Valve terminal type 03/05 Electronics Manual Field bus connection FB15

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1 Valve terminal type 03/05 Electronics Manual Field bus connection FB15 Field bus protocol: EAE field bus-2 Only valid in agreement with the printed documentation accompanying the product! Compare this edition code. 9506

2 Authors: Editors: Layout: Translation: Type setting: Eberhard Klotz, Heinz Hohner, Christiane Berger, Fa. EAE Arno Eikhof, Fa. EAE Michael Holder, H.-J. Drung Festo KG, Dept. PV-IDM D. Smith DUCOM Printed on 100% recycled paper 1st. edition 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 I

3 Order no.: Title: Designation: MANUAL P.BE-VIFB15-03/05-GB II 9506

4 Contents Contents Chapter 1 IMPORTANT USER INSTRUCTIONS AND SYSTEM SUMMARY 1.1 Important user instructions 1-3 Danger categories 1-3 Pictograms 1-4 Instructions on this manual System summary 1-8 System structure 1-8 Type 03: Description of components 1-10 Type 05: Description of components 1-14 Description of functions 1-16 Chapter 2 FITTING 2.1 Fitting the components 2-3 Input/output modules 2-4 End plates 2-6 Hat rail clamping unit 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) III

5 Chapter 3 INSTALLATION 3.1 General connection principles 3-3 Selecting the field bus cable 3-4 Selecting the operating voltage cable 3-4 Connecting the cables to the plugs/sockets Field bus node 3-7 Opening and closing the node 3-8 Configuring the valve terminal 3-9 Setting the station number 3-10 Setting the operating mode and the field bus baud rate Type 03: Connecting the operating voltages Type 05: Connecting the operating voltages Connecting the field bus Connecting the input modules 3-32 Pin assignment Connecting the output modules 3-35 Pin assignment 3-37 IV 9506

6 Chapter 4 COMMISSIONING 4.1 Basic principles of configuration and addressing 4-3 General 4-3 Switching on the operating voltages 4-4 Calculating the configuration data 4-5 Calculating the number of inputs/outputs (type 03) 4-6 Calculating the number of inputs/outputs (type 05) 4-7 Address assignment of the valve terminal 4-9 General (type 03 and 05) 4-9 Basic rule Basic rule Basic rule Address assignment after extension/conversion 4-14 Examples of address assignment Type 03: MIDI/MAXI valves 4-17 Examples of address assignment Type 05: ISO valves EAE field bus General 4-19 Configuration 4-20 Addressing 4-21 Inputs/outputs 4-22 Status bits V

7 Chapter 5 DIAGNOSIS AND ERROR TREATMENT 5.1 Summary of diagnostic possibilities On-the-spot diagnosis 5-4 LED displays 5-4 Node 5-4 Valves 5-6 Input/output modules 5-8 Testing the valves Diagnosis via field bus 5-11 Diagnostics word 1, Diagnostics word Diagnostics word Status bits 5-14 Function 5-14 Coding 5-15 Position of status bits 5-15 Example Seven segment display 5-17 Summary of error messages Error treatment 5-20 Reaction to faults 5-20 Short circuit/overload on output module 5-21 Appendix A TECHNICAL APPENDIX Technical specifications A-3 Cable length and cross section A-7 Examples of circuitry A-12 Appendix B INDEX VI 9506

8 1. User instructions 1. USER INSTRUCTIONS AND SYSTEM SUMMARY

9 1. User instructions Contents 1.1 IMPORTANT USER INSTRUCTIONS 1-3 Danger categories 1-3 Pictograms 1-4 Instructions on this manual SYSTEM SUMMARY 1-8 System structure 1-8 Type 03: Description of components 1-10 Type 05: Description of components 1-14 Description of functions

10 1. User instructions 1.1 IMPORTANT USER INSTRUCTIONS Danger categories This manual contains instructions on the possible dangers which can occur when the valve terminals are used. A distinction is made between the following: WARNING... means that damage to the machine and human injury can occur if the instructions are not observed. CAUTION... means that damage to the machine can occur if the instructions are not observed. PLEASE NOTE... means that this instruction should be followed as well

