Kendrion Kuhnke DI32 Bedienungsanleitung

Instruction Manual

Kuhnke FIO

IP20 EtherCAT I/O Modules

E 747GB-V2 28 January 2020

Table of Contents Kendrion Kuhnke Automation GmbH 
 
2(E 747GB-V2)
 28 January 2020
1 Preface ............................................................................................................................................................6 
1.1 Imprint ..................................................................................................................................................6 
1.2 About this Manual ................................................................................................................................6 
Limitation of Liability....................................................................................................................................6 
Terms of Delivery ........................................................................................................................................6 
Copyright.....................................................................................................................................................6 
Warranty......................................................................................................................................................6 
Manual Objective and Organisation............................................................................................................7 
2 Reliability, Safety.............................................................................................................................................8 
2.1 Intended Use........................................................................................................................................8 
2.2 Target Group of the Instruction Manual...............................................................................................8 
2.3 Intended Use........................................................................................................................................8 
2.4 Transport and Storage.........................................................................................................................8 
2.5 Reliability..............................................................................................................................................9 
2.6 Hazard and other Warnings...............................................................................................................10 
2.7 Safety.................................................................................................................................................11 
Project Planning ........................................................................................................................................11 
Maintenance and Servicing.......................................................................................................................11 
Disposal.....................................................................................................................................................12 
2.8 Electromagnetic Compatibility............................................................................................................12 
Definition....................................................................................................................................................12 
Interference Emission................................................................................................................................12 
General Notes on Installation....................................................................................................................12 
Electrical Immission Safeguard.................................................................................................................12 
Cable Routing and Wiring .........................................................................................................................12 
Location of Installation...............................................................................................................................13 
Particular Sources of Interference.............................................................................................................13 
3 Introduction....................................................................................................................................................14 
3.1 EtherCAT® —Ethernet Control Automation Technology..................................................................14 
3.2 Kuhnke FIO (Fast Input / Output).......................................................................................................14 
3.3 Kuhnke FIO —Ventura FIO...............................................................................................................15 
4 System Description........................................................................................................................................16 
4.1 General Service Conditions ...............................................................................................................16 
4.2 Mechanical Design.............................................................................................................................16 
Installation .................................................................................................................................................17 
4.3 System Power Supply........................................................................................................................19 
General Instructions..................................................................................................................................19 
System Power Supply...............................................................................................................................20 
Earth..........................................................................................................................................................20 
Bus Coupler...............................................................................................................................................21 
I/O Modules...............................................................................................................................................21 
4.4 Status LEDs .......................................................................................................................................22 
LED "EtherCAT Run" ................................................................................................................................22 
LED "In L/A", LED "Out L/A"......................................................................................................................23 
LED "IO"....................................................................................................................................................23 
LED "Power"..............................................................................................................................................23 
5 Kuhnke FIO Modules.....................................................................................................................................24 
5.1 Controller..........................................................................................................................................24 

