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

Kendrion Kuhnke Automation GmbH Preface
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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.