Compact Performance. Electronics manual. CPV valve terminal with direct connection Type CPV.. GE CC 8. Field bus protocol: CC link.

Transcription

1 Compact Performance Electronics manual CPV valve terminal with direct connection Type CPV.. GE CC 8 Field bus protocol: CC link Manual en 0304NH [ ]

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3 Contents and general instructions Author P. Mauch Editor M. Holder Original de Translation transline Deutschland Layout Festo AG & Co. KG, Dept. KG GD Type setting KI DT Edition en 0304NH Designation P.BE CP CC EN Order no E (Festo AG & Co. KG, D73726 Esslingen, Federal Republic of Germany, 2003) Internet: E Mail: service_international@festo.com The copying, distribution and utilization of this document as well as the communication of its contents to others without expressed authorization is prohibited. Offenders will be held liable for the payment of damages. All rights are, in particular the right to carry out patent, utility model or orna mental design registration. I

4 Contents and general instructions II

5 Contents and general instructions Contents Designated use Target group Service Notes on this manual Important user instructions V VI VI VI VII 1. Installation General instructions on installation Setting the CPV Direct Fitting and removing the switch module Setting the DIL switches Connecting the field bus Field bus cable Field bus baud rate and field bus length Field bus interface Connecting the field bus Bus termination with terminating resistors Power supply Cable for power supply Selecting the power unit Connecting the power supply Extending the CPV Direct Use in an explosion protected environment III

6 Contents and general instructions 2. Commissioning Preparing the CPV Direct for commissioning Switching on the operating voltages Address assignment of the CPV Direct Commissioning the CPV Direct on the field bus Bus configuration and addressing HOLD/CLEAR RAS function Commissioning the CP system on the CC link Diagnosis Diagnosis with LEDs Normal operating status Fault displays of the LEDs Run" and Power/Err" LEDs for status display of the valve solenoid coils Diagnosis via CC link Fault treatment A. Technical appendix and accessories A 1 A.1 Technical specifications A 3 A.2 Accessories A 7 B. Index B 1 IV

7 Contents and general instructions Designated use The CPV valve terminal type CPV.. with direct connection type CPV.. GE CC 8 described in this documentation is de signed exclusively for use as a slave on the field bus system Control & Communication Link (CC link) from Mitsubishi. The valve terminal may only be used as follows: as specified in industrial applications without any modifications by the user Only the conversions or modifications described in the documentation supplied with the product are permitted. in faultless technical condition. The maximum values specified for pressures, temperatures, electrical data, torques etc. must be observed. If additional commercially available components such as sen sors and actuators are connected, the specified limits for pressures, temperatures, electrical data, torques, etc. must not be exceeded. Please comply with national and local safety laws and regula tions. If you wish to implement an emergency stop function, please observe the measures listed in chapter Warning If the terminal is to be used as an explosion proof operat ing medium, make sure that: the electrical connections are not disconnected when power is still applied. the completely fitted valve terminal with all plugs, adapters and protective caps complies at least with protection class IP64. V

8 Contents and general instructions Target group This manual is intended exclusively for technicians trained in control and automation technology, who have experience in installing, commissioning, programming and diagnosing slaves on the field bus CC link. Service Please consult your local Festo repair service if you have any technical problems. Notes on this manual This manual contains specific information on installing, com missioning, programming and diagnosing CPV valve terminals with direct connection for the CC link. General information on the field bus CC link can be found in the documentation for your CC link master and for the rel evant control systems (e.g. from Mistubishi). An overview can be found under link.org. Information on fitting the pneumatic components of the CPV valve terminal can be found in the Pneumatics manual P.BE CPV... Information on further CP modules can be found in the sys tem manual P.BE CPSYS.. or in the manual for the relevant module. VI

9 Contents and general instructions Important user instructions Danger categories This manual contains instructions on the possible dangers which may occur if the product is not used correctly. These instructions are marked (Warning, Caution, etc.), printed on a shaded background and marked additionally with a picto gram. A distinction is made between the following danger warnings: Warning This means that failure to observe this instruction may result in serious personal injury or damage to property. Caution This means that failure to observe this instruction may result in personal injury or damage to property. Please note This means that failure to observe this instruction may result in damage to property. The following pictogram marks passages in the text which describe activities with electrostatically sensitive compo nents. Electrostatically sensitive components may be damaged if they are not handled correctly. VII

10 Contents and general instructions Marking special information The following pictograms mark passages in the text contain ing special information. Pictograms Information: Recommendations, tips and references to other sources of information. Accessories: Information on necessary or sensible accessories for the Festo product. Environment: Information on environment friendly use of Festo products. Text markings The bullet indicates activities which may be carried out in any order. 1. Figures denote activities which must be carried out in the numerical order specified. Hyphens indicate general activities. VIII

