Kendrion Ventura FIO User manual

Instruction Manual
Kuhnke FIO –Counter - Mixed Modules
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 ............................................................................................................................................................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

Kendrion Kuhnke Automation GmbH Table of Contents
(E 747GB-V2)3
17 May 2021
General Instructions ..................................................................................................................................20
System Power Supply...............................................................................................................................21
Earth..........................................................................................................................................................21
Bus Coupler...............................................................................................................................................22
I/O Modules...............................................................................................................................................22
4.4 Status LEDs .......................................................................................................................................24
LED "EtherCAT Run" ................................................................................................................................24
LED "In L/A", LED "Out L/A"......................................................................................................................24
LED "IO"....................................................................................................................................................24
LED "Power"..............................................................................................................................................24
5 Kuhnke FIO Modules.....................................................................................................................................25
5.1 Counter / Posi / Drive / CAM Modules............................................................................................25
5.1.1 Counter/Posi2 5V, Counter2 5V.......................................................................................................25
Terminals...............................................................................................................................................25
Status LEDs...........................................................................................................................................26
Function.................................................................................................................................................27
Examples...............................................................................................................................................35
Technical Data.......................................................................................................................................39
5.1.2 Counter / Encoder............................................................................................................................40
Front view and I/O connection...............................................................................................................40
Status LEDs...........................................................................................................................................41
Function.................................................................................................................................................43
Module configuration .............................................................................................................................43
Configuration - Overview of pluggable modules....................................................................................43
Encoder interface...................................................................................................................................44
Encoder interface configuration –Incremental encoder........................................................................44
Encoder interface configuration –SSI Encoder ....................................................................................45
Encoder interface configuration –ENDAT Encoder..............................................................................46
Encoder interface configuration –Event counter ..................................................................................47
Encoder interface configuration –User-defined units ...........................................................................48
Object dictionary....................................................................................................................................49
Technical Data.....................................................................................................................................102
5.1.3 Kuhnke FIO Drive Control..............................................................................................................103
Technical Data.....................................................................................................................................103
5.1.4 Kuhnke FIO CAM Control ..............................................................................................................104
Technical Data.....................................................................................................................................104
5.2 Mixed Modules ...............................................................................................................................105
5.2.1 MIX 02............................................................................................................................................105
Terminals.............................................................................................................................................105
Status LEDs.........................................................................................................................................106
Function (CoE Variant)........................................................................................................................106
Technical Data.....................................................................................................................................114
5.2.2 MIX 04............................................................................................................................................115
Front view and I/O connection.............................................................................................................115
Status LEDs.........................................................................................................................................116
Function...............................................................................................................................................117
Module configuration ...........................................................................................................................118
Configuration - Overview of pluggable modules..................................................................................119
Encoder interface.................................................................................................................................120

Table of Contents Kendrion Kuhnke Automation GmbH
4(E 747GB-V2)
17 May 2021
Encoder interface configuration –Incremental encoder......................................................................120
Encoder interface configuration –SSI Encoder ..................................................................................121
Encoder interface configuration –ENDAT Encoder............................................................................122
Encoder interface configuration –Event counter ................................................................................123
Encoder interface configuration –User-defined units .........................................................................124
Analogue interface configuration –Analogue inputs...........................................................................125
Analogue interface configuration –Analogue outputs.........................................................................126
Object dictionary..................................................................................................................................127
Technical Data.....................................................................................................................................214
6 Accessories .................................................................................................................................................215
6.1 Power Distributor 2 x 16...................................................................................................................215
Terminals.................................................................................................................................................215
Status LEDs ............................................................................................................................................215
Function...................................................................................................................................................215
Mounting..................................................................................................................................................216
Technical Data.....................................................................................................................................216
Power Distributor 2 x 16 ......................................................................................................................216
6.2 Shield Terminal................................................................................................................................217
Terminals.................................................................................................................................................217
Function...................................................................................................................................................217
Technical Data ........................................................................................................................................218
Shield Terminal 2x8mm.......................................................................................................................218
Shield Terminal 14mm.........................................................................................................................218
7 Configuration ...............................................................................................................................................219
7.1 CODESYS V3 (CODESYS Configurator) ........................................................................................219
Offline Configuration................................................................................................................................219
Online Configuration................................................................................................................................222
8 Appendix......................................................................................................................................................225
8.1 Technical Data (Summarised) .........................................................................................................225
System Properties of Kuhnke FIO...........................................................................................................225
Bus Coupler .......................................................................................................................................225
Kuhnke FIO bus coupler......................................................................................................................225
Kuhnke FIO Bus Coupler DI16/DO16..................................................................................................225
Kuhnke FIO Bus Coupler DI8 DO8......................................................................................................226
Kuhnke FIO Bus Coupler DI8 DO4......................................................................................................226
Kuhnke FIO I/O Modules (General) ........................................................................................................226
Extender .............................................................................................................................................227
Kuhnke FIO Extender 2 Port ...............................................................................................................227
Controller............................................................................................................................................227
Kuhnke FIO Controller 113..................................................................................................................227
Kuhnke FIO Controller 116..................................................................................................................227
Digital FIO Modules ...........................................................................................................................227
Kuhnke FIO DI16/DO16 1ms/0.5A ......................................................................................................227
Kuhnke FIO DI16/DO16 5ms/0.5A ......................................................................................................227
Kuhnke FIO DI16/DO16 1ms/0.5A LS.................................................................................................227
Kuhnke FIO DI16/DO8 1ms/1A ...........................................................................................................227
Kuhnke FIO DI8/DO8 1ms/0.5A ..........................................................................................................227
Kuhnke FIO DI8/DO8 5ms/0.5A ..........................................................................................................227

