Kuhnke FIO (V2) User manual

Instruction Manual
Kendrion Kuhnke Automation GmbH
Manual
Kuhnke FIO (V2)
EtherCAT I/O modules in IP20
E 747-1 GB 11/25/2016

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Table of Contents
1 Preface ................................................................................................................................................. 6
1.1 Imprint ....................................................................................................................................... 6
1.2 About this Manual ..................................................................................................................... 6
1.2.1 Target group............................................................................................................................ 6
1.2.2 Limitation of Liability................................................................................................................ 6
1.2.3 Terms of Delivery.................................................................................................................... 6
1.2.4 Copyright................................................................................................................................. 6
1.2.5 Warranty.................................................................................................................................. 7
1.2.6 Literature................................................................................................................................. 7
1.3 Reliability, Safety....................................................................................................................... 8
1.3.1 Intended Use........................................................................................................................... 8
1.3.2 Target Group of the Instruction Manual .................................................................................. 8
1.3.3 Intended Use........................................................................................................................... 8
1.3.4 Reliability................................................................................................................................. 8
1.3.5 Hazard and other Warnings .................................................................................................... 9
1.3.6 Other Notices .......................................................................................................................... 9
1.3.7 Safety...................................................................................................................................... 9
1.3.8 Electromagnetic Compatibility............................................................................................... 10
2 Introduction......................................................................................................................................... 13
2.1 EtherCAT® — Ethernet Control Automation Technology....................................................... 13
2.2 Kuhnke FIO (Fast Input Output).............................................................................................. 13
2.3 Kuhnke FIO — Ventura FIO.................................................................................................... 14
3 System Description............................................................................................................................. 15
3.1 General conditions of use ....................................................................................................... 15
3.2 Mechanical Design.................................................................................................................. 15
3.2.1 Earth...................................................................................................................................... 15
3.2.2 Installation............................................................................................................................. 16
3.3 System power supply.............................................................................................................. 18
3.3.1 General.................................................................................................................................. 18
3.3.2 Bus coupler ........................................................................................................................... 19
3.3.3 I/O-Modules........................................................................................................................... 19
3.4 Status LEDs ........................................................................................................................... 21
3.4.1 LED "EtherCAT Run" ............................................................................................................ 21
3.4.2 LED "In L/A", LED "Out L/A".................................................................................................. 21
3.4.3 LED "IO"................................................................................................................................ 21
3.4.4 LED "Power".......................................................................................................................... 21
4 Modules .............................................................................................................................................. 22
4.1 Bus Coupler ............................................................................................................................ 22
4.1.1 Terminals............................................................................................................................... 22
4.1.2 Status LEDs .......................................................................................................................... 22
4.1.3 Function................................................................................................................................. 23
4.1.4 Technical Data ...................................................................................................................... 23
4.2 Bus coupler DI16/DO16.......................................................................................................... 24
4.2.1 Terminals............................................................................................................................... 24
4.2.2 Status LEDs .......................................................................................................................... 25
4.2.3 Function................................................................................................................................. 26
4.2.4 Technical Data ...................................................................................................................... 26
4.3 DI8/DO8 .................................................................................................................................. 27