11 1. User instructions Pictograms Pictograms and symbols complement the danger warnings and draw attention to the nature and consequences of dangers. The following pictograms are used: Uncontrollable movements of loose tubing. Undesired movements of the connected actuators. High voltages or undefined switching states of the electronic components can influence connected circuits. Electrostatically vulnerable components can be destroyed by electrostatic charges if the 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

12 1. User instructions Instructions on this manual In this manual the following product-specific abbreviations are used: Abbreviation Meaning Terminal Valve terminal type 03 (MIDI/MAXI) or type 05 (ISO) with/without electrical I/Os Node Field bus node Valve sub-base Pneumatic sub-base for valves S-type sub-base module D-type sub-base module ISO sub-base I O I/O P module I/O module for two single solenoid valves of type 03 (MIDI/MAXI) for two double solenoid valves or mid-position valves of type 03 (MIDI/MAXI) Sub-base for 4, 8 or 12 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 Fig. 1/1: Abbreviations The valve terminal consists of the following components: the node pneumatic modules (sub-base with valve and bridge or air supply/intermediate supply) electronic modules (4 or 8 inputs, 4 outputs)

13 1. User instructions PLEASE NOTE For most drawings in this manual a valve terminal type 03 with four pneumatic MIDI valve sub-bases and four input/output modules (standard fitting) is used. Fig. 1/2: Standard fitting for the drawings

14 1. User instructions This electronics manual contains a description of node FB15 and the input/output modules. The valve terminals can be connected to the control systems of EAE. This manual deals with the installation and the addressing of the valve terminals for the following EAE automation systems: Controller manufacturer EAE SBC 4 Controller (PLC) Field bus module Field bus PC (IBM compatible) Fig. 1/3: EAE automation systems FVEF 2 FVNT 1 PCEF 2 EAE field bus 2 (ARCNET protocol) PLEASE NOTE All information on the pneumatic modules can be found in the Pneumatics manuals P.BE-MIDI/MAXI-03-GB or P.BE ISO-05-GB

15 1. User instructions 1.2 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 electronic modules, such as the following: SBC 4 Industrial PC/controller AAAA AAAA AAAA AAAAA A AAAA AAAAA AAAA AAAAA AAAA AAAAA AAAA AAAAA AAAAAAAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAAAAAAAAAAAAAAAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA Field bus SINEC L2 DP Valve terminal type 03: MIDI/MAXI valves and electronic modules ASI bus Valve terminal type 03: only MAXI valves Valve terminal type 05: ISO valves and electronic modules Further slaves Fig. 1/4: System summary and possible variants of valve terminals

16 1. User instructions The valve terminals with field bus connection offer 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

17 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 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 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. 1/5: Modules of valve terminal type

18 1. User instructions The following connection and display elements are to be found on the electronic modules: ASI master, analogue I/Os O4 O4 I4 I 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" End plate right Fuse for internal inputs/sensors Operating voltage connection ASI master for I/O periphery, analogue I/Os, further modules Fig. 1/6: Display and connection elements of the electronic modules

19 1. User instructions The connections, display and operating elements shown below are to be found on the pneumatic MIDI modules of type a 3a b 2b No. 1 2a 2b 3a 3b Meaning Node with LEDs and field bus interface, detailed description see chapter "Installation" Yellow LED upper valve solenoid coil Yellow LED lower valve solenoid coil Manual override upper valve solenoid coil (14, A) Manual override lower valve solenoid coil (12, B) Valve location inscription field Unused valve location with blanking plate Common pneumatic tubing connections Work connections (per valve) Fuse for internal inputs/sensors Operating voltage connection Fig. 1/7: Operating, display and connection elements of the pneumatic modules

