Valve terminal type 03/05 Electronics Manual Control block SB-202

Transcription

1 Valve terminal type 03/05 Electronics Manual Control block SB-202 Only valid in agreement with the printed documentation accompanying the product! Compare this edition code. 9602

2 Authors: Editors: Translation: E. Klotz, S.Rechenberger H.-J. Drung, M. Holder Douglas Smith Layout: Festo KG, Dept. PV-IDM Type setting: DUCOM Printed on 100% recycled paper Festo KG, D 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 Part no.: Title: Designation: MANUAL P.BE-SB202-03/05-GB II 9602

4 Contents Contents GENERAL SAFETY INSTRUCTIONS Designated use Target group Important user instructions Danger categories Pictograms Instructions on this manual Service VII VIII IX IX X XI XII Chapter 1 SYSTEM SUMMARY 1.1 System summary 1-3 Programmable valve terminal 1-3 System structure 1-4 Type 03: Description of components 1-6 Type 05: Description of components 1-8 Description of function 1-12 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 2-9 Hat rail fitting Type 05: Fitting the valve terminal 2-12 Wall fitting III

5 Contents Chapter 3 INSTALLATION 3.1 General connecting principles 3-3 Cable selection 3-3 Connecting the cables to the plugs/sockets Control block SB Opening and closing the control block 3-6 Structure of the control block 3-8 Diagnostic interface Type 03: Connecting the operating voltages Type 05: Connecting the operating voltages Connecting the input modules 3-25 Pin assignment Connecting the output modules 3-28 Pin assignment 3-30 Chapter 4 COMMISSIONING AND PROGRAMMING 4.1 Basic Principles of configuration and addressing 4-4 General 4-4 Calculating the configuration data 4-4 Calculating the number of inputs/outputs 4-5 IV 9602

6 Contents Address assignment of the valve terminal 4-7 Basic rule Basic rule Basic rule Address assignment after extension/conversion 4-12 Example of addressing Type 03: MIDI/MAXI valves 4-15 Type 05: ISO valves 4-16 Addressing with FST202C First steps with FST 4-20 Prerequisites 4-20 Create allocation list 4-24 Load programs 4-25 Creating EEPROM Programming 4-32 Programming with FST 202C Programming techniques 4-44 Task structure of the operating system 4-44 Program and data backup Practical applications 4-59 Control of a station 4-59 Basic stand-alone control 4-60 System operation with ABG 4-61 System operation with ABG Emulator as commissioning aid 4-67 Display and operate software package V

7 Contents Chapter 5 DIAGNOSIS AND ERROR TREATMENT 5.1 Summary of diagnostic possibilities Diagnosis on-the-spot 5-4 LED displays Diagnosis by program 5-9 Status byte 5-9 Function modules Error treatment 5-13 Error messages of the operating sytem 5-13 Reaction of the terminal to faults 5-15 Short circuit/overload at an output module 5-16 Chapter 6 COMMAND INTERPRETER Appendix A TECHNICAL APPENDIX Technical specifications A-3 Cable length and cross section A-7 Circuit diagrams A-12 Appendix B GLOSSARY Appendix C INDEX VI 9602

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

9 General safety instructions Target group This manual is directed exclusively at technicians who are trained in control and automation technology and who have experience in installing, commissioning, programming and diagnosing programmable logic controllers (PLC) and field bus systems. VIII 9602

10 General safety instructions IMPORTANT USER INSTRUCTIONS Danger categories This manual contains instructions on the possible dangers which can occur when the programmable valve terminals types 03/05 with control block SB-202 are used. A distinction is made between the following instructions: WARNING This means that injury to human beings as well as material damage can occur if these instructions are not observed. CAUTION This means that material damage can occur if these instructions are not observed. PLEASE NOTE This means that this instruction must also be observed IX

11 General safety instructions Pictograms Pictograms and symbols supplement the danger instructions and draw attention to the consequences of dangers. The following pictograms are used: Uncontrolled movements of loose tubing. High electric voltage or undefined switching states of the electronic components which affect the connected circuits. Electrostatically vulnerable components which will be destroyed if their contact surfaces are touched. Uncontrolled movement of the connected actuators. SF- 202 If you use a valve terminal with field bus connection SF-202, refere to the additional manual P.BE-SF202-03/05-GB and read the important notes given there. 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. X 9602

