Kendrion Kuhnke FIO Series User manual

Instruction Manual
Kuhnke FIO - analogue IO Modules
IP20 EtherCAT I/O Modules
E 747GB-V2 28.01.2020

Table of Contents Kendrion Kuhnke Automation GmbH
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1 Preface ............................................................................................................................................................7
1.1 Imprint ..................................................................................................................................................7
Contact Details ........................................................................................................................................7
1.2 About this Manual ................................................................................................................................7
Limitation of Liability....................................................................................................................................7
Terms of Delivery ........................................................................................................................................7
Copyright.....................................................................................................................................................7
Warranty......................................................................................................................................................7
Manual Objective and Organisation............................................................................................................8
2 Reliability, Safety.............................................................................................................................................9
2.1 Intended Use........................................................................................................................................9
2.2 Target Group of the Instruction Manual ...............................................................................................9
2.3 Intended Use........................................................................................................................................9
2.4 Transport and Storage.........................................................................................................................9
2.5 Reliability............................................................................................................................................10
2.6 Hazard and other Warnings...............................................................................................................11
2.7 Safety.................................................................................................................................................12
Project Planning ........................................................................................................................................12
Maintenance and Servicing.......................................................................................................................12
Disposal.....................................................................................................................................................13
2.8 Electromagnetic Compatibility............................................................................................................13
Definition....................................................................................................................................................13
Interference Emission................................................................................................................................13
General Notes on Installation....................................................................................................................13
Electrical Immission Safeguard.................................................................................................................13
Cable Routing and Wiring .........................................................................................................................13
Location of Installation...............................................................................................................................14
Temperature ..........................................................................................................................................14
Contamination........................................................................................................................................14
Impact and Vibration..............................................................................................................................14
Electromagnetic Interference.................................................................................................................14
Particular Sources of Interference.............................................................................................................14
Inductive Actuators ................................................................................................................................14
3 Introduction....................................................................................................................................................15
3.1 EtherCAT® —Ethernet Control Automation Technology..................................................................15
3.2 Kuhnke FIO (Fast Input / Output).......................................................................................................15
3.3 Kuhnke FIO —Ventura FIO...............................................................................................................16
4 System Description........................................................................................................................................17
4.1 General Service Conditions ...............................................................................................................17
4.2 Mechanical Design.............................................................................................................................17
Installation .................................................................................................................................................18
Position..................................................................................................................................................18
Order of Modules in Multi-FIO Systems ................................................................................................18
To Snap on a Single Module .................................................................................................................19
To Interconnect Two Modules ...............................................................................................................19
To Disconnect Two Modules .................................................................................................................19
To Take Down a Single Module ............................................................................................................19
4.3 System Power Supply........................................................................................................................20