20 1. User instructions The connections, display and operating elements shown below are to be found on the pneumatic MAXI modules of type No Fig. 1/8: Meaning Node with LEDs and field bus interface, detailed description see chapter "Installation" Yellow LEDs (per pilot solenoid) Manual override (per pilot solenoid, pressing or locking) Valve location inscription field Unused valve location with blanking plate Common pneumatic tubing connections Work connections (2 per valve, positioned vertically) Pressure regulator for pilot air Common pneumatic tubing connection Exhaust connections Operation, display and connection elements of MAXI modules type

21 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 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 components for vertical stacking (regulator plates, flow control plates etc.) blanking plates 5 Adapter plate for pneumatic modules (sub-bases) as per ISO5599/I sizes 1 or 2 6 Right-hand end plate with holes for fitting and with thread for lifting eye bolt (M8) Fig. 1/9: Modules of valve terminal type

22 1. User instructions The connections, display and operating elements shown below are to be found on the ISO modules of type No Meaning 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, pressing or locking) External air control connection Common connections Work connections (per valve) Adapter cable for operating voltage of node and I/O modules Fig. 1/10: Operation, display and connection elements of ISO modules type 05 The electronic modules are described in this chapter, "Description of components type 03"

23 1. User instructions Description of the functions Incoming field bus Continuing field bus 1 Node 4 2 AA AA AA A 1 2, 4 Compressed air Work air Electric signal flow Fig. 1/11: Function summary of valve terminal type 03/05 The node takes control of the following functions: connection of the terminal to the field bus module of the control system and to further slaves via the field bus interface adaption of field bus baud rate and protocol to the control system control of data transfer to/from the field bus module of the control system internal control of the terminal

24 1. User instructions The input modules process the input signals (e.g. from sensors) and transmit these signals via the field bus to the controller. The output modules are universal electrical outputs and control low-current consuming devices with positive logic, e.g. further valves, lights, etc.. The pneumatic modules supply the following: common channels for supply and exhaust air electrical signals from all solenoid valve coils On the individual pneumatic modules, the work connections 2 and 4 have been supplied for each valve location. The common channels on the pneumatic end plate or special 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 different work pressures or for fitting MIDI/MAXI valves or ISO valves onto a node. Please see the pneumatic manuals for detailed information on the pneumatic modules. Only the electronic modules and the node are described here

25 2. Fitting 2. FITTING

26 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: FITTING THE VALVE TERMINAL 2-9 Wall fitting 2-9 Hat rail fitting TYPE 05: FITTING THE VALVE TERMINAL 2-12 Wall fitting

27 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 danaging the valve terminal components

28 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 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

29 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 electronic 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

30 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 earthed/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 03/05 (MIDI/MAXI). All are supplied with pre-fitted earth cables. CAUTION The right-hand end plate of valve terminal type 03 must be earthed/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

31 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)

32 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

33 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

34 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 Fasten the valve terminal onto the hat rail with the 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 fastening of the hat rail clamping unit without screws (7) will be sufficient. 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

35 2. Fitting Make sure that the fastening surface can carry this weight. Fit a hat rail (support rail EN x15; width 35mm, height 15 mm). Fasten the hat rail to the mounting surface at least every 100mm. 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

36 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 (I/O side) natural resonances Proceed as follows: Calculate the weight of the terminal (weigh or estimate). General rule: ISO size 1 ISO size 2 Sub-base *) - 4 valve locations incl. valves - 8 valve locations incl. valves - 12 valve locations 8 kg 14 kg 20 kg 12 kg 20 kg 28 kg incl. valves 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

37 2. Fitting Proceed as follows when fitting the terminal: Use 3 M10 screws on the adapter plate and the right-hand end plate (2) Use 2 M6 screws 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 and use the M8 thread for the 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: Fitting the ISO valve terminal type 05 onto a wall

38 3. Installation 3. INSTALLATION

39 3. Installation Contents 3.1 GENERAL CONNECTION PRINCIPLES 3-3 Selecting the field bus cable 3-4 Selecting the operating voltage cable 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 Setting the station number 3-10 Setting the operating mode and the field bus baud rate Type 03: Connecting the operating voltages Type 05: Connecting the operating voltages Connecting the field bus 3-28 Connection instructions for EAE 3-30 Bus termination CONNECTING THE INPUT MODULES 3-32 Pin assignment CONNECTING THE OUTPUT MODULES 3-35 Pin assignment

