Beckhoff KL3041, KL3051, KL3042, KL3052, KL3044 Documentation

Documentation

KL304x, KL305x

Single-, Dual- and Four-Channel Analog Input Terminals,
Measuring range: 0...20 mA and 4...20 mA, Single ended

Version:
Date:

4.0
2017-10-06

Table of contents

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 KL3041, KL3051 – Introduction ...................................................................................................... 8

2.2 KL3042, KL3052 – Introduction ...................................................................................................... 9

2.3 KL3044, KL3054 – Introduction .................................................................................................... 10

2.4 KL304x, KL305x - Technical data................................................................................................. 11

2.5 Basic function principles ............................................................................................................... 11

3 Mounting and wiring ...............................................................................................................................13

3.1 Instructions for ESD protection ..................................................................................................... 13

3.2 Installation on mounting rails ........................................................................................................ 13

3.3 Installation instructions for enhanced mechanical load capacity .................................................. 17

3.4 Connection.................................................................................................................................... 17

3.4.1 Connection system...........................................................................................................17

3.4.2 Wiring...............................................................................................................................19

3.4.3 Shielding ..........................................................................................................................20

3.5 KL3041, KL3051 - Connection and LED description .................................................................... 21

3.6 KL3042, KL3052 - Connection and LED description .................................................................... 22

3.7 KL3044, KL3054 - Connection and LED description .................................................................... 23

3.8 ATEX - Special conditions (standard temperature range) ............................................................ 24

3.9 ATEX - Special conditions (extended temperature range) ........................................................... 25

3.10 ATEX Documentation ................................................................................................................... 26

4 Configuration Software KS2000.............................................................................................................27

4.1 KS2000 - Introduction ................................................................................................................... 27

5 Access from the user program ..............................................................................................................29

5.1 Terminal configuration .................................................................................................................. 29

5.2 Mapping in the Bus Coupler ......................................................................................................... 30

5.2.1 KL3041 and KL3051 ........................................................................................................30

5.2.2 KL3042 and KL3052 ........................................................................................................31

5.2.3 KL3044 and KL3054 ........................................................................................................32

5.3 Register overview ......................................................................................................................... 33

5.4 Register description ...................................................................................................................... 35

5.5 Control and status byte................................................................................................................. 39

5.5.1 Process data exchange ...................................................................................................39

5.5.2 Register communication...................................................................................................40

5.6 Examples of Register Communication.......................................................................................... 41

5.6.1 Example 1: reading the firmware version from Register 9 ...............................................41

5.6.2 Example 2: Writing to an user register.............................................................................42

6 Appendix ..................................................................................................................................................45

6.1 Support and Service ..................................................................................................................... 45

KL304x, KL305x 3Version: 4.0

Table of contents

KL304x, KL305x4 Version: 4.0

Foreword

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.

KL304x, KL305x 5Version: 4.0

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!

DANGER

WARNING

CAUTION

Attention

Note

Serious risk of injury!

Failure to follow the safety instructions associated with this symbol directly endangers the
life and health of persons.

Risk of injury!

Failure to follow the safety instructions associated with this symbol endangers the life and
health of persons.

Personal injuries!

Failure to follow the safety instructions associated with this symbol can lead to injuries to
persons.

Damage to the environment or devices

Failure to follow the instructions associated with this symbol can lead to damage to the en­vironment or equipment.

Tip or pointer

This symbol indicates information that contributes to better understanding.

KL304x, KL305x6 Version: 4.0

Foreword

1.3 Documentation issue status

Version Comment

4.0 • Migration

• Update Technical data

• Structure update

• Chapters KS2000 configuration software and Access from the user program added

Firmware (FW) and hardware (HW) versions

Documen­tation,
Version

4.0 3C 08 3C 07 3B 04 3C 07 3C 07 3B 04

The firmware and hardware versions (delivery state) can be found in the serial number printed on the side of
the terminal.

Syntax of the serial number

Structure of the serial number: WWYYFFHH

KL3041 KL3042 KL3044 KL3051 KL3052 KL3054

FW HW FW HW FW HW FW HW FW HW FW HW

WW - week of production (calendar week)
YY - year of production
FF - firmware version
HH - hardware version

Example with ser. no.: 35 04 1B 01:

35 - week of production 35
4 - year of production 2004
1B - firmware version 1B
1 - hardware version 1

KL304x, KL305x 7Version: 4.0

Product overview

2 Product overview

2.1 KL3041, KL3051 – Introduction

Fig.1: KL3041, KL3051

The job of the KL3041 and KL3051 analog input terminals is to supply power to measuring transducers
located in the field, and to transmit analog measurement signals with electrical isolation to the automation
device.
The KL3041 terminal processes signals in the range from 0mA to 20mA.
The KL3051 terminal processes signals in the range from 4mA to 20mA.
The voltage for the sensors is supplied to the terminals via the power contacts. The power contacts can
optionally be supplied with operating voltage in the standard way or via a power feed terminal (KL9xxx) with
electrical isolation. The input electronics is independent of the supply voltage of the power contacts. The 0 V
rail is the reference potential for the inputs. The Run LEDs indicate the exchange of data with the Bus
Coupler, while the Error LEDs indicate overload and wire breakage.

KL304x, KL305x8 Version: 4.0

2.2 KL3042, KL3052 – Introduction

Product overview

Fig.2: KL3042, KL3052

The job of the KL3042 and KL3052 analog input terminals is to supply power to measuring transducers
located in the field, and to transmit analog measurement signals with electrical isolation to the automation
device.
The KL3042 terminal processes signals in the range from 0mA to 20mA.
The KL3052 terminal processes signals in the range from 4mA to 20mA.
The voltage for the sensors is supplied to the terminals via the power contacts. The power contacts can
optionally be supplied with operating voltage in the standard way or via a power feed terminal (KL9xxx) with
electrical isolation. The input electronics is independent of the supply voltage of the power contacts. The 0 V
rail is the reference potential for the inputs. The Run LEDs indicate the exchange of data with the Bus
Coupler, while the Error LEDs indicate overload and wire breakage.

KL304x, KL305x 9Version: 4.0

Product overview

2.3 KL3044, KL3054 – Introduction

Fig.3: KL3044, KL3054

The job of the KL3044 and KL3054 analog input terminals is to transmit analog measurement signals with
electrical isolation to the automation device.
The KL3044 terminal processes signals in the range from 0mA to 20mA.
The KL3054 terminal processes signals in the range from 4mA to 20mA. The input electronics is
independent of the supply voltage of the power contacts. The ground connection is the reference potential
for the inputs. The error LEDs indicate an overload condition. The KL3044 and KL3054 combine four
channels in a single housing.

KL304x, KL305x10 Version: 4.0

Product overview

2.4 KL304x, KL305x - Technical data

Technical data KL3041 KL3051 KL3042 KL3052 KL3044 KL3054

Number of inputs 1 2 4

Power supply for the sensors 24VDC via the power contacts

Signal current 0mA to

Technology Single-ended

Internal resistance 80Ω + diode voltage 0.7V

Surge voltage resistance 35V max.

