Kendrion Kuhnke FIO CAM Control User manual

Instruction Manual
Kuhnke FIO
EtherCAT I/O Module in IP20
E808GB / 1023161 03.09.2020

Kendrion Kuhnke Automation GmbH Table of Contents
Kuhnke FIO CAM Control (E808GB / 1023161) 2
03.09.2020
Modifications
Modification history
Version Description / comments / modifications
19/07/2016 Original version
07/09/2016 New Download link (4.1 Download)
11/10/2017 Some names have been adapted (Ventura-> Kuhnke, Skaleo-> FIO Controller)
28/01/2020 Design change
Table of Contents
1 Preface ............................................................................................................................................................5
1.1 Imprint..................................................................................................................................................5
1.2 About this Manual ................................................................................................................................5
Limitation of Liability....................................................................................................................................5
Terms of Delivery........................................................................................................................................5
Copyright.....................................................................................................................................................5
Warranty......................................................................................................................................................5
2 Reliability, Safety.............................................................................................................................................7
2.1 Intended Use........................................................................................................................................7
2.2 Target Group of the Instruction Manual...............................................................................................7
2.3 Intended Use........................................................................................................................................7
2.4 Transport and Storage.........................................................................................................................7
2.5 Reliability..............................................................................................................................................8
2.6 Hazard and other Warnings.................................................................................................................9
2.7 Safety.................................................................................................................................................10
Project Planning ........................................................................................................................................10
Maintenance and Servicing.......................................................................................................................10
Disposal.....................................................................................................................................................11
2.8 Electromagnetic Compatibility............................................................................................................11
Definition ...................................................................................................................................................11
Interference Emission................................................................................................................................11
General Notes on Installation....................................................................................................................11
Electrical Immission Safeguard.................................................................................................................11
Cable Routing and Wiring .........................................................................................................................12
Location of Installation...............................................................................................................................12
Particular Sources of Interference.............................................................................................................12
3 Introduction....................................................................................................................................................14
3.1 Working principle of cam control units...............................................................................................14
3.1.1 From mechanical cam control units... ..............................................................................................14
3.1.2 ...to electronic cam control units.......................................................................................................14
3.1.3 Position detection.............................................................................................................................15
3.1.4 Further benefits of electronics..........................................................................................................15
3.2 Programming......................................................................................................................................15
4 Hardware.......................................................................................................................................................16
4.1 Mechanical design .............................................................................................................................16

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4.1.1 Earthing............................................................................................................................................17
4.1.2 Mounting...........................................................................................................................................18
4.2 Ports...................................................................................................................................................19
4.2.1 General information..........................................................................................................................19
4.2.2 I/O connector....................................................................................................................................19
4.2.3 CAN connector.................................................................................................................................20
5 CAM Control..................................................................................................................................................22
5.1.1 Supply voltage..................................................................................................................................22
5.1.2 Status LEDs .....................................................................................................................................22
5.1.3 Function............................................................................................................................................24
6 Software.........................................................................................................................................................26
6.1 Download...........................................................................................................................................26
6.2 Installation..........................................................................................................................................26
6.3 Start/Exit.............................................................................................................................................27
6.4 CAN USB driver.................................................................................................................................27
7 FIOCAM Creator............................................................................................................................................30
7.1 Cam programming .............................................................................................................................30
7.1.1 Editing the cams...............................................................................................................................30
7.1.2 Diagram view....................................................................................................................................32
7.2 Program .............................................................................................................................................33
7.2.1 Info ...................................................................................................................................................33
7.2.2 Exit ...................................................................................................................................................33
7.3 Project................................................................................................................................................34
7.3.1 new...................................................................................................................................................34
7.3.2 open .................................................................................................................................................34
7.3.3 save..................................................................................................................................................34
7.3.4 save as ............................................................................................................................................35
7.3.5 Settings ............................................................................................................................................35
7.4 Control................................................................................................................................................38
7.4.1 Dead-Times......................................................................................................................................38
7.4.2 Speed Change Scale .......................................................................................................................38
7.4.3 Track Masks.....................................................................................................................................39
7.4.4 Options.............................................................................................................................................40
7.5 Device................................................................................................................................................48
7.5.1 Online...............................................................................................................................................48
7.5.2 Offline...............................................................................................................................................49
7.5.3 Download .........................................................................................................................................49
7.5.4 Upload..............................................................................................................................................49
7.5.5 Erase................................................................................................................................................49
7.5.6 Parameter.........................................................................................................................................50
8 Examples.......................................................................................................................................................51
8.1 CODESYS software solution .............................................................................................................51
8.2 Time cam example.............................................................................................................................54
9 Appendix........................................................................................................................................................55
9.1 Technical data....................................................................................................................................55
9.2 Order specifications ...........................................................................................................................56
9.3 References.........................................................................................................................................57
9.4 Index ..................................................................................................................................................58
10 Sales & Service...........................................................................................................................................59

Kendrion Kuhnke Automation GmbH Vorwort
Kuhnke FIO CAM Control (E808GB / 1023161) 5
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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: +49 4523 402-0
Fax: +49 4523 402-201
Email: sales-ics@kendrion.com
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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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.

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Cable Routing and Wiring
Keep power circuits separate from control circuits:
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.

