Beckhoff KL5101 Documentation
Documentation
KL5101
Incremental encoder interface
Version:
Date:
3.1
2019-10-14
Table of content
Table of content
1 Foreword ....................................................................................................................................................5
1.1 Notes on the documentation..............................................................................................................5
1.2 Safety instructions .............................................................................................................................6
1.3 Documentation Issue Status..............................................................................................................7
1.4 Beckhoff Identification Code (BIC) ....................................................................................................7
2 Product overview.....................................................................................................................................10
2.1 KL5101 - Introduction ......................................................................................................................10
2.2 KL5101 - Technical data..................................................................................................................11
2.3 Basic Function Principles ................................................................................................................12
3 Mounting and wiring................................................................................................................................14
3.1 Instructions for ESD protection........................................................................................................14
3.2 Installation on mounting rails ...........................................................................................................14
3.3 Installation instructions for enhanced mechanical load capacity .....................................................18
3.4 Connection ......................................................................................................................................18
3.4.1 Connection system .......................................................................................................... 18
3.4.2 Wiring............................................................................................................................... 21
3.4.3 Shielding .......................................................................................................................... 22
3.5 ATEX - Special conditions (extended temperature range) ..............................................................22
3.6 ATEX Documentation ......................................................................................................................23
4 Configuration Software KS2000.............................................................................................................24
4.1 KS2000 - Introduction......................................................................................................................24
5 Access from the user program ..............................................................................................................26
5.1 KL5101 - Terminal configuration .....................................................................................................26
5.2 Mapping in the Bus Coupler ............................................................................................................28
5.2.1 Standard format ............................................................................................................... 28
5.3 Register overview ............................................................................................................................29
5.4 Register description.........................................................................................................................29
5.5 Control and status byte....................................................................................................................32
5.5.1 Process data exchange ................................................................................................... 32
5.5.2 Register communication .................................................................................................. 33
5.6 Examples of Register Communication ............................................................................................35
5.6.1 Example 1: reading the firmware version from Register 9............................................... 35
5.6.2 Example 2: Writing to an user register............................................................................. 35
6 Appendix ..................................................................................................................................................39
6.1 Support and Service ........................................................................................................................39
KL5101 3Version: 3.1
Table of content
KL51014 Version: 3.1
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®, EtherCATG®, EtherCATG10®, EtherCATP®, SafetyoverEtherCAT®,
TwinSAFE®, XFC®, XTS® and XPlanar® are registered trademarks of and licensed by Beckhoff Automation
GmbH. Other designations used in this publication may be trademarks whose use by third parties for their
own purposes could violate the rights of the owners.
Patent Pending
The EtherCAT Technology is covered, including but not limited to the following patent applications and
patents: EP1590927, EP1789857, EP1456722, EP2137893, DE102015105702 with corresponding
applications or registrations in various other countries.
EtherCAT® is registered trademark and patented technology, licensed by Beckhoff Automation GmbH,
Germany.
Copyright
© Beckhoff Automation GmbH & Co. KG, Germany.
The reproduction, distribution and utilization of this document as well as the communication of its contents to
others without express authorization are prohibited.
Offenders will be held liable for the payment of damages. All rights reserved in the event of the grant of a
patent, utility model or design.
KL5101 5Version: 3.1
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 instructions
In this documentation the following instructions are used.
These instructions must be read carefully and followed without fail!
DANGER
Serious risk of injury!
Failure to follow this safety instruction directly endangers the life and health of persons.
WARNING
Risk of injury!
Failure to follow this safety instruction endangers the life and health of persons.
CAUTION
Personal injuries!
Failure to follow this safety instruction can lead to injuries to persons.
NOTE
Damage to environment/equipment or data loss
Failure to follow this instruction can lead to environmental damage, equipment damage or data loss.
Tip or pointer
This symbol indicates information that contributes to better understanding.
