Valve terminal type 03/05 Electronics Manual Field bus connection FB13

Transcription

1 Valve terminal type 03/05 Electronics Manual Field bus connection FB13 Field bus protocol: PROFIBUS DP 12 MBaud GB Only valid in agreement with the printed documentation accompanying the product! Compare this edition code. 9701NH

2 Author: Editor: Layout: Translation: Type setting: E. Klotz, H.-J. Drung H.-J. Drung, M. Holder Festo KG, Dept. PV-IDM D. Smith DUCOM 9701 NH Printed on 100% recycled paper 1997 Festo KG, Esslingen, Federal Republic of Germany All rights reserved, including translation rights. No part of this publication may be reproduced or transmitted in any form or by any means, electronic, mechanical, photocopying or otherwise, without the prior written permission of Festo KG NH I

3 Order no.: Title: Designation: MANUAL P.BE-VIFB13-03/05-GB II 9701 NH

4 Contents GENERAL SAFETY INSTRUCTIONS Designated use Target group IMPORTANT USER INSTRUCTIONS Danger categories Pictograms Instructions on this manual Service VIII VIII IX X X XI XII XIV Chapter 1 SYSTEM SUMMARY SYSTEM SUMMARY 1-3 System structure 1-3 Type 03: Description of components 1-5 Type 05: Description of components 1-9 Description of the functions 1-11 Chapter 2 FITTING FITTING THE COMPONENTS 2-3 Input/output modules 2-4 End plates 2-6 Hat rail clamping unit (type 03) TYPE 03: FITTING THE VALVE TERMINAL 2-9 Wall fitting (type 03) 2-9 Hat rail fitting (type 03) TYPE 05: FITTING THE VALVE TERMINAL 2-12 Wall fitting (type 05) NH III

5 Chapter 3 INSTALLATION GENERAL CONNECTION PRINCIPLES 3-3 Cable selection field bus cable 3-4 Cable selection operating voltages 3-4 Connecting the cables to the plugs/sockets FIELD BUS NODE 3-7 Opening and closing the node 3-7 Configuring the valve terminal 3-9 Address selector switch 3-11 Summary of possible station addresses/station numbers 3-12 Field bus baud rate and field bus length Type 03: Connecting the operating voltages Type 05: Connecting the operating voltages CONNECTING THE PROFIBUS DP INTERFACE Screen connection Cable termination CONNECTING THE INPUT MODULES 3-32 Pin assignment CONNECTING THE OUTPUT MODULES 3-35 Pin assignment 3-37 IV 9701 NH

6 Chapter 4 COMMISSIONING BASIC PRINCIPLES OF CONFIGURATION AND ADDRESSING 4-5 General 4-5 Switching on the operating voltage 4-6 Calculating the configuration data 4-7 Calculating the number of inputs/outputs type Calculating the number of inputs/outputs type Summary of max. number of I/Os 4-10 Address assignment of the valve terminal 4-11 General (types 03 and 05) 4-11 Basic rule Basic rule Basic rule Address assignment after extension/conversion 4-16 Example of addressing type 03 MIDI/MAXI valves 4-19 Example of addressing type 05 ISO valves NH V

7 4.2 SIEMENS 4-21 General 4-21 Commissioning tips 4-22 FREEZE and SYNC 4-23 Status bits 4-25 Module consistency 4-25 Sequence of configuration entries 4-26 Station selection with COM ET200 version 4.x 4-27 Configuration COM ET200 version 4.x 4-28 Station selection with COM ET200 Windows/ COM PROFIBUS 4-31 Configuration COM ET200 Windows V2.x/ COM PROFIBUS 4-33 Station selection with STEP 7 V2.x or NCM S7-PROFIBUS V2.x 4-37 Configuration with STEP 7 V2.x or NCM S7-PROFIBUS V2.x GENERAL DP-MASTER 4-45 Status bits 4-45 Module consistency 4-46 Sequence of configuration entries 4-46 Bus start 4-46 Send parametrizing data 4-47 Send configuration data 4-49 Request diagnostic information 4-50 Cyclic exchange of data 4-51 Summary of implemented functions and service access points (SAP) 4-53 Bus parameter/reaction times 4-53 FREEZE and SYNC 4-54 Device master file (GSD) 4-56 Examples 4-58 VI 9701 NH

8 Chapter 5 DIAGNOSIS AND ERROR TREATMENT SUMMARY OF DIAGNOSTIC POSSIBILITIES ON-THE-SPOT DIAGNOSIS 5-4 LED displays 5-4 Field bus node 5-4 Valves 5-6 Input/output modules TEST ROUTINES 5-9 Display configuration data STATUS BITS 5-12 Position of status bits DIAGNOSIS VIA PROFIBUS-DP 5-16 General 5-16 Diagnostic words 5-16 Diagnostic possibilities 5-17 Summary of diagnostic bytes 5-18 Structure of station status Structure of station status 2 (only valve-terminal related bits) 5-19 Structure of device-related diagnosis Structure of device-related diagnosis Structure of device-related diagnosis Structure of device-related diagnosis DIAGNOSIS VIA PROFIBUS-DP (GENERAL DP-MASTER) 5-22 General 5-22 Diagnostic information NH VII

9 5.7 ERROR TREATMENT 5-27 Reaction to faults in the control system 5-27 Siemens SIMATIC S5/S General DP-master 5-28 Short circuit/overload at an output module 5-29 Appendix A TECHNICAL APPENDIX A-1 TECHNICAL SPECIFICATIONS A-3 CABLE LENGTH AND CROSS SECTION A-7 EXAMPLES OF CIRCUITRY A-12 Appendix B INDEX B-1 VIII 9701 NH

10 General safety instructions GENERAL SAFETY INSTRUCTIONS Designated use The valve terminal types 03/05 described in this manual are designated exclusively for use as follows: for controlling pneumatic and electrical actuators (valves and output modules) for interrogating electrical sensor signals by means of the input modules. Use the valve terminals only as follows: as designated in the instructions in technically faultless condition without any modifications. The specified limit values for pressures, temperatures, electrical data, moments, etc. must be observed when additional commercially-available components such as sensors and actuators are connected. Please comply also with national and local safety laws and regulations NH IX

11 General safety instructions Target group This manual is directed exclusively at technicians who are trained in control and automation technology and who have experience in installing, commissioning, programming and diagnosing programmable logic controllers (PLC) and field bus systems. X 9701 NH

12 General safety instructions IMPORTANT USER INSTRUCTIONS Danger categories This manual contains instructions on the hazards which may arise from improper or negligent use of the valve terminal. A distinction is made between the following instructions: WARNING This means that personal injury or damage to property may occur if these instructions are not observed. CAUTION This means that damage to property may occur if these instructions are not observed. PLEASE NOTE This means that this instruction must also be observed NH XI

13 General safety instructions Pictograms Pictograms and symbols supplement the danger instructions and draw attention to the consequences of dangers. The following pictograms are used: Uncontrolled movements of loose tubing. Unintentional movement of the connected actuators. High electric voltage or undefined switching states of the electronic components which affect the connected circuits. Electrostatically vulnerable components which will be destroyed if their contact surfaces are touched. The ISO valve terminal type 05 is very heavy. Please ensure that it is fastened correctly and see that all operating personnel wear safety shoes. XII 9701 NH

14 General safety instructions Instructions on this manual This manual contains specific information on the installation, commissioning, programming and diagnosis of the valve terminals types 03/05 and the input/output modules. The following product-specific abbreviations are used in this manual: 9701 NH XIII

15 General safety instructions PLEASE NOTE This manual includes a diskette with the device master files and the type files. The referenced file names refer to version V1.4. Explanations can be found on the file "Readme". Abbreviation Terminal or Valve terminal Node Valve-sub base S sub-base D sub-base ISO sub-base I O I/O P module I/O module PLC Meaning Valve terminal type 03 (MIDI/MAXI) or type 05 (ISO) with/without electric I/Os Field bus node Pneumatic sub-base for valves For two single valves type 03 (MIDI/MAXI) For two double solenoid valves or mid-position valves type 03 (MIDI/MAXI) Sub-base for 4, 8 or 12 ISO valves type 05 (as per ISO 5599/I, size 1 or 2) Input Output Input and/or output Pneumatic module in general Module with digital inputs/outputs in general (input/output modules) Programmable logic controller; or simply controller Fig. 0/1: Abbreviations All information on the pneumatic modules is to be found in the Pneumatics Manual P.BE-MIDI/MAXI-03-GB or P.BE-ISO-05-GB. XIV 9701 NH

