Beckhoff KS3403 Installation Manual
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Beckhoff KS3403 Installation Manual

Beckhoff KS3403 Installation Manual

3-phase power measurement terminals
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Documentation | EN
KL3403/KS3403
3-Phase Power Measurement Terminals
2022-09-30 | Version: 3.2.0

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Summary of Contents for Beckhoff KS3403

  • Page 1 Documentation | EN KL3403/KS3403 3-Phase Power Measurement Terminals 2022-09-30 | Version: 3.2.0...

  • Page 3: Table Of Contents

    LED display .............................  10 Technical data .......................... 11 Basic function principles........................ 12 Current transformer .........................  17 2.5.1 Current transformers from Beckhoff.................  18 3 Mounting and wiring .......................... 19 Instructions for ESD protection .......................  19 Installation on mounting rails...................... 20 Disposal ............................ 22 Connection ............................
  • Page 4 Table of contents Beckhoff Identification Code (BIC) .................... 62 Support and Service........................ 64 Version: 3.2.0 KL3403/KS3403...

  • Page 5: Foreword

    , 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...

  • Page 6: Safety Instructions

    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.

  • Page 7: Documentation Issue Status

    Foreword Documentation issue status Version Comment 3.2.0 • Chapter Technical data updated • Chapter Current transformers from Beckhoff added • Chapter Disposal added • Chapter Beckhoff Identification Code (BIC) updated • Document structure updated • New title page 3.1.0 • KL3403-0333 added •...
  • Page 8 WW - week of production (calendar week) 35 - week of production 35 YY - year 04 - year of production 2004 FF - firmware version 2E - firmware version 2E HH - hardware version 03 - hardware version 03 Version: 3.2.0 KL3403/KS3403...

  • Page 9: Product Overview

    The KL3403 thus enables a comprehensive network analysis to be carried out via the fieldbus. Based on the values for voltage, current, active power, apparent power and loading condition, the plant operator can optimize the supply of a drive or a machine and protect the plant from damage and downtime. KL3403/KS3403 Version: 3.2.0...

  • Page 10: Led Display

    Several variants of the KL3403 are available. Name Comment Nominal value KL3403-0000 Standard version 1 A KS3403-0000 KL3403-0026 Like KL3403-0000, but without EMC leakage capacitor between 1 A terminal points 4/8 [} 26] and the grounding contact for the mounting rail. KL3403-0010 Power measurement terminal with higher-capacity current circuits.

  • Page 11: Technical Data

    Product overview Technical data Technical data KL3403-... / KS3403-... 0000 0010 0014 0020 0022 0025 0026 0333 Measured values U, I U, I U, I U, I U, I U, I Calculated parameters Active power, energy, power factor (cosj) Measuring voltage max.

  • Page 12: Basic Function Principles

    3 T in a 60 Hz mains system. Experience shows that this is a good compromise between measuring speed and stability. Deviations from this value are only advisable in the event of particular measurement requirements (e.g. high measuring speed, low signal frequencies or special current curves). Version: 3.2.0 KL3403/KS3403...

  • Page 13: Fig. 4 Power S(T) Curve

    The situation for the active power is different: Here, the product of effective voltage and effective current is the apparent power. KL3403/KS3403 Version: 3.2.0...

  • Page 14: Fig. 5 U(T), I(T), P(T) Curves With Phase Shift Angle Φ

    Product overview The active power is smaller than the apparent power. S: Apparent power P: Active power Q: Reactive power φ: Phase shift angle curves with phase shift angle φ Fig. 5: u curves with phase shift angle φ Version: 3.2.0 KL3403/KS3403...
  • Page 15 • power factor cos φ The KL3403 determines the following values: • active power P • effective voltage U • effective current I From these values, the required parameters can be calculated: • apparent power: • reactive power: • Power factor: KL3403/KS3403 Version: 3.2.0...

  • Page 16: Fig. 6 Four-Quadrant Representation Of Active/Reactive Power In Motor And Generator Mode

    The KL3403 can measure the frequency of the input signals at the voltage circuits (L1, L2, L3). The measurement takes 5 seconds (measuring interval). Measuring error Frequency < 70 Hz ≥ 70 Hz ≥ 75 Hz ≥ 80 Hz ≥ 90 Hz ≥ 100 Hz Measuring error < 0.0 % < 0.2 % < 0.5 % < 1.5 % < 2.0 % < 3.0 % Version: 3.2.0 KL3403/KS3403...

  • Page 17: Current Transformer

    The insulation should be designed for the maximum conductor voltage of the system to be measured! The KL3403 allows a maximum voltage of 500 V for normal operating conditions. The conductor voltage on the current side must not exceed 500  V! For higher voltages, an intermediate transformer stage should be used! KL3403/KS3403 Version: 3.2.0...