Resolution 12bit

Conversion time ~1ms ~2ms ~4ms

Measuring error (total mea­suring range)

Electrical isolation 500V (K-Bus / signal voltage)

Power supply for the electron­ics

Current consumption from the
K-bus

Bit width in the K-bus I/O Input: 1 x 16bits of data (1 x

Configuration No address or configuration settings

Weight approx. 70g

Dimensions (W x H x D) approx. 15mmx100mmx70mm (width aligned: 12mm)

Mounting [}13]

Permissible ambient tempera­ture range during operation

Permissible ambient tempera­ture range during storage

Permissible relative air hu­midity

Vibration/shock resistance

EMC immunity/emission conforms to EN61000-6-2/ EN61000-6-4

Protection class IP20

Installation position variable

Approval

20mA

<±0.3% of the full scale
value

via the K-Bus

typically 65mA

8bit control/status optional)

on 35mm mounting rail conforms to EN60715

0°C ... + 55°C -25°C ... +60°C (extended

-25°C ... + 85°C -40°C ... +85°C -25°C ... + 85°C -40°C ... +85°C

95%, no condensation

conforms to EN60068-2-6/ EN60068-2-27, see also Installation instructions for enhanced mechanical

load capacity [}17]

CE, cULus, ATEX [}24],GLCE, cULus, ATEX [}25],GLCE, cULus, ATEX

4mA to
20mA

0mA to
20mA

<±0.30% (at 0°C to
+55°C)
<±0.75% (when the ex­tended temperature range
is used)

Input: 2 x 16bits of data (2
x 8bit control/status op­tional)

temperature range)

4mA to
20mA

-

0mA to 20mA 4mA to 20mA

<±0.3% of the full
scale value

Input: 4 x 16bits of data (4 x 8bit control/sta­tus optional)

0°C ... + 55°C -25°C ... +60°C (ex-

[}24], GL

<±0.30% (at 0°C to
+55°C)
<±0.75% (when the
extended temperature
range is used)

tended temperature
range)

CE, cULus, ATEX
[}25], GL

2.5 Basic function principles

The analog input terminals
KL304x process signals in the range from 0mA to 20mA
KL305x process signals in the range from 4mA to 20mA
with 12-bit resolution (4095 steps). The terminal inputs are single-ended inputs. The KL3041, KL3042,
KL3051 and KL3052 can supply the sensors with voltage supplied via the power contacts. The KL3044 and
KL3054 have no power contacts. The power contacts can optionally be supplied via the standard supply or
via a power feed terminal with electrical isolation.

The LEDs indicate the operating state of the associated terminal channels.

• green Run LED (omitted for KL3044 and KL3054):

◦ On: Normal operation

◦ Off: Watchdog-timer overflow has occurred. If no process data are transmitted by the Bus

Coupler for 100ms, the green LEDs go out.

• red Error LED:

KL304x, KL305x 11Version: 4.0

Product overview

◦ On: The limit stop of the A/D converter has been reached. The current is greater than 21.5mA.

◦ Off: Normal operation

Process data output format

In the delivery state the process data are shown in two's complement form (integer -1 corresponds to
0xFFFF). Other presentation types can be selected via the feature register (R32) [}37] (e.g.signed amount

representation, Siemens output format).

Measured value Output

KL304x KL305x dec hex

0mA 4mA 0 0x0000

10mA 12mA 16383 0x3FFF

20mA 20mA 32767 0x7FFF

Calculation of process data

The terminal continuously takes measured values and stores the raw values of its A/D converter in register
R0 [}35] (RAM ). The calculation of the correction with the calibration values takes place after each

sampling of the analog signal. This is followed by manufacturer and user scaling:

The process data that are transferred to the Bus Coupler are calculated using the following equations:

Y_a = (B_a + X_adc) * A_a
Y_aus = Y_a

Y_1 = B_h + A_h * Y_a
Y_aus = Y_1

Y_2 = B_w + A_w * Y_a
Y_aus = Y_2

Y_1 = B_h + A_h * Y_a
Y_2 = B_w + A_w * Y_1
Y_aus = Y_2

(1.0) Neither user nor manufacturer scaling is active.

(1.1) Manufacturer scaling active: (Default setting)

(1.2) User scaling active

(1.3)
(1.4)

Manufacturer and user scaling active

Key

Name Name Register

X_adc Output value of the A/D converter -

Y_aus Process data for controller -

B_a Vendor calibration: Offset

A_a Vendor calibration: Gain

B_h Manufacturer scaling: Offset

A_h Manufacturer scaling: Gain

B_w User scaling: Offset

A_w User scaling: Gain

R17 [}36]

R18 [}36]

R19 [}36]

R20 [}36]

R33 [}37]

R34 [}37]

The equations of the straight line are enabled via register R32 [}37].

Fig.4: KL304x, KL305x - Data flow

KL304x, KL305x12 Version: 4.0

3 Mounting and wiring

3.1 Instructions for ESD protection

Destruction of the devices by electrostatic discharge possible!

The devices contain components at risk from electrostatic discharge caused by improper

Attention

handling.

ü Please ensure you are electrostatically discharged and avoid touching the contacts of

the device directly.

a) Avoid contact with highly insulating materials (synthetic fibers, plastic film etc.).

b) Surroundings (working place, packaging and personnel) should by grounded probably,

when handling with the devices.

c) Each assembly must be terminated at the right hand end with an EL9011 bus end cap,

to ensure the protection class and ESD protection.

Mounting and wiring

Fig.5: Spring contacts of the Beckhoff I/O components

3.2 Installation on mounting rails

Risk of electric shock and damage of device!

Bring the bus terminal system into a safe, powered down state before starting installation,

WARNING

disassembly or wiring of the Bus Terminals!

KL304x, KL305x 13Version: 4.0

Mounting and wiring

Assembly

Fig.6: 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 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.

Fixing of mounting rails

The locking mechanism of the terminals and couplers extends to the profile of the mounting

Note

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).

KL304x, KL305x14 Version: 4.0

Mounting and wiring

Disassembly

Fig.7: 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 Termi-

Note

PE power contact

nals 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.

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.

KL304x, KL305x 15Version: 4.0

Mounting and wiring

Fig.8: Power contact on left side

Attention

WARNING

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 order 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.

Risk of electric shock!

The PE power contact must not be used for other potentials!

KL304x, KL305x16 Version: 4.0

Mounting and wiring

3.3 Installation instructions for enhanced mechanical load capacity

Risk of injury through electric shock and damage to the device!

Bring the Bus Terminal system into a safe, de-energized state before starting mounting,

WARNING

Additional checks

The terminals have undergone the following additional tests:

Verification Explanation

Vibration 10 frequency runs in 3 axes

Shocks 1000 shocks in each direction, in 3 axes

Additional installation instructions

disassembly or wiring of the Bus Terminals!

6 Hz < f < 60 Hz displacement 0.35 mm, constant amplitude

60.1Hz<f<500Hz acceleration 5g, constant amplitude

25 g, 6 ms

For terminals with enhanced mechanical load capacity, the following additional installation instructions apply:

• The enhanced mechanical load capacity is valid for all permissible installation positions

• Use a mounting rail according to EN 60715 TH35-15

• Fix the terminal segment on both sides of the mounting rail with a mechanical fixture, e.g. an earth
terminal or reinforced end clamp

• The maximum total extension of the terminal segment (without coupler) is:
64 terminals (12 mm mounting with) or 32 terminals (24 mm mounting with)

• Avoid deformation, twisting, crushing and bending of the mounting rail during edging and installation of
the rail

• The mounting points of the mounting rail must be set at 5 cm intervals

• Use countersunk head screws to fasten the mounting rail

• The free length between the strain relief and the wire connection should be kept as short as possible. A
distance of approx. 10 cm should be maintained to the cable duct.

3.4 Connection

3.4.1 Connection system

Risk of electric shock and damage of device!

Bring the bus terminal system into a safe, powered down state before starting installation,

WARNING

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.

KL304x, KL305x 17Version: 4.0

Mounting and wiring

• 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.9: 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.10: Pluggable wiring

The terminals of ESxxxx and KSxxxx series feature a pluggable connection level.
The assembly and wiring procedure for the KS series is the same as for the ELxxxx and KLxxxx series.
The KS/ES series terminals enable the complete wiring to be removed as a plug connector from the top of
the housing for servicing.
The lower section can be removed from the terminal block by pulling the unlocking tab.
Insert the new component and plug in the connector with the wiring. This reduces the installation time and
eliminates the risk of wires being mixed up.