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4.3.1 Terminals............................................................................................................................... 27
4.3.2 Status LEDs .......................................................................................................................... 27
4.3.3 Function................................................................................................................................. 28
4.3.4 Technical data....................................................................................................................... 28
4.4 DI16/DO16 .............................................................................................................................. 29
4.4.1 Terminals............................................................................................................................... 29
4.4.2 Status LEDs .......................................................................................................................... 29
4.4.3 Function................................................................................................................................. 30
4.4.4 Technical Data ...................................................................................................................... 30
4.5 DI16/DO8 ................................................................................................................................ 31
4.5.1 Terminals............................................................................................................................... 31
4.5.2 Status LEDs .......................................................................................................................... 31
4.5.3 Function................................................................................................................................. 32
4.5.4 Technical data....................................................................................................................... 32
4.6 DI16/DO16 LS (Low side)....................................................................................................... 33
4.6.1 Terminals............................................................................................................................... 33
4.6.2 Status LEDs .......................................................................................................................... 33
4.6.3 Function................................................................................................................................. 34
4.6.4 Technical data....................................................................................................................... 34
4.7 DI32......................................................................................................................................... 35
4.7.1 Terminals............................................................................................................................... 35
4.7.2 Status LEDs .......................................................................................................................... 35
4.7.3 Function................................................................................................................................. 36
4.7.4 Technical data....................................................................................................................... 36
4.8 DI16......................................................................................................................................... 37
4.8.1 Terminals............................................................................................................................... 37
4.8.2 Status LEDs .......................................................................................................................... 37
4.8.3 Function................................................................................................................................. 38
4.8.4 Technical data....................................................................................................................... 38
4.9 DO16....................................................................................................................................... 39
4.9.1 Terminals............................................................................................................................... 39
4.9.2 Status LEDs .......................................................................................................................... 39
4.9.3 Function................................................................................................................................. 40
4.9.4 Technical data....................................................................................................................... 40
4.10 DO8 ..................................................................................................................................... 41
4.10.1 Terminals............................................................................................................................. 41
4.10.2 Status LEDs ........................................................................................................................ 41
4.10.3 Function............................................................................................................................... 42
4.10.4 Technical data..................................................................................................................... 42
4.11 DO8 Relay NO 24V............................................................................................................. 43
4.11.1 Terminals............................................................................................................................. 43
4.11.2 Status LEDs ........................................................................................................................ 43
4.11.3 Function............................................................................................................................... 44
4.11.4 Technical data..................................................................................................................... 44
4.12 DO8 Relay NO 230 VAC..................................................................................................... 45
4.12.1 Terminals............................................................................................................................. 45
4.12.2 Status LEDs ........................................................................................................................ 45
4.12.3 Function............................................................................................................................... 46
4.12.4 Technical data..................................................................................................................... 46
4.13 CounterPosi2 5V, Counter2 5V........................................................................................... 47

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4.13.1 Terminals............................................................................................................................. 47
4.13.2 Status LEDs ........................................................................................................................ 48
4.13.3 Function............................................................................................................................... 49
4.13.4 Examples............................................................................................................................. 58
4.13.5 Technical Data .................................................................................................................... 63
4.14 Extender 2 Port.................................................................................................................... 64
4.14.1 Terminals............................................................................................................................. 64
4.14.2 Status LEDs ........................................................................................................................ 65
4.14.3 Function............................................................................................................................... 65
4.14.4 Technical data..................................................................................................................... 66
4.15 MIX 02 ................................................................................................................................. 67
4.15.1 Terminals............................................................................................................................. 67
4.15.2 Status LEDs ........................................................................................................................ 68
4.15.3 Function (CoE-variant)........................................................................................................ 69
4.15.4 Technical data..................................................................................................................... 76
4.16 AO4-U/I................................................................................................................................ 77
4.16.1 Terminals............................................................................................................................. 77
4.16.2 Status LEDs ........................................................................................................................ 77
4.16.3 Function............................................................................................................................... 78
4.16.4 Function 694 442 02 Kuhnke FIO AO4 12Bit...................................................................... 79
4.16.5 Function 694 442 52 Kuhnke FIO AO4 16Bit...................................................................... 81
4.16.6 Technical data..................................................................................................................... 86
4.17 AI4/8-U ................................................................................................................................ 87
4.17.1 Terminals............................................................................................................................. 87
4.17.2 Status LEDs ........................................................................................................................ 87
4.17.3 Function............................................................................................................................... 88
4.17.4 Function 694 441 52 Kuhnke FIO AI4/8-U.......................................................................... 89
4.17.5 Technical data..................................................................................................................... 94
4.18 AI8/16-U .............................................................................................................................. 95
4.18.1 Terminals............................................................................................................................. 95
4.18.2 Status LEDs ........................................................................................................................ 95
4.18.3 Function............................................................................................................................... 96
4.18.4 Function 694 441 53 Kuhnke FIO AI8/16-U........................................................................ 97
4.18.5 Technical data................................................................................................................... 103
4.19 AI4-I................................................................................................................................... 104
4.19.1 Terminals........................................................................................................................... 104
4.19.2 Status LEDs ...................................................................................................................... 104
4.19.3 Function............................................................................................................................. 105
4.19.4 Function 694 441 51 Kuhnke FIO AI4-I 12Bit................................................................... 106
4.19.5 Technical data................................................................................................................... 111
4.20 AI8-I................................................................................................................................... 112
4.20.1 Terminals........................................................................................................................... 112
4.20.2 Status LEDs ...................................................................................................................... 112
4.20.3 Function............................................................................................................................. 113
4.20.4 Function 694 441 51 Kuhnke FIO AI8-I 12Bit................................................................... 114
4.20.5 Technical data................................................................................................................... 120
4.21 AI4-Pt/Ni/TC ...................................................................................................................... 121
4.21.1 Terminals........................................................................................................................... 121
4.21.2 Status LEDs ...................................................................................................................... 121
4.21.3 Function............................................................................................................................. 122