11 Contents and general instructions The following product specific terms and abbreviations are used in this manual: Term/abbreviation CC link CP CP cable CP connection CP modules CP system CPV Direct Diagnostic bits DIL switch I I/O modules I/O point I/Os O PLC/IPC RWr/RWw RX/RY Meaning Field bus system Control & Communication Link von Mitsubishi Compact Performance Special cable for coupling the various CP modules Plug or socket on the CP modules which enables the modules to be connected with the CP cable Common term for various modules which can be incorporated in a CP system Complete system consisting of CPV Direct and CP modules CPV valve terminal with field bus direct connection Internal inputs which supply coded common diagnostic messages Dual in line switches consist of several switch elements with which settings can be made Digital input Common term for the CP modules which provide digital inputs and outputs (CP input modules and CP output modules) Input or output bit in the bit range of the CC link memory mapping. Digital inputs and outputs Digital output Programmable logic controller/industrial PC Input and output words (16 bits) in the word range of the CC link memory mapping (Register word read/register word write) Input and output bits in the bit range of the CC link memory mapping IX

12 Contents and general instructions X

13 Installation Chapter 1 1 1

14 1. Installation Contents 1. Installation General instructions on installation Setting the CPV Direct Fitting and removing the switch module Setting the DIL switches Connecting the field bus Field bus cable Field bus baud rate and field bus length Field bus interface Connecting the field bus Bus termination with terminating resistors Power supply Cable for power supply Selecting the power unit Connecting the power supply Extending the CPV Direct Use in an explosion protected environment

15 1. Installation 1.1 General instructions on installation Information on using the CPV Direct in explosion protected areas can be found in section 1.6. Warning Before carrying out installation and maintenance work, switch off the following: the compressed air supply the operating voltage for the internal logics the load voltage for the valves. You can thereby avoid: uncontrolled movements of loose tubing unexpected movements of the connected actuators non defined switching states of the electronic compo nents. Caution The CPV valve terminal with field bus direct connection (CPV Direct) contains electrostatically sensitive compo nents. Do not therefore touch any contacts. Observe the regulations for handling electrostatically sensitive components. You will then prevent the electronics from being damaged. 1 3

16 1. Installation Electrical connecting and display elements The following connecting and display elements can be found on the CPV valve terminal with field bus direct connection (CPV Direct): Field bus connection (9 pin sub D socket) 2 Switch module (can be removed) 3 Operating voltage connection for electronics/load voltage connection forcp valves (4 pin M12 plug) 4 Bus status and power LEDs (red resp. green) 5 CP extension connection 6 Switching status displays of the CPvalve coils (yellow LEDs) Fig.1/1: Connecting and display elements of the CPV Direct 1 4

17 1. Installation 1.2 Setting the CPV Direct Fitting and removing the switch module Caution The switch module contains electrostatically sensitive com ponents. Do not therefore touch any contacts. Observe the regulations for handling electrostatically sensitive components. The switch module must be removed before the CPV Direct can be set. Fig.1/2: Fitting/removing the switch module 1 5

18 1. Installation Removing: 1. Switch off the operating voltage. 2. Unscrew the two fastening screws on the switch module. 3. Lift up and remove the switch module. Fitting: 1. Place the switch module carefully in the recess. 2. Tighten the two fastening screws alternately. Please note Do not tilt the switch module when fitting it. The fitting position is clearly marked by a groove in the housing. Make sure that the seal is seated correctly. 1 6

19 1. Installation Setting the DIL switches When the switch module is opened, you will see two DIL switches (Fig.1/3). You can set the following parameters with the DIL switches: Baud rate Reaction to field bus communication faults (HOLD/CLEAR function) CC link slave address Proceed as follows: 1. Switch off the operating voltage. 2. Remove the switch module (see chapter 1.2.1). 3. Set the baud rate, the reaction to the field bus communi cation faults and the CC link slave address (see following pages). 4. Fit the switch module (see chapter 1.2.1). 1 7

20 1. Installation DIL switch 1 (4 position DIL switch): 1 Set the baud rate (switch elements 1 to 3) 2 Set HOLD/CLEAR (switch element 4) DIL switch 2 (8 position DIL switch): 3 Set the CC link slave address (switch elements 1 to 7) Fig.1/3: DIL switch in the switch module (further information on see next pages) 1 8

21 1. Installation Set the baud rate 1 The field bus baud rate can be set with switch elements 1 and 3 of the 4 position DIL switch. Set the field bus baud rate used in accordance with the table below: Baud rate 156 k 625 k 2.5 M 5 M 10 M DIL switch settings O 1 O N N O 1 N O 1 N O 1 N : 2: 3: 1: 2: 3: 1: 2: 3: 1: 2: 3: 1: 2: 3: 1 9

22 1. Installation Set the HOLD/CLEAR function 2 The reaction of the CPV Direct to field bus communication faults can be configured: HOLD: Logical communication outputs remain set. CLEAR: Logical communication outputs will be reset. Set the desired reaction with switch element 4 of the 4 posi tion DIL switch in accordance with the following table: HOLD/CLEAR HOLD DIL switch settings O N 4: CLEAR O N 4: (factory setting) 1 10

23 1. Installation Setting the CC link slave address 3 The CC link slave address is entered BCD coded with switch elements 1 to 7 of the 8 position DIL switch. Switch element 8 ist not used (). CC link address DIL switch 3 Decimal Permitted addresses: Factory setting: 0 (invalid address) : 3.7: 2 2 x : 2 1 x : 2 0 x : : : : 2 0 = 40 = 20 = 10 = 8 = 4 = 2 = 1 Please note CC link addresses may only be assigned once per field bus line. Recommendation: Assign the addresses in ascending order. Assign the ad dresses to suit the machine structure of your system. Example: Set address: 05 Example: Set address: = =1 Address: x 10 = = = 2 Address:

24 1. Installation The following pages contain a summary of the setting of the CC link addresses. Address Address

25 1. Installation Address Address

26 1. Installation 1.3 Connecting the field bus Field bus cable Please note With incorrect installation and high baud rates, data trans mission errors may occur as a result of signal reflections and attenuations. Causes of transmission faults may be: missing or incorrect terminating resistor incorrect screening/shield connection branches transmission over long distances unsuitable cables. Observe the cable specifications. Refer to the manual for your controller for information on the type of cable to be used. Please note If the valve terminal is fitted onto the moving part of a machine, the field bus cable on the moving part must be provided with strain relief. Please observe also the relevant regulations in EN Bus length Exact specifications on the bus length can be found in section and in the manuals for your control system. 1 14

27 1. Installation Bus cable specfication as per CC link Use a twisted, screened 3 wire cable for the field bus. Cross sectional area: 0.5 mm 2 (1 pair) Outer diameter: 8 mm Line resistance: 37.8 /km (20 C) Capacitance per unit length: 60 nf/km (1 khz) Impedance: 110 ± 15 % Insulation resistance: 10,000 M/km Electric strength: 500 V DC for 1 minute Reference cable: FANC 110SBH 0.5 mm 2 x 3 (Kurashige Electronics, Inc.) (terminating resistor 110, 0.5 W) Alternative: CSFV110 SLAB (Daiden K.K.), or appropriate cable as per cable specification 1.1 (terminating resistor 110, 0.5 W) Please note Normal data transmission cannot be guaranteed if differ ent types of cables are used. Make sure that only one type of cable is used in a field bus string. 1 15

28 1. Installation Field bus baud rate and field bus length The maximum permitted field bus length depends on the baud rate used. The following table shows the baud rates which can be used (CC link version 1.10 compatible reference cable, terminating resistor 110 ). Baud rate Cable length between the stations Max. total length of cable 156 kbd 1200 m 625 kbd 600 m 2.5 MBd > 0.2 m (for all baud rates) 200 m 5 MBd 150 m 10 MBd 100 m Master station Remote I/O station/ remote device station 1) Local station/ intelligent device station Remote I/O station/ remote device station 1) Local station/ intelligent device station Cable length between stations Total cable length 1) CPV direct with CC link = remote device station 1 16

29 1. Installation Branch lines The following table shows the specifications for branch lines (without repeater) with the CC link reference cable. Specification Remarks Baud rate 625 kbd 156 kbd 10 / 5 / 2.5 MBd not possible Max. length of main string Maximum branch line length Max. total branch line length 100 m 500 m Cable length between the terminating resistors without cable length of the branch lines. 8 m Total cable length for a branch line. 50 m 200 m Total cable length for all branch lines. Max. number of slaves per branch line Connecting cable Branch line sub bases Branch line connector Distance between branch lines 6 slaves per branch line CC link reference cable Commercially available branch line sub bases Recommended connectors for FA sensors: NECA4202 (IEC ) or compatible As desired Total number of connectable slaves depending on CC link specification. It is not possible to use the CC link high perfo mance cable (e.g. B. FANC SBH). It is not possible to use different types of cables. Remove as little as possible of the insulation when connecting the cable to the main string. Distance between branch lines (branch line sub bases or connectors). Length A <0.3 m Cable length between remote I/Os or remote device stations Length B < 1 m 1) < 2 m 2) Cable length for masters, local and intelligent device stations as well as the adjoining stations 1) More than 1 m if there are only remote I/Os and remote device stations. 2) More than 2 m if there are local or intelligent device stations. 1 17

30 1. Installation Field bus interface There is a 9 pin sub D plug on the CPV Direct for connecting the valve terminal to the field bus. Pin Signal Designation Housing 5 n.c. DA DG n.c. n.c. 1) n.c. DB n.c. n.c. SLD / FG 1 Not connected Data A Data reference potential (Data ground) Not connected FE via RC combination 1) Not connected Data B Not connected Not connected Connection to FE View of socket 9 6 1) Not used with CC link: Connection via R/C combination to FE of the CPX terminal (1M/220nF) 1 18

31 1. Installation Connecting the field bus Connection diagram 1 CC link master (master module) Intended CC link cable 3 CC link slave (Remote device station) DA DB DG SLD FG DA DB DG SLD FG DA DB DG SLD FG 4 Terminating resistor 5 Earthing (SLD and FG connected in the module) Fig.1/4: Connection diagram of CC link For connecting the CPV Direct to the field bus CC link, you have the following possibilities: Sub base/plug Festo sub base type FBA 1 KL 5POL Festo sub D plug type FBS SUB 9 GS 2X4POL B Other sub D plug Remarks Protection class IP20, connection with cable lugs Protection class IP65, connection with cable clamp Protection class IP20 Please note Only the Festo field bus plug complies with IP65. Before connecting the field bus plugs from other manufacturers: replace the two flat screws by bolts (type UNC 4 40/M3x5). 1 19