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3 Introduction
Cam control units are used wherever control actions should depend on a machine position. They are used in
machines running cyclically recurring processes.
A rotary encoder (in this case an incremental encoder) outputs the actual process values (axle position) to
the control unit which then controls the machine according to the current switch cam set up in the program.
Electronic cam control units are not only intended to replace mechanical program control mechanisms but
also designed to make their function more accurate, more generally applicable and more wear-resistant.
Operators benefit from the options of flexible manufacturing and shorter setup times. Latest electronic means
facilitate both operation and programming.
Conventional applications include:
Presses
Fillers
Glue application
Paper or foil feeding
Packaging machines
Figure 1: Kuhnke FIO CAM Control
3.1 Working principle of cam control units
When developing the electronic cam control unit, we referred to the working principle of mechanical cam
control units in order to keep understanding the method of operation and programming simple.
3.1.1 From mechanical cam control units...
A mechanical cam control unit uses a section of a circular line to actuate a push-button. This section defines
as a "cam". Reasons of construction very much restrict the number of circular lines.
3.1.2 ...to electronic cam control units
In terms of electronic cam control units, the mechanical methodology translates as: every output is a circular
line. Thus, the number of parallel circular lines is equivalent to the number of outputs.
Programming a cam is therefore based on entering the tripping and releasing points of each section. The
section between a tripping and a releasing point turns the output on.
0 90° 180° 270° 360°
Ausg. 1
Ausg. 2
Ausg. 3

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3.1.3 Position detection
An incremental encoder picks up the current machine position.
Incremental encoders provide the angular momentum signals A and B.
Changes in position are identified by counting the momentum signals.
Checking the 180° offset of signals A and B allows you to establish the sense of rotation.
Since the absolute position is unknown when the system turns on, each incremental encoder needs to be
referenced. (Meaning that changes in position cannot recognised when the system is off.)
The absolute position is made known to the control unit by defining a home position which can be found
either by means of marker switches or by means of the incremental encoder's reference impulse (index).
3.1.4 Further benefits of electronics
A large number of cams with accurate trigger and release points can be programmed for every
output.
Once programmed, a cam can be easily changed or deleted.
If a new cam overlaps an existing one, both cams are joined to make up a single cam.
If a new cam is contained in a previous cam already, the new cam will be ignored.
Once programmed, a cam can be copied to other cam control units.
Physical dead times of actuators can be levelled out by the adjustable dead time compensation
feature.
Time cams enable the use of cams with constant times which solely depend on the triggering edge.
3.2 Programming
Programs can be created by various means, as appropriate. Use them to
create, test and optimise programs,
check them in online mode,
copy them within the same cam control unit,
copy them from one cam control unit to another,
save them.

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4 Hardware
4.1 Mechanical design
The picture below illustrates the basic layout of the Kuhnke FIO modules:
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.
Figure 2 Module layout
Unlock button
Status LEDs
Shield-to-housing
mount connector
Module lock and E-
bus
DIN rail mount and
functional earth
Ventilation slots
Signal state indicators
(LEDs)
Grip
Label clip
Slot for spring-
assisted combi
plug

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4.1.1 Earthing
Connect the Kuhnke FIO modules to earth by attaching the metal housing to functional earth.
Since the functional earth connector dissipates HF currents, it is of utmost importance for the module's noise
immunity.
HF interference is dissipated from the electronics board to the metal housing. The metal housing therefore
needs to be suitably connected to a functional earth connector.
You will normally have to ensure that
the connection between module housing and DIN rail conducts well,
the connection between DIN rail and switching cabinet conducts well,
the switching cabinet is safely connected to earth.
In special cases you may attach the earth wire straight to the module.
NOTE
Earth wires should be short and have a large surface (copper mesh). Refer to
http://de.wikipedia.org/wiki/ground_(electronics) or a similar source for further details
F
i
Figure 4: Aluminium profile

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1
2
Unlock button
Figure6: Uninstalling a module
1
2
3
4.1.2 Mounting
Kuhnke's FIO modules are intended for mounting rail installation (DIN EN 50022, 35 x 7.5 mm).
4.1.2.1 To snap on a single module
1. 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.
2. Push the top of the module against the mounting wall until it snaps in.
4.1.2.2 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.
4.1.2.3 To disconnect two modules
Push down the unlock button (see Figure6) of the module that you wish to disconnect from the
module to the left of it.
Push both module away from one another until they are about 1 cm apart.
4.1.2.4 To take down a single module
1. Push the module up and against the metal spring located on the underside of the rail guide.
2. Tip the module away from the rail as shown in the illustration.
3. Pull the module down and out of the mounting rail.
Figure 5: Rail mounting of module

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4.2 Ports
4.2.1 General information
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.
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 [mm
2
]
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
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.
4.2.2 I/O connector
Both the system power supply and the I/Os connect to the same 36-pole module terminal block.
Figure 7: Two-row push-In connector with releasing lever

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4.2.3 CAN connector
The CAN bus connects to the front of the module by means of a 4-pole Molex Micro-Fit Connector 3.0 TM.
Connector (supplier: Farnell)
43025-0400: female Micro FIT 3.0
43030-0010: crimp socket PK100
MOLEX-79516-1043-MICRO-PASS 4WAY CABLE ASSEMBLY 3M
You may use a CAN to USB adapter to connect the CAN bus to the programming PC. (Source:
http://www.canusb.com/
You may also need to adapt the D-SUB connectors to Micro-Fit.
Pin
Function
1
2
CAN_L
3
CAN_GND
4
5
6
7
CAN_H
8
9
Housing
Earth (GND)
Information
Please note that both ends of CAN cables require a 120Ω termination
between CAN_L and
CAN_H.
GND CAN_
L
CAN_
GND CAN_
H
Figure 8: 4-pole male to female CAN connector
Figure 9: CAN to USB adapter (Lawicel)
This manual suits for next models
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