Kendrion Kuhnke FIO User manual

Instruction Manual
Kuhnke FIO
IP20 EtherCAT I/O Modules
E 747GB-V2 17 May 2021

Table of Contents Kendrion Kuhnke Automation GmbH
2(E 747GB-V2)
17 May 2021
1 Preface ............................................................................................................................................................6
1.1 Imprint ..................................................................................................................................................6
1.2 About this Manual ................................................................................................................................6
Limitation of Liability....................................................................................................................................6
Terms of Delivery ........................................................................................................................................6
Copyright.....................................................................................................................................................6
Warranty......................................................................................................................................................6
Manual Objective and Organisation............................................................................................................7
2 Reliability, Safety.............................................................................................................................................8
2.1 Intended Use........................................................................................................................................8
2.2 Target Group of the Instruction Manual...............................................................................................8
2.3 Intended Use........................................................................................................................................8
2.4 Transport and Storage.........................................................................................................................8
2.5 Reliability..............................................................................................................................................9
2.6 Hazard and other Warnings...............................................................................................................10
2.7 Safety.................................................................................................................................................11
Project Planning ........................................................................................................................................11
Maintenance and Servicing.......................................................................................................................11
Disposal.....................................................................................................................................................12
2.8 Electromagnetic Compatibility............................................................................................................12
Definition....................................................................................................................................................12
Interference Emission................................................................................................................................12
General Notes on Installation....................................................................................................................12
Electrical Immission Safeguard.................................................................................................................12
Cable Routing and Wiring .........................................................................................................................12
Location of Installation...............................................................................................................................13
Particular Sources of Interference.............................................................................................................13
3 Introduction....................................................................................................................................................14
3.1 EtherCAT® —Ethernet Control Automation Technology..................................................................14
3.2 Kuhnke FIO (Fast Input / Output).......................................................................................................14
3.3 Kuhnke FIO —Ventura FIO...............................................................................................................15
4 System Description........................................................................................................................................16
4.1 General Service Conditions ...............................................................................................................16
4.2 Mechanical Design.............................................................................................................................16
Installation .................................................................................................................................................17
4.3 System Power Supply........................................................................................................................19
General Instructions ..................................................................................................................................19
System Power Supply...............................................................................................................................20
Earth..........................................................................................................................................................20
Bus Coupler...............................................................................................................................................21
I/O Modules...............................................................................................................................................21
4.4 Status LEDs .......................................................................................................................................23
LED "EtherCAT Run" ................................................................................................................................23
LED "In L/A", LED "Out L/A"......................................................................................................................23
LED "IO"....................................................................................................................................................23
LED "Power"..............................................................................................................................................23
5 Kuhnke FIO Modules.....................................................................................................................................24
5.1 Controller..........................................................................................................................................24

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5.1.1 Controller 113...................................................................................................................................24
5.1.2 Controller 116...................................................................................................................................25
5.2 Bus Coupler and Extender..............................................................................................................26
5.2.1 Bus Coupler......................................................................................................................................27
5.2.2 Bus Coupler DI16/DO16 ..................................................................................................................29
5.2.3 Bus Coupler DI8 DO8.......................................................................................................................33
5.2.4 Extender 2 Port ................................................................................................................................36
5.3 Digital FIO Modules..........................................................................................................................38
5.3.1 DI16/DO16 .......................................................................................................................................38
5.3.2 DI16/DO16 LS (Low Side)................................................................................................................40
5.3.3 DI16/DO8 .........................................................................................................................................42
5.3.4 DI8/DO8 ...........................................................................................................................................44
5.3.5 DI16..................................................................................................................................................46
5.3.6 DI16 2-Wire......................................................................................................................................48
5.3.7 DI32..................................................................................................................................................51
5.3.8 DO8..................................................................................................................................................53
5.3.9 DO16................................................................................................................................................55
5.3.10 DO16 2-Wire ..................................................................................................................................57
5.3.11 DO8 Relay NO 24V........................................................................................................................59
5.3.12 DO8 Relay NO 230VAC ................................................................................................................61
5.4 Analogue FIO Modules....................................................................................................................63
5.4.1 AI4 12Bit / AO4 16Bit CoE ...............................................................................................................63
5.4.2 AO4-U/I - 12-Bit..............................................................................................................................144
5.4.3 AO4-U/I - 16-Bit CoE......................................................................................................................149
5.4.4 AI4/8-U ...........................................................................................................................................157
5.4.5 AI8/16-U .........................................................................................................................................165
5.4.6 AI4-I................................................................................................................................................174
5.4.7 AI8-I................................................................................................................................................181
5.4.8 AI4-Pt/Ni/TC ...................................................................................................................................189
5.4.9 AI8-Pt/Ni/TC ...................................................................................................................................198
5.5 Counter / Posi / Drive / CAM Modules..........................................................................................210
5.5.1 Counter/Posi2 5V, Counter2 5V.....................................................................................................210
5.5.2 Counter / Encoder..........................................................................................................................225
5.5.3 Kuhnke FIO Drive Control..............................................................................................................288
5.5.4 Kuhnke FIO CAM Control ..............................................................................................................289
5.6 Mixed Modules ...............................................................................................................................290
5.6.1 MIX 02............................................................................................................................................290
5.6.2 MIX 04............................................................................................................................................300
5.7 Interface and Communication Modules.......................................................................................399
5.7.1 RS485 1 Port..................................................................................................................................399
5.7.2 RS232 2 Port..................................................................................................................................413
5.7.3 CAN Master/Slave..........................................................................................................................427
5.8 Safety Modules...............................................................................................................................442
5.8.1 Kuhnke FIO Safety PLC.................................................................................................................442
5.8.2 Kuhnke FIO Safety SDI4 SDO2.....................................................................................................443
5.8.3 Kuhnke FIO Safety SDI8 SDO2.....................................................................................................444
5.8.4 Kuhnke FIO Safety SDI16 SDO4...................................................................................................445
5.8.5 Kuhnke FIO Safety SDI16..............................................................................................................446
6 Accessories .................................................................................................................................................447