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General Instructions ..................................................................................................................................20
System Power Supply...............................................................................................................................21
Earth..........................................................................................................................................................21
Bus Coupler...............................................................................................................................................22
I/O Modules...............................................................................................................................................22
4.4 Status LEDs .......................................................................................................................................23
LED "EtherCAT Run" ................................................................................................................................23
LED "In L/A", LED "Out L/A"......................................................................................................................24
LED "IO"....................................................................................................................................................24
LED "Power"..............................................................................................................................................24
5 Kuhnke FIO Modules.....................................................................................................................................25
5.1 Analogue FIO Modules....................................................................................................................25
5.1.1 AI4 12Bit / AO4 16Bit CoE ...............................................................................................................25
Status LEDs...........................................................................................................................................26
Functions ...............................................................................................................................................27
Configuration examples.........................................................................................................................27
Object dictionary....................................................................................................................................32
Technical data .....................................................................................................................................107
Analog inputs.......................................................................................................................................107
Analog Outputs....................................................................................................................................108
General information .............................................................................................................................108
5.1.2 AO4-U/I - 12-Bit..............................................................................................................................109
Terminals.............................................................................................................................................109
Status LEDs.........................................................................................................................................110
Function...............................................................................................................................................111
Technical Data.....................................................................................................................................113
5.1.3 AO4-U/I - 16-Bit CoE......................................................................................................................114
Terminals.............................................................................................................................................114
Status LEDs.........................................................................................................................................117
Function...............................................................................................................................................118
Technical Data.....................................................................................................................................121
5.1.4 AI4/8-U ...........................................................................................................................................122
Terminals.............................................................................................................................................122
Status LEDs.........................................................................................................................................122
Function...............................................................................................................................................123
Technical Data.....................................................................................................................................129
5.1.5 AI8/16-U .........................................................................................................................................130
Terminals.............................................................................................................................................130
Status LEDs.........................................................................................................................................130
Function...............................................................................................................................................131
Technical Data.....................................................................................................................................138
5.1.6 AI4-I................................................................................................................................................139
Terminals.............................................................................................................................................139
Status LEDs.........................................................................................................................................139
Function...............................................................................................................................................140
Technical Data.....................................................................................................................................145
5.1.7 AI8-I................................................................................................................................................146
Terminals.............................................................................................................................................146
Status LEDs.........................................................................................................................................146

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Function...............................................................................................................................................147
Technical Data.....................................................................................................................................153
5.1.8 AI4-Pt/Ni/TC ...................................................................................................................................154
Terminals.............................................................................................................................................154
Status LEDs.........................................................................................................................................154
Function...............................................................................................................................................155
Technical Data.....................................................................................................................................162
5.1.9 AI8-Pt/Ni/TC ...................................................................................................................................163
Terminals.............................................................................................................................................163
Status LEDs.........................................................................................................................................163
Function...............................................................................................................................................164
Technical Data.....................................................................................................................................174
6 Accessories .................................................................................................................................................175
6.1 Power Distributor 2 x 16...................................................................................................................175
Terminals.................................................................................................................................................175
Status LEDs ............................................................................................................................................175
Function...................................................................................................................................................175
Mounting..................................................................................................................................................176
Technical Data.....................................................................................................................................176
Power Distributor 2 x 16 ......................................................................................................................176
6.2 Shield Terminal................................................................................................................................177
Terminals.................................................................................................................................................177
Function...................................................................................................................................................177
Technical Data ........................................................................................................................................178
Shield Terminal 2x8mm.......................................................................................................................178
Shield Terminal 14mm.........................................................................................................................178
7 Configuration ...............................................................................................................................................179
7.1 CODESYS V3 (CODESYS Configurator) ........................................................................................179
Offline Configuration................................................................................................................................179
Online Configuration................................................................................................................................182
8 Appendix......................................................................................................................................................185
8.1 Technical Data (Summarised) .........................................................................................................185
System Properties of Kuhnke FIO...........................................................................................................185
Bus Coupler .......................................................................................................................................185
Kuhnke FIO bus coupler......................................................................................................................185
Kuhnke FIO Bus Coupler DI16/DO16..................................................................................................185
Kuhnke FIO Bus Coupler DI8 DO8......................................................................................................186
Kuhnke FIO Bus Coupler DI8 DO4......................................................................................................186
Kuhnke FIO I/O Modules (General) ........................................................................................................186
Extender .............................................................................................................................................187
Kuhnke FIO Extender 2 Port ...............................................................................................................187
Controller............................................................................................................................................187
Kuhnke FIO Controller 113..................................................................................................................187
Kuhnke FIO Controller 116..................................................................................................................187
Digital FIO Modules ...........................................................................................................................187
Kuhnke FIO DI16/DO16 1ms/0.5A......................................................................................................187
Kuhnke FIO DI16/DO16 5ms/0.5A ......................................................................................................187
Kuhnke FIO DI16/DO16 1ms/0.5A LS.................................................................................................187