KL51016 Version: 3.1
1.3 Documentation Issue Status
Version Comment
3.1 • Update chapter “Instructions for ESD protection”
• Update Firmware and hardware versions
• Chapter “Beckhoff Identification Code (BIC)” added
3.0.1 • Translation correction
3.0 • Migration
• Structure update
Firmware (FW) and hardware (HW) versions
Foreword
Documentation,
version
3.1 5B 18
3.0 5B 15
The firmware and hardware versions (delivery state) of the terminal can be found in the serial number printed
on the side.
Syntax of the serial number
Structure of the serial number: WWYYFFHH
WW - week of production (calendar week)
YY - year of production
FF - firmware version
HH - hardware version
Example with ser. no.: 35 04 1B 01:
35 - week of production 35
4 - year of production 2004
1B - firmware version 1B
1 - hardware version 1
KL5101
FW HW
1.4 Beckhoff Identification Code (BIC)
The Beckhoff Identification Code (BIC) is increasingly being applied to Beckhoff products to uniquely identify
the product. The BIC is represented as a Data Matrix Code (DMC, code scheme ECC200), the content is
based on the ANSI standard MH10.8.2-2016.
KL5101 7Version: 3.1
Foreword
Fig.1: BIC as data matrix code (DMC, code scheme ECC200)
The BIC will be introduced step by step across all product groups.
Depending on the product, it can be found in the following places:
• on the packaging unit
• directly on the product (if space suffices)
• on the packaging unit and the product
The BIC is machine-readable and contains information that can also be used by the customer for handling
and product management.
Each piece of information can be uniquely identified using the so-called data identifier
(ANSIMH10.8.2-2016). The data identifier is followed by a character string. Both together have a maximum
length according to the table below. If the information is shorter, spaces are added to it. The data under
positions 1 to 4 are always available.
The following information is contained:
Item
Type of
no.
information
1 Beckhoff order
number
2 Beckhoff Traceability
Number (BTN)
3 Article description Beckhoff article
4 Quantity Quantity in packaging
5 Batch number Optional: Year and week
6 ID/serial number Optional: Present-day
7 Variant number Optional: Product variant
...
Explanation Data
identifier
Beckhoff order number 1P 8 1P072222
Unique serial number,
see note below
description, e.g.
EL1008
unit, e.g. 1, 10, etc.
of production
serial number system,
e.g. with safety products
number on the basis of
standard products
S 12 SBTNk4p562d7
1K 32 1KEL1809
Q 6 Q1
2P 14 2P401503180016
51S 12 51S678294104
30P 32 30PF971, 2*K183
Number of digits
incl. data identifier
Example
KL51018 Version: 3.1
Foreword
Further types of information and data identifiers are used by Beckhoff and serve internal processes.
Structure of the BIC
Example of composite information from item 1 to 4 and 6. The data identifiers are marked in red for better
display:
BTN
An important component of the BIC is the Beckhoff Traceability Number (BTN, item no.2). The BTN is a
unique serial number consisting of eight characters that will replace all other serial number systems at
Beckhoff in the long term (e.g. batch designations on IO components, previous serial number range for
safety products, etc.). The BTN will also be introduced step by step, so it may happen that the BTN is not yet
coded in the BIC.
NOTE
This information has been carefully prepared. However, the procedure described is constantly being further
developed. We reserve the right to revise and change procedures and documentation at any time and without prior notice. No claims for changes can be made from the information, illustrations and descriptions in
this information.
KL5101 9Version: 3.1
Product overview
2 Product overview
2.1 KL5101 - Introduction
Fig.2: KL5101
Incremental encoder interface
The KL5101 terminal is an interface for direct connection of incremental encoders with difference signal
(RS422) or single inputs. A 16-bit counter with a quadrature decoder and a 16-bit latch for the zero pulse can
be read, set or enabled. Incremental encoders with alarm outputs can be connected at the interface's status
input. Period duration measurement with a resolution of 200ns is possible. The G2 input allows the counter
to be halted (high = stop), and the value is read with a positive edge at G1.