40 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 undefind switched states of the electronic components

41 3. Installation Selecting the field bus cable A twisted screened four-wire cable (2 x 2 core pairs) must be used as the field bus cable. Please consult the manual for your controller for the type of cable to be used. The distance and the field bus baud rate must also be taken into account. Recommendation Cable type: LifYC 2x2x0.20 mm 2 Connector (0000 = length in cm): PC Festo valve terminal EAE part no PCEF00000 SBC4 Festo valve terminal EAE part no SBC Supplier: Fa. EAE Ewert Ahrensburg Electronic GmbH Kornkamp Ahrensburg, Germany Selecting the operating voltage cable Several parameters must be taken into account when the two operating voltages are connected. Further information can be found in the following chapters/sections: Chapter 3: Installation - Connecting the operating voltages - Calculating the current consumption - Power unit design - Cable cross section and length Appendix A: Cable cross section and length - Determining the cross section and length with tables - Calculating with a formula

42 3. Installation Connecting the cables to the plugs/sockets CAUTION The position of the pins is different depending on whether plugs or sockets are used. The connections of the input and output modules are in the form of sockets The connections of the field bus interface and the operating voltage connection are in the form of plugs Please refer to the following chapters for the pin assignment. When you have selected suitable cables, connect them in accordance with 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 and remove it. The socket remains inserted in the operating voltage connection. Sensor plug and field bus socket Unscrew the centre knurled nut

43 3. Installation 2. Open the strain relief on the rear part of the housing. Pass the cable through as shown in the diagram below (see diagram). Cable outer diameter PG7: mm PG9: mm PG13.5: mm Plugs/sockets (straight or angled) Power supply socket: PG7, 9 or 13.5 Sensor plug: PG7 Bus cable socket PG7, 9 or 13.5 AAA AAA AA Cable Strain relief Housing AAAAAAA AAAAAA AAAAAAA AAAAAAA AAA AAA AAA AAA AAA AAAAAAA AAAAAA 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. Connect the cables. 6. Close the strain relief again and screw the housing back onto the socket. Pull the cable back so that it is not looped inside the housing. 7. Tighten the strain relief

44 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: the compressed air supply the operating voltage for the electronic components (pin 1) the operating voltage for the outputs/valves (pin 2). You thereby avoid: uncontrolled movement of loose tubing undesired movements of the connected actuators undefined switching states of the electronic components CAUTION The node of the valve terminal contains elements which are liable to damage by electrostatic charges. Do not therefore touch any elements Observe the instructions for dealing with electrostatically vulnerable elements. In this way you can avoid damage to the electronic components on the node

45 3. Installation The following connection and display elements are to be found on the cover of the node: Green LED Red LED Plug for field bus cable BUS Operating voltage connetion Fuse for supply voltage to inputs Fig. 3/2: Cover of the node PLEASE NOTE The cover is connected to the internal printed circuit boards by means of the operating voltage cable and 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 throughmechanical stress. Closing Replace the cover. Place the cables for the operating voltage back into the housing so that they are not clamped. Tighten the Philips screws in the cover in diagonally opposite sequence

46 3. Installation Configuring the valve terminal There are four printed circuit boards in the node. Board 2 contains an LED and two plugs for the field bus cables; board 3 contains an LED, a switch for setting the configuration and a seven segment display for diagnosis. Green LED Plug for field bus cables Jumper for bus terminating resistor Screening/shield Board 2 Red LED Code switch for station number Code switch for operating mode and field bus baud rate Status and error display Board 4 Board 3 Flat plug for operating voltage connection Fig. 3/3: Connection, display and operating elements on the node