The familiar dimensions of the terminal only had to be changed slightly. The new connector adds about 3
mm. The maximum height of the terminal remains unchanged.

A tab for strain relief of the cable simplifies assembly in many applications and prevents tangling of individual
connection wires when the connector is removed.

Conductor cross sections between 0.08mm2 and 2.5mm2 can continue to be used with the proven spring
force technology.

The overview and nomenclature of the product names for ESxxxx and KSxxxx series has been retained as
known from ELxxxx and KLxxxx series.

High Density Terminals (HD Terminals)

Fig.11: High Density Terminals

KL304x, KL305x18 Version: 4.0

Mounting and wiring

The Bus 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 (HD) Terminals of the ELx8xx and KLx8xx series doesn't support plug-

Note

Ultrasonically "bonded" (ultrasonically welded) conductors

gable wiring.

Ultrasonically “bonded" conductors

It is also possible to connect the Standard and High Density Terminals with ultrasonically

Note

"bonded" (ultrasonically welded) conductors. In this case, please note the tables concern­ing the wire-size width below!

3.4.2 Wiring

Risk of electric shock and damage of device!

Bring the bus terminal system into a safe, powered down state before starting installation,

WARNING

disassembly or wiring of the Bus Terminals!

Terminals for standard wiring ELxxxx/KLxxxx and for pluggable wiring ESxxxx/KSxxxx

Fig.12: 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.

KL304x, KL305x 19Version: 4.0

Mounting and wiring

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mm
Wire size width (fine-wire conductors) 0.08 ... 2.5mm
Wire size width (conductors with a wire end sleeve) 0.14 ... 1.5mm

2

2

2

0.08 ... 2.5mm
0,08 ... 2.5mm

0.14 ... 1.5mm

2

2

2

Wire stripping length 8 ... 9mm 9 ... 10mm

High Density Terminals (HD Terminals [}18]) 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mm
Wire size width (fine-wire conductors) 0.25 ... 1.5mm
Wire size width (conductors with a wire end sleeve) 0.14 ... 0.75mm
Wire size width (ultrasonically “bonded" conductors) only 1.5mm

2

2

2

2

Wire stripping length 8 ... 9mm

3.4.3 Shielding

Shielding

Encoder, analog sensors and actors should always be connected with shielded, twisted

Note

paired wires.

KL304x, KL305x20 Version: 4.0

Mounting and wiring

3.5 KL3041, KL3051 - Connection and LED description

Risk of injury through electric shock and damage to the device!

Bring the Bus Terminals system into a safe, de-energized state before starting mounting,

WARNING

disassembly or wiring of the Bus Terminals!

Fig.13: KL3041, KL3051 - Connection and LEDs

Connection of KL3041, KL3051

Terminal point No. Comment

+Input 1 1 + Input 1

+24V 2 +24V (internally connected to terminal point 6 and positive power contact)

0V 3 0V (internally connected to terminal point 7 and negative power contact)

Shield 4 PE contact (internally connected to terminal point 8)

n.c. 5 not used

+24V 6 +24V (internally connected to terminal point 2 and positive power contact)

0V 7 0V (internally connected to terminal point 3 and negative power contact)

Shield 8 PE contact (internally connected to terminal point 4)

KL3041, KL3051 - LED description

LED Color Description

Run1 LED green On: Normal operation

Off: Watchdog-timer overflow has occurred. If no process data is transmitted to the bus

Error1 LED red On: The limit stop of the A/D converter has been reached. The current is greater than

Off: Normal operation

coupler for 100ms, the green LEDs go out

21.5mA.

KL304x, KL305x 21Version: 4.0

Mounting and wiring

3.6 KL3042, KL3052 - Connection and LED description

Risk of injury through electric shock and damage to the device!

Bring the Bus Terminals system into a safe, de-energized state before starting mounting,

WARNING

disassembly or wiring of the Bus Terminals!

Fig.14: KL3042, KL3052 - Connection and LEDs

Connection of KL3042, KL3052

Terminal point No. Comment

+Input 1 1 + Input 1

+24V 2 +24V (internally connected to terminal point 6 and positive power contact)

0V 3 0V (internally connected to terminal point 7 and negative power contact)

Shield 4 PE contact (internally connected to terminal point 8)

+Input 2 5 + Input 2

+24V 6 +24V (internally connected to terminal point 2 and positive power contact)

0V 7 0V (internally connected to terminal point 3 and negative power contact)

Shield 8 PE contact (internally connected to terminal point 4)

KL3042, KL3052 - LED description

LED Color Description

Run1 LED,
Run2 LED

Error1 LED,
Error2 LED

green On: Normal operation

Off: Watchdog-timer overflow has occurred. If no process data is transmitted to the bus

coupler for 100ms, the green LEDs go out

red On: The limit stop of the A/D converter has been reached. The current is greater than

21.5mA.

Off: Normal operation

KL304x, KL305x22 Version: 4.0

Mounting and wiring

3.7 KL3044, KL3054 - Connection and LED description

Risk of injury through electric shock and damage to the device!

Bring the Bus Terminals system into a safe, de-energized state before starting mounting,

WARNING

disassembly or wiring of the Bus Terminals!

Fig.15: KL3044, KL3054 - Connection and LEDs

Connection of KL3044, KL3054

Terminal point No. Comment

+Input 1 1 + Input 1

GND 2 Internal ground (internally connected to terminal point 6)

+Input 3 3 + Input 3

GND 4 Internal ground (internally connected to terminal point 8)

+Input 2 5 + Input 2

GND 6 Internal ground (internally connected to terminal point 2)

+Input 4 7 + Input 4

GND 8 Internal ground (internally connected to terminal point 4)

KL3044, KL3054 - LED description

LED Color Description

Error1 LED,
Error2 LED,
Error3 LED,
Error4 LED

red On: The limit stop of the A/D converter has been reached. The current is greater than

21.5mA.

Off: Normal operation

KL304x, KL305x 23Version: 4.0

Mounting and wiring

3.8 ATEX - Special conditions (standard temperature range)

Observe the special conditions for the intended use of Beckhoff fieldbus
components with standard temperature range in potentially explosive areas
(directive 94/9/EU)!

WARNING

• The certified components are to be installed in a suitable housing that guarantees a
protection class of at least IP54 in accordance with EN 60529! The environmental con­ditions during use are thereby to be taken into account!

• If the temperatures during rated operation are higher than 70°C at the feed-in points of
cables, lines or pipes, or higher than 80°C at the wire branching points, then cables
must be selected whose temperature data correspond to the actual measured tempera­ture values!

• Observe the permissible ambient temperature range of 0 to 55°C for the use of Beck­hoff fieldbus components standard temperature range in potentially explosive areas!

• Measures must be taken to protect against the rated operating voltage being exceeded
by more than 40% due to short-term interference voltages!

• The individual terminals may only be unplugged or removed from the Bus Terminal sys­tem if the supply voltage has been switched off or if a non-explosive atmosphere is en­sured!

• The connections of the certified components may only be connected or disconnected if
the supply voltage has been switched off or if a non-explosive atmosphere is ensured!

• The fuses of the KL92xx/EL92xx power feed terminals may only be exchanged if the
supply voltage has been switched off or if a non-explosive atmosphere is ensured!

• Address selectors and ID switches may only be adjusted if the supply voltage has been
switched off or if a non-explosive atmosphere is ensured!

Standards

The fundamental health and safety requirements are fulfilled by compliance with the following standards:

• EN 60079-0:2012+A11:2013

• EN 60079-15:2010

Marking

The Beckhoff fieldbus components with standard temperature range certified for potentially explosive areas
bear one of the following markings:

II 3GKEMA 10ATEX0075 X Ex nA IIC T4 GcTa: 0…55°C

or

II 3GKEMA 10ATEX0075 X Ex nC IIC T4 GcTa: 0…55°C

KL304x, KL305x24 Version: 4.0

Mounting and wiring

3.9 ATEX - Special conditions (extended temperature range)

Observe the special conditions for the intended use of Beckhoff fieldbus
components with extended temperature range (ET) in potentially explosive
areas (directive 94/9/EU)!