16 General safety instructions The valve terminals can be connected to the control systems of various manufacturers. This manual deals with the configuration of the controller and the addressing of the valve terminals for the following control/addressing systems. The following diagram lists examples of available master modules for the PROFIBUS- DP: Controller manufacturer Siemens Controller (PLC) SIMATIC S5 series S7 series Bosch CL300, 400, 500 PC600 Field bus module various BM DESI-DP Festo SF 50 integrated PC / IPC CP5410 from Siemens etc. Allen-Bradley PLC 5 PFBIB (extract of possible control systems) Filed bus SINEC L2-DP COMNET-DP PROFIBUS-DP 9701 NH XV

17 General safety instructions This manual describes the operation of the Festo valve terminals types in conjunction with the field bus protocols PROFIBUS-DP as per EN (DIN 19245). PLEASE NOTE In conjunction with a Siemens SIMATIC S5, both the SINEC L2-DP and the PROFIBUS- DP protocols can be used; in conjunction with other PLCs, PCs, industrial PCs, the PROFIBUS-DP protocol must be set. In this manual, the protocol variants are designated as follows: DP-standard for PROFIBUS-DP DP-Siemens for the SINEC L2-DP. The valve terminal does not contain the PROFIBUS-FMS protocol (no combi-slave functions). Service If you have any technical problems, please consult your local Festo Service. XVI 9701 NH

18 1. User instructions 1. SYSTEM SUMMARY 9701 NH 1-1

19 1. User instructions Contents 1.1 SYSTEM SUMMARY 1-3 System structure 1-3 Type 03: Description of components 1-5 Type 05: Description of components 1-9 Description of the functions NH

20 1. User instructions 1.1 SYSTEM SUMMARY System structure Festo offers a solution to automation problems at machine level in the form of the valve terminal. Valve terminals of type 03/05 are constructed on a modular basis and permit combinations of pneumatic and electric modules, such as the following: Industrial PC Controller - Simatic S5/S7 - Bosch - etc. Valve terminal type 03: MIDI/MAXI valves and electric modules PROFIBUS-DP Valve terminal type 03: only MAXI valves Valve terminal type 05: ISO valves and electric modules further slaves Fig. 1/1: System summary and possible variants of valve terminals 9701 NH 1-3

21 1. User instructions The valve terminal with field bus connection offers the following advantages: can be fitted with digital I/Os and pneumatic valve locations subsequent extension/conversion possible small-scale valves can be connected to various control systems less wiring due to two-core cables clarity in system structure due to separation of controller and machine valves already fitted wired (pilot) valve solenoid coils central compressed air supply central exhaust device already tested A field bus system also offers the following advantages: a reduction in the number of output modules in the controller economic data transfer over long distances high baud rate a large number of slaves can be connected error diagnosis is made easier NH

22 1. User instructions Type 03: Description of components Valve terminal type 03 consists of individual modules. Each module is designed with different functions, connections, display and operating elements as shown below Figure Meaning 1 Node FB9 2 Electric modules (input/output modules), fitted with digital inputs (modules with 4 or 8 inputs) digital outputs (modules with 4 outputs) 3 End plate left with hole for additional earth cable connection 4 Pneumatic modules (valve sub-bases) fitted with S valves: 5/2 single solenoid valves 5/2 double solenoid valves 5/3 mid-position valves (exhausted, pressurized, blocked) blanking plates S = Auxiliary pilot air 5 Pneumatic MIDI or MAXI modules: pressure supply with integrated exhaust (MIDI) intermediate air supply with integrated exhaust (MIDI) pressure supply adapter with/without regulator (MIDI/MAXI) additional air supply module (MAXI) 6 End plate right, depending on the size of the last sub-base: with common pneumatic tubing connections and integrated regulator for 5 bar auxiliary pilot air (unregulated pilot air is not permitted) with common pneumatic tubing connections, but without integrated regulator without common pneumatic tubing connections (only MAXI) Fig. 1/2: Modules of valve terminal type NH 1-5

23 1. User instructions The following connection and display elements are to be found on the electric modules: O4 O4 I4 I8 AS-i master; analogue IOs No Meaning Output socket for electrical output Yellow LED (status display per output) Red LED (error display per output) Input socket for one electrical input Green LED (per input) Input socket for two electrical inputs Two green LEDs (one LED per input) Node with LEDs and field bus interface, detailed description in Chapter "Installation" Right-hand end plate Operating voltage connection Fuse for inputs/sensors AS-i master for I/O periphery; analogue I/Os; further modules Fig. 1/3: Display and connection elements of the electronic modules NH

24 1. User instructions The connections, display and operating elements shown below are to be found on the MIDI modules of type No Meaning Node with LEDs and field bus interface, detailed description see chapter "Installation" Yellow LEDs (status) Manual override for valve coils Valve location inscription field Unused valve location with blanking plate Common pneumatic tubing connections Work connections (2 per valve, one above the other) Operating voltage connection Fuse for inputs/sensors Fig. 1/4: Operating, display and connection elements of the pneumatic modules 9701 NH 1-7

25 1. User instructions The connections, display and operating elements shown below are to be found on the MAXI modules of type No Meaning Node with LEDs and field bus interface, detailed description see chapter "Installation" Yellow LEDs (per valve solenoid coil) Manual override (per valve solenoid coil) Valve location inscription field (signs) Unused valve location with blanking plate Common pneumatic tubing connections Work connections (2 per valve, one above the other) Pressure regulator for pilot air Common pneumatic tubing connection Exhaust connections 7 Fig. 1/5: Operation, display and connection elements of MAXI modules type NH

26 1. User instructions Type 05: Description of components Valve terminal type 05 consists of individual modules. Each module is assigned with different functions, connections, display and operating elements. These are shown in the diagram below No. Meaning 1 Node 2 Electronic modules (input/output modules), fitted with digital inputs (modules with 4 or 8 inputs) digital outputs (modules with 4 outputs) 3 End plate left with opening for additional earth connection 4 Adapter plate for pneumatic modules (sub-bases) as per ISO5599/I sizes 1 and 2 5 Pneumatic modules (sub-bases) to be fitted with: Pneumatic valves as per ISO 5599/I - single pneumatic valves - double pneumatic valves - pneumatic mid-position valves (blocked, pressurized, exhausted) components for vertical stacking (regulator plates, flow control plates etc.) blanking plates 6 Right-hand end plate with holes for fitting and with thread for lifting eye bolt (M8) Fig. 1/6: Modules of valve terminal type NH 1-9

27 1. User instructions The connections, display and operating elements shown below are to be found on the ISO modules of type No Meaning 9 11 Node with LEDs and field bus interface, detailed description see chapter "Installation" Fuse for inputs/sensors Adapter module Operating voltage connection of valve terminal type 05 Fuse for valves Valve location inscription field Yellow LEDs (per pilot solenoid) Manual override (per pilot solenoid, pushing or locking) Connection for external pilot air Common connections Work connections (per valve) Adapter cable for operating voltage of node and I/O modules Fig. 1/7: Operation, display and connection elements of ISO modules type 05 The electronic modules are described in this chapter, "Description of components type 03" NH

28 1. User instructions Description of the functions Incoming field bus Continuing field bus Node AA AA AA AA Compressed air Work air Electric signal flow Fig. 1/8: Function summary of valve terminal type 03/05 The node takes control of the following functions: connection of the terminal to the bus controller and to further slaves via the bus interface adaption to the field bus baud rate and protocol of the control system control of the terminal periphery NH 1-11

29 1. User instructions The input modules process the input signals (e.g. from sensors) and transmit these signals via the field bus to the bus controller. The output modules are universal electric outputs and control low-current consuming devices with positive logic, e.g. further valves, lights, etc.. The pneumatic modules create the following connection: common channels for supply and exhaust air electric signals from all solenoid valve coils On the individual pneumatic modules, the work connections 2 and 4 have been provided for each valve location. The common channels on the pneumatic end plate or specific intermediate air supply modules are used to supply the valves with compressed air and to remove the exhaust and pilot exhaust. Additionally intermediate air supply modules are also available for the use of e.g. different work pressures, MIDI/MAXI valves or ISO valves. Please see the pneumatic manuals for detailed information. Only the electric modules and the node are described in this manual NH

30 2. Fitting 2. FITTING 9701 NH 2-1

31 2. Fitting Contents 2.1 FITTING THE COMPONENTS 2-3 Input/output modules 2-4 End plates 2-6 Hat rail clamping unit (type 03) TYPE 03: FITTING THE VALVE TERMINAL 2-9 Wall fitting (type 03) 2-9 Hat rail fitting (type 03) TYPE 05: FITTING THE VALVE TERMINAL 2-12 Wall fitting (type 05) NH