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4.21.4 Function 694 443 57 Kuhnke FIO AI4-Pt/Ni/TC................................................................ 123
4.21.5 Technical data................................................................................................................... 130
4.22 AI8- Pt/Ni/TC ..................................................................................................................... 131
4.22.1 Terminals........................................................................................................................... 131
4.22.2 Status LEDs ...................................................................................................................... 131
4.22.3 Function............................................................................................................................. 132
4.22.4 Function 694 443 58 Kuhnke FIO AI8-Pt/Ni/TC................................................................ 133
4.22.5 Technical data................................................................................................................... 140
5 Accessories ...................................................................................................................................... 141
5.1 Potential distributor 2 x 16 .................................................................................................... 141
5.1.1 Terminals............................................................................................................................. 141
5.1.2 Status LEDs ........................................................................................................................ 141
5.1.3 Function............................................................................................................................... 141
5.1.4 . Technical data................................................................................................................... 141
5.2 Shield connection terminal block .......................................................................................... 142
5.2.1 Terminals............................................................................................................................. 142
5.2.2 Function............................................................................................................................... 142
5.2.3 Technical data..................................................................................................................... 142
6 Configuration .................................................................................................................................... 143
6.1 CoDeSys V2 (Beckhoff Configurator)................................................................................... 143
6.1.1 Offline Configuration............................................................................................................ 143
6.1.2 Online Configuration............................................................................................................ 146
6.2 CODESYS V3 (CODESYS Configurator)............................................................................. 147
6.2.1 Offline Configuration............................................................................................................ 147
6.2.2 Online Configuration............................................................................................................ 150
7 Appendix........................................................................................................................................... 153
7.1 Technical data (Overview) .................................................................................................... 153
7.1.1 System properties Kuhnke FIO........................................................................................... 153
7.1.2 Kuhnke FIO bus coupler ..................................................................................................... 153
7.1.3 Kuhnke FIO bus coupler DI16/DO16 .................................................................................. 153
7.1.4 Kuhnke FIO I/O modules..................................................................................................... 154
7.2 Order specifications .............................................................................................................. 158
7.2.1 Kuhnke FIO modules........................................................................................................... 158
7.2.2 Kuhnke FIO Accessories..................................................................................................... 159
8 Sales & Service ................................................................................................................................ 161
8.1 Index...................................................................................................................................... 162

Kendrion Kuhnke Automation GmbH Preface
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1 Preface
1.1 Imprint
Contact Details
Kendrion Kuhnke Automation GmbH
Industrial Control Systems
Lütjenburger Straße 101
D-23714 Malente, Deutschland
Phone: [phone]
Fax: [phone]
Email: [e-mail]
Web: http://kuhnke.kendrion.com
Version Details
History of the manual
Date
Comments / Modifications
29.05.2015
Original version
31.08.2015
AO, AI-U, AI-I added
11.11.2015
Coupler DI16/DO16 added
14.12.2015
Translation
01.03.2016
Counter/Posi2 added
07.03.2016
Correction analogue modules
26.04.2016
Extension at digital modules with 36-poled connectors: Both terminals of L+ and of L- are
each connected internally! (4.4-4.6) Note regarding installation position added (3.2.2.1) Note
regarding installation order added (3.2.2.2) Connectable ferrules Weidmüller plug (3.3.1)
06.06.2016
Added Relay-Modules - 4.11 DO8 Relay NO 24V; 4.12 DO8 Relay NO 230 VAC
10.07.2016
Revision of the measured value tables Figure 47, Analog values voltage and Figure 44: Analog
values voltage/current
10.11.2016
Revision of 4.21.4 Function 694 443 57 Kuhnke FIO AI4-Pt/Ni/TC and 4.22.4 Function 694 443 58
Kuhnke FIO AI8-Pt/Ni/TC
25.11.2016
Data type adaptation in the chapter 4.13 CounterPosi2 5V,
1.2 About this Manual
1.2.1 Target group
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.
1.2.2 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.
1.2.3 Terms of Delivery
The general conditions of sales and service of Kendrion Kuhnke Automation GmbH shall apply.
1.2.4 Copyright
© Kendrion Kuhnke Automation GmbH