32 1. Installation Connection with Festo sub base With sub base type FBA 1 KL 5POL you can connect the CPV Direct to the field bus CC link. Use claw cable lugs similar to DIN formb, size B4 1 for connecting the field bus cable to the sub base. 1 Sub base: FG (Ground, FE) SLD (cable screening) DG (Data Ground) DB (Data B) DA (Data A) 1 FBA 1 KL 5POL FG SLD DG DB DA Festo 2 CPV Direct 3 Earthing the CPV Direct 4 Connecting the FG at low impedance with FE 2 FBA 1 KL 5POL FG SLD DG DB DA Festo 3 4 Fig.1/5: Festo sub base 1 20

33 1. Installation Connection with field bus plugs from Festo Alternatively you can connect the CPV Direct with the field bus plug (type FBS SUB 9 GS 2X4POL B). Observe the fitting instructions for the field bus plug. Fasten the screening/shield for the field bus cable under the clamp strap of the Festo sub D plug. Please note The clamp strap in the Festo field bus plug is connected internally with the metallic housing of the sub D plug. The connection NC must not be connected. 1 Hinged cover with display window Field bus cable, seal the unused connection with a blanking plate (IP65) 3 3 Clamp strap for screening/shield connection *NC* DA DB DG *NC* DA DB DG 4 4 Terminal strip for field bus incom ing or continuing 5 CPV Direct (smaller than actual size) 5 Fig.1/6: Field bus plug from Festo, type FBS SUB 9 GS 2x4POL B 1 21

34 1. Installation Please note Use a protective cap or blanking plug to seal unused con nections. You will then comply with protection class IP65. Connection with sub D plugs of other manufacturers Connecting sub D plugs of other manufacturers: Replace the two flat screws by bolts (type UNC 4 40/M3x6). Connect the cable screening with the plug housing. 1 22

35 1. Installation Bus termination with terminating resistors Please note If the CPV Direct is at the beginning or the end of the field bus system, a bus termination is necessary. Fit a bus termination to both ends of a bus segment. A resistor is fitted between Data A and Data B as a bus ter mination (depending on cable type, see table). 1 Festo field bus plug 2 Seal connection for continuing field bus with blanking plug 3 Terminating resistor between DA and DB 4 Festo sub base DA DB DG *NC* DA DB DG *NC* DA DB DG *NC* FG SLD DG DB DA FBS AB 1 KL 5POL Festo Fig.1/7: Bus termination Cable type FANC 110SBH 0.5 mm 2 x 3 1) CSFV110 SLAB 2) Terminating resistor 110, 0.5 W 110, 0.5 W 1) Kurashige Electronics, Inc. 2) Daiden K.K. 1 23

36 1. Installation 1.4 Power supply Cable for power supply The connection for the power supply is in the form of a plug. The pin assignment of the plug can be found on the following pages. Use a power supply cable with sufficient cross sectional area. Avoid long distances between the power unit and the CPV Direct. Long cables reduce the voltage supplied by the power unit. If necessary, ascertain the suitable cross sectional area and the maximum permitted cable length. For connecting the power supply, use plugs from the Festo range which correspond to the outer diameter of the cable used (see Appendix A.2). 1 24

37 1. Installation Preparing When you have selected suitable cables connect them as follows: 1. Open the socket: Loosen the centre knurled nut. 2. Open the strain relief on the rear of the housing. Pass the cable through. 1 Cable 2 Strain relief 3 Housing 4 Centre knurled nut 5 Connecting part Fig.1/8: Individual parts of the socket and cable exit 3. Remove 5 mm of the insulation from the end of the cable and fit core end sleeves. 4. Connect the conductors. 5. Replace the connecting part on the housing of the socket and screw it tight. Pull the cable back so that there are no loops inside the housing. 6. Tighten the strain relief. 1 25

38 1. Installation Selecting the power unit Warning Use only power units which guarantee reliable isolation of the operating voltages as per IEC 742/EN 60742/VDE 0551 with at least 4 kv isolation resistance (Protected Extra Low Voltage PELV). Switch power packs are permitted, provid ing they guarantee reliable isolation in accordance with EN60950/VDE0805. Please note: By the use of PELV power units, protection against electric shock (protection against direct and indirect contact) is guar anteed in accordance with EN /IEC 204. Safety trans formers with the adjacent symbol must be used for supplying PELV networks. The device must be earthed to ensure that it functions correctly (e.g. EMC). The current consumption of a CP system depends on the number of CP modules and valve coils. Recommendation: Used closed loop power units. When selecting the power units, check that they provide sufficient output. Ascertain here the total current con sumption according to the following table. 1 26

39 1. Installation Total current consumption The table below shows how to calculate the total current consumption for a CP system. The values specified have been rounded up. Current consumption of CP electronics (pin 1) Sums CPV Direct CP input module Sensors on the CP input module max. 100 ma max. 40 ma see manufacturer s specifications Carry forward = ma Current consumption of valve supply (pin 2) Current consumption of all simultaneously energized valve coils 1) x ma = ma 1) Current consumption depends on the valve type (see Technical specifications for the valves in the relevant pneumatics manuals) 1 27