47 3. Installation Setting the station number (node address) The station number of the valve terminal must be set with the uppermost of the two coding switches on board 3. The switch is numbered from 0-FH. The arrow on the coding switch indicates the station number set. PLEASE NOTE Station numbers may only be assigned once per module. Max. 10 valve terminals per module are permitted on the EAE field bus-2. Proceed as follows: 1. Switch off the operating voltage. 2. Assign a non-reserved station number to the valve terminal. 3. Use a screwdriver to set the arrow of the coding switch to the desired station number. Example Station number AAAA AAAAAAA AAAA AAAAAAA AAAA AAAAAAA AAAA AAAAAAA AAAA AAAAAAA AAAA AAAAAAA AAAA AAAAAAA AAAA AAAAAAA AAAA AAAAAAA Set station number: 06H Operating mode/baud rate Fig. 3/4: Example of set station number

48 3. Installation PLEASE NOTE Station number 0 must never be used. It is only used as broadcast address for test purposes. Possible station numbers Manufacturer/ controller (PLC) EAE SBC 4 PC Address Station number (node address) Address numbers 1; 2;...FH (1; 2;...15D) Fig. 3/5: Station numbers Recommendation Assign the station numbers in ascending order. Adapt the assignment of station numbers to the machine structure of your system

49 3. Installation Setting the operating mode and the field bus baud rate The operating mode and the field bus baud rate of the valve terminal must be set with the lower of the two coding switches on board 3. The switch is numbered from 0-FH. The arrow on the coding switch indicates the desired operating mode. Proceed as follows: 1. Switch off the operating voltage. 2. Select the desired operating mode and field bus baud rate from the table below. 3. Use a screwdriver to set the arrow of the coding switch to the desired operating mode and field bus baud rate. Station number AAAA AAAA AAAA AAAAAAA AAAA AAAAAAA AAAA AAAAAAA AAAA AAAAAAA AAAA AAAAAAA AAAA AAAAAAA AAAA AAAAAAA AAAA AAAAAAA AAAAAAAAA AAA Operating mode set: baud rate 2500 kbaud with monitoring telegram Operating mode/baud rate Fig. 3/6: Example of operating mode set

50 3. Installation Possible operating modes Setting of code switch Operating mode 0 Non-permitted operating mode 1 Baud rate kbd without monitoring telegram 2 Baud rate kbd " 3 Baud rate kbd " 4 Baud rate kbd " 5 Baud rate kbd with monitoring telegram 6 Baud rate kbd " 7 Baud rate kbd " 8 Baud rate kbd " 9 to EH Non-permitted operating mode FH Test mode Fig. 3/7: Operating modes The operating mode "with monitoring telegram" serves for checking the interface as regards the PLC and the valve terminal. The PLC (SBC4 or PC) sends cyclically a monitoring telegram which is acknowledged by the valve terminal. If the valve terminal does not acknowledge the monitoring telegram, this will be indicated as a fault by the SBC 4. CAUTION If more than 1.5 s elapses before the valve terminal receives a monitoring telegram, the valve terminal will automatically reset all outputs. Please see Chapter 5 "Testing the valves" for information on testing

51 3. Installation Type 03: Connecting the operating voltages WARNING An isolating transformer with at least 4kV isolation resistance as per EN (DIN/VDE 0551) is required for reliable isolation of the operating voltages. CAUTION The operating voltage for the outputs/valves (pin 2) must be fused externally with max. 10 A. The external fuse prevents the valve terminal from being destroyed in the event of a short circuit

52 3. Installation The 24V operating voltages are connected at the lower left-hand edge of the node. Operating voltage connection Fig. 3/8: Position of operating voltage connection The following +24 V DC supplies are made via this connection: the operating voltage for internal electrical components and the inputs of the input modules (pin 1: DC +24 V, tolerance ± 25%). 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/valves should be connected via the EMERGENCY STOP circuit

53 3. Installation PLEASE NOTE If there is a 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 running. Ensure that the operating voltage of the outputs is always within the permitted tolerances, even when the maximum number of valves are fitted. Recommendation Use a closed loop power unit. Calculate the total 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 = 2.2 A Pin 2 = 10 A Cable cross section Distance 1.5 mm 2 8 m VO = 24 V 2.5 mm 2 14 m