WARNING

• The certified components are to be installed in a suitable housing that guarantees a
protection class of at least IP54 in accordance with EN 60529! The environmental con­ditions during use are thereby to be taken into account!

• If the temperatures during rated operation are higher than 70°C at the feed-in points of
cables, lines or pipes, or higher than 80°C at the wire branching points, then cables
must be selected whose temperature data correspond to the actual measured tempera­ture values!

• Observe the permissible ambient temperature range of -25 to 60°C for the use of Beck­hoff fieldbus components with extended temperature range (ET) in potentially explosive
areas!

• Measures must be taken to protect against the rated operating voltage being exceeded
by more than 40% due to short-term interference voltages!

• The individual terminals may only be unplugged or removed from the Bus Terminal sys­tem if the supply voltage has been switched off or if a non-explosive atmosphere is en­sured!

• The connections of the certified components may only be connected or disconnected if
the supply voltage has been switched off or if a non-explosive atmosphere is ensured!

• The fuses of the KL92xx/EL92xx power feed terminals may only be exchanged if the
supply voltage has been switched off or if a non-explosive atmosphere is ensured!

• Address selectors and ID switches may only be adjusted if the supply voltage has been
switched off or if a non-explosive atmosphere is ensured!

Standards

The fundamental health and safety requirements are fulfilled by compliance with the following standards:

• EN 60079-0:2012+A11:2013

• EN 60079-15:2010

Marking

The Beckhoff fieldbus components with extended temperature range (ET) certified for potentially explosive
areas bear the following marking:

II 3GKEMA 10ATEX0075 X Ex nA IIC T4 GcTa: -25…60°C

or

II 3GKEMA 10ATEX0075 X Ex nC IIC T4 GcTa: -25…60°C

KL304x, KL305x 25Version: 4.0

Mounting and wiring

3.10 ATEX Documentation

Notes about operation of the Beckhoff terminal systems in potentially explo­sive areas (ATEX)

Note

Pay also attention to the continuative documentation

Notes about operation of the Beckhoff terminal systems in potentially explosive areas
(ATEX)

that is available in the download area of the Beckhoff homepage http:\\www.beckhoff.com!

KL304x, KL305x26 Version: 4.0

Configuration Software KS2000

4 Configuration Software KS2000

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.16: 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.

KL304x, KL305x 27Version: 4.0

Configuration Software KS2000

Commissioning

The KS2000 software facilitates commissioning of machine components or their fieldbus stations: Configured
settings can be transferred to the fieldbus modules by means of a download. After a login to the terminal
station, it is possible to define settings in couplers, terminals and Fieldbus Box modules directly online. The
same high-level dialogs and register access are available for this purpose as in the configuration phase.

The KS2000 offers access to the process images of the bus couplers and Fieldbus Box modules.

• Thus, the coupler's input and output images can be observed by monitoring.

• Process values can be specified in the output image for commissioning of the output modules.

All possibilities in the online mode can be used in parallel with the actual fieldbus mode of the terminal
station. The fieldbus protocol always has the higher priority in this case.

KL304x, KL305x28 Version: 4.0

Access from the user program

5 Access from the user program

5.1 Terminal configuration

The terminal can be configured and parameterized via the internal register structure. Each terminal channel
is mapped in the Bus Coupler. Mapping of the terminal data in the Bus Coupler memory may differ,
depending on the Bus Coupler type and the set mapping configuration (e.g.Motorola/Intel format, word
alignment etc.). For parameterizing a terminal, the control and status byte also has to be mapped.

BK2000 Lightbus Coupler

In the BK2000 Lightbus Coupler, the control/status byte is always mapped, in addition to the data bytes. This
is always located in the low byte at the offset address of the terminal channel.

Fig.17: Mapping in the Lightbus coupler - example for KL3042 and KL3052

BK3000 Profibus Coupler

For the BK3000 Profibus coupler, the master configuration should specify for which terminal channels the
control and status byte is to be inserted. If the control and status byte are not evaluated, the terminals
occupy 2bytes per channel:

• KL3041 and KL3051: 2bytes of input data

• KL3042 and KL3052: 4bytes of input data

• KL3044 and KL3054: 8bytes of input data

Fig.18: Mapping in the Profibus coupler - example for KL3042 and KL3052

BK4000 Interbus Coupler

The BK4000 Interbus Coupler maps the terminals in the delivery state with 2bytes per channel:

KL304x, KL305x 29Version: 4.0

Access from the user program

• KL3041 and KL3051: 2bytes of input data

• KL3042 and KL3052: 4bytes of input data

• KL3044 and KL3054: 8bytes of input data

Parameterization via the fieldbus is not possible. If the control and status byte is to be used, the KS2000
configuration software is required.

Fig.19: Mapping in the Interbus coupler - example for KL3042 and KL3052

Other Bus Couplers and further information

Further information about the mapping configuration of Bus Couplers can be found in the Appendix of the
respective Bus Coupler manual under Master configuration.

The chapter on Mapping in the Bus Coupler [}30] contains an overview of possible mapping
configurations, depending on the configurable parameters.

Parameterization with KS2000

The KS2000 configuration software can be used for parameterizations via the serial inter­face of the Bus Coupler, independent of the fieldbus system.

Note

5.2 Mapping in the Bus Coupler

As already described in the Terminal Configuration section, each Bus Terminal is mapped in the Bus
Coupler. This mapping is usually done with the default setting in the Bus Coupler / Bus Terminal. The
KS2000 configuration software or a master configuration software (e.g.ComProfibus or TwinCAT System
Manager) can be used to change this default setting.
If the terminals are fully evaluated, they occupy memory space in the input and output process image.
The following tables provide information about how the terminals map themselves in the Bus Coupler,
depending on the parameters set.

5.2.1 KL3041 and KL3051

Default mapping for: CANopen, CANCAL, DeviceNet, ControlNet, Modbus, RS232 and RS485 coupler

Conditions Word offset High byte Low byte

Complete evaluation: no
Motorola format: no
Word alignment: any

0 Ch1 D1 Ch1 D0

1 - -

2 - -

3 - -

KL304x, KL305x30 Version: 4.0

Access from the user program

Default mapping for: Profibus and Interbus Coupler

Conditions Word offset High byte Low byte

Complete evaluation: no
Motorola format: yes
Word alignment: any

Conditions Word offset High byte Low byte

Complete evaluation: yes
Motorola format: no
Word alignment: no

Conditions Word offset High byte Low byte

Complete evaluation: yes
Motorola format: yes
Word alignment: no

0 Ch1 D0 Ch1 D1

1 - -

2 - -

3 - -

0 Ch1 D0 Ch1 CB/SB

1 - Ch1 D1

2 - -

3 - -

0 Ch1 D1 Ch1 CB/SB

1 - Ch1 D0

2 - -

3 - -

Default mapping for: Lightbus & Ethernet coupler and Bus Terminal Controller (BCxxxx, BXxxxx)

Conditions Word offset High byte Low byte

Complete evaluation: yes
Motorola format: no
Word alignment: yes

0 Res. Ch1 CB/SB

1 Ch1 D1 Ch1 D0

2 - -

3 - -

Conditions Word offset High byte Low byte

Complete evaluation: yes
Motorola format: yes
Word alignment: yes

0 Res. Ch1 CB/SB

1 Ch1 D0 Ch1 D1

2 - -

3 - -

Key

Complete evaluation The terminal is mapped with control and status byte.

Motorola format Motorola or Intel format can be set.

Word alignment The terminal is positioned on a word boundary in the Bus Coupler.