40 1. Installation Connecting the power supply Warning If the valve terminal is supplied with load voltage via an output of a safety I/O module," switch on test pulses of the safety I/O module" can cause unexpected reactions of the valve terminal. Make sure that these switch on test pulses are reliably suppressed or switched off. Power is supplied via a 4 pin M12 plug (see Fig.1/1). The current consumption depends on the type of valve ter minal. Please refer to the Pneumatics manual, P.BE CPV.." and the previous section for the values. When connecting the 24 V load voltage at pin2, observe the tolerance: V DC. Check the 24 V load volt age of the valves while your system is operating. Caution Protect the load voltage of the CPV valve coils with an external fuse max. 2 A. In this way you can avoid functional damage to the CPV Direct in the event of a short circuit. 1 28

41 1. Installation Please note Check within the framework of your EMERGENCY STOP circuit, to ascertain the measures necessary for putting your machine/system into a safe state in the event of an EMERGENCY STOP. Switch off the load voltage of the valves and output modules in the secondary circuit of the power unit. Switch off the compressed air supply to the valve terminal. When the load voltage is switched off, there may be a delay before the valves are switched off, due to energy being stored in the input circuit of the valve terminals. Take this into consideration, e.g. as follows: Register the fact that the load voltage is switched off by means of an input signal in the controller. Block the control signal of the valves by locking the out put signal with the input signal load voltage." 1 29

42 1. Installation Pin assignment of the power supply connection Pin assignment 1: 24 V DC operating voltage for electronics (and inputs; in the case of connected modules on the extension connection) (max. 2 A) 2: 24 V DC load voltage for valves (max. 2 A) 3: 0 V 4: Earth/ground connection 1 Fig.1/9: Pin assignment of power supply connection Potential equalization The CPV Direct has two earth connections for potential equal ization: on the power supply connection on the end plate. 1 30

43 1. Installation Please note Always connect the earth potential to pin 4 of the power supply connection. Connect the earth connection of the end plate with low impedance (short cable with large cross sectional area) to the earth potential. With low impedance connections you can ensure that the housing of the valve terminal and the earth connec tion at pin 4 have the same potential and that there are no equalizing currents. In this way, you will avoid interference caused by electro magnetic influences. Connection example 1 PE 2 Potential equalization 3 Load voltage can be switched off separately 24 V 0 V 2 A 2 A 4 The earth connection at pin4 is designed for 3 A Fig.1/10: Example of connection with PELV power unit and potential equalization 1 31

44 1. Installation 1.5 Extending the CPV Direct You can connect further modules of the CP system to the CPV Direct via the CP extension connection BUS POWER 1 CP extension connection Fig.1/11: CP extension connection You can connect the following CP modules to the CP exten sion connection: CP input modules with maximum 16 inputs. Please note The CPV Direct can be extended by maximum: one CP input module. Caution The maximum cable length between the CPV Direct and the CP module must not exceed 10 m. The CP connecting cables must have special electrical characteristics. Always use, therefore, Festo CP connecting cables. You can obtain ready to use CP connecting cables from Festo. These are available in various lengths and types. You will find a summary in Appendix A. 1 32

45 1. Installation Seal unused CP connections of your CP system with the rel evant seal provided. You will then comply with protection class IP65. The following table gives an overview of the possible exten sions: Extension to the CP system CPV Direct Output module or CP valve terminal not permitted Input module BUS POWER 1 POWER INPUT P POWER DIAG Total cable length of the CP system: maximum 10 m 1 CPV Direct 2 CP connecting cable 0.5 m, 2 m, 5 m, 8 m 3 CP input module with 16 inputs 1 33

46 1. Installation 1.6 Use in an explosion protected environment Warning If the terminal is to be used as an explosion protected op erating medium, make sure that: the electrical connections are not disconnected when power is still applied. the completely fitted product with all plugs, adapters and protective caps used complies at least with protec tion class IP64. Explanations of the explosion protection marking on the prod uct can be found in the Appendix Technical specifications." Overview of the installation steps: 1. Set the DIL switches and close the switch covers again. Make sure that the seals are seated correctly. 2. Install the product. CP cables and CP plugs from Festo are regarded as accessories within the framework of the con formity test as per 94/9/EG and may be used in poten tially explosive environments, in accordance with the Ex marking of the CP system. 3. Connect the field bus cable. Use only plugs which comply at least with protection class IP64. Close the cover of the plug if one is fitted. 4. Seal unused connections of the product with protective caps and blanking plugs which comply at least with protection class IP Connect a power supply with PELV power units, as de scribed in the chapter Installation." The conformity declaration as per EU directive 94/9/EG can be obtained from Festo. 1 34

47 Commissioning Chapter 2 2 1

48 2. Commissioning Contents 2. Commissioning Preparing the CPV Direct for commissioning Switching on the operating voltages Address assignment of the CPV Direct Commissioning the CPV Direct on the field bus Bus configuration and addressing HOLD/CLEAR RAS function Commissioning the CP system on the CC link