  • Page 18: Current Transformers From Beckhoff

    2.5.1 Current transformers from Beckhoff With the seamless completion of the power measurement chain from the sensor to the cloud Beckhoff enables a much simpler energy management system and at the same time optimizes the availability of machines and systems. Constant power measurement across the board allows comprehensive inline analyses to be carried out, which record any deviation and enable quick intervention.

  • Page 19: Mounting And Wiring

    • Surroundings (working place, packaging and personnel) should by grounded probably, when handling with the devices. • Each assembly must be terminated at the right hand end with a KL9010 bus end terminal, to ensure the protection class and ESD protection. Fig. 8: Spring contacts of the Beckhoff I/O components KL3403/KS3403 Version: 3.2.0...

  • Page 20: Installation On Mounting Rails

    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). Version: 3.2.0 KL3403/KS3403...

  • Page 21: Fig. 10 Disassembling Of Terminal

    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. KL3403/KS3403 Version: 3.2.0...

  • Page 22: Disposal

    Products marked with a crossed-out wheeled bin shall not be discarded with the normal waste stream. The device is considered as waste electrical and electronic equipment. The national regulations for the disposal of waste electrical and electronic equipment must be observed. Version: 3.2.0 KL3403/KS3403...

  • Page 23: Connection

    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. KL3403/KS3403 Version: 3.2.0...

  • Page 24: Wiring

    (ultrasonically welded) conductors. In this case, please note the tables concerning the wire-size width [} 25]! 3.4.2 Wiring 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! Version: 3.2.0 KL3403/KS3403...

  • Page 25: Fig. 14 High Density Terminals

    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 (see notice [} 24]) Wire stripping length 8 ... 9 mm KL3403/KS3403 Version: 3.2.0...

  • Page 26: Connection

    If you do not connect the terminal point N with the neutral conductor of your mains supply (e.g. if the KL3403 is used purely for current measurements [} 30]), terminal point N should be earthed, in order to avoid dangerous overvoltages in the event of a current transformer fault! Version: 3.2.0 KL3403/KS3403...

  • Page 27: Application Examples

    BKxxxx, BCxxxx, BXxxxx, LCxxxx, CXxxxx, KLxxxx, KSxxxx or KMxxxx from Beck- hoff. CAUTION cULus verification For the cULus verification, the Beckhoff I/O system only examined for risk of fire or electric shock (in accordance with UL508 and CSA C22.2 No. 142). CAUTION Phase voltage according to UL specifications 300 V max.

  • Page 28: Application Examples For Alternating Current

    Avoid confusing the current and voltage circuit during connection, since the direct connection of mains volt- age to the terminal points for the current transformers (typical input resistance 33 mΩ) would destroy the power measurement terminal! Fig. 17: Application example - power measurement at a machine Version: 3.2.0 KL3403/KS3403...

  • Page 29: Fig. 18 Application Example - Current Measurement At A Motor

    If you do not connect the terminal point N with the neutral conductor of your mains supply (e.g. if the KL3403 is used purely for current measurements), terminal point N should be earthed, in order to avoid dangerous overvoltages in the event of a current transformer fault! Fig. 18: Application example - current measurement at a motor KL3403/KS3403 Version: 3.2.0...

  • Page 30: Application Example For Dc

    In the example, the special type KL3403-0010 [} 11] is used with an extended current measuring range (5 A max.). The standard KL3403 type is not suitable for this application example because the current mea- suring range is too small (1A)! Version: 3.2.0 KL3403/KS3403...

  • Page 31: Application Example With Frequency Converter

    Bring the Bus Terminals system into a safe, de-energized state before starting mounting, disassembly or wiring of the Bus Terminals! The example illustrates power measurement at several three-phase motors that are controlled by a frequency converter (AC converter), e.g. at a conveyor system. Each motor is monitored by a KL3403. KL3403/KS3403 Version: 3.2.0...

  • Page 32: Fig. 20 Application Example With Frequency Converter

    Due to the electrical isolation through the three-phase transformer, the terminal points N of the power mea- surement terminals have to be grounded, in order to avoid dangerous overvoltages in the event of a fault in a current transformer! Version: 3.2.0 KL3403/KS3403...

  • Page 33: Application Example For Kl3403-0014

    Otherwise the measuring errors could be significant, since the voltage drop on this cables can be comparatively high and could result in a large error in the power calculation. KL3403/KS3403 Version: 3.2.0...
  • Page 34 A voltage drop of 60 mV / x A is typically indicated for the shunts. Examples Nominal value of the shunt 60 mV / 1 A 60 mV / 25 A 60 mV / 100 A Sample current 1 A 25 A 100 A Current output value of the terminal 25000 (0x61A8) 25000 (0x61A8) 25000 (0x61A8) Version: 3.2.0 KL3403/KS3403...