32 2. Fitting 2.1 FITTING THE COMPONENTS WARNING Before fitting the components, switch off the following: compressed air supply power supply to the outputs (pin 2) power supply to the electronic components (pin 1) You can thereby avoid: uncontrolled movements of loose hoses undesired movement of the connected actuators undefined switching states of the electronic components CAUTION The components of the valve terminal contain elements which are liable to damage by electrostatic charges. Do not therefore touch any contact surfaces on the side plug connectors of the components. Observe the instructions for handling elements liable to damage by electrostatic charges. You thereby avoid destroying the valve terminal components NH 2-3

33 2. Fitting PLEASE NOTE Treat all the modules and the components of the valve terminal with great care. Pay special attention to the following: Screw connections must not be distorted or subjected to mechanical stress. The screws must fit correctly (otherwise the threads will be damaged). The specified torques must be observed. The modules must be aligned correctly (IP 65). The connecting surfaces must be clean (avoid leaks and faulty contacts). The contacts of the type 03 MIDI valve solenoid coils must not be bent (they are not protected against alternate bending, i.e. they will break off when bent backwards). Please observe also the fitting instructions in the packet in the case of modules which are ordered at a later stage. Input/output modules Before the valve terminal can be extended or converted, it must be dismantled. Dismantling (see also following diagram): Remove completely the screws of the relevant modules. The modules are now held together only by the electric plug. Pull the modules carefully and without tipping away from the electric plug connections. Replace broken or damaged seals NH

34 2. Fitting Fitting (see also following diagram): PLEASE NOTE Always place subsequently ordered modules behind the last module before the end plate. Do not fit more than 12 electric modules. Fit the modules as follows: Fit a (new) seal on the right-hand contact surface facing the node. Fit the module as shown below. Seal Fastening screws max. 1 Nm Fig. 2/1: Fitting electronic I/O modules 9701 NH 2-5

35 2. Fitting End plates A left-hand and a right-hand end plate are required as a mechanical termination of the terminal. These end plates fulfil the following functions: They comply with protection class IP65. They contain connections/holes for the protective earth cable. They contain holes for fitting on walls and to the hat rail clamping unit. The right-hand end plate of the ISO valve terminal is sufficiently grounded via the screw connections and pre-fitted spring contacts of the sub-bases. There are different types of right-hand end plate for valve terminals of type 03 (MIDI/MAXI). All are supplied with pre-fitted earth cables. CAUTION The right-hand end plate of valve terminal type 03 must be grounded via the earth cable before it is fitted. This is to avoid high voltages on the metal surface in the case of a fault NH

36 2. Fitting Earth the end plates as follows: Right-hand end plate (type 03): In order to earth the right-hand end plate, connect the fitted cable on the inside to the appropriate contacts on the pneumatic modules or on the node (see diagram below). Left-hand end plate (types 03 and 05): Connect the left-hand end plate conductively to the other components via the spring contacts which are already fitted. Instructions on grounding the complete valve terminal are to be found in the chapter "Installation". The following diagram shows how both end plates are fitted. Seal Contact for earth cable Seal Fastening screws max. 1 Nm Ready-fitted earth cable Fig. 2/2: Fitting the end plates (Example for terminal type 03) 9701 NH 2-7

37 2. Fitting Hat rail clamping unit (type 03) The hat rail clamping unit is required if the terminal is to be fitted onto a hat rail (support rail as per EN 50022). The hat rail clamping unit is fastened to the back of the end plates as shown in the following diagram: Before fitting ensure that: the fastening surfaces are clean (cleaned with spirit) the flat head screws are tightened (6) After fitting ensure that: the levers are secured with a retaining screw (7). 1 Rubber foot, self-adhesive 2 Clamping elements 3 Left-hand lever *) 4 Right-hand lever *) 5 O ring 6 Flat head screw 7 Retaining screw *) Levers differ in length for MIDI or MAXI Fig. 2/3: Fitting the hat rail clamping unit NH

38 2. Fitting 2.2 TYPE 03: FITTING THE VALVE TERMINAL Wall fitting (type 03) WARNING With long terminals use additional supporting brackets every 200 mm. This is to avoid the following: overloading the fastening eyes on the left-hand end plate the terminal sagging natural resonances 7.6 mm Proceed as follows: Calculate the weight of the terminal (weigh or estimate). General rule: MIDI MAXI per pneumatic module 800 g 1200 g per node 1000 g 1000 g per electronic module 400 g 400 g Make sure that the fastening surface can carry this weight. Fasten the terminal with four M6 screws as shown below (fitting position as desired). Use washers if necessary. M6 Fig. 2/4: Fitting terminal type 03 onto a wall 9701 NH 2-9

39 2. Fitting Hat rail fitting (type 03) The terminal is suitable for fitting onto a hat rail (support rail as per EN 50022). For this purpose there is a guide groove on the rear of all modules for hanging the terminal on the hat rail. CAUTION A hat rail fitting must not be used without a hat rail clamping unit. If the terminal is fitted in a sloping position or at a point subjected to vibration, use screw (7) to protect the hat rail clamping unit against unintentional loosening/opening. PLEASE NOTE If fitted in a horizontal position and with a non-vibrating load the hat rail clamping unit need not to be fastened with screws (7). If there is no hat rail clamping unit on the terminal, it can be ordered and fitted at a later stage. The use of MIDI or MAXI clamping units depends on the end plate fitted (MIDI/MAXI). Proceed as follows: Calculate the weight of the terminal (weigh or estimate). General rule: MIDI MAXI per pneumatic module 800 g 1200 g per node 1000 g 1000 g per electronic module 400 g 400 g NH

40 2. Fitting Make sure that the fastening surface can carry this weight. Fit a hat rail (support rail EN x15; width 35 mm, height 15 mm). Fasten the hat rail to the mounting surface at least every 100 mm. Hang the terminal onto the hat rail. Secure the terminal on both sides against tilting or slipping with the hat rail clamping unit (see diagram below). If the terminal is fitted in a sloping position or at a point subjected to vibration, use two screws (7) to protect the hat rail clamping unit against unintentional loosening/opening. Valve terminal type 03 Hat rail clamping unit locked Retaining screw (7) Fig. 2/5: Fitting the valve terminal type 03 onto a hat rail 9701 NH 2-11

41 2. Fitting 2.3 TYPE 05: FITTING THE VALVE TERMINAL Wall fitting (type 05) WARNING With long terminals (e.g. several I/O modules) use additional supporting brackets every 200 mm. This is to avoid the following: overloading the fastening eyes on the left-hand end plate the terminal sagging natural resonances Proceed as follows: Calculate the weigh of the terminal (weigh or estimate). General rule: Sub-base *) - 4 valve locations incl. valves - 8 valve locations incl. valves - 12 valve locations incl. valves ISO size 1 ISO size 2 8 kg 14 kg 20 kg 12 kg 20 kg 28 kg per node 1 kg 1 kg per electronic module 0.4 kg 0.4 kg *) Components for vertical stacking: Please see pneumatics manual P.BE-ISO-GB for weights. Make sure that the fastening surface can carry this weight NH

42 2. Fitting Fasten the terminal as follows: Use 3 screws M10 on the adapter plate and the right-hand end plate (2) 2 screws M6 on the left-hand end plate (1) If necessary use additional fitting possibilities as follows: Fastening hole on the back of the right-hand end plate with M10 thread ("blind hole" (3)) supporting angles for I/O modules (see fitting instructions supplied with the angles) The ISO valve terminal can be fitted as desired. Use washers if necessary. Use the M8 thread for lifting eye bolt (e.g. for safe transport). 1 2 M8 thread in end plate for lifting eye bolt 3 M6 M10 Fig. 2/6: Wall fitting of an ISO valve terminal type NH 2-13

43 2. Fitting NH

44 3. Installation 3. INSTALLATION 9701 NH 3-1

45 3. Installation Contents 3.1 GENERAL CONNECTION PRINCIPLES 3-3 Cable selection field bus cable 3-4 Cable selection operating voltages 3-4 Connecting the cables to the plugs/sockets FIELD BUS NODE 3-7 Opening and closing the node 3-7 Configuring the valve terminal 3-10 Address selector switch 3-12 Summary of possible station addresses/station numbers 3-13 Field bus baud rate and field bus length Type 03: Connecting the operating voltages Type 05: Connecting the operating voltages CONNECTING THE PROFIBUS DP INTERFACE Screening connection Cable termination CONNECTING THE INPUT MODULES 3-32 Pin assignment CONNECTING THE OUTPUT MODULES 3-35 Pin assignment NH

46 3. Installation 3.1 GENERAL CONNECTION PRINCIPLES WARNING Before installation or maintenance work is carried out, the following must be switched off: the compressed air supply power supply to the electronic components (pin 1) power supply to the outputs/valves (pin 2) You thereby avoid: uncontrolled movements of loose tubing undesired movements of the connected actuators undefined switching states of the electronic components 9701 NH 3-3