49 2. Commissioning 2.1 Preparing the CPV Direct for commissioning Switching on the operating voltages Please note Please observe also the switching on instructions in the manual for your PLC. When the controller is switched on, it will automatically carry out a comparison between the NOMINAL and the ACTUAL configurations. For this configuration procedure it is import ant that: the specifications for the field bus configuration are com plete and correct. the power supplies for the programmable logic controller and that for the field bus slaves are switched on either simultaneously or in the sequence indicated below. Please observe the following points when switching on the power supply: Common supply Separate supply If there is a common supply for the control system and for all the field bus slaves, the power should be switched on via a central power unit or central switch. If there is a separate supply for the control system and for the field bus slaves, the power should be switched on in the following sequence: 1. the power supply for all the field bus slaves 2. the power supply for the controller. 2 3

50 2. Commissioning Address assignment of the CPV Direct The CPV Direct always represents a station on the CC link, it therefore occupies: 32 digital inputs Remote input (RY) and 32 digital outputs Remote output (RX) 4 register words Read (RWr) and 4 register words Write (RWw) Inputs RX 0... RX F RWr 0 16 remote inputs for the diagnostic byte 16 remote inputs for the CP input module on the CPextension connection Outputs RY 0... RY F RWw 0 16 digital outputs for the valve coils of the CPV Direct Reserved The counting method typical for the CP system applies within the CP valve terminals and the CP input/output modules. 2 4

51 2. Commissioning CC link memory mapping The following table shows the assignment of the bit range: Remote > master Master > remote Device no. Signal name Device no. Signal name RXn0 RXn1 RXn2 RXn3 RXn4 RXn5 RXn6 RXn7 RXn8 RXn9 RXnA RXnB RXnC RXnD RXnE RXnF Diagnostic bit: Off Diagnostic bit: On: Diagnostic bit: Short circuit/overload Diagnostic bit: V off Diagnostic bit: V sen Diagnostic bit: V tol Diagnostic bit: Diagnostic bit: V load RYn0 RYn1 RYn2 RYn3 RYn4 RYn5 RYn6 RYn7 RYn8 RYn9 RYnA RYnB RYnC RYnD RYnE RYnF Digital output 00 Digital output 01 Digital output 02 Digital output 03 Digital output 04 Digital output 05 Digital output 06 Digital output 07 Digital output 08 Digital output 09 Digital output 10 Digital output 11 Digital output 12 Digital output 13 Digital output 14 Digital output 15 RX(n+1)0 RX(n+1)1 RX(n+1)2 RX(n+1)3 RX(n+1)4 RX(n+1)5 RX(n+1)6 RX(n+1)7 RX(n+1)8 RX(n+1)9 RX(n+1)A RX(n+1)B RX(n+1)C RX(n+1)D RX(n+1)E RX(n+1)F Remote ready 1) RY(n+1)0 RY(n+1)1 RY(n+1)2 RY(n+1)3 RY(n+1)4 RY(n+1)5 RY(n+1)6 RY(n+1)7 RY(n+1)8 RY(n+1)9 RY(n+1)A RY(n+1)B RY(n+1)C RY(n+1)D RY(n+1)E RY(n+1)F 1) The Remote Ready bit is set by the CPV Direct when initialization is successfully completed. A description of the diagnostic bits can be found in section

52 2. Commissioning The following table shows the assignment of the word range: Remote > master Master > remote Address Description Address Description RWrm 16 inputs for input modules on the CPstring 1) RWwm RWrm+1 RWwm+1 RWrm+2 RWwm+2 RWrm+3 RWwm+3 1) Address assignment see manual for CP I/O modules 2 6

53 2. Commissioning The following diagrams show the address assignment of the inputs and outputs with and without extension module on the CP string (address assignment corresponds to Valve ter minal profile"). Without input module on the CP string ( 16 A) 1 station Outputs for valve solenoid coils of the CPV Direct in the bit range Diagnostic bits = 8 I RR = Remote ready Bit range RX Inputs RY Outputs Word range RWr Inputs Station 1 Diag. (8 I) O 0... O 15 0 RR RWw Outputs Fig.2/1: CC link memory mapping ( 16 digital outputs) With input module on the CP string (only input module permitted 16 I) 1 station Outputs for valve solenoid coils of the CPV Direct in the bit range Inputs for input module on the CP string in the word range Bit range RX Inputs RY Outputs Word range RWr Inputs Station 1 Stat. bits (8 I) O 0... O 15 0 I 0... I 15 RR RWw Outputs Diagnostic bits = 8 I RR = Remote ready Fig.2/2: CC link memory mapping ( 16 digital inputs, 16 digital outputs) 2 7

54 2. Commissioning The following diagram shows the addressing sequence of the individual CPV valve plates Fig.2/3: Address assignment of a CPV valve terminal A valve location on the CPV valve terminal always oc cupies 2 addresses, even if it is fitted with a blanking plate or pressure separator plate. If a valve location is fitted with a double solenoid valve, the following assign ment applies: pilot solenoid 14 occupies the lower value address pilot solenoid 12 occupies the higher value address. With single solenoid valves the higher value address remains unused. Addresses are assigned from left to right on the CPV valve terminal and from the front to the rear on the individual valve locations. 2 8

55 2. Commissioning Run Power/Err RYn0 RYn1 RYn2 RYn3 RYn4 RYn5 RYn6 RYn7 RYn8 RYn9 RYnA RYnB RYnC RYnD RYnE RYnF Fig.2/4: Address assignment of a CPV valve terminal (outputs) 2 9