Ch n CB Control byte for channel n (appears in the process image of the outputs).

Ch n SB Status byte for channel n (appears in the process image of the inputs).

Ch n D0 Channel n, data byte 0 (byte with the lowest value)

Ch n D1 Channel n, data byte 1 (byte with the highest value)

"-" This byte is not used or occupied by the terminal.

Res. Reserved: This byte is assigned to the process data memory, although it has no function.

5.2.2 KL3042 and KL3052

Default mapping for: CANopen, CANCAL, DeviceNet, ControlNet, Modbus, RS232 and RS485 coupler

Conditions Word offset High byte Low byte

Complete evaluation: no
Motorola format: no
Word alignment: any

0 Ch1 D1 Ch1 D0

1 Ch2 D1 Ch2 D0

2 - -

3 - -

KL304x, KL305x 31Version: 4.0

Access from the user program

Default mapping for: Profibus and Interbus Coupler

Conditions Word offset High byte Low byte

Complete evaluation: no
Motorola format: yes
Word alignment: any

Conditions Word offset High byte Low byte

Complete evaluation: yes
Motorola format: no
Word alignment: no

Conditions Word offset High byte Low byte

Complete evaluation: yes
Motorola format: yes
Word alignment: no

0 Ch1 D0 Ch1 D1

1 Ch2 D0 Ch2 D1

2 - -

3 - -

0 Ch1 D0 Ch1 CB/SB

1 Ch2 CB/SB Ch1 D1

2 Ch2 D1 Ch2 D0

3 - -

0 Ch1 D1 Ch1 CB/SB

1 Ch2 CB/SB Ch1 D0

2 Ch2 D0 Ch2 D1

3 - -

Default mapping for: Lightbus & Ethernet coupler and Bus Terminal Controller (BCxxxx, BXxxxx)

Conditions Word offset High byte Low byte

Complete evaluation: yes
Motorola format: no
Word alignment: yes

0 Res. Ch1 CB/SB

1 Ch1 D1 Ch1 D0

2 Res. Ch2 CB/SB

3 Ch2 D1 Ch2 D0

Conditions Word offset High byte Low byte

Complete evaluation: yes
Motorola format: yes
Word alignment: yes

0 Res. Ch1 CB/SB

1 Ch1 D0 Ch1 D1

2 Res. Ch2 CB/SB

3 Ch2 D0 Ch2 D1

Key

Complete evaluation The terminal is mapped with control and status byte.

Motorola format Motorola or Intel format can be set.

Word alignment The terminal is positioned on a word boundary in the Bus Coupler.

Ch n CB Control byte for channel n (appears in the process image of the outputs).

Ch n SB Status byte for channel n (appears in the process image of the inputs).

Ch n D0 Channel n, data byte 0 (byte with the lowest value)

Ch n D1 Channel n, data byte 1 (byte with the highest value)

"-" This byte is not used or occupied by the terminal.

Res. Reserved: This byte is assigned to the process data memory, although it has no function.

5.2.3 KL3044 and KL3054

Default mapping for: CANopen, CANCAL, DeviceNet, ControlNet, Modbus, RS232 and RS485 coupler

Conditions Word offset High byte Low byte

Complete evaluation: no
Motorola format: no
Word alignment: any

0 Ch1 D1 Ch1 D0

1 Ch2 D1 Ch2 D0

2 Ch3 D1 Ch3 D0

3 Ch4 D1 Ch4 D0

KL304x, KL305x32 Version: 4.0

Access from the user program

Default mapping for: Profibus and Interbus Coupler

Conditions Word offset High byte Low byte

Complete evaluation: no
Motorola format: yes
Word alignment: any

Conditions Word offset High byte Low byte

Complete evaluation: yes
Motorola format: no
Word alignment: no

Conditions Word offset High byte Low byte

Complete evaluation: yes
Motorola format: yes
Word alignment: no

0 Ch1 D0 Ch1 D1

1 Ch2 D0 Ch2 D1

2 Ch3 D0 Ch3 D1

3 Ch4 D0 Ch4 D1

0 Ch1 D0 Ch1 CB/SB

1 Ch2 CB/SB Ch1 D1

2 Ch2 D1 Ch2 D0

3 Ch3 D0 Ch3 CB/SB

4 Ch4 CB/SB Ch3 D1

5 Ch4 D1 Ch4 D0

0 Ch1 D1 Ch1 CB/SB

1 Ch2 CB/SB Ch1 D0

2 Ch2 D0 Ch2 D1

3 Ch3 D1 Ch3 CB/SB

4 Ch4 CB/SB Ch3 D0

5 Ch4 D0 Ch4 D1

Default mapping for: Lightbus & Ethernet coupler and Bus Terminal Controller (BCxxxx, BXxxxx)

Conditions Word offset High byte Low byte

Complete evaluation: yes
Motorola format: no
Word alignment: yes

Conditions Word offset High byte Low byte

Complete evaluation: yes
Motorola format: yes
Word alignment: yes

0 Res. Ch1 CB/SB

1 Ch1 D1 Ch1 D0

2 Res. Ch2 CB/SB

3 Ch2 D1 Ch2 D0

4 Res. Ch3 CB/SB

5 Ch3 D1 Ch3 D0

6 Res. Ch4 CB/SB

7 Ch4 D1 Ch4 D0

0 Res. Ch1 CB/SB

1 Ch1 D0 Ch1 D1

2 Res. Ch2 CB/SB

3 Ch2 D0 Ch2 D1

4 Res. Ch3 CB/SB

5 Ch3 D0 Ch3 D1

6 Res. Ch4 CB/SB

7 Ch4 D0 Ch4 D1

Key

Complete evaluation The terminal is mapped with control and status byte.

Motorola format Motorola or Intel format can be set.

Word alignment The terminal is positioned on a word boundary in the Bus Coupler.

Ch n CB Control byte for channel n (appears in the process image of the outputs).

Ch n SB Status byte for channel n (appears in the process image of the inputs).

Ch n D0 Channel n, data byte 0 (byte with the lowest value)

Ch n D1 Channel n, data byte 1 (byte with the highest value)

Res. Reserved: This byte is assigned to the process data memory, although it has no function.

5.3 Register overview

These registers exist once for each channel.

KL304x, KL305x 33Version: 4.0

Access from the user program

Address Name Default value R/W Storage medium

R0 [}35]

R1 to R5 reserved 0x0000 R

R6 [}35]

R7 [}35]

R8 [}35]

R9 [}35]

R10 [}35]

R11 [}35]

R12 [}35]

R13 [}35]

R14 reserved 0x0000 R

R15 [}36]

R16 [}36]

R17 [}36]

R18 [}36]

R19 [}36]

R20 [}36]

R21 [}36]

R22 [}36]

R23 [}36]

R24 to R30 reserved 0x0000 R/W SEEROM

R31 [}36]

R32 [}37]

R33 [}37]

R34 [}37]

R35 [}37]

R36 [}38]

R37 to R63 reserved 0x0000 R/W SEEROM

Raw ADC value variable R RAM

Diagnostic register variable R RAM

Command register - not used 0x0000 R

Terminal type e.g.3042 R ROM

Software version number 0x???? R ROM

Multiplex shift register 0x0218/0130 R ROM

Signal channels 0x0218 R ROM

Minimum data length 0x0098 R ROM

Data structure 0x0000 R ROM

Alignment register variable R/W RAM

Hardware version number 0x???? R/W SEEROM

Hardware compensation: Offset specific R/W SEEROM

Hardware compensation: Gain specific R/W SEEROM

Manufacturer scaling: Offset 0x0000 R/W SEEROM

Manufacturer scaling: Gain 0x2002 R/W SEEROM

Overrange limit 0x0FFF R/W SEEROM

Under range limit 0x0000 R/W SEEROM

ADC hardware preset 0x0000 R/W SEEROM

Code word register variable R/W RAM

Feature register 0x01106 R/W SEEROM

User scaling: Offset 0x0000 R/W SEEROM

User scaling: Gain 0x0100 R/W SEEROM

Limit value 1 0x0000 R/W SEEROM

Limit value 2 0x0000 R/W SEEROM

KL304x, KL305x34 Version: 4.0

Access from the user program

5.4 Register description

The registers can be read or written via the register communication. They are used for the parameterization
of the terminal.