Kendrion Kuhnke Automation GmbH Table of Contents
(E 747GB-V2)5
17 May 2021
Kuhnke FIO DI16 1ms.........................................................................................................................228
Kuhnke FIO DI16 2-wire......................................................................................................................228
Kuhnke FIO DI32 1ms.........................................................................................................................228
Kuhnke FIO DO8 1A............................................................................................................................228
Kuhnke FIO DO8 2A............................................................................................................................228
Kuhnke FIO DO16 0.5A.......................................................................................................................228
Kuhnke FIO DO16 2-wire ....................................................................................................................228
Kuhnke FIO DO8 NO Relay 24V.........................................................................................................228
Kuhnke FIO DO8 NO Relay 230 VAC.................................................................................................228
Analogue FIO Modules......................................................................................................................228
Kuhnke FIO AI4, 12 Bit / AO4, 16Bit ...................................................................................................228
Kuhnke FIO AO4, 16-Bit......................................................................................................................229
Kuhnke FIO AO4, 12-Bit......................................................................................................................229
Kuhnke FIO AI4/8-U 13-Bit..................................................................................................................229
Kuhnke FIO AI8/16-U 13-Bit................................................................................................................229
Kuhnke FIO AI4-I 12-Bit.......................................................................................................................229
Kuhnke FIO AI8-I 12-Bit.......................................................................................................................229
Kuhnke FIO AI4-Pt/Ni/TC 16-Bit..........................................................................................................230
Kuhnke FIO AI8-Pt/Ni/TC 16-Bit..........................................................................................................230
Mixed I/O Modules .............................................................................................................................230
Kuhnke FIO MIX 02.............................................................................................................................230
Counter / Posi / Drive / CAM Modules ............................................................................................230
Counter2 5V.........................................................................................................................................230
Kuhnke FIO CounterPosi2 5V .............................................................................................................230
Kuhnke FIO Drive Control....................................................................................................................231
Kuhnke FIO CAM Control....................................................................................................................231
Interface and Communication Modules ..........................................................................................231
Kuhnke FIO RS485 1 Port...................................................................................................................231
Kuhnke FIO RS232 2 Port...................................................................................................................231
Kuhnke FIO CAN Master/Slave...........................................................................................................231
FIO Safety Modules ...........................................................................................................................231
Kuhnke FIO Safety PLC ......................................................................................................................231
Kuhnke FIO Safety SDI4/SDO2 ..........................................................................................................231
8.2 Order Specifications.........................................................................................................................232
Kuhnke FIO Modules...............................................................................................................................232
Kuhnke FIO Accessories.........................................................................................................................233
9 Sales & Service ...........................................................................................................................................235

Preface Kendrion Kuhnke Automation GmbH
6(E 747GB-V2)
17 May 2021
Modification history
Date
Comments / modifications
25 Aug 2017
Source version after separation of the instructions into categories and translation
14 Jan 2019
Mounting instructions for the potential distributor added
28 Jan 2020
Design change
04 Feb 2021
Minor corrections in the document

Kendrion Kuhnke Automation GmbH Vorwort
(E 747GB-V2)7
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.

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

Kendrion Kuhnke Automation GmbH Reliability, Safety
(E 747GB-V2)9
17 May 2021
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

Reliability, Safety Kendrion Kuhnke Automation GmbH
10 (E 747GB-V2)
17 May 2021
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.