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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.
1.2.5 Warranty
Warranty is subject to the provisions of the conditions of sale of Kendrion Kuhnke Automation GmbH
or any contractual agreements between the parties.
Structure and goal of the manual
Kuhnke FIO are EtherCAT slave IO modules. They provide information about sensors and
actuators for the EtherCAT Master. Furthermore, there are modules for communicating with other
systems.
How to create network configuration and control program depends on the used EtherCAT master
controller.
This guide aims to familiarize you with the use of the modules.
In examples preferably CODESYS Version 3 is used, which contains an EtherCAT Master and
configurator. Use of other tools may need to be acted differently.
Further knowledge of the programming in accordance with IEC 611131-3, please refer to the
CoDeSys online help or the literature.
For beginners in CoDeSys it may be appropriate to use the comprehensive training offer from 3S-
Smart Software Solutions GmbH.
This manual is structured as follows:
Chapter 1 contains general information on the use of equipment
Chapter 2 provides an introduction to the EtherCAT technology
Chapter 3 describes the system properties of Kuhnke FIO
Chapter 4 describes the Kuhnke FIO modules
Chapter 5 provides information on the configuration of EtherCAT networks
Chapter 6 lists the Kuhnke FIO modules and accessories
1.2.6 Literature
Title / Theme
Number/ Author
Source
User Manual Kuhnke FIO (V2)
E747-1 GB
http://kuhnke.kendrion.com/ics/en/
User Manual Ventura FIO (V1)
E 747 GB
http://kuhnke.kendrion.com/ics/en/
Technical Info Kuhnke FIO
E 740 GB
http://kuhnke.kendrion.com/ics/en/
EtherCAT, Technology, FAQs, Downloads
http://www.ethercat.org
CODESYS manuals
(available as PDF in the CODESYS –
directory of the Programming PC)
http://www.CODESYS.com
IEC61131-3 mit CODESYS V3:
Jochen Petry
3S-Smart Software Solutions GmbH
SPS Programmierung nach IEC 61131-3
Heinrich Lepers
Franzis Verlag GmbH

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1.3 Reliability, Safety
1.3.1 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.
1.3.2 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 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.
1.3.3 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.
1.3.4 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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1.3.5 Hazard and other Warnings
Despite the actions described in section 1.3.4, 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.
1.3.6 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).
1.3.7 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

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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
24 VDC power 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 BGV A3 (Elektrische Anlagen und Betriebsmittel) 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.
Spare parts: 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 recognizably!) inhibit their functionality.
Always dispose of (rechargeable) batteries as hazardous waste.
1.3.8 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.

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Information
Refer to IEC 61131-4, User's Guideline, for general installation instructions to be complied with
to ensure that hardware interface factors and the ensuing noise voltages are limited to tolerable
levels.
Interference Emission
Interfering emission of electromagnetic fields, HF
compliant to EN 55011, limiting value class A, Group 1
Information
If the controller is designed for use in residential areas, high-frequency emissions must comply
with limiting value class B as described in EN 55011.
Fitting the controller into earthed metal cabinets and installing filters in the supply lines may
produce a shielding compliant to the above standard.
General Notes on Installation
As component parts of machines, facilities and systems, electronic control systems must comply with
valid rules and regulations, depending on their field of application.
General requirements concerning the electrical equipment of machines and aiming at the safety of
these machines are contained in Part 1 of European Standard EN 60204 (corresponds to VDE 0113).
Electrical Immission Safeguard
To eliminate electromagnetic interference, connect the control system to the protective earth
conductor. Practice best cable routing.
Cable Routing and Wiring
Keep power circuits separate from control circuits:
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.