47 3. Installation Cable selection field bus cable The field bus cable is a shielded twisted-pair wire. Please consult the PLC manual for the controller for the type of cable to be used. The distance and the field bus baud rate must also be taken into account. Cable selection operating voltages Several parameters must be taken into account when the two operating voltages are connected. Further information is to be found in the following chapters: Chapter 3, Installation Section: "Connecting the operating voltages" - Calculating the current consumption - Power unit design - Cable cross section and length APPENDIX A, Cable length and cross section - Determining the cross section and length with tables - Calculating with a formula NH

48 3. Installation Connecting the cables to the plugs/sockets CAUTION The position of the pins on the plugs is different from that on the sockets. The connections of the input and output stages have been designed as sockets. The connections of the operating voltage have been designed as plugs. Please refer to the following chapters for the pin assignment. When you have selected suitable cables, connect these according to steps below. 1. Open the plugs/sockets as follows (see diagram): Power supply socket: Insert the power supply socket into the operating voltage connection on the valve terminal. Unscrew the housing of the socket, then remove the connection part of the socket which you have inserted into the operating voltage connection. Sensor plug: Unscrew the centre knurled nut NH 3-5

49 3. Installation 2. Open the strain relief on the rear part of the housing. Pass the cable through as shown in the diagram below (PG = Conduit thread). Cable diameter: PG 7: mm PG 9: mm PG 13.5: mm Plugs/sockets (straight/angled): Power supply socket: PG 7, 9 or 13.5 Sensor plug: PG 7 AAA AAA Cable Strain relief Housing AAAAAA AAAAAA AAAAAA AAAAAA AAAA AAAA AAAA AAAA AAAAAAA AAAAAAA AAAAAAA AAAAAAA Connection part Socket Plug Fig. 3/1: Individual plug/socket parts and cable routing 3. Remove 5 mm of insulation from the end of the cable. 4. Fit the strands with cable end sleeves. 5. Connnect the ends of the cables. 6. Insert the connection part onto the housing of the plug/socket again. Pull the cable back so that it is not looped inside the housing. 7. Tighten the strain relief NH

50 3. Installation 3.2 FIELD BUS NODE Opening and closing the node WARNING Before installation or maintenance work is carried out, the following must be switched off: compressed air supply power supply to the electronic components (pin 1) power supply to the outputs/valves (pin 2) You thereby avoid: uncontrolled movements of loose tubing undesired movements of the connected actuators undefined switching states of the electronic components CAUTION The components of the valve terminal contain elements which are liable to damage by electrostatic charges. Do not therefore touch any contact surfaces on the side plug connectors of the components. Observe the instructions for handling elements liable to damage by electrostatic charges. You thereby avoid destroying the valve terminal components NH 3-7

51 3. Installation The following connection and display elements are to be found on the cover of the node: Green LED Green LED Red LED Plug for field bus cable Fuse for power supply to inputs Power supply connection Fig. 3/2: Cover of the node PLEASE NOTE The cover is connected to the internal PC boards via the operating voltage cable. It cannot therefore be removed completely. Opening Unscrew the 6 Philips screws in the cover and carefully remove the cover by lifting upwards. Do not damage the cable through mechanical stress. Closing Replace the cover. Place the cables for the operating voltage connection back into the housing so that they are not clamped. Tighten the Philips screws in the cover in diagonally opposite sequence NH

52 3. Installation Configuring the valve terminal There are four PC boards in the node. Board 2 contains an LED and a plugs for the cables. Board 3 contains two LEDs and switches for setting the configuration. Green LED Green LED Plug for field bus cables Shield AA 1 AA 2 3 A AA 4 Red LED Address selector switches (station number) Voltage monitoring on/off Reserved Reserved Plug for operating voltage connection Fig. 3/3: Connection, display and operation elements of the node PLEASE NOTE Boards 2 and 3 are connected with each other. They can only be removed or inserted together NH 3-9

53 1 2 VIFB13-03/05 3. Installation Setting the station number and voltage monitoring Dual in-line switch (DIL switch) The following functions can be set on the DIL switch: Station number Voltage monitoring - supply to valves - supply to output modules The DIL switch consists of four switch elements. These are numbered from The position "ON" is marked. 3 4 A A DIL switch ON AA AA AA AA Address hundreds (station no.) 1 1 A AA AA A AA AA DIL switch Protocol 1 AA ON AA AA AA 2 AA A AA active 2 AA AA inactive Fig. 3/4: Position of the DIL switch NH

54 3. Installation Address selector switches The station number of the valve terminal should be set with the two address selector switches and DIL switch element no. 1 on board 3. The switches are numbered from The arrow on the address selector switches indicates the tens or units figure of the station number set. UNITS TENS 1 2 AA AA Address selector switch UNIT figure Address selector switch TENS figure Address selector switch HUNDREDS figure Fig. 3/5: Function of the addr. selector switches PLEASE NOTE Station numbers (DP slave addresses) can not be changed by the DP master module. Addressing the valve terminals is only possible by using the station number set on the address selector switch NH 3-11

55 3. Installation Summary of possible station addresses/ station numbers PLEASE NOTE Station addresses/station numbers may be assigned only once per field bus module/ PROFIBUS-DP interface. Observe also any limitations as regards the assignment of station numbers via the DP master. Recommendation Assign the station addresses/station numbers in ascending order and adapter them to the machine structure of the system. Permitted station numbers 0;...; 125 Fig. 3/6: Permitted station numbers Proceed as follows: 1. Switch off the power supply. 2. Assign a non-reserved field bus address to the valve terminal. 3. Use a screwdriver to set the arrow of the relevant address selector switch or DIL switch 1 to the units, tens or hundreds figure of the desired station number NH

56 3. Installation Example: Example1 Example 2 UNITS UNITS TENS TENS AA AA AA AA HUNDREDS Station number set: A AA AA AA HUNDREDS Station number set: 121 Fig. 3/7: Examples of set station numbers PLEASE NOTE Check whether you wish to display the configuration data before closing the cover of the node (see chapter 5.3) NH 3-13

57 3. Installation Field bus baud rate and field bus length PLEASE NOTE The Festo valve terminals types 03/05 set themselves automatically to the correct baud rate. The maximum field bus length depends on the baud rate used. The table below shows the baud rates which can be used. Baud rate Field bus length (max.) 9.6 kb 1200 m 19.2 kb 1200 m kb 1200 m kb 1000 m 500 kb 400 m 1500 kb 200 m kb 100 m Cable specification as per DIN part 3 (cable A): Surge impedance: Ohm (2-20 MHz) Capacitance per unit length < 30 pf/m Loop resistance < 110 Ohm/km Core diameter > 0.64 mm Core cross section > 0.34 mm 2 Permitted outer diameter of cable for Festo plug no : mm NH

58 3. Installation Type 03: Connecting the operating voltages WARNING In order that the operating voltage can be isolated reliably, you must use an isolating transformer with at least 4 kv isolation resistance complying with standard EN CAUTION The power supply to the outputs/valves (pin 2) must be separately fused externally with max. 10 A. The external fuse prevents the valve terminal from being damaged in the event of a short circuit NH 3-15

59 3. Installation The 24 V operating voltages are connected at the lower right-hand edge of the node. Operating voltage connection Fig. 3/8: Operating voltage connection The following + 24 V DC supplies are made via this connection: the operating voltage for internal electric components and the power supply to the inputs of the input modules (pin 1: DC 24 V, tolerance ± 25 %; external fuse recommended max A). the operating voltage for the outputs of the valves and the outputs of the output modules (pin 2: DC +24 V, tolerance ± 10 %; external fuse max. 10 A required). Recommendation The operating voltage for the outputs should be connected via the EMERGENCY STOP circuit NH

60 3. Installation PLEASE NOTE Please note that with common voltage supply for pin 1 (electronic components and inputs) and pin 2 (outputs/valves), the lower tolerance of ± 10 % for both circuits must be observed. Check the 24 V operating voltage of the outputs while your system is operating. Please see that the operating voltage of the outputs lies within the permitted tolerances even during full operation. Recommendation Use a closed loop power unit. Calculate the complete current consumption according to the following table and select both a suitable power unit and cable cross section. Avoid long distances between the power unit and the terminal. Calculate the permitted distance according to Appendix A. The following rule applies for type 03: Operating voltage Pin 1 Pin 2 VB = 2.2 A = 10 A = 24 V Cable cross section Distance 1.5 mm 2 8 m 2.5 mm 2 14 m 9701 NH 3-17