Kendrion Kuhnke Automation GmbH Table of Contents 
 
(E 747GB-V2)3
January 2020
1.1 Controller 113...................................................................................................................................24 
1.2 Controller 116...................................................................................................................................25 
2 Bus Coupler and Extender..............................................................................................................26 
2.1 Bus Coupler......................................................................................................................................26 
2.2 Bus Coupler DI16/DO16 ..................................................................................................................29 
2.3 Extender 2 Port ................................................................................................................................32 
3 Digital FIO Modules..........................................................................................................................39 
3.1 DI16/DO16 .......................................................................................................................................39 
3.2 DI16/DO16 LS (Low Side)................................................................................................................41 
3.3 DI32..................................................................................................................................................43 
3.4 DI16..................................................................................................................................................45 
3.5 DI16/DO8 .........................................................................................................................................47 
3.6 DI8/DO8 ...........................................................................................................................................49 
3.7 DO16................................................................................................................................................51 
3.8 DO8..................................................................................................................................................53 
3.9 DO8 Relay NO 24V..........................................................................................................................55 
3.10 DO8 Relay NO 230VAC.................................................................................................................57 
3.11 ........................................................................................................................................................57 
4 Analogue FIO Modules....................................................................................................................59 
4.1 AO4-U/I - 12-Bit..............................................................................................................................143 
4.2 AO4-U/I - 16-Bit CoE......................................................................................................................148 
4.3 AI4/8-U ...........................................................................................................................................156 
4.4 AI8/16-U .........................................................................................................................................164 
4.5 AI4-I................................................................................................................................................173 
4.6 AI8-I................................................................................................................................................180 
4.7 AI4-Pt/Ni/TC...................................................................................................................................188 
4.8 AI8-Pt/Ni/TC...................................................................................................................................197 
5 Counter / Posi / Drive / CAM Modules..........................................................................................209 
5.1 Counter/Posi2 5V, Counter2 5V.....................................................................................................209 
5.2 Kuhnke FIO Drive Control..............................................................................................................224 
5.3 Kuhnke FIO CAM Control ..............................................................................................................225 
6 Mixed Modules ...............................................................................................................................226 
6.1 MIX 02............................................................................................................................................226 
7 Interface and Communication Modules.......................................................................................236 
7.1 RS485 1 Port..................................................................................................................................236 
7.2 RS232 2 Port..................................................................................................................................250 
7.3 CAN Master/Slave..........................................................................................................................264 
8 Safety Modules...............................................................................................................................279 
8.1 Kuhnke FIO Safety PLC.................................................................................................................279 
8.2 Kuhnke FIO Safety SDI4/SDO2.....................................................................................................280 
Accessories .................................................................................................................................................282 
1 Power Distributor 2 x 16...................................................................................................................282 
Terminals.................................................................................................................................................282 
Status LEDs ............................................................................................................................................282 
Function...................................................................................................................................................282 
Mounting..................................................................................................................................................283 
2 Shield Terminal................................................................................................................................284 
Terminals.................................................................................................................................................284 
Function...................................................................................................................................................284 

Table of Contents Kendrion Kuhnke Automation GmbH 
 
4(E 747GB-V2)
 28 January 2020
Technical Data ........................................................................................................................................285 
7 Configuration ...............................................................................................................................................286 
7.1 CODESYS V3 (CODESYS Configurator)........................................................................................286 
Offline Configuration................................................................................................................................286 
Online Configuration................................................................................................................................289 
8 Appendix......................................................................................................................................................292 
8.1 Technical Data (Summarised) .........................................................................................................292 
System Properties of Kuhnke FIO...........................................................................................................292 
Kuhnke FIO I/O Modules (General) ........................................................................................................293 
8.2 Order Specifications.........................................................................................................................299 
Kuhnke FIO Modules...............................................................................................................................299 
Kuhnke FIO Accessories.........................................................................................................................300 
9 Sales & Service ...........................................................................................................................................302 
 
 

Kendrion Kuhnke Automation GmbH Modification History

(E 747GB-V2)5

28 January 2020

Modification history

Date

Comments / modifications

29 May 2015

Original version

31 Aug 2015

Plus chapters on AO, AI-U, AI-I

11 Nov 2015

Plus chapter on DI16/DO16 bus coupler

01 Mar 2016

Plus chapter on Counter/Posi2, new UL logo

07 Mar 2016

Analogue modules corrected

26 Apr 2016

Addition to 2-row digital terminals: L+ and L- are both internally jumpered (5.3.1)

Note on installation position added (Position)

Note added on order of modules in multi-FIO systems (Order of Modules in Multi-FIO

Systems)

Connector sleeves for Weidmüller connector (General Instructions)

06 June 2016

Chapter Relay Modules added –(5.3.9 / 5.3.10)

10 July 2016

Tables of sensor values revised (5.4)

10 Nov 2016

Chapter Thermal Modules revised (5.4.8 / 5.4.9)

25 Nov 2016

Data types modified in chapter Counter2 CounterPosi2 (5.5.1)

17 Jan 2017

Chapter Analogue Output Modules revised (5.4.2 / 5.4.3)

20 Jan 2017

Chapter General Instructions revised under connector sleeves

23 Feb 2017

Note on unused encoder signals in chapter Counter2 CounterPosi2 (5.5.1)

03 Feb 2017

Table of sensor values revised in chapter 5.4.2 / 5.4.3, UL logo added for 16/16 bus coupler

added to chapter 5.2.2

08 Mar 2017

New thermo module sub-chapters on cold point compensation and calibration (5.4.8 / 5.4.9)

21 Mar 2017

Chapter 5.4.2 AO4-U/I - 12-Bit“ revised with regard to compatibility with the module's

predecessor

25 Aug 2017

Formatting of entire Instruction Manual revised.