R0 to R7: Registers in the internal RAM of the terminal

The process variables can be used in addition to the actual process image. Their function is specific to the
terminal.

• R0 ADC raw value (X_R)
This register contains the raw ADC value with gain and offset error

• R1 to R5: Reserved

• R6: Diagnostic register

◦ High byte: reserved

◦ Low byte: Status byte

• R7: Command register
High-Byte_Write = function parameter
Low-Byte_Write = function number
High-Byte_Read = function result
Low-Byte_Read = function number

R8 to R15: Registers in the internal ROM of the terminal

The type and system parameters are hard programmed by the manufacturer, and the user can read them
but cannot change them.

• R8: Terminal type
The terminal type in register R8 is needed to identify the terminal.

• R9: Software version (X.y)
The software version can be read as a string of ASCII characters.

• R10: Data length
R10 contains the number of multiplexed shift registers and their length in bits.
The Bus Coupler sees this structure.

• R11: Signal channels
Related to R10, this contains the number of channels that are logically present. Thus for example a
shift register that is physically present can perfectly well consist of several signal channels.

• R12: Minimum data length
The particular byte contains the minimum data length for a channel that is to be transferred. If the MSB
is set, the control and status byte is not necessarily required for the terminal function and is not
transferred to the control, if the Bus Coupler is configured accordingly.

• R13: Data type register

Data type register Meaning

0x00 Terminal with no valid data type

0x01 Byte array

0x02 Structure 1 byte n bytes

0x03 Word array

0x04 Structure 1 byte n words

0x05 Double word array

0x06 Structure 1 byte n double words

0x07 Structure 1 byte 1 double word

0x08 Structure 1 byte 1 double word

0x11 Byte array with variable logical channel length

0x12 Structure 1 byte n bytes with variable logical channel length (e.g. 60xx)

0x13 Word array with variable logical channel length

0x14 Structure 1 byte n words with variable logical channel length

0x15 Double word array with variable logical channel length

0x16 Structure 1 byte n double words with variable logical channel length

KL304x, KL305x 35Version: 4.0

Access from the user program

• R14: reserved

• R15: Alignment bits (RAM)
The alignment bits are used to place the analog terminal in the Bus Coupler on a byte boundary.

R16 to R30: Manufacturer parameter area (SEEROM)

The manufacturer parameters are specific for each type of terminal. They are programmed by the
manufacturer, but can also be modified by the controller. The manufacturer parameters are stored in a serial
EEPROM in the terminal, and are retained in the event of voltage drop-out.

These registers can only be altered after a code word has been set in R31 [}36].

• R17: Hardware compensation - offset (B_a)
16bit signed integer

This register is used for offset compensation of the terminal (Eq. 1.1 [}12]).
Register value approx. 0xFFXX

• R18: Hardware compensation - gain (A_a)
16bit signed integer*2-

12

This register is used for gain compensation of the terminal (Eq. 1.1 [}12]).
1 corresponds to register value 01000
Register value approx. 0x11XX

• R19: Manufacturer scaling - offset (B_h)
16bits signed integer [0x0000]

This register contains the offset of the manufacturer straight-line equation (equation 1.3 [}12]). The
straight-line equation is activated via register R32 [}37].

• R20: Manufacturer scaling - gain (A_h)
16bit signed integer*2

-10

[0x2002]

This register contains the scale factor of the manufacturer's equation of the straight line (Eq. 1.3 [}12]).
The straight-line equation is activated via register R32 [}37].

1 corresponds to register value 0x0400.

• R21: Over range limit (OVRL)
16bits signed integer in Y_a (Eq. 1.0 [}12]) [0x0FFF]

This limit value limits the maximum measuring range of the input terminal. If it is exceeded, the
associated status bit is set, and the maximum value is displayed.

• R22: Under range limit (UNRL)
16bit signed integer in Y_a (Eq. 1.0 [}12]) [0x0000]

If the actual value falls below this limit, the associated status bit is set, and the minimum value is
displayed.

• R23: ADC hardware preset
[0x0000]
Initialization of the ADC offset register.

R31 to R47: User parameter area (SEEROM)

The user parameters are specific for each type of terminal. They can be modified by the programmer. The
user parameters are stored in a serial EEPROM in the terminal, and are retained in the event of voltage
drop-out. The user area is write-protected by a code word.

• R31: Code word register in RAM

The code word 0x1235 must be entered here so that parameters in the user area can be

Note

• R32: Feature register
[0x1106]
This register specifies the operation modes of the terminal. Thus, forinstance, a user-specific scaling
can be activated for the analog I/Os.

modified. If any other value is entered into this register, the write-protection is active. When
write protection is not active, the code word is returned when the register is read. If the
write protection is active, the register contains a zero value.

KL304x, KL305x36 Version: 4.0

Feature bit no. Description of the operation mode
Bit 0 1

Bit 1 1

User scaling (R33, R34 [}37]) active [0]

Manufacturer scaling (R19, R20 [}36]) active [1]

Bit 2 1 Watchdog timer active [1]

In the delivery state, the watchdog timer is switched on.

Bit 3 1 Sign / amount representation [0]

Sign / amount representation is active instead of two's-complement
representation. (-1=0x8001).

Bit 4 1 Siemens output format [0]

This bit is used for inserting status information on the lowest 3 bits (see
below).

Bits 5 to 7 - Reserved, don't change
Bit 8 1 Over range Protection [1]

If values exceed or fall below the limits of the registers OVRL (R21 [}36])
and UNRL (R22 [}36]), the status bits are set and the measuring range is

restricted accordingly.

Bit 9 1 Limit value 1 active [0]

The process data are compared with limit value 1 (R35 [}37]), and
appropriate status bits are set.

Bit 10 1 Limit value 2 active [0]

The process data are compared with limit value 2 (R36 [}38]), and
appropriate status bits are set.

Bit 11 1 Filter1 active [0]

For filter properties, see R37 [}38]

Bits 12 to 15 - Reserved, don't change

Access from the user program

If the Siemens output format is selected, the lowest threebits are used for status evaluation. The process
data is represented in bits 15 to 3, with bit15 representing the sign bit. Scaling of the measured value

according to the Siemens standard has to be done via user scaling (R33, R34 [}37]).

KL3041, KL3042 and KL3044

Measured value Bits 15 to 3 Bit 2

X

Bit1
Error

Bit 0
Overflow

Measured value > 20mA 0 0 1
Measured value <20mA Process data 0 0 0

KL3051, KL3052 and KL3054

Measured value Bits 15 to 3 Bit 2

X

Bit1
Error

Bit 0
Overflow

Measured value > 20mA 0 0 1
4mA < measured value

Process data 0 0 0

<20mA
Measured value < 4mA Process data 0 1 1

• R33: User scaling - offset (B_w)
16bit signed integer

This register contains the offset of the user straight-line equation (Eq. 1.4 [}12]). The straight-line
equation is activated via register R32 [}37].

• R34: User scaling - gain (Aw_)
16bit signed integer*2

-8

This register contains the scale factor of the user straight-line equation (Eq. 1.4 [}12]). The straight-line
equation is activated via register R32 [}37].

• R35: Limit value 1 (Y_2)
If the process data are outside this threshold, the appropriate bits are set in the status byte.

KL304x, KL305x 37Version: 4.0

Access from the user program

• R36: Limit value 2 (Y_2)
If the process data are outside this threshold, the appropriate bits are set in the status byte.