61 3. Installation Calculating the current consumption type 03 The following table shows the calculation of the total current consumption for type 03 terminals. The values are rounded up. If you use other valves or modules, you should consult the appropriate technical specifications for their consumption. Current consumption of electronic components, node type 03 and inputs (pin 1, 24 V ± 25 %) Node A Number of simultaneously occupied sensor inputs: x A + A Sensor supplies: x A (see manufacturer specifications) + A Current consumption of electronic components, node and inputs (pin 1) max. 2.2 A = A A Current consumption of outputs type 03 (pin 2, 24 V ± 10 %) Number of MIDI valve coils (simultaneously under power): x A + A Number of MAXI valve coils (simultaneously under power): x A + A Number of simultaneously activated electrical outputs: x A + A Load current of simultaneously activated electrical outputs x A + A Current consumption of outputs (pin 2) max. 10 A = A + A Total current consumption of valve terminal type 03 = A Fig. 3/9: Calculating the total current consumption of type NH

62 3. Installation The following diagram shows the pin assignment of the operating voltage connection. 24 V supply for electronic components and inputs 1 24 V supply for valves, outputs PE 3 (protective earth connection, leading contact) V Fig. 3/10: Pin assignment of the operating voltage connection Protective earthing The valve terminal has two protective earth connections: at the operating voltage connection (pin 4 incoming socket). at the left-hand end plate (M4 thread). PLEASE NOTE Always connect the earth cable to pin 4 of the operating voltage connection. Connect an earth cable of sufficient crosssection to the left-hand end plate if the valve terminal is not mounted on an earthed machine stand. Make sure that the housing of the valve terminal and the earth cable at pin 4 have the same potential and that no equalizing currents flow. In this way you can avoid interference due to electromagnetic sources NH 3-19

63 3. Installation Connection example (type 03) The following diagram shows the connection of a common 24 V supply for pins 1 and 2. Please note that: the outputs/valves must be protected against short circuit/overload with an external 10 A fuse the supply to the electronic components and inputs should be fused externally with 3.15 A against short circuit/overload (recommendation) the common tolerance of DC 24 V ± 10 % must be observed equalizing currents must be avoided when both earth cables are connected, e.g. by means of cables with appropriate cross section as a potential compensation NH

64 3. Installation Connecting cable for potential compensation of earth connections Fuse for inputs/sensors (2A) AC DC 24V ± 10% 0 V 24 V 3.15 A External fuses 10 A EMERGENCY STOP Earth cable connection pin 4 designed for 12 A Fig. 3/11: Example connecting a common 24 V supply and both earth cables 9701 NH 3-21

65 3. Installation Type 05: Connecting the operating voltages WARNING In order that the operating voltage can be isolated reliably, you must use an isolating transformer with at least 4 kv isolation resistance complying with standard EN CAUTION The power supply to the outputs/valves (pin 2) must be separately fused externally with max. 10 A. The external fuse prevents the valve terminal from being damaged in the event of a short circuit NH

66 3. Installation The 24 V operating voltages are connected at the adapter plate between the node and the valves. The operating voltage connection for the node and the I/O modules is supplied via the adapter cable. Operating voltage connection type 05 Fuse for valves (4A slow blowing) Adapter cable Fig. 3/12: Position of the operating voltage connection The following components on valve terminal type 05 are supplied separately + 24 V DC via this connection: the internal electric components and the input modules (pin 1: DC + 24 V, tolerance ± 25 % external fuse recommended with max A). the outputs of the valves and of the output modules (pin 2: DC + 24 V, tolerance ± 10 %, external fuse max. 10 A, slow blowing, required). Recommendation The operating voltage for the outputs/valves should be connected via the EMERGENCY STOP circuit or contacts NH 3-23

67 3. Installation PLEASE NOTE Please note that with common voltage supply for pin 1 (electronic components and inputs) and pin 2 (outputs/valves), the lower tolerance of ± 10 % for both circuits must be observed. Check the 24 V operating voltage of the outputs while your system is operating. Please see that the operating voltage of the outputs lies within the permitted tolerances even during full operation. Recommendation Use a closed loop power unit. Calculate the complete current consumption according to the following table and select both a suitable power unit and cable cross section. Avoid long distances between the power unit and the terminal. Calculate the permitted distance according to Appendix A. The following rule applies for type 05: Current consumption *) Cable cross section Distance Pin 1 = 2.2 A 1.5 mm 2 8 m Pin 2 = 10 A 2.5 mm 2 14 m VB = 24 V *) Please note that the max. total current consumption (pins 1 and 2) is 12.2 A NH

68 3. Installation Calculating the current consumption type 05 The following table shows the calculation of the total current consumption for the ISO terminal type 05. The values are rounded up. If you use other valves or modules, you should consult the appropriate technical specifications for their consumption. Current consumption of electronic components, node type 05 and inputs (pin 1, 24 V ± 25 %) Node A Number of simultaneously occupied sensor inputs: x A + A Sensor supplies: x A (see manufacturer specifications) + A Current consumption of electronic components, Node and inputs (pin 1) max. 2.2 A = A A Current consumption of outputs type 05 (pin 2, 24 V ± 10 %) Number of valve coils (simultaneously under power): x A + A Number of simultaneously activated electrical outputs: x A + A Load current of simultaneously activated electrical outputs x A + A Current consumption of outputs (pin 2) max. 10 A = A + A Total current consumption of valve terminal type 05 = A Fig. 3/13: Calculating the total current consumption type NH 3-25

69 3. Installation The following diagram shows the pin assignment of the operating voltage connection on the adapter plate. 24 V supply for electronic components and inputs 24 V supply for valves, outputs PE (protective earth connection, leading contact) Protective earthing The valve terminal has two protective earth connections: at the operating voltage connection (pin 4, incoming socket) 0 V Fig. 3/14: Pin assignment of the operating voltage connection at the left-hand end plate (M4 thread). PLEASE NOTE Always connect the earth cable to pin 4 of the operating voltage connection. Make sure that the housing of the valve terminal and the earth cable at pin 4 have the same potential and that no equalizing currents flow. Connect an earth cable of sufficient crosssection to the left-hand end plate if the valve terminal is not mounted on an earthed machine stand. In this way you can avoid interference due to electromagnetic sources NH

70 3. Installation Connection example (type 05) The following diagram shows the connection of a common 24 V supply for pins 1 and 2. Please note that: the outputs/valves must be protected against short circuit/overload with an external 10 A fuse (slow blowing) the supply to the electronic components and inputs should be fused externally with 3.15 A against short circuit/overload (recommendation) that the operating voltage of the sensors is separately fused (2 A) that the operating voltage of the valves is separately fused (4 A, slow blowing) the common tolerance of DC 24 V ± 10 % must be observed the operating voltage supply to the node is made via the adapter cable equalizing currents must be avoided when both earth cables are connected, e.g. by means of cables with appropriate cross section as a potential compensation NH 3-27

71 3. Installation Operating voltage connection Fuse for valves (4 A) Connected adapter cable Connecting cable for potential compensation of earth connections AC DC 24V ± 10% 0 V 24 V 10 A 3.15 A External fuses EMERGENCY STOP Earth cable connection pin 4 designed for 12 A Fig. 3/15: Example connecting a common 24 V supply and both earth cables (type 05) NH

72 3. Installation 3.3 CONNECTING THE PROFIBUS DP INTERFACE PLEASE NOTE Only the Festo plug will fulfill requirement IP 65. There is a sub-d connection on the node for connecting the CP system to the PROFIBUS- DP. This connection is used for the incoming cable, as well as for the continuing fieldbus cable. The node can be connected with the sub-d plug from Festo (part no ). Outer diameter of cable for Festo Sub-D plug: mm. Pin assignment Pin Signal Designation Housing n.c. n.c. RxD/TxD-P CNTR-P 1 DGND VP n.c. RxD/TxD-N n.c. Screening Not connected Not connected Receive/send data-p Repeater control signal Data reference potential (M5V) Positive power supply (P5V) Not connected Receive/send data-n Not connected Direct connection to the housing 1 Repeater control signal CNTR-P is produced as a TTL signal. Fig. 3/16: Connecting the PROFIBUS DP interface PLEASE NOTE Before connecting Sub-D plugs of other manufacturers, you must replace both flat screws by bolts (part no ) NH 3-29

73 3. Installation Screening connection The Festo plug enables the screening in a floating manner: Clamp the screening of the fieldbus cable under the cable clip of the Festo plug (see diagram). Cable clip, screening connection Connection on housing of Sub-D plug Fig. 3/17: Screening connection PLEASE NOTE The cable clip in the Festo plug is capacitively connected internally with the metal housing of the Sub-D plug. This is to prevent equalizing currents from flowing via the screening of the fieldbus cable (see diagram) NH