New FIO modules added –communication modules, chapter 5.7

Technical data of complex FIO modules added (Controller/Safety/Drive/CAM)

Old modules removed from manual (separate Instruction Manual on FIO V1 modules)

Translation

31 Aug 2017

Inserting a note for the AI-U modules

01 Dez 2017

Device "Kuhnke FIO DO8 2A" Order number 694.452.06 ID: 190485 added

02 Mar 2018

Revision of the complete manual with regard to the Low Voltage Directive.

Renaming in chapter Bus Coupler DI16 / DO16 - U24_Load to undervoltage_load and

U24_Logic to undervoltage_logic

14 Jan 2019

Mounting instructions for the potential distributor added.

Added information for recommended Ethernet cable.

03 Jul 2019

FIO Bus Coupler DI8 DO8 and DI8 DO4 added.

Info about the new Safety Modules added.

28 Jan 2020

Design change and analog module Kuhnke AI4 12Bit / AO4 16Bit CoE added

Preface Kendrion Kuhnke Automation GmbH

6(E 747GB-V2)

28 January 2020

1 Preface

1.1 Imprint

Contact Details

Kendrion Kuhnke Automation GmbH

Industrial Control Systems

Lütjenburger Straße 101

D-23714 Malente, Deutschland

Phone: +49 4523 402-0

Fax: +49 4523 402-201

Email: sales-ics@kendrion.com

Web: http://kuhnke.kendrion.com

1.2 About this Manual

This technical information is primarily directed to system designers, project engineers and device

developers. It does not contain any availability information. We reserve the rights for errors, omissions and

modifications. Pictures are similar.

Limitation of Liability

Specifications are for description only and are not to be understood as guaranteed product properties in a

legal sense. Exact properties and characteristics shall be agreed in the specific contract. Claims for

damages against us - on whatever grounds - are excluded, except in instances of deliberate intent or gross

negligence on our part.

Terms of Delivery

The general conditions of sales and service of Kendrion Kuhnke Automation GmbH shall apply.

This instruction manual is proprietary and protected by copyright.

No part of this document may be reproduced or copied in any way or by any means except expressly

permitted in writing by Kendrion Kuhnke Automation GmbH.

Microsoft®, Windows® and the Windows® logo are registered trademarks of Microsoft Corp. in the USA and

other countries. EtherCAT® is a registered trademark and patented technology, licenced by Beckhoff

Automation GmbH, Germany. Further information about the PLCopen organisation is available at

www.plcopen.org. CiA® and CANopen® are registered joint brands of CAN in Automation e.V. Title to all

companies and company names mentioned heron as well as to products and product names is held by the

respective enterprises.

CODESYS V3©is a product of 3S-Smart Software GmbH.

Warranty

Warranty is subject to the provisions of the conditions of sale of Kendrion Kuhnke Automation GmbH or any

contractual agreements between the parties.

Kendrion Kuhnke Automation GmbH Preface

(E 747GB-V2)7

28 January 2020

Manual Objective and Organisation

This manual describes the EtherCAT slave IO modules of Kuhnke FIO. These modules provide the

EtherCAT master with the sensor details and operate the actuators. Other modules control the

communication with other systems.

The EtherCAT master control unit decides how to configure the network and create the control program.

This manual aims to introduce you to using the modules.

The examples are preferably based on CODESYS version 3 which has an EtherCAT master and an

EtherCAT configuration utility. The procedures may change if you are using other tools.

For in-depth knowledge of IEC 611131-3 programming, please refer to the CODESYS online help engine

and the references listed below.

CODESYS beginners may benefit from the comprehensive training offerings of 3S-Smart Software Solutions

GmbH.