56 2. Commissioning 2.2 Commissioning the CPV Direct on the field bus In order to avoid faults when commissioning (e.g. configur ation and parametrizing faults): Check the DIL switch settings before using or replacing the CPV Direct. Check the address assignment of the I/Os on the CPV Direct Bus configuration and addressing If a slave is added to the CC link master, various configuration settings must be made, e.g.: Number of connected modules Number of stations to be reconnected to the system during a scanning cycle Status if there is a CPU fault in the main computer Station data (settings of the slave): station type number of stations occupied by the module CC link slave address. The configuration settings are saved in the master station buffer memory. The settings can be made as follows e.g. (depending partly on the master): with the GX developer (see following example), by manual programming via the PLC code (see section Master station buffer memory"). 2 10

57 2. Commissioning Setting the network parameter with the GXdeveloper (example) Network parameter 2 CC link parameter 3 Setting the station data (see Fig.2/6) 4 Status if there is a CPU fault in the main computer 5 Number of stations to be reconnected to the system during a scanning cycle 6 Configuration example (depends on the controller, see also Fig.2/7) 7 Number of connected modules Fig.2/5: GX developer: Network parameter 2 11

58 2. Commissioning Number of module/cc link slave address (station number/station address) 2 Station type (CPV Direct: Remote device station") 3 Set the module as or invalid 4 Number of stations per module (CPV Direct: Exclusive station 1") Fig.2/6: GX developer: Setting the station information 2 12

59 2. Commissioning Example of address assignment as seen by the master The following diagram shows as an example the address as signment with the settings of the GX developer example from Fig.2/5 as seen by the master (hexadecimal). Inputs (RX, RWr) Assigned addresses X X1007 D1000 (bit 0... F) RX RY RWr RWw RX RY RWr RWw 1 1 Diagnostic bits POWER INPUT P POWER DIAG RX RY RWr RWw 1 Y Y100F Outputs (RY, RWw) Assigned addresses Fig.2/7: Addressing the CPV Direct and the modules on the CP string in the example from Fig.2/5 2 13

60 2. Commissioning Master station buffer memory Address Meaning Description Read/write 0 H... 5F H Parameter information Saving parameter data Read/write 60 H... DF H Not defined E0 H... 15F H Decentral inputs (RX) Master station: Input signal states of the decentral/local stations are saved. Local station: Saves the input data of the master station. 160 H... 1DF H Decentral outputs (RY) Master station: Output signal states of the decentral/local stations are saved. Local station: Saves the input data of the master station. Read only Read only Read/write Write only 1E0 H... 2DF H Decentral register (RWw) output data Master station: Transmitted data are saved in the decentral/local stations. Read/write Local station: Transmitted data are saved in the master station/other local stations. Receive data are also saved by decentral/other local stations. Read/write 2E0 H... 3DF H Decentral register (RWr) input data Master station: Receive data are also saved by decentral/local stations. Read only Local station: Receive data are saved by the master station. Read only 3E0 H... 5DF H Not defined 5E0 H... 5FF H Special flag (SB) Saves status data Read/write 600 H... 7FF H Special register (SW) Saves status data Read/write 2 14

61 2. Commissioning Entries for the CPV Direct in the master station buffer memory Address Meaning Description 1 H Number of connected modules Number of physically connected modules or nodes including the stations (modules which are connected at a later stage). A module can have several stations. Setting range: H Number of stations to be reconnected to the system during a scanning cycle 6 H Status if there is a CPU fault in the main computer Number of decentral/local stations which can be reconnected to the system during a scanning cycle. Setting range: Here the status when there is a CPU fault in the main computer is determined: 0 = Stop 1 = Continue operation 20 H... 5F H Station data The data words as from station 20H define the module type and the number of the stations (addresses) occupied by the modules. Each data word in the buffer memory as from address 20 H defines a module in ascending sequence. The station data must be determined for all connected modules and stations. Description of a data word see folllowing table. 2 15

62 2. Commissioning Station data in the master station buffer memory Address Bit H + x Station type: 1: Remote device station Number of assigned stations: 1: Module occupies 1 station CC link slave address: (01 H H ) x = CC link slave address This results for the CPV Direct in: 1 1 * *" (* * = ). Examples: Memory address Value Meaning 20 H 1101 H CC link slave address 1, 1 station per module, Remote device station 1C H 111B H CC link slave address 27, 1 station per module, Remote device station 2 16

63 2. Commissioning HOLD/CLEAR The CPV Direct supports the CC link HOLD/CLEAR function. System specific I/O states can therefore be defined in the event of a fault. The reaction of the outputs to faults is determined by the relevant DIL switch setting (see section 1.2.2). The field bus communication faults count as fault cases: Communication interruption Communication time out Depending on the DIL switch setting, the CPV Direct reacts to a fault as follows: With the setting CLEAR," the outputs are always reset if there is a fault. With the setting HOLD," the signal states of the outputs are retained if there is a fault. 2 17