74 3. Installation Cable termination PLEASE NOTE A cable termination is required at both ends of the bus cable. This also applies if the module or the communication processor is at the beginning of the bus cable. Recommendation: If the CP system is at the end of the fieldbus system, a cable termination is required. Use the Sub-D plug from Festo (part no ) for this purpose. A suitable RC network has already been fitted into the housing of the Festo-sub-D plug. The cable termination must be switched manually. Pin Ω Pin Ω Pin Ω Pin 5 Pin 6 Power supply Pin 3 RxD/TxD-P Pin 8 RxD/TxD-N Pin 5 DGND Fig. 3/18: Termination for cable A 9701 NH 3-31

75 3. Installation 3.4 CONNECTING THE INPUT MODULES WARNING Before installation or maintenance work is carried out, the following must be switched off: the compressed air supply the power supply to the electronic components (pin 1). the power supply to the outputs/valves (pin 2). You thereby avoid: uncontrolled movements of loose tubing undesired movements of the connected actuators undefined switching states of the electronic components NH

76 3. Installation Four or eight inputs are available on the input modules of the valve terminal for user applications. The switching logic depends on the type of input module: Type of input module INPUT INPUT-N Switching logic PNP (positive) NPN (negative) Input module 4 inputs Input module 8 inputs Socket with one digital input Green LED Socket with two digital inputs One green LED per digital input Fig. 3/19: Digital PNP input modules (4/8 inputs) Recommendation for 8-input modules: Use the Festo duo-cable to connect two sensors via one plug at low cost NH 3-33

77 3. Installation Pin assignment The following diagram shows the pin assignment of all the PNP/NPN inputs. Pin assignment 4 inputs LED Pin assignment 8 inputs LED n. c V 0 Input 0 V 0 Ix V 1 4 Input Ix + 24 V 1 4 Input Ix 1 n. c V Input 0 V 1 Ix V 1 4 Input Ix V 1 4 Input Ix+2 3 n. c V Input 0 V 2 Ix V 1 4 Input Ix V 1 4 Input Ix+4 5 n. c V Input 0 V 3 Ix V 1 4 Input Ix V Input Ix+6 Fig. 3/20: Input module: pin assignment 4/8 inputs (PNP/NPN) NH

78 3. Installation 3.5 CONNECTING THE OUTPUT MODULES WARNING Before installation or maintenance work is carried out, the following must be switched off: the compressed air supply the power supply to the electronic components (pin 1). the power supply to the outputs/valves (pin 2). You thereby avoid: uncontrolled movements of loose tubing undesired movements of the connected actuators undefined switching states of the electronic components NH 3-35

79 3. Installation Four transistor outputs are available for the user on the output modules of the valve terminal. The outputs have positive logic (PNP outputs). Output module (4 outputs) Yellow LED per output Red LED per output Socket with one digital output Fig. 3/21: Digital output modules (4 outputs) NH

80 3. Installation Pin assignment The following diagram shows the pin assignment of all outputs. Pin assignment 4 inputs LED n. c. 0 V n. c. 1 4 Output Ox n. c V 1 n. c. 1 4 Output Ox+1 n. c V 2 n. c. 1 4 Output Ox+2 n. c V 3 n. c. 1 4 Output Ox+3 Fig. 3/22: Output module: pin assignment (4 outputs) 9701 NH 3-37

81 3. Installation NH

82 4. Commissioning 4. COMMISSIONING 9701 NH 4-1

83 4. Commissioning Contents 4.1 BASIC PRINCIPLES OF CONFIGURATION AND ADDRESSING 4-5 General 4-5 Switching on the operating voltage 4-6 Calculating the configuration data 4-7 Calculating the number of inputs/outputs type Calculating the number of inputs/outputs type Summary of max. number of I/Os 4-10 Address assignment of the valve terminal 4-11 General (types 03 and 05) 4-11 Basic rule Basic rule Basic rule Address assignment after extension/conversion 4-16 Example of addressing type 03 MIDI/MAXI valves 4-19 Example of addressing type 05 ISO valves SIEMENS 4-21 General 4-21 Commissioning tips 4-22 FREEZE and SYNC 4-23 Status bits 4-25 Module consistency 4-25 Sequence of configuration entries 4-26 Station selection with COM ET200 version 4.x 4-27 Configuration COM ET200 version 4.x 4-28 Station selection with COM ET200 Windows / COM PROFIBUS NH

84 4. Commissioning Configuration COM ET200 Windows V2.x / COM PROFIBUS 4-33 Station selection with STEP 7 V2.x or NCM S7-PROFIBUS V2.x 4-37 Configuration with STEP 7 V2.x or NCM S7-PROFIBUS V2.x GENERAL DP-MASTER 4-45 Status bits 4-45 Module consistency 4-46 Sequence of configuration entries 4-46 Bus start 4-46 Send parametrizing data 4-47 Send configuration data 4-49 Request diagnostic information 4-50 Cyclic exchange of data 4-51 Summary of implemented functions and service access points (SAP) 4-53 Bus parameter/reaction times 4-53 FREEZE and SYNC 4-54 Device master file (GSD) 4-56 Examples NH 4-3

85 4. Commissioning NH

86 4. Commissioning 4.1 BASIC PRINCIPLES OF CONFIGURATION AND ADDRESSING General Before commissioning or programming, the user should compile a configuration list for the connected field bus slaves. On the basis of this list he can: make a comparison between the ACTUAL and NOMINAL configurations in order to recognise connection errors; access these specifications during the syntax check of a program, in order to avoid addressing errors. The valve terminal must be configured very accurately, since different configuration specifications may be necessary for each terminal due to the modular structure. Observe here also the specifications in the following sections. PLEASE NOTE You can display the configuration data of the valve terminal via the LEDs "POWER V" and "BUS ERROR" (see chapter 5.3) NH 4-5

87 4. Commissioning Switching on the operating voltage PLEASE NOTE Observe also the switching on instructions in the manual for the PLC/PC. When the control system is switched on, the controller compares the nominal and the actual configuration. For the configuration run it is important that: the specifications on configuration are as complete as possible and are correct; the power supply to the controller and to the connected slaves is made either simultaneously or in the correct sequence. Please observe the following points regarding switching on the power supply: Common supply: If the control system and the valve terminal have a common power supply, they should be switched on via a common power supply unit or common central switch. Separate supply: If the control system and the valve terminal have separate power supplies, they should be switched on in the following sequence: 1. operating voltage for valve terminal 2. operating voltage for the control system NH

88 4. Commissioning Calculating the configuration data Before configuring, calculate the exact number of available inputs/outputs. A modular valve terminal consists of a varying number of I/Os, depending on the type ordered. PLEASE NOTE The terminal provides four status bits for diagnosis. These are always assigned automatically within the terminal there are input modules. The status bits occupy four input addresses. The following table specifies the I/Os required per module for the configuration. Module type Single-type valve sub-base (type 03) Double-type valve sub-base (type 05) ISO sub-base modules (type 05) - 4 valve locations - 8 valve locations - 12 valve locations 4-output module (4 digital outputs) 4-input module (4 digital inputs) 8-input module (8 digital inputs) Number of assigned I/Os*) 2 outputs 4 outputs 8 outputs 16 outputs 24 outputs 4 outputs 4 inputs 8 inputs Status bits**) 4 inputs *) The I/Os are assigned automatically in the terminal, irrespective of whether an input/output is actually used. **) The status bits are assigned automatically in the terminal when there are input modules Fig. 4/1: Number of assigned I/Os per module 9701 NH 4-7

89 4. Commissioning Calculating the number of inputs/outputs type 03 Copy the table for further use and calculate the number of inputs and outputs. Table for calculating the inputs/outputs of type 03 INPUTS 1. Number of 4-input modules 4 Σ I 2. Number of 8-input modules 8 + Σ I 3. The 4 status bits are assigned internally automatically by the terminal. They must be treated like inputs and must be added to the intermediate sum: + 4I Total sum of inputs Σ I OUTPUTS 4. Number of S-type sub-base modules (type 03) 2 Σ O 5. Number of D-type sub-base modules (type 03) 4 + Σ O Intermediate total of = Σ O 6. Check whether the sum of can be divided by 4 without remainder. This check is necessary because of the 4-bit orientated internal addressing of the terminal. Different cases: a) If divisible by 4 without remainder: continue with 7. b) If not, round up (+ 2 outputs) + 2O 7. Number of electronic output modules 4 + Σ O Total sum of outputs = Σ O Fig. 4/2: Calculating the number of inputs/outputs of type NH

90 4. Commissioning Calculating the number of inputs/outputs type 05 Copy the table for further calculations. Table for calculating the number of inputs/outputs of type 05 INPUTS 1. Number of 4-input modules 4 Σ I 2. Number of 8-input modules 8 + Σ I 3. The 4 status bits are assigned internally automatically by the terminal. They must be treated like inputs and must be added to the intermediate sum: + 4I Total sum of inputs to be configured Σ I OUTPUTS 4. ISO sub-base modules for 4 valve locations 8 O 8 valve locations 16 O 12 valve locations 24 O Σ O 5. Number of electronic output modules 4 = Σ O Total sum of outputs to be configured = Σ O Fig. 4/3: Calculating the number of inputs/outputs for type NH 4-9