12 General safety instructions Instructions on this manual This manual contains specific information on the installation, commissioning, programming and disgnosis of the programmable valve terminals types 03/05 with control block SB- 202 and the input/output modules. The following product-specific abbreviations are used in this manual: Abbreviation Terminal or Valve terminal Node Valve-sub base S sub-base D sub-base Meaning Programmable valve terminal type 03 (MIDI/MAXI) or type 05 (ISO) with control block SB202 with/without electric I/Os Field bus node or control block SB-202 Pneumatic sub-base for valves For two single valves type 03 (MIDI/MAXI) For two double solenoid valves or mid-position valves type 03 (MIDI/MAXI) ISO sub-base I O I/O P module I/O module PLC Fig. 1: Abbreviations Sub-base for 4, 8 or 12 ISO valves type 05 (as per ISO 5599/I, size 1 or 2) Input Output Input and/or output pneumatic module in general Module with digital inputs/outputs in general (input/output modules Programmable logic controller; or simply controller 9602 XI

13 General safety instructions PLEASE NOTE All information on the pneumatic modules is to be found in the Pneumatics Manual P.BE-MIDI/MAXI-03-GB or P.BE-ISO-05-GB. A valve terminal with four pneumatic valve sub-bases and four input/output modules is used for the diagrams in this manual. Fig. 2: Standard fitting for the drawings Technical terms from the fields of pneumatics, electronics and programming are explained in the Glossary, Appendix B. Service If you have any technical problems, please consult your local Festo Service XII 9602

14 1. System summary 1. SYSTEM SUMMARY

15 1. System summary Contents 1.1 SUMMARY OF SYSTEM 1-3 System structure 1-3 Type 03: Description of components 1-6 Type 05: Description of components 1-8 Description of function

16 1. System summary 1.1 SYSTEM SUMMARY Programmable valve terminal The control block contains its own PLC and thereby makes valve terminals types 03/05 into a programmable valve terminals. Independent automation tasks require the use of sensors. These can be connected directly to the valve terminal. There are four or eight sensor connections per input module. In addition there are output modules each with four electronic outputs. Independent automation tasks can therefore be solved on-the-spot. Advantages of the programmable valve terminal with control block SB-202: integrated PLC protection class IP 65 is fulfilled a control cabinet is not required the manufacturing process is relieved due to independent on-the-spot control fewer cables required easy-to-understand system structure with the controller on the machine valves already fitted pilot valve solenoid coils already wired central exhaust device already tested electrical inputs e.g. for sensors electrical outputs e.g. for actuators variable fitting with digital I/Os and pneumatic valves subsequent extension/conversion is possible different valve sizes

17 1. System summary System structure The controller fitted is similar in most respects to the Festo FPC 202 controller. It can be operated as follows: by push buttons (START/STOP) by keyboard with text display (ABG) by user-friendly keyboard with text display (ABG2) For programming you will require a PC and the Festo programming software FST 202C V3.11 or later. The PC must be connected to the diagnostic interface of the valve terminal. The following programming languages can be used. LDR (Ladder diagram) STL (Statement list) The following diagram summarizes the system:

18 1. System summary Operate Program Display and operating panel FST 202C V3.11 *) STL FST 202C V3.11 *) LDR Operating field ABG Start/stop operating field ABG 2 *) Software status V3.11 or later PC (IBM compatible) with programming software FST 202C V3.11*) Fig. 1/1: System structure of the programmable valve terminals types 03/

19 1. System summary Type 03: Description of components Valve terminal type 03 consists of individual modules. Each module is assigned with different functions, connection, display and operation elements. These are summarized in the diagram below No. Modules 1 Node with control block SB 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 pneum. tubing connections, but without integrated regulator without common pneumatic tubing connections (only MAXI) Fig. 1/2: Modules of valve terminal type

20 1. System summary The electronic modules contain the following connection and display elements: ASI Master O4 O4 I4 I No Meaning Output socket for electronic output Yellow LED (status display per output) Red LED (error display per output) Input socket for one electric input Green LED (per input) Input socket for two electric inputs Two green LEDs (one LED per input) Node with LEDs and diagnostic interface detailed description in Chapter "Installation" Right-hand end plate Fuse for inputs/sensors Operating voltage connection ASI master for I/O periphery Fig. 1/3: Display and connection elements of the electronic modules