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Contamination
Use suitable casings to avoid possible negative influences due to humidity, corrosive gas, liquid or
conducting dust.
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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2 Introduction
2.1 EtherCAT®1— Ethernet Control Automation Technology
EtherCAT is the most powerful Ethernet-based fieldbus system currently available on the market. EtherCAT
puts up the top speed mark, and its flexible topology and simple configuration make it the perfect means of
controlling extremely fast processes. To give you a clue: 1000 I/Os can be addressed in 30 μs.
Because of its high performance, the simple wiring and its open protocol support, EtherCAT is often used as
a fast motion control and I/O bus driven by an industrial PC or in conjunction with control technology on a
smaller scale. EtherCAT moves beyond the limits of conventional fieldbus systems. Its interconnections
between the controller at one end and both the I/O modules and drives at the other are as fast as those of a
backplane bus. EtherCAT controllers thus nearly act like centralised control systems, overcoming the issue
of bus transfer times that conventional fieldbus systems are burdened with.
2.2 Kuhnke FIO (Fast Input Output)
Kuhnke FIO is a system of I/O modules for connecting the process signals to an EtherCAT network.
Kuhnke FIO consists of the Ventura FIO bus coupler and a range of Ventura FIO I/O modules.
The Ventura FIO bus coupler converts the physical transfer technology (twisted pair) to LVDS (E-bus) and
generates the system voltages required by the LVDS modules. The standard 100 Base Tx lines used for
office network communications connect to the one side, the Ventura FIO I/O modules for the process signals
connect to the other. This is how the Ethernet EtherCAT protocol is retained right through to the last I/O
module. At the end of the modular device, the connection between the forward and return lines is
automatically closed, the effect being that another 100 BaseTx line can be plugged in to connect the next
EtherCAT unit to the second bus coupler port.
If the bus coupler is the last device of the EtherCAT network, i.e. the RJ45-socket "Out" remains free, the
connection of the forward and return line are closed automatically.
1EtherCAT® is a registered trade mark and a patented technology of Beckhoff Automation GmbH, Germany.
Figure 1: Kuhnke FIO Buscoupler with I/O-modules

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2.3 Kuhnke FIO — Ventura FIO
In the course of product maintenance the Ventura FIO modules have been revised progressively from 2014.
Focus of the revision was to improve the EMC / ESD properties and the preparation of the ETG-conformity.
The revised modules bear the name of Kuhnke FIO, or FIO V2.
Kuhnke FIO with the same part number as Ventura FIO are compatible, i.e., they can be interchanged
without control programs need to be modified.
Ventura FIO modules are controlled via a broad process image.
For Kuhnke FIO modules with controllers such as the analog modules are offered both to the Ventura FIO
modules compatible versions with process image control, as well as variants with object control CoE (CAN
over EtherCAT).
Exceptions, such as the signal range in case of the AO4 module are noted in this manual in the respective
module description.
The externally visible differences between Ventura FIO and Kuhnke FIO are listed in the following table.
Characteristic
Ventura FIO
Kuhnke FIO
Manufacturing date
successively from
2014
Design
green dot
no dot
Module locking
green
gray
Release latch
green
black
LED designation
EtherCAT
EtherCAT Run
EtherCAT LED
green/red
green/off
LED designation (RJ45)
In, Out
In L/A, Out L/A
Module control process image
process image
CoE
Process signal plug
extra
inclusive
green release latch
(also 2-pole)
black release latch
(2-pole screw flange)
spring terminal (36-pole)
Push In (36-pole)

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Unlock button
Status LEDs
Shield-to-housing
mount connector
Module lock and E-
bus
Carrier rail mount and
operative earth
Ventilation slots
Signal state indicators
(LEDs)
Grip
Label clip
Slot for spring-
assisted combi plug
3 System Description
3.1 General conditions of use
This section describes the general characteristics of Kuhnke FIO modules which are important for the
installation, wiring and troubleshooting.
You can find an overview of the system properties of Kuhnke FIO in section 7.1.1 on page 153.
The specific characteristics of the individual modules will be presented in chapter 4.
3.2 Mechanical Design
For the basic layout of the Kuhnke FIO-modules see Figure 2: Module layout.
The bus coupler and the I/O modules differ in their connectors and indicators, however.
The housing mount consists of an aluminum profile with an integral snap-on device used to snap the module
to a 35mm DIN rail. The housing trough including the optical fibers for the status indicators, the side face and
the front is made of plastic and contains the module. The optical fibers 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.
3.2.1 Earth
Connect the Ventura FIO modules to earth by attaching the metal housing to operative earth.
Since the operative 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 an operative 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.
.
Figure 2: Module layout

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Earth wires should be short and have a large surface (copper mesh). Further
details has site
http://en.wikipedia.org/wiki/Ground_(electricity)
3.2.2 Installation The Ventura FIO modules are intended for mounting rail installation (DIN EN
50022, 35 x 7.5 mm).
3.2.2.1 Installation position
The mounting rail is placed horizontally and the female connector
strip of the modules face forward. For a sufficient ventilation of the
convection slits the minimum distance must not fall below 20mm
upward and 35mm to adjacent equipment and control cabinets The
lateral distance to external devices and cabinet controls must not fall
below 20mm.
Figure 3: Aluminium profile
Attach cable shield here
Connect DIN rail with
operati
ve earth
M3x5 bolt
connection
Figure 4: Installation position

