Beckhoff KL3202 Documentation

Documentation

KL320x

Analog Input Terminals for Pt100 (RTD) or NTC10K

4.4

2019-09-10

Version:

Date:

Overview Analog Input Terminals

KL320x 3Version: 4.4

Overview Analog Input Terminals

1-, 2- and 4 channel analog input terminals for Pt100 (RTD)

• KL3201 [}11]

• KL3202 [}11]

• KL3204-0000 [}13]

4 channel analog input terminal for NTC10K

• KL3204-0030 [}14]

Table of contents

KL320x4 Version: 4.4

Table of contents

1 Foreword ....................................................................................................................................................7

1.1 Notes on the documenation...............................................................................................................7

1.2 Safety instructions .............................................................................................................................7

1.3 Documentation Issue Status..............................................................................................................9

2 Product overview.....................................................................................................................................11

2.1 Introduction......................................................................................................................................11

2.2 Technical data .................................................................................................................................15

2.3 Basic function principles ..................................................................................................................16

3 Mounting and wiring................................................................................................................................19

3.1 Installation on mounting rails ...........................................................................................................19

3.2 Installation instructions for enhanced mechanical load capacity .....................................................22

3.3 Connection system ..........................................................................................................................22

3.4 Connection and LED description .....................................................................................................26

3.5 ATEX - Special conditions (standard temperature range) ...............................................................29

3.6 ATEX - Special conditions (extended temperature range) ..............................................................30

3.7 ATEX Documentation ......................................................................................................................31

4 KS2000 Configuration software .............................................................................................................32

4.1 KS2000 - Introduction......................................................................................................................32

5 Access from the user program ..............................................................................................................34

5.1 Mapping...........................................................................................................................................34

5.1.1 KL3201 ............................................................................................................................ 34

5.1.2 KL3202 ............................................................................................................................ 35

5.1.3 KL3204, KL3204-0030..................................................................................................... 36

5.2 Terminal configuration .....................................................................................................................38

5.3 Register overview ............................................................................................................................40

5.4 General description of registers.......................................................................................................40

5.4.1 Process variables ............................................................................................................ 41

5.4.2 Type register.................................................................................................................... 41

5.4.3 Manufacturer parameters ................................................................................................ 42

5.4.4 User parameters .............................................................................................................. 42

5.4.5 Extended user area ......................................................................................................... 43

5.5 Terminal-specific register description ..............................................................................................43

5.5.1 Process variables ............................................................................................................ 43

5.5.2 Manufacturer parameters ................................................................................................ 43

5.5.3 User parameters .............................................................................................................. 44

5.5.4 Output format................................................................................................................... 45

5.6 Control and status byte....................................................................................................................46

5.6.1 Control byte for process data exchange .......................................................................... 46

5.6.2 Status byte for process data exchange ........................................................................... 46

5.6.3 Compensation.................................................................................................................. 46

5.6.4 Default setting of the registers ......................................................................................... 47

5.6.5 KL3202 as resistance input 0 to 1 kΩ.............................................................................. 47

5.7 Register communication ..................................................................................................................47

Table of contents

KL320x 5Version: 4.4

5.7.1 Register access via process data exchange ................................................................... 47

5.7.2 Example 1........................................................................................................................ 49

5.7.3 Example 2........................................................................................................................ 49

6 TwinCAT ...................................................................................................................................................50

6.1 Programming ...................................................................................................................................52

6.2 Function block FB_KL320xConfig ...................................................................................................52

7 Appendix ..................................................................................................................................................53

7.1 Support and Service ........................................................................................................................53

List of illustrations...................................................................................................................................54

Table of contents

KL320x6 Version: 4.4

Foreword

KL320x 7Version: 4.4

1 Foreword

1.1 Notes on the documenation

Copyright

The reproduction, distribution and utilization of this document as well as the communication of its contents to

others without express authorization are prohibited.

patent, utility model or design.

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.

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.

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.

Trademarks

Beckhoff

®

, TwinCAT

®

, EtherCAT

®

, EtherCATG

®

, EtherCATG10

®

, EtherCATP

®

, SafetyoverEtherCAT

®

,

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.

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.

Foreword

KL320x8 Version: 4.4

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.

Foreword

KL320x 9Version: 4.4

1.3 Documentation Issue Status

Version Comment

4.4 • Update Firmware and hardware versions

• Update chapter “Basic Function Principles”

4.3 • Update Firmware and hardware versions

• Update Technical data

• Chapter "Installation instructions for enhanced mechanical load capacity" added

• Chapter "TwinCAT" including Link to FB_KL320xConfig added

4.2 • KL3204-0030 added

4.1 • Update appendix

4.0 • Migration in ST4

• Update structure

Firmware and hardware versions

Documentation

Version

KL3201

Firmware Hardware

4.4 3G 09

4.3 3G 09

4.0 3G 08

Documentation

Version

KL3202

Firmware Hardware

4.4 3G 09

4.3 3G 09

4.0 3G 08

Documentation

Version

KL3204

Firmware Hardware

4.4 3E 05

4.3 3E 05

4.0 3E 05

Documentation

Version

KL3204-0030

Firmware Hardware

4.4 42 05

4.3 42 05

4.2 42 05

The firmware and hardware versions (delivery state) can be taken from the serial number printed on the side

of the terminal.