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Kuhnke FIO DI32 1ms.........................................................................................................................187
Kuhnke FIO DI16 1ms.........................................................................................................................187
Kuhnke FIO DI16/DO8 1ms/1A ...........................................................................................................187
Kuhnke FIO DI8/DO8 1ms/0.5A ..........................................................................................................187
Kuhnke FIO DI8/DO8 5ms/0.5A ..........................................................................................................188
Kuhnke FIO DO16 0.5A.......................................................................................................................188
Kuhnke FIO DO8 1A............................................................................................................................188
Kuhnke FIO DO8 2A............................................................................................................................188
Kuhnke FIO DO8 NO Relay 24V.........................................................................................................188
Kuhnke FIO DO8 NO Relay 230 VAC.................................................................................................188
Analogue FIO Modules......................................................................................................................188
Kuhnke FIO AO4, 16-Bit......................................................................................................................188
Kuhnke FIO AO4, 12-Bit......................................................................................................................189
Kuhnke FIO AI4/8-U 13-Bit..................................................................................................................189
Kuhnke FIO AI8/16-U 13-Bit................................................................................................................189
Kuhnke FIO AI4-I 12-Bit.......................................................................................................................189
Kuhnke FIO AI8-I 12-Bit.......................................................................................................................189
Kuhnke FIO AI4-Pt/Ni/TC 16-Bit..........................................................................................................189
Kuhnke FIO AI8-Pt/Ni/TC 16-Bit..........................................................................................................190
Mixed I/O Modules .............................................................................................................................190
Kuhnke FIO MIX 02.............................................................................................................................190
Counter / Posi / Drive / CAM Modules ............................................................................................190
Counter2 5V.........................................................................................................................................190
Kuhnke FIO CounterPosi2 5V .............................................................................................................190
Kuhnke FIO Drive Control....................................................................................................................190
Kuhnke FIO CAM Control....................................................................................................................190
Interface and Communication Modules ..........................................................................................191
Kuhnke FIO RS485 1 Port...................................................................................................................191
Kuhnke FIO RS232 2 Port...................................................................................................................191
Kuhnke FIO CAN Master/Slave...........................................................................................................191
FIO Safety Modules ...........................................................................................................................191
Kuhnke FIO Safety PLC ......................................................................................................................191
Kuhnke FIO Safety SDI4/SDO2 ..........................................................................................................191
8.2 Order Specifications.........................................................................................................................192
Kuhnke FIO Modules...............................................................................................................................192
Kuhnke FIO Accessories.........................................................................................................................193
9 Sales & Service ...........................................................................................................................................195

Preface Kendrion Kuhnke Automation GmbH
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Modification history
Date
Comments / modifications
25 Aug 2017
Source version after separation of the instructions into categories and translation
31 Aug 2017
Inserting a note for the AI-U modules
14 Jan 2019
Mounting instructions for the potential distributor added
18 Dec 2019
Design change
21 Jan 2020
Analog module Kuhnke FIO AI4 12Bit /AO4 16Bit CoE added

Kendrion Kuhnke Automation GmbH Vorwort
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1 Preface
1.1 Imprint
Contact Details
Kendrion Kuhnke Automation GmbH
Industrial Control Systems
Lütjenburger Straße 101
D-23714 Malente, Deutschland
Phone: [phone]
Fax: [phone]
Email: [e-mail]
Web: http://kuhnke.kendrion.com
1.2 About this Manual
This technical information is primarily directed to system designers, project engineers and device
developers. It does not contain any availability information. We reserve the rights for errors, omissions and
modifications. Pictures are similar.
Limitation of Liability
Specifications are for description only and are not to be understood as guaranteed product properties in a
legal sense. Exact properties and characteristics shall be agreed in the specific contract. Claims for
damages against us - on whatever grounds - are excluded, except in instances of deliberate intent or gross
negligence on our part.
Terms of Delivery
The general conditions of sales and service of Kendrion Kuhnke Automation GmbH shall apply.
Copyright
© Kendrion Kuhnke Automation GmbH
This instruction manual is proprietary and protected by copyright.
No part of this document may be reproduced or copied in any way or by any means except expressly
permitted in writing by Kendrion Kuhnke Automation GmbH.
Microsoft®, Windows® and the Windows® logo are registered trademarks of Microsoft Corp. in the USA and
other countries. EtherCAT® is a registered trademark and patented technology, licenced by Beckhoff
Automation GmbH, Germany. Further information about the PLCopen organisation is available at
www.plcopen.org. CiA® and CANopen® are registered joint brands of CAN in Automation e.V. Title to all
companies and company names mentioned heron as well as to products and product names is held by the
respective enterprises.
CODESYS V3©is a product of 3S-Smart Software GmbH.
Warranty
Warranty is subject to the provisions of the conditions of sale of Kendrion Kuhnke Automation GmbH or any
contractual agreements between the parties.

