Phoenix AXL E Series: Industrial Digital I/O Modules - Comprehensive Application & Selection Guide

Core Positioning

The Phoenix AXL E Series represents a comprehensive family of industrial digital I/O modules designed for distributed automation systems. These rugged, compact modules provide reliable signal acquisition and control in demanding industrial environments, connecting field devices to higher-level automation networks. With multiple variants supporting different communication protocols (Sercos III or PROFINET), various I/O configurations, and flexible connection options, AXL E modules serve as the vital link between sensors/actuators and control systems in modern manufacturing, process automation, and machine building applications.

Product Family Overview

The AXL E Series is divided into two main communication variants:

1. AXL E S3 Series (Sercos III Communication)

• Designed for real-time motion control applications requiring precise synchronization
• Ideal for robotics, packaging machinery, and machine tools with high-speed axes
• Supports Sercos III protocol at 100 Mbps for deterministic data exchange

2. AXL E PN Series (PROFINET Communication)

• Optimized for industrial Ethernet environments with standard PROFINET IO protocol
• Suitable for general automation, process control, and factory automation applications
• Supports standard PROFINET features including DCP, SNMP, and HTTP for diagnostics

Both variants share common features like:

• IP65/IP67 protection for harsh industrial environments
• M12 connector technology for fast, tool-free wiring
• Compact design for space-constrained applications
• LED status indicators for easy diagnostics
• Operating temperature range of -25°C to +60°C

Model Nomenclature Decoding

Technical Specifications (Universal)

I/O Configuration Options & Features

1. DIO16 Series (16-channel I/O)

• Model Examples: 2701545 (S3), 2701511 (PN)
• Core Features: 16 bidirectional I/O channels, each configurable as input or output
• Typical Applications: General purpose I/O expansion, connecting multiple sensors/actuators in a single module

2. DI16 Series (16-input)

• Model Examples: 2701544 (S3), 2701510 (PN)
• Core Features: 16 digital inputs with noise filtering, reverse polarity protection
• Typical Applications: Monitoring sensors, switches, and status signals in machinery

3. DI8DO8 Series (8-input + 8-output)

• Model Examples: 2701542 (S3), 2701509 (PN)
• Core Features: Balanced I/O configuration, ideal for applications requiring equal input/output capacity
• Typical Applications: Machine control where 8 actuators need to be controlled based on 8 sensor inputs

4. DI8DO4 2A Series (8-input + 4-output, 2A)

• Model Examples: 2701546 (S3), 2701512 (PN)
• Core Features: 4 high-power outputs (2A each) for driving larger loads like solenoids or small motors
• Typical Applications: Industrial machinery requiring direct control of high-power devices

5. Special Variants

• AXL E PN IOL8 DI4: PROFINET module with 4 digital inputs + 8 IO-Link ports for connecting smart devices
• AXL E PN DIO16 M12 6M-L: PROFINET module with male connector and extended cable (M12 6M-L)

Applications

1. Automotive Manufacturing

• Recommended Setup: AXL E PN DI16 + AXL E PN DO8DI8
• Application: Monitoring assembly line sensors and controlling pneumatic actuators
• Benefit: IP67 protection withstands oil, coolant, and cleaning agents in automotive plants

2. Robotics & Motion Control

• Recommended Setup: AXL E S3 DIO16 + AXL E S3 DI8DO4 2A
• Application: Connecting robot joints, grippers, and safety sensors in robotic cells
• Benefit: Sercos III protocol provides precise synchronization for coordinated motion control

3. Packaging Machinery

• Recommended Setup: AXL E PN DI8DO8 (multiple)
• Application: Controlling conveyor belts, filling systems, and labeling equipment
• Benefit: Fast switching speeds (up to 5,500 Hz) handle high-speed packaging operations

4. Process Automation

• Recommended Setup: AXL E PN IOL8 DI4 + AXL E PN DIO16
• Application: Monitoring process parameters and controlling valves in chemical/petrochemical plants
• Benefit: IO-Link ports connect smart sensors for enhanced diagnostics and predictive maintenance

Selection Guide

Step 1: Choose Communication Protocol

• PROFINET (PN): For general automation, factory networks, and systems with PLCs
• Sercos III (S3): For motion control, robotics, and applications requiring precise synchronization

Step 2: Select I/O Configuration

• DI16: When input signals outnumber outputs (e.g., sensor arrays)
• DO16/DIO16: When output signals dominate or balanced I/O is needed
• DI8DO8: For typical machine control with equal input/output requirements
• DI8DO4 2A: When some outputs need to drive high-power loads (solenoids, small motors)

Step 3: Determine Connector Type

• M12 6P (Female): For connecting to male-ended field devices or cables
• M12 6M (Male): For connecting to female sockets or panels
• M12 6M-L: For applications requiring extended cable length (pre-wired solutions)

Step 4: Additional Considerations

• IP Protection: All AXL E modules offer IP65/67 protection, suitable for most industrial environments
• Power Requirements: Ensure sufficient 24V DC power supply for all connected modules
• Space Constraints: Compact design (30.5mm width) allows dense installation in crowded cabinets

Installation & Operation Notes

Wiring Instructions

1. Connector Connection: Align M12 connector and twist until it locks (quarter-turn)
2. Conductor Requirements: Use stranded or solid wires (0.25-1.5mm²) with proper insulation
3. Grounding: Ensure proper grounding of the module and connected devices for noise immunity
4. Power Connection: Connect 24V DC power supply to the designated terminals

Status Monitoring

• Power LED: Green indicates proper power supply
• Communication LED: Blinking indicates active data transmission
• I/O LEDs: Indicate status of individual input/output channels (on/off)

Maintenance & Troubleshooting

• Module Replacement: Simply disconnect the M12 connector, remove the old module, and install the new one
• Diagnostics: Use LED indicators to identify faulty channels or communication issues
• Reset: Power cycle the module to recover from non-critical errors

AXL E vs. Traditional I/O Solutions

Summary & Next Steps

The Phoenix AXL E Series provides a reliable, versatile solution for industrial digital I/O needs, combining robust construction with easy installation and advanced communication capabilities. By selecting the appropriate protocol (S3/PN), I/O configuration (DI16/DIO16/DI8DO8/DI8DO4 2A), and connector type (M12 6P/6M), you can tailor the solution to your specific automation requirements.

For detailed technical specifications or application-specific questions, refer to the product datasheets or contact your local Phoenix Contact representative. For complex automation systems, consider combining AXL E modules with other Axioline E components (bus couplers, IO-Link masters) to create a comprehensive distributed I/O network.