91 4. Commissioning Summary of maximum number of I/Os PLEASE NOTE The maximum possible number of inputs/ outputs is influenced by the following: max. 26 valve coils can be actuated max. 12 electrical modules (including AS-i master analogue I/Os). The following table shows the possible combinations of digital I/Os. The maximum values with AS-i I/Os and analogue I/Os must be considered separately. Input modules Number of inputs/outputs Output modules Valve coils NH

92 4. Commissioning Address assignment of the valve terminal General (types 03 and 05) The address assignment of the outputs of a modular valve terminal depends on the number of valve locations fitted on the terminal. A distinction must be made between the following fitting variants: valves and digital I/O modules valves only digital I/O modules only. The basic rules described below apply to the address assignment of these fitting variants. Explicit examples of addressing valve terminals type 03 and type 05 are described in separate chapters following these basic rules. PLEASE NOTE If one valve location occupies two addresses the addresses are assigned as follows: lower address pilot solenoid coil 14 higher address pilot solenoid coil NH 4-11

93 4. Commissioning Basic rule 1 With a mixed fitting, consideration is given to the address assignment of the valves, digital I/O modules and status bits. 1. Outputs: The address assignment of the outputs does not depend on the inputs. 1.1 Address assignment of valves: Addresses should be assigned in ascending order without gaps. Counting should begin on the node from left to right. S-type sub-base mod. always occupy 2 add. D-type sub-base mod. always occupy 4 add. ISO valve locations always occupy 2 add. Maximum 26 solenoid valve coils can be add. 1.2 Round up to 4 bits: different cases: a) If the number of valve addresses can be divided by 4 without remainder, continue with section 1.3. b) If the number of valve addresses is not divisible by 4 without remainder, it must be rounded up to 4 bits because of the 4-bit orientated addressing. The rounded up 2 bits in the address range cannot be used. 1.3 Address assignment of the output modules: The digital outputs are addressed after the (rounded up 4-bit) addresses of the valves. Addresses should be assigned in ascending order without gaps. Counting should begin on the node from right to left. Counting on the individual modules is from top to bottom. Digital output modules always occupy 4 addresses NH

94 4. Commissioning 2. Inputs: The address assignment of the inputs does not depend on the outputs. 2.1 Address assignment of the input modules: Addresses should be assigned in ascending order without gaps. Counting should begin on the node from right to left. Counting on the individual module is from top to bottom. 4-input modules occupy 4 addresses. 8-input modules occupy 8 addresses. 2.2 Status bits The addressing of the status bits depends on the output fittings and on the configuration. The following always applies: The status bits are only available when input modules are connected to the terminal and when at least eight inputs are configured in the PLC. Addressing. The status bits are transferred to the four highest positions on the configured address range. When the operating voltage is switched on, the valve terminal automatically recognises all available pneumatic modules (type 03: max. 13 modules; type 05: 4, 8 or 12 valve locations) and digital input/output modules and assigns the appropriate addresses. If a valve location remains unused (blanking plate) or if a digital input/output is not connected, the appropriate address is still assigned NH 4-13

95 4. Commissioning The diagram below shows the address assignment with mixed fitting. 4-input module 8-input module 4-output module 4-output module S-type sub-base D-type sub-base D-type sub-base D-type sub-base Do not round up Fig. 4/4: Address assignment of a valve terminal with digital I/Os Remarks on the diagram If single solenoid valves are fitted onto D-type sub-base modules, four addresses will be assigned for solenoid valve coils; the higher address in each case then remains unused (see address 3). If unused valve locations are covered with blanking plates, the addresses are still assigned (see addresses 12, 13). Due to the 4-bit orientated addressing of the modular valve terminal, the address of the last location is always rounded up to four full bits (unless the fitting already uses the full four bits). This may mean that two addresses cannot be used (see addresses 14, 15) NH

96 4. Commissioning Basic rule 2 If only valves are used, the address assignment is always as described in basic rule 1. PLEASE NOTE Maximum 26 solenoid valve coils can be addressed. There is no rounding up of the last two positions on the valve side. Valve terminals without input modules do not require a configuration of inputs. Status bits are then not available. Basic rule 3 If only electrical I/Os are used, the address assignment is always the same as in basic rule 1. PLEASE NOTE Counting begins immediately to the left of the node. There is no rounding up of the last two positions on the valve side NH 4-15

97 4. Commissioning Address assignment after extension/ conversion A special feature of the modular valve terminal is its flexibility. If the demands placed on the machine change, then the number of valves fitted on the terminal can also be modified. CAUTION If extensions or conversions are made to the terminal at a later stage, this may result in a shifting of the input/output addresses. This applies in the following cases: If one or more pneumatic modules is/are fitted/removed at a later stage (type 03). If an S-type sub-base module with single solenoid valves is replaced by a D-type module with double solenoid valves or vice versa (type 03). If additional input/output stages are inserted between the node and existing input/output modules. If existing 4-input modules are replaced by 8-input modules or vice versa. These modifications may also require configuration modifications to the master. If the configuration of the inputs is modified, the addresses of the status bits will be shifted NH

98 4. Commissioning The diagram below shows the modifications to the address assignment in the example of an extension to the standard fitting shown in the previous diagram. 4-input module 8-input module 4-output module 4-output module S-type sub-base D-type sub-base D-type sub-base D-type sub-base Intermediate air supply D-type sub-base S-type sub-base Do not round up Fig 4/5: Address assignment of a valve terminal after extension/ conversion Air supply modules and intermediate air supply modules do not occupy any addresses NH 4-17

99 4. Commissioning NH

100 4. Commissioning Example of addressing type 03 MIDI/MAXI valves 4-input module 8-input module 4-output module 4-output module Double sub-base Double sub-base Double sub-base Double sub-base Single sub-base Double sub-base Round up Please note If a valve location occupies two addresses, the assignment is as follows: low value addresses pilot solenoid coil 14 higher value addresses pilot solenoid coil 12 Fig. 4/6: Address assignment of a valve terminal type 03 (MIDI/MAXI valves) 9701 NH 4-19

101 ple of addressing type 05 ISO valves 4-input module 8-input module 4-output module 4-output module Double solenoid valve Double solenoid valve Double solenoid valve Single solenoid valve Double solenoid valve Double solenoid valve Double solenoid valve Single solenoid valve Do not round up 13-03/05 4. Commissioning ease note a valve location occupies two addresses, the assignment is as follows: low value addresses pilot solenoid coil 14 higher value addresses pilot solenoid coil 12 /7: Address assignment of a valve terminal type 05 (ISO-valves) 9701 NH

102 4. Commissioning 4.2 SIEMENS General This chapter describes the entries required for configuring a valve terminal for a Siemens DP master. In order to understand this chapter, you must use your configuration program correctly. Different configuration programs are available, depending on the control system used (S5, S7,...). Examples COM ET200 (DOS version) COM ET200 (Windows version) COM PROFIBUS SINEC NCM S7 PROFIBUS STEP 7 (V2.X) SINEC NCM... The configuration programs are subject to modifications which may not already have been taken into account in this manual NH 4-21

103 4. Commissioning Commissioning tips PLEASE NOTE You must observe the following points in order to guarantee reliable operation of your applications with the Festo valve terminal. Insert the IM 308-B, IM 308-C, CP xx etc. into the correct location on your automation device. The ET200 location number bears no relationship to the physical arrangement of the input/output modules. Observe any limitations in the number of digital inputs/outputs e.g. CPU 941. max The station number set does not correspond to the configured periphery address. When configuring the outputs (e.g. 8DO 8DO 8DO), note that the number and type of pneumatic sub-bases is decisive, and not the number of valves fitted. The periphery addresses of automation device components must not be the same as the configured periphery addresses. The number of input bits always increases by 4 (= status bits). Reserved addresses for future requirements are not permitted. Switch on terminating resistor on both sides NH

104 4. Commissioning FREEZE and SYNC The method of accessing the FREEZE or SYNC command depends on your controller. Please refere here to the documentation for your field bus module. CAUTION In the following cases the FREEZE or SYNC mode is reset automatically: when the valve terminal is switched on/off when the field bus module is stopped. The FREEZE mode is also reset automatically in the following case: when the bus connection to the valve terminal is interrupted (response monitoring active) NH 4-23

105 4. Commissioning FREEZE With this function all the inputs of the valve terminal can be "frozen". The valve terminal then sends a constant input image of all the inputs to the master. The following FREEZE command causes the input image to be updated. The updated input image is then sent constantly to the master. You can return to normal mode with the command UNFREEZE. SYNC With this function all the outputs of the valve terminal can be "frozen". As a result the valve terminal no longer reacts to modifications to the output image in the master. The following SYNC command causes the output image of the master to be updated and transferred. You can return to normal mode with the command UNSYNC NH