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Manual Objective and Organisation
This manual describes the EtherCAT slave IO modules of Kuhnke FIO. These modules provide the
EtherCAT master with the sensor details and operate the actuators. Other modules control the
communication with other systems.
The EtherCAT master control unit decides how to configure the network and create the control program.
This manual aims to introduce you to using the modules.
The examples are preferably based on CODESYS version 3 which has an EtherCAT master and an
EtherCAT configuration utility. The procedures may change if you are using other tools.
For in-depth knowledge of IEC 611131-3 programming, please refer to the CODESYS online help engine
and the references listed below.
CODESYS beginners may benefit from the comprehensive training offerings of 3S-Smart Software Solutions
GmbH.

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2 Reliability, Safety
2.1 Intended Use
For reasons of personal safety and to avoid material damages when working with or handling this Kuhnke
product, you are advised to take heed of the notes and information contained in this instruction manual.
2.2 Target Group of the Instruction Manual
This instruction manual contains all information necessary for the use of the described product (control
device, control terminal, software, etc.) according to instructions. It is written for qualified design, project
planning, servicing and commissioning experts. For proper understanding and error-free application of
technical descriptions, instructions for use and particularly of notes of danger and warning, extensive
knowledge of automation technology is compulsory.
2.3 Intended Use
Kuhnke's products are designed, developed and manufactured for standard industrial use. They must not be
used for any other purposes than the ones specified in the catalogue or the associated technical
documentation. Proper and safe operation depends on the products being transported, stored, lined up,
mounted, installed, put into service, operated, and serviced correctly. Ambient conditions must be within the
admissible limits. Notes and information in the associated documentation apply at all times.
2.4 Transport and Storage
At times of transport and storage, protect Kuhnke FIO Module against inadmissible exposure such as
mechanical stress, temperature, humidity and/or aggressive atmospheres. Transport and store Kuhnke FIO
Modules only in its original packaging if possible.
Verify that the contacts are neither soiled nor damaged when consigning the unit to stock or re-packaging it.
Keep and transport Kuhnke FIO Modules in a container/packaging ensuring electrostatic discharge (ESD)
compliance. Some parts of the units are sensitive to ESD and may be damaged if handled inappropriately.
Thus, best transport practice is to place open assemblies in statically shielded transport bags with a metal
coating which avoid contamination by amines, amides or silicone. When putting Kuhnke FIO Modules into
service and performing any maintenance, you should also take the appropriate precautions against
electrostatic discharge.
CAUTION
Electrostatic discharge
Destruction of or damage to the unit.
Transport and store FIO Safety I/O in its original packaging.
Ensure that the ambient conditions are as specified at all times during transport and
storage.
Handle FIO Safety I/O in a well-earthed environment (persons, place of work, packaging).
Do not touch electrically conductive parts such as data contacts. Some of the electronic
components may be destroyed if exposed to electrostatic discharge.
DANGER
Only use devices that are in perfect condition, ie that they do not show any transport
damage, fluid effects or other damage

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2.5 Reliability
Reliability of Kuhnke products is brought to the highest possible standards by extensive and cost-effective
means in their design and manufacture.
These include:
selecting high-quality components,
quality agreements with our suppliers,
actions to avoid static charges when handling MOS circuits,
worst case planning and design of all circuits,
visual inspections at various stages of fabrication,
computer-aided tests of all assemblies and their interaction in the circuit,
statistical assessment of the quality of fabrication and of all returned goods for the immediate taking
of appropriate corrective actions.