  • Page 35: Ks2000 Configuration Software

    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. KL3403/KS3403 Version: 3.2.0...

  • Page 36: Parameterization With Ks2000

    Click on the Login button. The configuration software will now load the information for the connected fieldbus station. In the example shown, this is • a BK9000 Ethernet Coupler • a KL1xx2 digital input terminal • a KL3403 Power Measurement Terminal • a KL9010 bus end terminal Version: 3.2.0 KL3403/KS3403...

  • Page 37: Fig. 23 Display Of The Fieldbus Station In Ks2000

    The right-hand KS2000 window contains a graphic display of the fieldbus station terminals. In the tree structure of the left-hand window, click on the plus-sign next to the terminal whose parameters you wish to change (item 2 in the example). Fig. 24: KS2000 branch for channel 1 of the KL3403 KL3403/KS3403 Version: 3.2.0...

  • Page 38: Settings

    Header Pos.: Position of the terminal in the Bus Terminal block. Type: Terminal type Firmware: Firmware version [} 8] installed on the terminal. Operation mode User scaling active (R32.0 [} 47]) You can activate user scaling here (default: deactivated). Version: 3.2.0 KL3403/KS3403...
  • Page 39 65535! If the calculated result does exceed 65535, the transformer ratio should be taken into account in the PLC. Measuring cycle time (R39 [} 49]) Here you can change the measuring cycle time (resolution: 1 ms) (default: 200 ms). KL3403/KS3403 Version: 3.2.0...
  • Page 40 (R5 [} 46]) to change the password. Energy consumption Here you can clear the stored energy consumption. Enter the password and click Delete. Deleting the energy consumption Once the energy consumption has been deleted, the value cannot be restored! Version: 3.2.0 KL3403/KS3403...

  • Page 41: Programming

    Output values Terminal type Nominal value (effective) Output for nominal value KL3403-0000 1.0 A 1000 KL3403-0010 5.0 A 1000 KL3403-0014 60 mV 25000 KL3403-0020 20 mA 1000 KL3403-0022 20 mA 4000 KL3403-0025 250 mA 1000 KL3403-0026 1.0 A 1000 KL3403-0333 333 mV 1000 KL3403/KS3403 Version: 3.2.0...

  • Page 42: Control And Status Bytes

    Peak active power see index 2 value 1000 0.1 Hz (measuring interval: 5 s) Frequency [} 16] 1001 Minimum current see index 0 value 1010 Minimum voltage see index 1 value 1011 Minimum active see index 2 power value further reserved Version: 3.2.0 KL3403/KS3403...
  • Page 43 Index of the measured value [} 42] that was read with input data word 1 (DataIN1 [} 41]). Register communication Control byte 1 in register communication Control byte 1 (CB1) is located in the output image [} 41], and is transmitted from the controller to the KL3403. KL3403/KS3403 Version: 3.2.0...
  • Page 44 Control byte 0). Pay attention to the assignment of the control bytes to the process input data words in process data mode. Status byte 3 (SB3) is in the input image [} 41] and is transferred from the KL3403 to the controller (configuration and application see Status byte 0). Version: 3.2.0 KL3403/KS3403...

  • Page 45: Register Overview

    If the register for the energy consumption (read via process data index [} 42] 0x4) overflows, this overflow register is incremented. 32 bits are thus available for storing the energy consumption. The overflow register for the energy consumption must be read via the register communication. KL3403/KS3403 Version: 3.2.0...
  • Page 46 EEPROM. Command 0x1020: clear all minimum and maximum values Write the value 0x1020 into the command register, in order to clear all minimum and maximum values. Version: 3.2.0 KL3403/KS3403...
  • Page 47 RAM registers and in the SEEPROM registers and are therefore retained if the terminal is restarted. The code word is reset if the terminal is restarted. R32: Feature register The feature register specifies the terminal's operation mode. KL3403/KS3403 Version: 3.2.0...
  • Page 48 The KL3403 should only take the transformer ratio into account if the calculated resulting current does not exceed the value 65535! If the calculated result does exceed 65535, the transformer ratio should be taken into account in the PLC. Version: 3.2.0 KL3403/KS3403...

  • Page 49: Examples Of Register Communication

    • 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. KL3403/KS3403 Version: 3.2.0...

  • Page 50: Example 2: Writing To An User Register

    Byte 0: Status byte Byte 1: DataIN1, high byte Byte 2: DataIN1, low byte 0x9F (1001 1111 0x12 0x35 Explanation: • The terminal returns the value of the control byte as a receipt in the status byte. Version: 3.2.0 KL3403/KS3403...
  • Page 51 Byte 0: Status byte Byte 1: DataIN1, high byte Byte 2: DataIN1, low byte 0xA0 (1010 0000 0x00 0x02 Explanation: • The terminal returns the value of the control byte as a receipt in the status byte. KL3403/KS3403 Version: 3.2.0...