Reliability, Safety Kendrion Kuhnke Automation GmbH

8(E 747GB-V2)

28 January 2020

2 Reliability, Safety

2.1 Intended Use

For reasons of personal safety and to avoid material damages when working with or handling this Kuhnke

product, you are advised to take heed of the notes and information contained in this instruction manual.

2.2 Target Group of the Instruction Manual

This instruction manual contains all information necessary for the use of the described product (control

device, control terminal, software, etc.) according to instructions. It is written for qualified design, project

planning, servicing and commissioning experts. For proper understanding and error-free application of

technical descriptions, instructions for use and particularly of notes of danger and warning, extensive

knowledge of automation technology is compulsory.

2.3 Intended Use

Kuhnke's products are designed, developed and manufactured for standard industrial use. They must not be

used for any other purposes than the ones specified in the catalogue or the associated technical

documentation. Proper and safe operation depends on the products being transported, stored, lined up,

mounted, installed, put into service, operated, and serviced correctly. Ambient conditions must be within the

admissible limits. Notes and information in the associated documentation apply at all times.

2.4 Transport and Storage

At times of transport and storage, protect Kuhnke FIO Module against inadmissible exposure such as

mechanical stress, temperature, humidity and/or aggressive atmospheres. Transport and store Kuhnke FIO

Modules only in its original packaging if possible.

Verify that the contacts are neither soiled nor damaged when consigning the unit to stock or re-packaging it.

Keep and transport Kuhnke FIO Modules in a container/packaging ensuring electrostatic discharge (ESD)

compliance. Some parts of the units are sensitive to ESD and may be damaged if handled inappropriately.

Thus, best transport practice is to place open assemblies in statically shielded transport bags with a metal

coating which avoid contamination by amines, amides or silicone. When putting Kuhnke FIO Modules into

service and performing any maintenance, you should also take the appropriate precautions against

electrostatic discharge.

CAUTION

Electrostatic discharge

Destruction of or damage to the unit.

Transport and store FIO Safety I/O in its original packaging.

Ensure that the ambient conditions are as specified at all times during transport and

storage.

Handle FIO Safety I/O in a well-earthed environment (persons, place of work, packaging).

Do not touch electrically conductive parts such as data contacts. Some of the electronic

components may be destroyed if exposed to electrostatic discharge.

DANGER

Only use devices that are in perfect condition, ie that they do not show any transport

damage, fluid effects or other damage

Kendrion Kuhnke Automation GmbH Reliability, Safety

(E 747GB-V2)9

28 January 2020

2.5 Reliability

Reliability of Kuhnke products is brought to the highest possible standards by extensive and cost-effective

means in their design and manufacture.

These include:

selecting high-quality components,

quality agreements with our suppliers,

actions to avoid static charges when handling MOS circuits,

worst case planning and design of all circuits,

visual inspections at various stages of fabrication,

computer-aided tests of all assemblies and their interaction in the circuit,

statistical assessment of the quality of fabrication and of all returned goods for the immediate taking

of appropriate corrective actions.

Reliability, Safety Kendrion Kuhnke Automation GmbH

10 (E 747GB-V2)

28 January 2020

2.6 Hazard and other Warnings

Despite the actions described in section 2.4, the occurrence of faults or errors in electronic control units -

even if most highly improbable - must be taken into consideration.

Please pay particular attention to the additional notices which we have marked by symbols throughout this

instruction manual. While some of these notices make you aware of possible dangers, others are intended

as a means of orientation. They are described further down below in descending order of importance.

Every alert and hazard warning is made up as follows:

Type and source of risk

Potential consequences of non-observance

Preventive measures

DANGER

A DANGER warning makes you aware of an immediately hazardous situation which WILL

cause a serious or fatal accident if not observed.

WARNING

A WARNING makes you aware of a potentially hazardous situation which MAY cause a

serious or fatal accident or damage to this or other devices if not observed.

CAUTION

A CAUTION alert makes you aware of a potentially hazardous situation which MAY cause

an accident or damage to this or other devices if not observed.

NOTE

A NOTE makes you aware of a potentially hazardous situation which MAY cause damage

to this or other devices if not observed.

Other Notices

Information

This symbol draws your attention to additional information concerning the use of the

described product. This may include cross references to information found elsewhere

(e.g. in other manuals).

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