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2.6 Hazard and other Warnings
Despite the actions described in section 2.4, the occurrence of faults or errors in electronic control units -
even if most highly improbable - must be taken into consideration.
Please pay particular attention to the additional notices which we have marked by symbols throughout this
instruction manual. While some of these notices make you aware of possible dangers, others are intended
as a means of orientation. They are described further down below in descending order of importance.
Every alert and hazard warning is made up as follows:
Type and source of risk
Potential consequences of non-observance
Preventive measures
DANGER
A DANGER warning makes you aware of an immediately hazardous situation which WILL
cause a serious or fatal accident if not observed.
WARNING
A WARNING makes you aware of a potentially hazardous situation which MAY cause a
serious or fatal accident or damage to this or other devices if not observed.
CAUTION
A CAUTION alert makes you aware of a potentially hazardous situation which MAY cause
an accident or damage to this or other devices if not observed.
NOTE
A NOTE makes you aware of a potentially hazardous situation which MAY cause damage
to this or other devices if not observed.
Other Notices
Information
This symbol draws your attention to additional information concerning the use of the
described product. This may include cross references to information found elsewhere
(e.g. in other manuals).

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2.7 Safety
Our products normally become part of larger systems or installations. The information below is intended to
help you integrate the product into its environment without dangers to humans or material/equipment.
DANGER
Non-observance of the instruction manual
Measures for the prevention of dangerous faults or errors may be rendered ineffective or new
hazard sources created.
Thoroughly read the instruction manual
Take particular heed of the hazard warnings
Information
To achieve a high degree of conceptual safety in planning and installing an electronic controller,
it is essential to exactly follow the instructions given in the manual because wrong handling could
lead to rendering measures against dangers ineffective or to creating additional dangers.
Project Planning
Recommendation for 24V DC supply: Generate as electrically safely separated low voltage.
Suitable devices include split-winding transformers built in compliance with European Standard EN
60742 (corresponds to VDE 0551).
Power breakdowns or power fades: the program structure is to ensure that a defined state at restart
excludes all dangerous states.
Emergency-off installations must comply with EN 60204/IEC 204 (VDE 0113). They must be
operative at any time.
Safety and precautions regulations for qualified applications have to be complied with.
Please pay particular attention to the notices of warning which, at relevant places, will make you
aware of possible sources of dangerous mistakes or faults.
Relevant standards and VDE regulations are to be complied with in every case.
Control elements are to be installed in such a way as to exclude unintended operation.
Lay control cables such that interference (inductive or capacitive) is excluded if this interference
could influence controller operation or its functionality.
Maintenance and Servicing
Precautions regulation VBG 4.0 to be observed when measuring or checking a controller after
power-up. This applies to section 8 (Admissible deviations when working on parts) in particular.
Repairs must be carried out by specially trained Kuhnke staff only (usually in the main factory in
Malente). Warranty expires in every other case.
Only use parts approved of by Kuhnke. Only genuine Kuhnke modules must be used in modular
controllers.
Modular systems: always plug or unplug modules in a power-down state. You may otherwise
damage the modules or (possibly not immediately recognisably!) inhibit their functionality.
Always dispose of (rechargeable) batteries as hazardous waste.