Table of Contents Kendrion Kuhnke Automation GmbH
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6.1 Power Distributor 2 x 16...................................................................................................................447
Terminals.................................................................................................................................................447
Status LEDs ............................................................................................................................................447
Function...................................................................................................................................................447
Mounting..................................................................................................................................................448
6.2 Shield Terminal................................................................................................................................449
Terminals.................................................................................................................................................449
Function...................................................................................................................................................449
Technical Data ........................................................................................................................................450
7 Configuration ...............................................................................................................................................451
7.1 CODESYS V3 (CODESYS Configurator) ........................................................................................451
Offline Configuration................................................................................................................................451
Online Configuration................................................................................................................................454
8 Appendix......................................................................................................................................................457
8.1 Technical Data (Summarised) .........................................................................................................457
System Properties of Kuhnke FIO...........................................................................................................457
Kuhnke FIO I/O Modules (General) ........................................................................................................458
8.2 Order Specifications.........................................................................................................................464
Kuhnke FIO Modules...............................................................................................................................464
Kuhnke FIO Accessories.........................................................................................................................465
9 Sales & Service ...........................................................................................................................................467

Kendrion Kuhnke Automation GmbH Modification History
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Modification history
Date
Comments / modifications
29 May 2015
Original version
31 Aug 2015
Plus chapters on AO, AI-U, AI-I
11 Nov 2015
Plus chapter on DI16/DO16 bus coupler
01 Mar 2016
Plus chapter on Counter/Posi2, new UL logo
07 Mar 2016
Analogue modules corrected
26 Apr 2016
Addition to 2-row digital terminals: L+ and L- are both internally jumpered (5.3.1)
Note on installation position added (Position)
Note added on order of modules in multi-FIO systems (Order of Modules in Multi-FIO
Systems)
Connector sleeves for Weidmüller connector (General Instructions)
06 June 2016
Chapter Relay Modules added –(5.3.9 / 5.3.12)
10 July 2016
Tables of sensor values revised (5.4)
10 Nov 2016
Chapter Thermal Modules revised (5.4.8 / 5.4.9)
25 Nov 2016
Data types modified in chapter Counter2 CounterPosi2 (5.5.1)
17 Jan 2017
Chapter Analogue Output Modules revised (5.4.2 / 5.4.3)
20 Jan 2017
Chapter General Instructions revised under connector sleeves
23 Feb 2017
Note on unused encoder signals in chapter Counter2 CounterPosi2 (5.5.1)
03 Feb 2017
Table of sensor values revised in chapter 5.4.2 / 5.4.3, UL logo added for 16/16 bus coupler
added to chapter 5.2.2
08 Mar 2017
New thermo module sub-chapters on cold point compensation and calibration (5.4.8 / 5.4.9)
21 Mar 2017
Chapter 5.4.2 AO4-U/I - 12-Bit“ revised with regard to compatibility with the module's
predecessor
25 Aug 2017
Formatting of entire Instruction Manual revised.
New FIO modules added –communication modules, chapter 5.7
Technical data of complex FIO modules added (Controller/Safety/Drive/CAM)
Old modules removed from manual (separate Instruction Manual on FIO V1 modules)
Translation
31 Aug 2017
Inserting a note for the AI-U modules
01 Dez 2017
Device "Kuhnke FIO DO8 2A" Order number 694.452.06 ID: 190485 added
02 Mar 2018
Revision of the complete manual with regard to the Low Voltage Directive.
Renaming in chapter Bus Coupler DI16 / DO16 - U24_Load to undervoltage_load and
U24_Logic to undervoltage_logic
14 Jan 2019
Mounting instructions for the potential distributor added.
Added information for recommended Ethernet cable.
03 Jul 2019
FIO Bus Coupler DI8 DO8 and DI8 DO4 added.
Info about the new Safety Modules added.
28 Jan 2020
Design change and analog module Kuhnke AI4 12Bit / AO4 16Bit CoE added
29 Jan 2021
Minor corrections in the document
30 Mar 2021
Modules DI16 2-wire and DO16 2-wire added

Preface Kendrion Kuhnke Automation GmbH
6(E 747GB-V2)
17 May 2021
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.

Kendrion Kuhnke Automation GmbH Preface
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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.

Reliability, Safety Kendrion Kuhnke Automation 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

Kendrion Kuhnke Automation GmbH Reliability, Safety
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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.

Reliability, Safety Kendrion Kuhnke Automation GmbH
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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).