KL510110 Version: 3.1
2.2 KL5101 - Technical data
Technical data KL5101
Encoder connection A, A(inv), B, B(inv), Null, Null(inv)
Differential inputs (RS485), status input
Encoder operating voltage 5V
Encoder output current 0.5A
Counter 16 bit, binary
Limit frequency 4 million increments/s (with 4-fold evaluation)
Quadrature decoder 1, 2, or 4-fold evaluation
Zero-pulse latch 16 bit
Commands read, set, enable
Power supply 24VDC (-15%/+20%)
Supply voltage 24VDC (-15%/+20%)
Current consumption power contacts - (no power contacts)
Current consumption K-bus typ. 60mA
Bit width in process image Input: 1 x 16 bit data, 1 x 8 bit control/status
Weight approx. 85g
Permissible ambient temperature range
during operation
Permissible ambient temperature range
during storage
Permissible relative air humidity 95%, no condensation
Vibration / shock resistance
EMC immunity/emission conforms to EN61000-6-2 / EN61000-6-4
Protection class IP20
Installation position variable
Approval
DC
-25°C ... + 60°C (extended temperature range)
-40°C ... + 85°C
conforms to EN60068-2-6/ EN60068-2-27, see also Installation
instructions for enhanced mechanical load capacity [}18]
CE, cULus, ATEX [}22]
Product overview
KL5101 11Version: 3.1
Product overview
2.3 Basic Function Principles
The KL5101 incremental encoder interface terminal enables the connection of any incremental encoder to
the Bus Coupler or PLC. A 16-bit counter with a quadrature decoder and a 16-bit latch can be read, set or
enabled. In addition to the encoder inputs A, B and C, an additional latch input G1 (24V) and a gate input
G2 (24V) for locking the counter are available.
It is also possible for the 16-bit up/down counter operating mode to be selected. In this mode, input B is the
counter input.
1, 2, or 4-fold evaluation of the encoder signals A, B, C in simple or complementary form can be
parameterized via the fieldbus.
The terminal is supplied as a 4-fold quadrature decoder with complementary evaluation of the sensor signals
A, B, C. To operate the encoder interface, the 24VDC operating voltage must be connected to the terminal
contacts in addition to the encoder inputs.
From hardware version 03 (i.e. from 18 June 1998) the KL5101 is delivered with new, additional features:
• If the incremental encoder has an alarm output, it can be connected to the status input of the KL5101.
• A period duration measurement with a resolution of 200ns can also be carried out.
Operation modes
Can be set via the feature register (default setting incremental encoder):
A, B, zero pulse incremental encoder (default)
Up/down counter with:
• A = count; the positive edges of the input pulses are counted
• B = up/down input
◦ B = 0: Up count direction
◦ B = 1: Down count direction
• C = gate input
◦ C = 0: Counter enabled
◦ C = 1: Counter is locked
Functions
• Counting
• Set counter
• Activate zero pulse and save valid value
• Determination of the period duration between two pulses with a resolution of 200ns (the time between
two positive edges of input signal A is evaluated).
• Display of a counter overflow or underflow.
Process data
The KL5101 always occupies 6bytes of input data and 6bytes of output data. The control/status byte is
located at the lowest byte offset. The data word D0/D1 contains the counter word (read/set), the data word
D3/D4 contains the latch word (read). In period duration measurement mode, the period duration is output in
D2 together with D3/D4.
LED display
The signal LEDs indicate the states of the encoder inputs A, B, C and the status input, as well as the state of
the logic inputs of the gate and the additional external latch. The RUN LED indicates cyclic data exchange
with the higher-level controller. If no process data is exchanged for 100ms, the RUN LED goes out. The
Power UE LED indicates the operating voltage for the power supply of the incremental encoder.
KL510112 Version: 3.1
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