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Disposal
When disposing of the FIO modules, ensure that the modules are disposed of in accordance with
the applicable environmental regulations.
Treat the packaging as recyclable paper and cardboard.
2.8 Electromagnetic Compatibility
Definition
Electromagnetic compatibility is the ability of a device to function satisfactorily in its electromagnetic
environment without itself causing any electromagnetic interference that would be intolerable to other
devices in this environment.
Of all known phenomena of electromagnetic noise, only a certain range occurs at the location of a given
device. These kinds of noise are specified in the applicable product standards.
The design and immunity to interference of programmable logic controllers are internationally governed by
standard
IEC 61131-2 which, in Europe, has been the basis for European Standard
EN 61131-2.
Information
Refer to IEC 61131-4, User's Guideline, for general installation instructions to be complied with
to ensure that hardware interface factors and the ensuing noise voltages are limited to tolerable
levels.
Interference Emission
Interfering emission of electromagnetic fields, HF compliant to EN 55011, limiting value class A, Group 1
Information
If the controller is designed for use in residential areas, high-frequency emissions must comply
with limiting value class B as described in EN 55011.Fitting the controller into earthed metal
cabinets and installing filters in the supply lines may produce a shielding compliant to the above
standard.
General Notes on Installation
As component parts of machines, facilities and systems, electronic control systems must comply with valid
rules and regulations, depending on their field of application.
General requirements concerning the electrical equipment of machines and aiming at the safety of these
machines are contained in Part 1 of European Standard EN 60204 (corresponds to VDE 0113).
Electrical Immission Safeguard
To eliminate electromagnetic interference, connect the control system to the protective earth conductor.
Practice best cable routing.
Cable Routing and Wiring
Keep power circuits separate from control circuits:

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DC voltages 60 V ... 400 V
AC voltages 25 V ... 400 V
Joint laying of control circuits is allowed for:
shielded data signals
shielded analogue signals
unshielded digital I/O lines
unshielded DC voltages < 60 V
unshielded AC voltages < 25 V
Location of Installation
Ensure that temperatures, contaminations, impact, vibration or electromagnetic interference are no
impediment to the installation.
Temperature
Consider heat sources such as general heating of rooms, sunlight, heat accumulation in assembly rooms or
control cabinets.
Contamination
Use appropriate enclosures / cabinets to ensure operation of the FIO modules in a suitable environment. It
is designed to prevent possible adverse effects of moisture, corrosive gases, liquids and conductive dust.
Operation of an impermissibly dirty module is not permitted. Cleaning the device is also prohibited.
Impact and Vibration
Consider possible influences caused by motors, compressors, transfer lines, presses, ramming machines
and vehicles.
Electromagnetic Interference
Consider electromagnetic interference from various local sources: motors, switching devices, switching
thyristors, radio-controlled devices, welding equipment, arcing, switched-mode power supplies, converters /
inverters.
Particular Sources of Interference
Inductive Actuators
Switching off inductances (such as from relays, contactors, solenoids or switching magnets) produces surge
voltages. It is necessary to reduce these extra voltages to a minimum.
Throttling elements could be diodes, Z-diodes, varistors or RC elements. Their rating should conform to the
specifications provided by the manufacturer or supplier of the actuators.