54 3. Installation Calculating the current consumption type 03 The following table shows how to calculate 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 and inputs type 03 (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) = A + A max. 10 A Total current consumption of valve terminal type 03 = A Fig. 3/9: Calculating the total current consumption of type

55 3. Installation 24 V supply for electronic components and inputs 1 24 V supply valves and outputs 4 2 PE 3 (earth/ground connection, incoming contact) The following diagram shows the pin assignment of the operating voltage connection. 0 V Fig. 3/10: Pin assignment of the operating voltage connection Protective earthing The valve terminal has two protective earth connections: on the operating voltage connection (pin 4, incoming contact) on the left-hand end plate (M4 thread). PLEASE NOTE Always connect the earth cable to pin 4 of the operating voltage connection. The protective earth connection on the lefthand end plate can also be used. Ensure here that both earth cables have the same potential and that no equalizing currents flow during operation

56 3. Installation Connection example (type 03) The following diagram shows the connection of a common 24V 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) 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

57 3. Installation Connecting cable for potential compensation of earth connections AC 230 V/ 115 V 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 Fuse for inputs/sensors (2A) Fig. 3/11: Example connecting a common 24V supply and both earth cables (type 03)

58 3. Installation Type 05: Connecting the operating voltages WARNING An isolating transformer as per EN60742 (DIN/VDE 0551) with at least 4kV isolation resistance is required for separating the operating voltages as per VDE 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

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

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 24V 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 when the maximum number of valves are fitted. Recommendation Use a closed loop power unit. Calculate the total 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 *) Pin 1 = 2.2 A Pin 2 = 10 A Cable cross section Distance 1.5 mm 2 8 m VO = 24 V 2.5 mm 2 14 m *) Please note that the max. total current consumption (pins 1 and 2) is 12.2 A

61 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 have been 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) = A + A max. 10 A Total current consumption of valve terminal type 05 = A Fig. 3/13: Calculating the total current consumption type

62 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 1 24 V supply valves, outputs 4 2 PE 3 (protective earth connection, incoming contact) 0 V Fig. 3/14: Pin assignment of the operating voltage connection (type 05) Protective earthing The valve terminal has two protective earth connections: on the operating voltage connection (pin 4, incoming contact) on the left-hand end plate (M4 thread). PLEASE NOTE Always connect the earth cable to pin 4 of the operating voltage connection. The protective earth connection on the lefthand end plate can also be used. Ensure here that both earth cables have the same potential and that no equalizing currents flow during operation

63 3. Installation Connection example (type 05) The following diagram shows the connection of a common 24V 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 can be fused externally with 3.15 A against short circuit/overload (recommendation) the operating voltage of the sensors is separately fused with the fitted fuse (2 A) the operating voltage of the valves is separately fused with the fitted fuse (4 A) 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

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

65 3. Installation Connecting the field bus There are two field bus plugs on the node for connecting the valve terminal to the field bus. One of these connections is for the incoming field bus cable, the other is for the continuing cable. The signal cables of both plugs are connected internally with each other. Incoming field bus BUS Continuing field bus Fig. 3/16: Connecting the field bus

66 3. Installation CAUTION Please observe the correct polarity when connecting the field bus interface. Also connect the screening. The diagram below shows the pin assignment of the field bus interface. Connect the field bus cables to the appropriate pins of the bus cable socket. Please observe also the connection instructions in the further diagrams as well as the instructions in the PLC manual for your controller. Screening TR- Screening/ shield GND bus TR+ BUS 1MΩ TR- Screening/ shield 100 nf GND bus TR+ Internal RC network Housing of node Fig. 3/17: Pin assignment of the field bus interface

