated current 3.5A, peak current 5A (short-circuit-proof,
common thermal overload warning for both output stages)
PWM clock frequency 36kHz, channels out of phase by 180° relative to each other
Duty factor 0...100% (voltage-controlled)
Resolution Current 12bit
Voltage (velocity) 16bit
Number of digital inputs 2 (for end positions)
Rated voltage of the inputs 24VDC (-15%/ +20%)
Signal voltage at digital input "0" -3V... 2V
Signal voltage at digital input "1" 15V ...30V
Input filter 0.2ms
Input current typically 5mA
Number of encoder inputs 4 (for an encoder system)
Encoder voltage "0" -3V...1.5V
Encoder voltage "1" 2.5V...24V
Encoder frequency max. 250kHz
Electrical isolation 500V (K-bus/mains voltage)
Power supply for the electronics via the K-bus
Current consumption from K-bus typically: 100mA
Current consumption from power contacts typically: 20mA
Bit width in the input process image 2 x 16bit data, 2 x 8bit status
Bit width in the output process image 2 x 16bit data, 2 x 8bit control
Configuration via the Bus Coupler or the controller
Weight approx. 100g
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. 27mm x 100mm x 70mm (width aligned: 24mm)
Mounting on 35mm mounting rail conforms to EN
Vibration/ shock resistance conforms to EN60068-2-6/ EN60068-2-27
EMC immunity/ emission conforms to EN61000-6-2/ EN61000-6-4
Protection class IP 20
Installation position variable
Approval CE
Product overview
KL254210 Version: 2.0.0
2.3 LEDs
Fig.2: KL2542 - 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
Motor power (green) off The motor supply voltage is not available (less than 7V).
on The motor supply voltage is available (greater than 8V).
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 11Version: 2.0.0
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.3: Attaching on mounting rail
The Bus Coupler and Bus Terminals are attached to commercially available 35mm mounting rails (DIN rails
according to EN60715) 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 components with tongue and groove and push the terminals against the mounting rail, until the lock clicks
onto the mounting rail.
If the Terminals are clipped onto the mounting rail first and then pushed together without tongue and
groove, the connection will not be operational! When correctly assembled, no significant gap should
be visible between the housings.
Note
Fixing of mounting rails
The locking mechanism of the terminals and couplers extends to the profile of the mounting
rail. At the installation, the locking mechanism of the components must not come into conflict with the fixing bolts of the mounting rail. To mount the mounting rails with a height of
7.5mm under the terminals and couplers, you should use flat mounting connections (e.g.
countersunk screws or blind rivets).
Mounting and wiring
KL254212 Version: 2.0.0
Disassembly
Fig.4: Disassembling of terminal
Each terminal is secured by a lock on the mounting rail, which must be released for disassembly:
1. Pull the terminal by its orange-colored lugs approximately 1cm 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 24V)
or for higher voltages via power feed terminals.
Note
Power Contacts
During the design of a bus terminal block, the pin assignment of the individual Bus Terminals must be taken account of, since some types (e.g. analog Bus Terminals or digital 4channel Bus Terminals) do not or not fully loop through the power contacts. Power Feed
Terminals (KL91xx, KL92xx or EL91xx, EL92xx) interrupt the power contacts and thus 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 125A.
Mounting and wiring
KL2542 13Version: 2.0.0
Fig.5: Power contact on left side
Attention
Possible damage of the device
Note that, for reasons of electromagnetic compatibility, the PE contacts are capacitatively
coupled to the mounting rail. This may lead to incorrect results during insulation testing or
to damage on the terminal (e.g. disruptive discharge to the PE line during insulation testing
of a consumer with a nominal voltage of 230V). For insulation testing, disconnect the PE
supply line at the Bus Coupler or the Power Feed Terminal! In order to decouple further
feed points for testing, these Power Feed Terminals can be released and pulled at least
10mm from the group of terminals.
WARNING
Risk of electric shock!
The PE power contact must not be used for other potentials!
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