Kendrion Kuhnke Automation GmbH Introduction
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3 Introduction
3.1 EtherCAT®
1
—Ethernet Control Automation Technology
EtherCAT is the most powerful Ethernet-based fieldbus system currently available on the market.
EtherCAT puts up the top speed mark, and its flexible topology and simple configuration make it the
perfect means of controlling extremely fast processes. To give you a clue: 1000 I/Os can be
addressed in 30 μs.
Because of its high performance, the simple wiring and its open protocol support, EtherCAT is often
used as a fast motion control and I/O bus driven by an industrial PC or in conjunction with control
technology on a smaller scale. EtherCAT moves beyond the limits of conventional fieldbus systems.
Its interconnections between the controller at one end and both the I/O modules and drives at the
other are as fast as those of a backplane bus. EtherCAT controllers thus nearly act like centralised
control systems, overcoming the issue of bus transfer times that conventional fieldbus systems are
burdened with.
3.2 Kuhnke FIO (Fast Input / Output)
Kuhnke FIO is a system of modules interconnecting via the backplane bus to make up a so-called
EtherCAT network able to transfer process signals. For example, a Kuhnke FIO system may comprise
a Kuhnke FIO controller or bus coupler plus any number of Kuhnke FIO I/O modules.
The head module (controller or bus coupler) converts the physical transfer technology (twisted pair) to
LVDS (E-bus) and generates the system voltages required by the LVDS modules. The standard 100
Base Tx lines used for office network communications connect to the one side, the Kuhnke FIO I/O
modules for the process signals connect to the other. This is how the Ethernet EtherCAT protocol is
retained right through to the last I/O module. At the end of the modular device, the connection
between the forward and return lines is automatically closed, the effect being that another 100 Base
Tx line can be plugged in to connect the next EtherCAT unit to the second bus coupler port.
If the bus coupler is the last EtherCAT network station, i.e. if its RJ45 "Out" socket remains unplugged,
the connection between the forward and return lines is automatically closed.
Kuhnke FIO Controller 113 and several Kuhnke FIO I/O modules
1
EtherCAT® is a registered trademark and patented technology, licenced by Beckhoff Automation
GmbH, Germany.

Introduction Kendrion Kuhnke Automation GmbH
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3.3 Kuhnke FIO —Ventura FIO
Regular product update cycles include successive revisions of the Ventura FIO modules since 2014.
Revisions focused on improving the ESD properties and ensuring conformity with the guidelines of
ETG (power engineering association of VDE). The revised modules are therefore referred to Kuhnke
FIO or FIO V2.
Kuhnke FIO and Ventura FIO are compatible if they share the same order number. If so they are
interchangeable without having to modify the control programs.
Ventura FIO modules are controlled by a wide process model map.
Kuhnke FIO modules equipped with a controller such as the analogue modules are available as
variants compatible with the process map control methodology of the Ventura FIO modules or as
object-controlled variants (CoE - CAN over EtherCAT).
The module descriptions in this manual will make readers aware of exceptions such as the signal
range of the AO4 module.
The table below lists the visible differences between Ventura FIO and Kuhnke FIO.
Feature
Ventura FIO
Kuhnke FIO
Production date
2014, successively
Design
green dot
no dot
Module lock
green
grey
Unlock button
(connector)
green
black
LED label
EtherCAT
EtherCAT Run
EtherCAT LED
green/red
green/off
LED label (RJ45)
In, Out
In L/A, Out L/A
Module control
process image
process image
CoE
Process signal plug
extra
included
green unlock button
(including 2-pole)
black unlock button
(2-pole: screw-type)
Spring return (36-pole)
Push-in (36-pole)

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4 System Description
4.1 General Service Conditions
This section describes the general requirements of installing, wiring and troubleshooting the Kuhnke
FIO modules.
For a list of System Properties of Kuhnke FIO refer to chapter 0, page 185.
Subsequent chapters explain the specific properties of each of the modules.
4.2 Mechanical Design
The picture below shows the basic layout of the Kuhnke FIO modules.
The bus coupler and the I/O modules differ in their connectors and indicators, however.
The housing mount consists of an aluminium profile with an integral snap-on device used to snap the
module to a 35mm DIN rail. The housing trough including the optical fibres for the status indicators,
the side face and the front is made of plastic and contains the module. The optical fibres for the signal
state indicators (LEDs) are located next to the spring-assisted combi plug. They slightly protrude from
the housing and allow a clear diagnosis at a glance.