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1
2
Figure 6: Uninstalling a module
1
2
3
3.2.2.2 Installation order within a FIO system
NOTE
To ensure smooth function of the entire FIO system, the FIO modules must be arranged based
on their e
-bus load. The modules with the biggest e-bus load are to be arranged directly next to
the head modules (bus coupler or
controller). Make sure that you note the maximum bus load of
the head module. Kuhnke FIO Safety I/O shall be arranged directly next to the head module.
3.2.2.3 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 module against the mounting wall until is snaps in.
3.2.2.4 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.
3.2.2.5 To disconnect two modules
•Push down the unlock button (see Figure 6) of the module that you wish to disconnect from the
module to the left of it.
•Push both modules away from one another until they are about 1 cm apart.
3.2.2.6 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.
Das verknüpfte Bild kann nicht angezeigt werden. Möglicherweise wurde
Figure 5: Rail mounting of module
Unlock button

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3.3 System power supply
3.3.1 General
Multipole connectors stand for high port density in a confined space.
Release latches facilitate the separation of the plug connection in tight spaces.
Screw flanges ensure for a snug fit, if the plugs are small
Spring-assisted plugs ensure quick and easy wiring.
1-row:
Tool: Screwdriver blade 0,4 x 2,5 x 75 (DIN 5264-A)
Wires: 320V/ 10 A/ 0.2 – 1.5 mm² (IEC)
Rated current: 300V/ 10 A/ 28 - 14 AWG (UL)
Connectable conductors with ferrules: Conductor cross ssection [mm
2
]
Type of core end sleeve
0,13
0,25
0,34
0,50
0,75
1
1,5
Wire end sleeve with collar to
DIN 46 228/4 8 / 10 8 / 10 8 / 10
Wire end sleeve without collar
to DIN 46 228/1 8 / 10 8 / 10 8 / 10
Stripping length [mm] / sleeve length [mm]
The Push-in spring connector enables fast, tool-free wire connection by direct plug-in technology. The
stripped solid wires or flexible wires with crimped ferrules are plugged all the way into the terminal point.
2 rows:
Wires: 320V/ 13.4 A/ 0.14 – 1.5 mm² (IEC)
Rated current: 300V/ 9.5A/ 26 - 16 AWG (UL)
Connectable conductors with ferrules: Conductor cross ssection [mm
2
]
Type of core end sleeve
0,14
0,25
0,34
0,50
0,75
1
1,5
Wire end sleeve with collar to
DIN 46 228/4 8 / 10 8 / 10 8 / 10 10 / 12 12 / 14 12 / 15
Wire end sleeve without collar
to DIN 46 228/1 10 / 10
Stripping length [mm] / sleeve length [mm]
NOTE
The power supply lines may not be connected by one supply terminal of the Kuhnke FIO
to the next. In order to ensure trouble-free operation, the supply lines must be routed in
star formation with the shortest possible lines from a central supply terminal to Kuhnke
FIO.

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3.3.2 Bus coupler
A 2-pin plug-in terminal block with screw flange is used to connect the system supply to the bus coupler.
Since the bus coupler supplies power to both the E-bus and the logic circuits of the I/O modules, its power
consumption depends on the number of I/O modules connected.
Power to the I/O module outputs is supplied separately
Figure 7: Spring-assisted terminal block with screw flange for the Bus coupler
3.3.3 I/O-Modules
The connection of the I/O supply takes place via the IO plug. Plug-in terminal blocks can be used with
different numbers of poles
The logic of I/O modules without own microcontroller is powered by the bus coupler. Modules with
microcontroller can have its own power supply, which is then supplied via the IO connector.
Figure 8: Spring-assisted terminal block, 1 row with release latch for I/O-modules
Figure 9: Push In terminal block, 2 rows with release latch for I/O-modules
A rapid shut-down of all outputs can be performed by external switch-off of
the I/O supply voltage L+.
The missing supply voltage is indicated by the power LED.
However, not all modules have an undervoltage monitoring, which can
report this status to the control unit.
If you need the monitoring of the I/O power supply in the control program,
connect L+ with a digital input and use it representative for the IO power
supply.

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Here however, note the following:
Outputs must not be supplied reverse, when the power supply of the
outputs is switched.
This is the case if the system continues to be supplied with power.
Outputs that are set forth by the program can be supplied via the protection diode of a reverse supplied
output and in this way set the switch off function for these outputs overridden. In addition, the protection
diode of the feeding output can be destroyed at high load.