• R37: Filter constant
[0x0000]

If the internal filter is activated via R32.11 [}37], you can choose between the following filter constants
in R37 (not possible with KL3044 and KL3054). In the standard setting, the corresponding conversion
time is 2.5ms:

Applies to all terminals from firmware version 3x.

This documentation applies to all terminals from firmware version 3x. The version informa-

Note

R37 Explanation

0x0000 2nd order FIR filter default value
0x0100 1st order IIR filter, cut-off frequency f

approx.1kHz

0x0200 1st order IIR filter, cut-off frequency fg approx.

100Hz

0x0300 1st order IIR filter, cut-off frequency fg approx.

50Hz

0x0400 1st order IIR filter, cut-off frequency fg approx.

20Hz

0x0500 1st order IIR filter, cut-off frequency fg approx.

10Hz

0x0600 1st order IIR filter, cut-off frequency fg approx.

5Hz

0x0700 1st order IIR filter, cut-off frequency fg approx.

1Hz

0x1000 50Hz FIR filter

Averaging over 16 values and first notch 25Hz

0x2000 60Hz FIR filter

Averaging over 16 values and first notch 20Hz

Other

No filter active

values

tion can be found on the right-hand side of the terminal in the serial number: xxxx3xxx.

Example: 52983A2A => the firmware version is 3A.

g

The implemented IIR filters do not have any
notch behavior, i.e.,they do not explicitly
suppress any frequency.

In contrast to the IIR filters, FIR filter have notch
behavior. The timer settings of the notch filter
are made via channel 0 of the terminal. This
means that the 50Hz filter on channel 0 and the
60Hz filter on channel 1 cannot be active
simultaneously.

KL304x, KL305x38 Version: 4.0

Access from the user program

5.5 Control and status byte

The control and status byte is transmitted from the controller to the terminal. It can be used

• in register mode [}40] (REG = 1

• in process data exchange [}39] (REG = 0

) or

bin

).

bin

5.5.1 Process data exchange

Control byte in process data exchange (REG=0)

A gain and offset calibration of the terminal can be carried out with the control byte. The code word must be
entered in R31 [}36] so that the terminal calibration can be carried out. The gain and offset of the terminal

can then be calibrated. The parameter will only be saved permanently once the code word is reset!

Bit Description
Bit 7 0
Bit 6 1
Bit 5 reserved
Bit 4 1
Bit 3 1
Bit 2 0

Bit 1 1
Bit 0 1

bin

: Terminal compensation function is enabled

bin

: Gain calibration

bin

: Offset calibration

bin

: slower cycle = 1000ms

bin

1

: fast cycle = 50ms

bin

: up

bin

: down

bin

Status byte in process data exchange (REG=0)

The status byte is transferred from the terminal to the controller. The status byte contains various status bits
for the analog input channel:

Bit Description
Bit 7 0
Bit 6 1

bin

: Error (general error bit)

bin

Bit 5 Bit 4

0

bin

0

bin

1

bin

1

bin

0
1
0
1

Limit value 2 not enabled

bin

Process data < limit value 2

bin

Process data > limit value 2

bin

Process data = limit value 2

bin

Bit 3 Bit 2

Bit 1 1
Bit 0 1

0

bin

0

bin

1

bin

1

bin

bin

bin

0

bin

1

bin

0

bin

1

bin

: Overrange
: Underrange

Limit value 1 not enabled
Process data < limit value 1
Process data > limit value 1
Process data = limit value 1

KL304x, KL305x 39Version: 4.0

Access from the user program

5.5.2 Register communication

Register access via process data exchange

• Bit 7=1: Register mode
If bit 7 of the control byte is set, the first two bytes of the user data are not used for process data
exchange but written into the register set of the terminal or read from it.

• Bit 6=0: read, bit 6=1: write
Bit 6 of the control bytes is used to specify whether a register should be read or written.

◦ Bit 6=0: A register is read without changing it. The value can be found in the input process

image.

◦ Bit 6=1: The user data are written into a register. The process is complete once the status

byte in the input process image has returned an acknowledgment (see example).

• Bit 0 to 5: Address
The address of the register to be addressed is entered in bits 0 to 5 of the control byte.

Control byte in register mode (REG=1)

MSB

REG=1 W/R A5 A4 A3 A2 A1 A0

REG = 0
REG = 1

W/R = 0
W/R = 1

: Process data exchange

bin

: Access to register structure

bin

: Read register

bin

: Write register

bin

A5..A0 = register address
Addresses A5...A0 can be used to address a total of 64 registers.

Fig.20: Register mode control byte

The control or status byte occupies the lowest address of a logical channel. The corresponding register
values are located in the following 2 data bytes. (The BK2000 is an exception: here, an unused data byte is
inserted after the control or status byte, and the register value is therefore placed on a word boundary).

KL304x, KL305x40 Version: 4.0

Access from the user program

Example 1:
Reading of register 8 in the BK2000 with a KL3042 and the end terminal:

If the following bytes are transferred from the control to the terminal,

Byte Byte 3 Byte 2 Byte 1 Byte 0
Name DataOUT 1 DataOUT 0 Not used Control byte
Value 0xXX 0xXX 0xXX 0x88

The terminal returns the following type identifier (0x0BE2 corresponds to unsigned integer 3042).

Byte Byte 3 Byte 2 Byte 1 Byte 0
Name DataIN 1 DataIN 0 Not used Status byte
Value 0x0B 0xE2 0x00 0x88

Example 2:
Writing of register 31 in the BK2000 with an intelligent terminal and the end terminal:

If the following bytes (code word [}36]) are transferred from the control to the terminal,

Byte Byte 3 Byte 2 Byte 1 Byte 0
Name DataOUT 1 DataOUT 0 Not used Control byte
Value 0x12 0x35 0xXX 0xDF

the code word [}36] is set, and the terminal returns the register address with bit7 for register access as
acknowledgment.

Byte Byte 3 Byte 2 Byte 1 Byte 0
Name DataIN 1 DataIN 0 Not used Status byte
Value 0x00 0x00 0x00 0x9F

5.6 Examples of Register Communication

The numbering of the bytes in the examples corresponds to the display without word alignment.

5.6.1 Example 1: reading the firmware version from Register 9

Output Data

Byte 0: Control byte Byte 1: DataOUT1, high byte Byte 2: DataOUT1, low byte

0x89 (1000 1001

Explanation:

• Bit 0.7 set means: Register communication switched on.

• Bit 0.6 not set means: reading the register.

• Bits 0.5 to 0.0 specify the register number 9 with 00 1001

• The output data word (byte 1 and byte 2) has no meaning during read access. To change a register,
write the required value into the output word.

) 0xXX 0xXX

bin

.

bin

Input Data (answer of the bus terminal)

Byte 0: Status byte Byte 1: DataIN1, high byte Byte 2: DataIN1, low byte

0x89 0x33 0x41

Explanation:

KL304x, KL305x 41Version: 4.0

Access from the user program

• The terminal returns the value of the control byte as a receipt in the status byte.

• The terminal returns the firmware version 0x3341 in the input data word (byte 1 and byte 2). This is to
be interpreted as an ASCII code:

◦ ASCII code 0x33 represents the digit 3

◦ ASCII code 0x41 represents the letter A

The firmware version is thus 3A.

5.6.2 Example 2: Writing to an user register

Code word

In normal mode all user registers are read-only with the exception of Register 31. In order

Note

I. Write the code word (0x1235) into Register 31.

Output Data

to deactivate this write protection you must write the code word (0x1235) into Register 31. If
a value other than 0x1235 is written into Register 31, write protection is reactivated. Please
note that changes to a register only become effective after restarting the terminal (power­off/power-on).