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Installation
Kuhnke FIO I/Os mount on 35 mm x 7.5 mm rails to DIN EN 50022.
Position
Mount with rail horizontally with the modules' multiple socket connectors pointing away from the wall.
To ensure that enough air gets in through the ventilation slots, leave at least 20 mm to the top and 35
mm to adjacent devices or cabinet surfaces. Leave at least 20 mm of lateral distance to third-party
units and cabinet surfaces.
Order of Modules in Multi-FIO Systems
NOTE
In order to ensure that the entire FIO system works properly, arrange the FIO modules by their
specific E-bus load, placing the modules with the highest E-bus load immediately next to the
head module (bus coupler or controller). Take account of the head module's maximum bus
load.
If possible, place the Kuhnke FIO Safety I/O modules immediately next to the head module.

Kendrion Kuhnke Automation GmbH System Description
(E 747GB-V2) 19
28. January 2020
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Uninstalling a module
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2
3
To Snap on a Single Module
Push up the module against the mounting rail from below, allowing
the metal spring to snap in between mounting rail and
mounting area as illustrated.
Push the top of the module against the mounting wall until it snaps in.
To Interconnect Two Modules
After snapping on the first module to the rail, snap on the second module about 1cm
away towards the right of the first module.
Push the second module along the rail towards the first module until you hear the locking
device snap in.
To Disconnect Two Modules
Push down the unlock button of the module that you wish to disconnect from the module to
the left of it.
With the button still pressed, push both modules away from one another until they are about 1
cm apart.
To Take Down a Single Module
Push the module up and against the metal spring located on the underside of the rail guide.
Tip the module away from the rail
as shown in the illustration.
Pull the module down and out of the mounting rail.
Rail mounting of module
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System Description Kendrion Kuhnke Automation GmbH
20 (E 747GB-V2)
28. January 2020
4.3 System Power Supply
General Instructions
Multi-connector plugs provide many connections in a tight space.
Unlock buttons make it easier to unplug larger connectors where there is little space.
Screw fittings reliably hold small connectors in place.
Note
The connectors must not be subjected to any inadmissible tension / pressure in order to avoid
excessive force transmission to the board or contact problems.
Avoid e.g. too strong pull due to too short wiring.
Spring-assisted multiple socket connectors support quick and easy wiring.
Single row
Tool: Screwdriver, 0.4 x 2.5 x 75 [mm] blade (DIN 5264-A)
Wires: 320 V / 10 A / 0.2 - 1.5 mm² (IEC)
Nominal current: 300 V / 10 A / 28 - 14 AWG (UL)
Supported wires with connector sleeves:
Wire cross section [mm2]
Connector sleeve type
0.13
0.25
0.34
0.50
0.75
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1.5
Connector sleeve w/ collar to
DIN 46 228/4
8 / 10
8 / 10
8 / 10
8 / 10
10 / 12
10 / 12
Connector sleeve w/o collar to
DIN 46 228/1
8 / 10
8 / 10
8 / 10
8 / 10
8 / 10
8 / 10
8 / 10
Stripped end [mm] / sleeve length [mm]
The spring-assisted PUSH-IN connector allows you to quickly attach the wires by direct insertion
without any tools. Just insert the connector sleeve end of the stripped solid or fine wire in the correct
opening.
Two rows:
Wires: 320V / 13.4 A / 0.14 - 1.5 mm² (IEC)
Nominal current: 300 V / 9.5 A / 26 - 16 AWG (UL)
Supported wires with connector sleeves:
Wire cross section [mm2]
Connector sleeve type
0.14
0.25
0.34
0.50
0.75
1
1.5
Connector sleeve w/ collar to
DIN 46 228/4
8 / 10
8 / 10
8 / 10
10 / 12
12 / 14
12 / 15
Connector sleeve w/o collar to
DIN 46 228/1
10 / 10
10 / 10
10 / 10
10 / 10
10 / 10
10 / 10
10 / 10
Stripped end [mm] / sleeve length [mm]
NOTE
Do not connect the power supply lines through from one Kuhnke FIO to the next. To ensure that
there is as little interference as possible, install a central power supply point and establish a star
topology of as short wires as possible between the central point and Kuhnke FIO.