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