Byte 0: Control byte Byte 1: DataOUT1, high byte Byte 2: DataOUT1, low byte

0xDF (1101 1111

) 0x12 0x35

bin

Explanation:

• Bit 0.7 set means: Register communication switched on.

• Bit 0.6 set means: writing to the register.

• Bits 0.5 to 0.0 specify the register number 31 with 01 1111

.

bin

• The output data word (byte 1 and byte 2) contains the code word (0x1235) for deactivating write
protection.

Input Data (answer of the bus terminal)

Byte 0: Status byte Byte 1: DataIN1, high byte Byte 2: DataIN1, low byte

0x9F (1001 1111

) 0xXX 0xXX

bin

Explanation:

• The terminal returns a value as a receipt in the status byte that differs only in bit 0.6 from the value of
the control byte.

• The input data word (byte 1 and byte 2) is of no importance after the write access. Any values still
displayed are invalid!

II. Read Register 31 (check the set code word)

Output Data

Byte 0: Control byte Byte 1: DataOUT1, high byte Byte 2: DataOUT1, low byte

0x9F (1001 1111

) 0xXX 0xXX

bin

Explanation:

• Bit 0.7 set means: Register communication switched on.

• Bit 0.6 not set means: reading the register.

• Bits 0.5 to 0.0 specify the register number 31 with 01 1111

.

bin

• The output data word (byte 1 and byte 2) has no meaning during read access.

KL304x, KL305x42 Version: 4.0

Access from the user program

Input Data (answer of the bus terminal)

Byte 0: Status byte Byte 1: DataIN1, high byte Byte 2: DataIN1, low byte

0x9F (1001 1111

) 0x12 0x35

bin

Explanation:

• The terminal returns the value of the control byte as a receipt in the status byte.

• The terminal returns the current value of the code word register in the input data word (byte 1 and byte

2).

III. Write to Register 32 (change contents of the feature register)

Output data

Byte 0: Control byte Byte 1: DataIN1, high byte Byte 2: DataIN1, low byte

0xE0 (1110 0000

) 0x00 0x02

bin

Explanation:

• Bit 0.7 set means: Register communication switched on.

• Bit 0.6 set means: writing to the register.

• Bits 0.5 to 0.0 indicate register number 32 with 10 0000

.

bin

• The output data word (byte 1 and byte 2) contains the new value for the feature register.

Observe the register description!

The value of 0x0002 given here is just an example!

CAUTION

Input data (response from the Bus Terminal)

Byte 0: Status byte Byte 1: DataIN1, high byte Byte 2: DataIN1, low byte

0xA0 (1010 0000

Explanation:

• The terminal returns a value as a receipt in the status byte that differs only in bit 0.6 from the value of
the control byte.

• The input data word (byte 1 and byte 2) is of no importance after the write access. Any values still
displayed are invalid!

IV. Read Register 32 (check changed feature register)

Output Data

Byte 0: Control byte Byte 1: DataOUT1, high byte Byte 2: DataOUT1, low byte

0xA0 (1010 0000

The bits of the feature register change the properties of the terminal and have a different
meaning, depending on the type of terminal. Refer to the description of the feature register
of your terminal (chapter Register description) regarding the meaning of the individual bits
before changing the values.

) 0xXX 0xXX

bin

) 0xXX 0xXX

bin

Explanation:

• Bit 0.7 set means: Register communication switched on.

• Bit 0.6 not set means: reading the register.

• Bits 0.5 to 0.0 indicate register number 32 with 10 0000

.

bin

• The output data word (byte 1 and byte 2) has no meaning during read access.

KL304x, KL305x 43Version: 4.0

Access from the user program

Input Data (answer of the bus terminal)

Byte 0: Status byte Byte 1: DataIN1, high byte Byte 2: DataIN1, low byte

0xA0 (1010 0000

) 0x00 0x02

bin

Explanation:

• The terminal returns the value of the control byte as a receipt in the status byte.

• The terminal returns the current value of the feature register in the input data word (byte 1 and byte 2).

V. Write Register 31 (reset code word)

Output Data

Byte 0: Control byte Byte 1: DataOUT1, high byte Byte 2: DataOUT1, low byte

0xDF (1101 1111

) 0x00 0x00

bin

Explanation:

• Bit 0.7 set means: Register communication switched on.

• Bit 0.6 set means: writing to the register.

• Bits 0.5 to 0.0 specify the register number 31 with 01 1111

.

bin

• The output data word (byte 1 and byte 2) contains 0x0000 for reactivating write protection.

Input Data (answer of the bus terminal)

Byte 0: Status byte Byte 1: DataIN1, high byte Byte 2: DataIN1, low byte

0x9F (1001 1111

) 0xXX 0xXX

bin

Explanation:

• The terminal returns a value as a receipt in the status byte that differs only in bit 0.6 from the value of
the control byte.

• The input data word (byte 1 and byte 2) is of no importance after the write access. Any values still
displayed are invalid!

KL304x, KL305x44 Version: 4.0

Appendix

6 Appendix

6.1 Support and Service

Beckhoff and their partners around the world offer comprehensive support and service, making available fast
and competent assistance with all questions related to Beckhoff products and system solutions.

Beckhoff's branch offices and representatives

Please contact your Beckhoff branch office or representative for local support and service on Beckhoff
products!

The addresses of Beckhoff's branch offices and representatives round the world can be found on her internet
pages:

http://www.beckhoff.com

You will also find further documentation for Beckhoff components there.

Beckhoff Headquarters

Beckhoff Automation GmbH & Co. KG

Huelshorstweg 20
33415 Verl
Germany

Phone: [phone]
Fax: [phone]
e-mail: [e-mail]

Beckhoff Support

Support offers you comprehensive technical assistance, helping you not only with the application of
individual Beckhoff products, but also with other, wide-ranging services:

• support

• design, programming and commissioning of complex automation systems

• and extensive training program for Beckhoff system components

Hotline: [phone]
Fax: [phone]
e-mail: [e-mail]

Beckhoff Service

The Beckhoff Service Center supports you in all matters of after-sales service:

• on-site service

• repair service

• spare parts service

• hotline service

Hotline: [phone]
Fax: [phone]
e-mail: [e-mail]

KL304x, KL305x 45Version: 4.0

List of illustrations

List of illustrations

Fig. 1 KL3041, KL3051 .......................................................................................................................... 8

Fig. 2 KL3042, KL3052 .......................................................................................................................... 9

Fig. 3 KL3044, KL3054 .......................................................................................................................... 10

Fig. 4 KL304x, KL305x - Data flow ........................................................................................................ 12

Fig. 5 Spring contacts of the Beckhoff I/O components......................................................................... 13

Fig. 6 Attaching on mounting rail ........................................................................................................... 14

Fig. 7 Disassembling of terminal............................................................................................................ 15

Fig. 8 Power contact on left side............................................................................................................ 16

Fig. 9 Standard wiring............................................................................................................................ 18

Fig. 10 Pluggable wiring .......................................................................................................................... 18

Fig. 11 High Density Terminals................................................................................................................ 18

Fig. 12 Connecting a cable on a terminal point ....................................................................................... 19

Fig. 13 KL3041, KL3051 - Connection and LEDs .................................................................................... 21

Fig. 14 KL3042, KL3052 - Connection and LEDs .................................................................................... 22

Fig. 15 KL3044, KL3054 - Connection and LEDs .................................................................................... 23

Fig. 16 KS2000 configuration software .................................................................................................... 27

Fig. 17 Mapping in the Lightbus coupler - example for KL3042 and KL3052 .......................................... 29

Fig. 18 Mapping in the Profibus coupler - example for KL3042 and KL3052 .......................................... 29

Fig. 19 Mapping in the Interbus coupler - example for KL3042 and KL3052........................................... 30

Fig. 20 Register mode control byte .......................................................................................................... 40

KL304x, KL305x46 Version: 4.0