  • Page 52: Reading The Process Data

    The voltage (rms value) of phase L2 is returned in process data word DataIN2. • Enter process data index 0x1 in control byte 3. The voltage (rms value) of phase L3 is returned in process data word DataIN3. Version: 3.2.0 KL3403/KS3403...
  • Page 53 The voltage (rms value) of phase L1 is returned in process data word DataIN2. • Enter 0x11 in control byte 3 (channel index 01 , process data index 0001 The voltage (rms value) of phase L2 is returned in process data word DataIN3. KL3403/KS3403 Version: 3.2.0...

  • Page 54: Sample Program For Register Communication Via Ethercat On Kl3314 Exemplary

    R32 and user scaling offset and gain (R33/ R34) similar as per KS2000. Fig. 26: Settings of KL3314 via visualization of TwinCAT 3 At least following configuration setup shall be present: [coupler (e.g. BK1120) or embedded PC] + KL3314 + KL9010. Version: 3.2.0 KL3403/KS3403...

  • Page 55: Fig. 27 Opening The *. Tnzip Archive

    TwinCAT environment above, where a pull down menu can be opened to choose a target system (by clicking right in the text field). The number blocks are placed in brackets there next to each computer name of a target system. KL3403/KS3403 Version: 3.2.0...
  • Page 56 “Change NetId...” have to be selected. The first four numbers of the NetId of the target computer must be entered; both last values are 4.1 usually. Example: ◦ NetId of project:       myComputer (123.45.67.89.1.1) ◦ Entry via „Change NetId...“:     123.45.67.89.4.1 Version: 3.2.0 KL3403/KS3403...

  • Page 57: Appendix

    • Use current transformers with a higher ratio. Measuring inaccuracies In the range 10 to 20 V, the voltage inputs of the KL3403 exhibit a small non- occur when measuring linearity (see chapter Measuring error with DC voltage measurement [} 61]). low DC voltages. KL3403/KS3403 Version: 3.2.0...

  • Page 58: Measuring Error Due To Input Overload

    If the input current exceeds the rated terminal current, the terminal also outputs the value 1414 for the peak values (which are greater than the rated current times root 2). For this interpolation points a measuring error occurs due to input overload. Version: 3.2.0 KL3403/KS3403...

  • Page 59: Fig. 30 Current And Sampling Curve For 20% Overload

    The measuring error increases with the degree of overload With increasing overload, the RMS value "I" calculated from the interpolation points still increases with the input voltage "î", but it no longer increased linearly with the input signal, and the measuring error "∆" increases quickly! KL3403/KS3403 Version: 3.2.0...

  • Page 60: Fig. 32 Increase In Measuring Error "∆" With Increasing Overload

    Appendix Fig. 32: Increase in measuring error "∆" with increasing overload The output values indicated for input overloads of 20% and 50% are typical values. They may differ to some degree, due to component tolerances between terminals. Version: 3.2.0 KL3403/KS3403...

  • Page 61: Measuring Error For Dc Voltage Measurement

    Measurements of small DC voltages may be subject to small measuring inaccuracies, since the voltage inputs are subject to a small non-linearity. Fig. 33: Measuring error for DC voltage measurement This stepped drop is approx. 1 to 2 V and typically occurs between 10 and 20 V. KL3403/KS3403 Version: 3.2.0...

  • Page 62: Fig. 34 Bic As Data Matrix Code (Dmc, Code Scheme Ecc200)

    Appendix 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.

  • Page 63: Fig. 35 Example Dmc 1P072222Sbtnk4P562D71Kel1809 Q1 51S678294

    Fig. 35: Example DMC 1P072222SBTNk4p562d71KEL1809 Q1 51S678294 An important component of the BIC is the Beckhoff Traceability Number (BTN, position 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.
  • Page 64 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: https://www.beckhoff.com You will also find further documentation for Beckhoff components there.
  • Page 65 φ................Fig. 6 Four-quadrant representation of active/reactive power in motor and generator mode ....Fig. 7 SCT current transformers - Starting point of the Beckhoff measurement chain......Fig. 8 Spring contacts of the Beckhoff I/O components ................. Fig. 9 Attaching on mounting rail......................
  • Page 67 More Information: www.beckhoff.com/KL3403 Beckhoff Automation GmbH & Co. KG Hülshorstweg 20 33415 Verl Germany Phone: +49 5246 9630 info@beckhoff.com www.beckhoff.com...

This manual is also suitable for:

Kl3403Kl3403-0000Kl3403-0010Kl3403-0014Kl3403-0020Kl3403-0022 ... Show all

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