106 4. Commissioning Status bits The valve terminal always makes 4 status bits (= inputs) available for diagnostic purposes, if the valve terminal is fitted with at least one input module (4 or 8-inputs). PLEASE NOTE The 4 status bits always increase the number of inputs to be configured by 4. Valve terminals without inputs do not have any status bits. Please refer to chapter 5 Diagnostics/error treatment for the function and position of the status bits. Module consistency The valve terminal supports the following variants in module consistency: over the complete length of the valve terminal over the selected format (byte/word) NH 4-25

107 4. Commissioning Sequence of configuration entries CAUTION You must always configure inputs before outputs. The number of inputs/outputs (rounded up to full bytes) must correspond to the equipment fitted on the terminal. No additional inputs or outputs may be configured as reserves. PLEASE NOTE Information on using the GSD files and type files can be found in: the file Readme on the diskette supplied the manual for your configuration program Copy the type files or the GSD files supplied into the appropriate directory in your configuration program. The following screen masks show different examples. Station selection Configuration NH

108 4. Commissioning Station selection with COM ET200 version 4.x Fig.4/8: Station selection with COM ET200 version 4.x The station type "FB13 VI DP" will appear, if the valve terminal type files are stored in the same directory as your configuration program "COM ET200". The type files can be found in the following directory on the diskette supplied: A:\SIEMENS\COMET200\TYPE-03\GB\ file name: FEFB13TE NH 4-27

109 4. Commissioning Configuration COM ET200 version 4.x Prerequirements The type file must be in the directory of your configuration program The mask ET SYSTEM PARAMETER must be processed The mask CONFIGURE must be accessed The diagram below shows the entries for a typical valve terminal configuration Fig. 4/9: Configuration COM ET200 version 4.x 1 Entry for station number (3,..., 124) 2 Recommended entry: P 3 Selection of station type: FB13 VI DP NH

110 4. Commissioning 4 Select the I/O start addresses, e.g.: DI = 24, DO = Configuration ( = equipment on valve terminal) Enter: for each group of 8 inputs: 8DI for each group of 8 outputs: 8DO The entry fields must be assigned in ascending order without gaps. No field may be unused. Inputs must be entered before outputs. Example 1: Valve terminal with 4 x 8-input modules, + 12 single solenoid valves. Configuration: 8DI, 8DI, 8DI, 8DI, 8DI, 8DO, 8DO The 4 status bits increase the number of inputs to 40 in this case (32I + 4I unused + 4 status bits). Example 2: Valve terminal with 10 single solenoid valves and 6 double solenoid valves. Configuration: 8DO, 8DO, 8DO 9701 NH 4-29

111 4. Commissioning Alternatively, the complete number of inputs (including the 4 status bits) as well as the complete number of outputs can be entered as the sum identifier. 6 The identifiers (individual identifiers or sum identifiers) can also be entered with a help mask. This mask can be accessed in the address field with: <F7> HELP. Select the format "Byte" for the inputs and outputs. The format "Word" is not permitted. Example Valve terminal with 3 input modules, 16 valve coils. 1. DP identifier 019 for 24I + 4I unused + 4 ststus bits. 2. DP identifier 033 for coils This completes the address assignment with COM ET 200 V4.x NH

112 4. Commissioning Station selection with COM ET200 Windows/ COM PROFIBUS Fig. 4/10: Station selection with COM ET200 Windows The slave type "VALVES" appears if the valve terminal type files are in the directory \COMWIN2x\TYPDAT5x or \COMPB3x\TYPDAT5x of your PC/programmer. The type files can be found in the following directory on the diskette supplied: A:\SIEMENS\COMWIN2\D\TYPE-03\GB File: FEFB133E NH 4-31

113 4. Commissioning Icons In order to make configuration easy for you, the diskette contains files with valve terminal icons in directory: A:\SIEMENS\COMWIN2\TYPE-03\BMP\ File: FE-TYP3N.200 and FE-TYP3S.200 The icon appears, if the icon files are in the following directory on your programmer/pc: \COMWIN2\BITMAPS\ PLEASE NOTE Update the slave catalogue when you copy the type files whilst processing the COM ET200/ COM PROFIBUS. Menu: File - Read type files NH

114 4. Commissioning Configuration COM ET200 Windows V2.x/ COM PROFIBUS Prerequirements The type files must be in the directory of your PC/programmer The mask BUS PARAMETER must be processed - bus profile - baud rate The station type must be selected The slave station number must be assigned The mask CONFIGURE must be accessed The diagram below shows the entries for a typical valve terminal configuration Fig. 4/11: Configuration with COM ET200 Windows 9701 NH 4-33

115 4. Commissioning 1 Configuration (= equipment on valve terminal) Enter: for each group of 8 inputs: 8DI for each group of 8 outputs: 8DO The entry fields must be assigned in ascending order without gaps; no field may be unused. Always enter inputs before outputs. Example 1: Valve terminal with 3 x 8-input modules, + 12 single solenoid valves. Configuration: 8DI, 8DI, 8DI, 8DI, 8DO, 8DO The 4 status bits increase the number of inputs to 32 in this case (24I + 4I unused + 4 status bits). Example 2: Valve terminal with 10 single solenoid valves and 6 double solenoid valves. Configuration: 8DO, 8DO, 8DO NH

116 4. Commissioning Alternatively, the complete number of inputs (including the 4 status bits) as well as the complete number of outputs can be entered as the sum identifier. The DP identifiers (individual identifiers or sum identifiers) can also be entered in the window Identifier Type: Select inputs or outputs. PLEASE NOTE The I/O types Input/output, Empty space etc. are not permitted. 3 Length: Enter 1 for 8 inputs or 8 outputs. Alternatively you can enter the sum of the inputs or outputs in bytes (gives sum identifier). PLEASE NOTE Add the 4 status bits to the number of inputs. 4 Format: Select Byte for the configuration of the inputs and outputs. The setting Word is not permitted NH 4-35

117 4. Commissioning 5 Input address/output address: Enter the start addresses of the inputs and outputs. Example: Valve terminal with 3 x 8 input modules, 16 valve coils 1. DP identifier 8DI for 1st. 8-input module 2. DP identifier 8DI for 2nd. 8-input module 3. DP identifier 8DI for 3rd. 8-input module 4. DP identifier 8DI for 4I reserves + 4 status bits 5. DP identifier 8DO for coils DP identifier 8DO for coils 9-16 This completes the configuration/address assignment with COM ET 200 Windows/ COM PROFIBUS NH

118 4. Commissioning Station selection with STEP 7 V2.x or NCM S7-PROFIBUS V2.x The configuration of DP slaves, e.g. Festo valve terminals, is similar to a large extent in both configuration programs. Fig. 4/12: Station selection STEP 7 V NH 4-37

119 4. Commissioning The directory VALVES appears if the type file exists in the directory TYPEFILE in the hardware catalogue. The type file can be found on the enclosed diskette in the file: A:\SIEMENS\COMWIN2\TYPE-03\GB\ File: FEFB133E.200 The directory can be found in: STEP_V2 and S7DATA. PLEASE NOTE Update the hardware catalogue after copying the type files. Menu sequence: extras - Update DP type files NH

120 4. Commissioning Configuration with STEP 7 V2.x or NCM S7-PROFIBUS V2.x Prerequirements The type file must be in the appropriate directory of your programmer/pc. The menu Configure hardware must be accessed. The DP master must be active in the rack. The mask Characteristics - DP master must be processed. Menu sequence: Process - Object characteristics - SINEC L2. The master system must be opened in the rack. Either CPU with integrated DP interface or CP processor. Menu sequence: Process - Master system - Open. Carry out the following steps in order to add a valve terminal to the DP master and in order to configure it. The following diagrams show entries of a typical valve terminal configuration NH 4-39

121 4. Commissioning Fig. 4/13: Adding valve terminals 1 Click the catalogue symbol. You thereby open the hardware catalogue. 2 Open the directory PROFIBUS-DP - Standard slave - Valves. Shift the directory FB13 type to the next free L2 address in your L2-DP network. 3 <Mask not shown> Mask Characteristics - SINEC L2 node : Enter the station number set on the valve terminal as L2 address. 4 Open the inserted L2 node. 5 Open the directory FB13 type in the menu Hardware catalogue NH

122 4. Commissioning 6 Integrate the contents of the directory (= standard module) into the first free location. PLEASE NOTE Assign the locations in ascending order without gaps ! Fig. 4/14: Configuring valve terminals 7 Open the mask Characteristics DP slave by double clicking the inserted location NH 4-41