67 3. Installation Connection instructions for EAE PLEASE NOTE Always check the pin assignment of the module in the manual for your controller. Connect the field bus cable of your control system to the field bus interface of the valve terminal as follows: Manufacturer/ module EAE PCEF 2 PLC/PC Plug/socket assignment Valve terminal pin assignment of field bus interface View Pin Signal/ designation Screening/ shield nc nc nc nc nc TR+ TR- Bus GND Screening/ shield TR+ TR- Bus GND Pin 4 Pin 1 Pin 3 Pin 2 nc: not connected EAE SBC 4 SBCE 4x View Pin Signal/ designation Screening/ shield nc nc nc nc nc TR+ TR- Bus GND nc Screening/ shield TR+ TR- Bus GND Pin 4 Pin 1 Pin 3 Pin 2 nc: not connected Fig. 3/18: Connection instructions for EAE

68 3. Installation Bus termination If the valve terminal to be connected is at the end of the field bus, a terminating resistor is required as the bus termination. A terminating resistor has already been fitted in the node for this purpose. It is switched on by means of two jumpers as indicated below. Jumper position Meaning (Bus termination) Terminating resistor not switched on Terminating resistor switched on Jumper position not permitted Fig. 3/19: Position and function of bus terminating jumper PLEASE NOTE The unused field bus plug must be fitted with a protective cap to comply with protection class IP

69 3. Installation 3.3 CONNECTING THE INPUT MODULES WARNING Before installation or maintenance work is carried out, the following must be switched off: the compressed air supply the operating voltage for the electronic components (pin 1). the operating voltage for 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

70 3. Installation Four or eight inputs are available for the user on the input modules of the valve terminal. The inputs have positive logic (PNP inputs). Input module 4 inputs Input module 8 inputs Socket each with one digital input INPUT Green LED Socket each with two digital inputs INPUT One green LED per each digital input Fig. 3/20: Digital input modules 4/8 inputs (pnp) Recommendation for 8-input modules: Use the Festo duo-cable to connect two sensors via one plug at low costs

71 3. Installation Pin assignment The following diagram shows the pin assignment of all the inputs. Pin assignment 4 inputs LED Pin assignment 8 inputs LED free V Input 0 V 0 Ix V 1 4 Input Ix + 24 V 1 4 Input Ix 1 free V Input 0 V Ix V 1 4 Input Ix V 1 4 Input Ix+2 3 free V Input 0 V Ix V 1 4 Input Ix V 1 4 Input Ix+4 5 free V Input 0 V Ix V 1 4 Input Ix V Fig. 3/21: Input module: pin assignment (4/8 inputs) 1 4 Input Ix

72 3. Installation 3.4 CONNECTING THE OUTPUT MODULES WARNING Before installation or maintenance work is carried out, the following must be switched off: the compressed air supply the operating voltage for the electronic components (pin 1). the operating voltage for 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

73 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 each with one digital output OUTPUT Fig. 3/22: Digital output modules 4 outputs (pnp)

74 3. Installation Pin assignment The following diagram shows the pin assignment of all outputs. Pin assignment 4 inputs LED free V 0 free 1 4 Output Ox free 0 V free 1 4 Output Ox+1 free 0 V free 1 4 Output Ox+2 free V 3 free 1 4 Output Ox+3 Fig. 3/23: Output module: pin assignment 4 outputs

75 4. Commissioning 4. COMMISSIONING

76 4. Commissioning Contents 4.1 BASIC PRINCIPLES OF CONFIGURATION AND ADDRESSING 4-3 General 4-3 Switching on the operating voltages 4-4 Calculating the configuration data 4-5 Calculating the number of inputs/outputs type Calculating the number of inputs/outputs type Address assignment of the valve terminal 4-9 General (types 03 and 05) 4-9 Basic rule Basic rule Basic rule Address assignment after extension/conversion 4-14 Example of addressing type 03 MIDI/MAXI valves 4-17 Example of addressing type 05 ISO valves EAE field bus General 4-19 Configuration 4-19 Addressing 4-21 Inputs/Outputs 4-22 Status bits

77 4. Commissioning 4.1 BASIC PRINCIPLES OF CONFIGURATION AND ADDRESSING General Before commissioning or programming, the user should compile a configuration list for all 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