64 2. Commissioning RAS function The CPV Direct supports the RAS functions (reliability, avail ability, serviceability) of the field bus CC link. Functions for separating slave stations: Even if a decentral or local station fails (e.g. voltage drop), network operation will not be impaired. A defective slave station can be replaced when the net work is running (the voltage of the station to be replaced must be switched off). When a station is linked into the network again after the fault has been rectified, it is not necessary to reset the master station. Monitoring the communication status: The network can be monitored by the master station when the system is built up or during debugging and maintenance. 2 18

65 2. Commissioning Commissioning the CP system on the CC link Please note Please observe also the switching on instructions in the manual for your controller. Proceed as follows: 1. Connect the field bus cable to the CPV Direct. 2. Switch on the operating voltage: of all field bus slaves of the CP system. 3. Switch on the operating voltage for the master module. Recommendation: Providing the safety concept of your machine/system permits this, commission the CP system with both operating voltages (pins 1 and 2), but without compressed air. A suitable test function is therefore available, which does not trigger unde sired reactions. 2 19

66 2. Commissioning 2 20

67 Diagnosis Chapter 3 3 1

68 3. Diagnosis Contents 3. Diagnosis Diagnosis with LEDs Normal operating status Fault displays of the LEDs Run" and Power/Err" LEDs for status display of the valve solenoid coils Diagnosis via CC link Fault treatment

69 3. Diagnosis 3.1 Diagnosis with LEDs The LEDs on the cover indicate the operating status of the CPV Direct. 1 LED Run" (green): Bus status LED Power/Err" (red/green): Operating voltage/fault 3 LED row for pilot solenoid 12 (yellow) 4 LED row for pilot solenoid 14 (yellow) 1 2 Run Power/Err 3 4 Fig.3/1: LEDs of the CPV Direct 3 3

70 3. Diagnosis Normal operating status In normal operating status the LEDs Run" and Power/Err" light up green. lights up; ; flashes; out LED Colour Operating status Fault treatment Run Green lights up Normal bus operation None Power/Err Green lights up Supply voltage OK, no fault message of the CC link ASICs None Fault displays of the LEDs Run" and Power/Err" Fault diagnosis with the LED Run" LED Colour Operating status Fault treatment Run None No bus operation Check bus communication Check bus connnection After RESET: If necessary, switch controller to RUN 3 4

71 3. Diagnosis Fault diagnosis with the LED Power/Err" LED Colour Operating status Fault treatment Power/Err Green flashes Undervoltage in the load voltage supply, no fault message of the CC link ASICs Check the load voltage supply (pin 2) Power/Err Red flashes Switch module missing or defective Fit the switch module If necessary, replace the switch module Fault message of the CC link ASICs Check cabling and terminating resistors Servicing required Power/Err Red lights up Fault message of the CC link ASICs Check cabling and terminating resistors Servicing required Load voltage faults are always displayed with the LED Power/Err". 3 5

72 3. Diagnosis LEDs for status display of the valve solenoid coils There is a yellow LED for every valve solenoid coil (see Fig.3/1). The LED indicates the switching status of the valve solenoid coil. Please note The LEDs show the signal states only when there are valve coils at the relevant valve locations. For this purpose the load voltage must lie within the per mitted tolerance. LED Colour Switch position Valve solenoid coil Meaning None Yellow lights up Basic position or Switch position Switch position or Basic position Logical 0 (no signal) Logical 1 (signal present) but: load voltage of the valves lies below the permitted tolerance range (< 20.4 V DC) Logical 1 (signal present) Logical 1 (signal present) but: compressed air supply not OK or pilot exhaust blocked or servicing required Please note The LEDs light up only in the holding phase of the valve. During the pickup phase or if there is no valve solenoid coil, the LEDs will not show control of the output. 3 6

73 3. Diagnosis 3.2 Diagnosis via CC link The diagnostic bytes of the CPV Direct are stored in the re mote input (e.g. RXn0). Assignment of the diagnostic bits: Bit Name Status (at logical 1) 0 Off Reserved 1) (always = 1; output module on the CP exten sion connection is missing or is not connected) 1 On Input module on the CP extension connection is missing or is not connected 2 Short circuit/ overload Reserved 1) (always = 0; short circuit/overload at the output module) 3 V off Reserved 1) (always = 0; failure of load voltage at the output module) 4 V sen Failure of sensor supply at the input module or short circuit/overload in sensor supply 5 V tol Reserved 1) (always = 0; load voltage for valves on the CP extension connection is less than 20.4 V) 6 Reserved 7 V load Load voltage for valves on the CPV Direct (pin2) is less than 20.4 V 8... F Reserved 1) No output modules permitted on the extension string 3 7

74 3. Diagnosis 3.3 Fault treatment The reaction of the CP system to the following faults depends on the HOLD/CLEAR setting of the DIL switches: communication interruption communication time out. Depending on the setting, all the outputs (valves and electric outputs) will be switched off or retain their status. Warning Make sure that valves and outputs are put into a safe state when the faults named occur. An incorrect status of the valves and outputs may lead to dangerous situations. Please note Please observe the following if the outputs are reset in the event of a PLC stop, field bus interruption or field bus fault: Single solenoid valves move to the basic position Double solenoid valves remain in the current position Mid position valves move to the mid position (depend ing on valve type: pressurized, exhausted or blocked). 3 8