Syntax of the serial number

Structure of the serial number: WW YY FF HH

WW - week of production (CW, calendar week)

YY - year of production

FF - firmware version

HH - hardware version

Example with ser. no.: 47 15 1A 00:

Foreword

KL320x10 Version: 4.4

47 - week of production 47

15 - year of production 2015

1A - firmware version 1A

00 - hardware version 00

Product overview

KL320x 11Version: 4.4

2 Product overview

2.1 Introduction

KL3201, KL3202

Fig.1: KL3201

Product overview

KL320x12 Version: 4.4

Fig.2: KL3202

The KL3201 and KL3202 analog input terminals allow resistance sensors to be connected directly. The Bus

Terminal's circuitry can operate the sensors using 2-wire or 3-wire connection techniques.

Linearization over the full temperature range is realized with the aid of a microprocessor. The temperature

range can be selected freely. The Bus Terminal's standard settings are: Resolution 0.1°C in the temperature

range of PT100 sensors in 3-wire connection.

The two Run LEDs indicate data exchange with the Bus Coupler, the error LEDs show sensor faults (e.g.

broken wire).

Product overview

KL320x 13Version: 4.4

KL3204-0000

Fig.3: KL3204-0000

The KL3204-0000 analog input terminal allows resistance sensors to be connected directly. The Bus

Terminal's circuitry can handle sensors using the 2-wire technique.

Linearization over the full temperature range is realized with the aid of a microprocessor. The temperature

range can be selected freely. The Bus Terminal's standard settings are: Resolution 0.1°C over the

temperature range of PT100 sensors.

The error LEDs indicate sensor faults (e.g. a broken wire). The KL3204-0000 combines four channels in a

single housing.

Product overview

KL320x14 Version: 4.4

KL3204-0030

Fig.4: KL3204-0030

The KL3204-0030 analog input terminal enables four NTC resistance sensors to be connected directly. The

Bus Terminal's circuitry can handle sensors using the 2-wire technique. Linearization over the full

temperature range is realised with the aid of a microprocessor. The standard setting of the Bus Terminal is a

resolution of 0.1°C in the temperature range of the NTC 10kΩ sensors. The error LEDs indicate sensor

faults (e.g. a broken wire). The KL3204-0030 combines four channels in a single housing.

Product overview

KL320x 15Version: 4.4

2.2 Technical data

Technical data - KL3201, KL3202, KL3204, KL3204-0030

Technical data KL3201 KL3202 KL3204-0000 KL3204-0030

Number of inputs 1 2 4

Power supply via the K-bus

Sensor types PT100, PT200, PT500, PT1000, Ni100, Ni120, Ni1000

resistance measurement (e.g. potentiometer connection)

NTC (10kΩ)

Connection technology 2 or 3-wire (pre-set to 3-wire) 2-wire

Temperature range -200°C ... +850°C (PT sensors); -60°C ... +250°C (Ni sensors)

Resolution 0.1°C per digit (measuring range 10 to 5000Ω: 0.5°C per digit)

Electrical isolation 500 V (K-bus/signal voltage)

Conversion time ~ 200ms ~ 250ms

Measuring current typically 0.5mA typically

<0.5mA

Measuring error (total

meas. range)

< ± 1°C < ± 1C (at 0°C ... +55°C)

< ± 1.5% (when the extended temperature range is used)

Bit width in process image Input: 1 x 16bit

data

(1 x 8bit Control/

Status optional)

Input: 2 x 16bit data

(2 x 8bit Control/

Status optional)

Input: 4 x 16bit data

(4 x 8bit Control/ Status optional)

Current consumption from

K-bus

typically 60mA

Configuration no address setting, configuration via bus coupler or controller

Special features Wiring fail indication

Weight approx. 70g

Permissible ambient

temperature range

(operation)

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

temperature range)

0°C ... +55°C

Permissible ambient

temperature range

(storage)

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

Relative humidity 95%, no condensation

Vibration/ shock resistance conforms to EN 60068-2-6 / EN 60068-2-27,

see also installation instructions for enhanced mechanical

load capacity [}22]

conforms to EN

60068-2-6 / EN

60068-2-27

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

Installation position variable

Protection class IP20

Approvals CE,

cULus,

ATEX [}29]

(standard

temperature

range),

GL

CE,

cULus,

ATEX [}30] (extended temperature

range),

GL

CE

Product overview

KL320x16 Version: 4.4

2.3 Basic function principles

Properties

The KL320x analog input terminals enable resistance sensors to be connected directly. A micro-controller

within the terminal is used for converting and linearizing the resistance to a temperature value. The

temperatures are displayed as follows:

• for KL3201, KL3202, KL3204, KL3204-0030:

◦ Measuring range 10 to 5000 Ω: 1/2 °C (1 digit = 0.5 °C)

◦ Measuring range 10 to 1200 Ω: 1/10 °C (1 digit = 0.1 °C)

◦ All other measuring ranges: 1/10 °C (1 digit = 0.1 °C)

• for KL3204-0030:

◦ Measuring range -40°C to 110°C: 1/10 °C (1 digit = 0.1°C)

◦ Resistor at 0°C: 27 280Ω

Note: since there are different NTC10K types, this value characterizes the characteristic curve

stored in the KL3204-0030.

In addition to this, a broken wire or short circuit is reported to the Bus Coupler or to the controller, and

indicated by the ERROR LED.

PT100, NI100, PT200, PT500, NI120, NI1000 and PT1000 as well as NTC10K of the KL3204-0030 elements

are implemented over their full measuring ranges as resistance sensors. The terminal can be fully configured

over a fieldbus. A self-defined scaling of the output can, for instance, be performed, or the temperature

conversion can be switched off. In the latter case, the measurement is output in the range from 10Ω up to

1.2kΩ with a resolution of 1/16Ω (the internal resolution of the resistance value is 1/255Ω).

Process data output format

In the delivery state, the measured value is displayed in increments of 1/10° C in two's complement format

(integer). The complete measuring range is output for each resistance sensor. Other display types can be

selected via the feature register (e.g. sign/amount representation, Siemens output format).

Measured value Hexadecimal output Signed integer output

-250.0°C 0xF63C -2500

-200.0°C 0xF830 -2000

-100.0°C 0xFC18 -1000

-0.1°C 0xFFFF -1

0.0°C 0x0000 0

0.1°C 0x0001 1

100.0°C 0x03E8 1000

200.0°C 0x07D0 2000

500.0°C 0x1388 5000

850.0°C 0x2134 8500

Resistance limit values

• R > 400 Ω: Bits 1 and 6 (over range and error bits) in the status byte are set.

The linearization of the characteristic curve is continued with the coefficients of the upper range limit up to

the limit stop of the A/D converter (approx. 500 Ω for PT100).

• R<18 Ω: Bits 0 and 6 (under range and error bits) in the status byte are set.

The smallest negative number is displayed (0x8001 corresponds to -32767).

For over range or under range the red error LED is switched on.

Product overview

KL320x 17Version: 4.4

Process data

The process data that are transferred to the terminal bus are calculated using the following equations:

Variable Meaning

X_RL ADC value of the supply cables

X_RTD ADC value of the temperature sensor, including one supply cable

X_R ADC value of the temperature sensor

A_a, B_a Manufacturer gain and offset calibration (R17, R18)

A_h, B_h Manufacturer scaling

A_w, B_w: User scaling

Y_R Temperature sensor resistance value

Y_T measured temperature in 1/16 °C

Y_THS Temperature after manufacturer scaling (1/10 °C)

Y_TAS Temperature after user scaling

Y_AUS Process data to PLC

a) Calculation of the resistance value:

X_R = X_RTD-X_RL (1.0)

Y_R = A_a * (X_R - B_a) (1.1)

b) Curve linearization:

Y_T = a1 * Y_R2 + b1* Y_R + c1 (1.2)

or

Y_T = Y_R if output in Ω (1.3)

c) Neither user nor manufacturer scaling are active:

Y_AUS = Y_T (1.4)

d) Manufacturer scaling active (factory setting):

Y_THS = A_h * Y_T + B_h (1.5)

Y_AUS = Y_THS

e) User scaling active:

Y_TAS = A_w * Y_T + B_w (1.6)

Y_AUS = Y_TAS

f) Manufacturer and user scaling active: (1.7)

Y_1 = A_h * Y_T + B_h

Y_2 = A_w * Y_1 + B_w

Y_AUS = Y_2

Product overview

KL320x18 Version: 4.4

Fig.5: Data flow of the KL320x

Mounting and wiring

KL320x 19Version: 4.4

3 Mounting and wiring

3.1 Installation on mounting rails

WARNING

Risk of electric shock and damage of device!

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

wiring of the bus terminals!

Assembly

Fig.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 compo-

nents 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 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).

Mounting and wiring

KL320x20 Version: 4.4

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 Terminals must

be taken account of, since some types (e.g. analog Bus Terminals or digital 4-channel Bus Termi-

nals) do not or not fully loop through the power contacts. Power Feed Terminals (KL91xx, KL92xx

or EL91xx, EL92xx) interrupt the power contacts and thus represent the start of a new supply rail.

PE power contact

The power contact labeled PE can be used as a protective earth. For safety reasons this contact mates first

when plugging together, and can ground short-circuit currents of up to 125A.

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