21 1. System summary The connections, display and operation elements shown below are to be found on the pneumatic MIDI modules of type a 3a b No. 1 2a 2b 3a 3b Meaning Node with LEDs and diagnostic 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. 1/4: Operating, display and connection elements of the pneumatic MIDI modules type 03 2b

22 1. System summary The connections, display and operation elements shown below are to be found on the pneumatic MAXI modules of type No Meaning Node with LEDs and diagnostic interface, detailed description see chapter "Installation" Yellow LEDs (per valve solenoid coil) Manual override (per valve solenoid coil) Valve location inscription field (labels) Unused valve location with blanking plate Common pneumatic tubing connections Work connections (2 per valve, positioned vertically) Pressure regulator for auxiliary pilot air Common pneumatic tubing connection Exhaust connections Fig. 1/5: Operating, display and connection elements of MAXI modules type

23 1. System summary 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 with control block SB Electronic modules (input/output modules), fitted with digital inputs (modules with 4 or 8 inputs) digital outputs (modules with 4 outputs) 3 End plate left with opening for additional earth connection 4 Adapter plate for ISO sub-base (manifold) as per ISO 5599/I sizes 1 or 2 5 ISO sub-base (manifolds for 4, 8 or 12 locations) fitted with: Pneumatic valves with hole pattern 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 6 Right-hand end plate with holes for fitting and with thread for lifting eye bolts (M8) Fig. 1/6: Modules of valve terminal type

24 1. System summary The connections, display and operating elements shown below are to be found on the pneumatic ISO modules of type No Module 8 11 Node with LEDs and diagnostic interface, detailed description see chapter "Installation" Fuse for inputs/sensors (pin 1) Adapter plate Operating voltage connection of valve terminal type 05 Fuse for valves (pin 2) 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. 1/7: Operating, display and connection elements of ISO modules type 05 The electronic modules are described in this chapter, "Description of components type 03"

25 1. System summary Description of function Laptop/PC with FST 202C V3.11 or later Node I8 I8 O4 O4 1 Digital inputs 4 2 Digital output AA AA AA AA Actuator Sensors 1 2, 4 = Compressed air = Work air Electric signal flow Fig. 1/8: Function summary of the programmable valve terminal type 03/05 The nucleus of the programmable valve terminal is the control block SB-202. This contains a PLC and the electronic components required for controlling a valve terminal independently. In this way you can solve your automation task on-the-spot independently. The user programs for the programmable valve terminal are created on a PC with the programming software FST 202C V3.11 or later. The programming languages LDR and STL can be used. The programs are loaded into the programmable valve terminal via the RS 232 diagnostic interface. Both RAM and EEPROM modes are possible

26 1. System summary The input modules process the input signals (e.g. from sensors) and transmit these signals to the internal 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 provide the following: common channels for supply and exhaust air electrical signals from all solenoid valve coils Work connections 2 and 4 are provided for each valve location on the pneumatic modules. The common channels of the pneumatic end plate are used for supplying the valves with compressed air and for venting the exhaust and pilot exhaust. Modules for pressure supply are also available, e.g. for working with different pressures or for fitting MIDI/MAXI valves or ISO valves onto a node. Further information on their use can be found in the pneumatics manual for your valve terminal. Only the electronic modules and the control block are described here

27 2. Fitting 2. FITTING

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

29 2. Fitting 2.1 FITTING THE COMPONENTS WARNING Before fitting switch off the following: the compressed air supply the operating voltage supply for the electronic components (pin 1) the operating voltage supply for the outputs (pin 2) You thereby avoid: uncontrolled movements of loose hoses; undesired movements of the connected actuators; undefined switching states of the electronic components. CAUTION The components of the valve terminal contain electrostatically vulnerable components. Do not therefore touch any contact surfaces on the side plug connectors of the components. Please observe the regulations for dealing with electrostatically vulnerable components. In this way you can prevent the valve terminal components from being destroyed

30 2. Fitting SF- 202 PLEASE NOTE Treat all modules and components of the valve terminal with the utmost care. Pay particular attention to the following: The screw connectors 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 always be clean (in order to avoid leakage and contact faults). The contacts of the type 03 MIDI valve solenoid coils must not be bent (they are not resistant to bending, i.e. they will break off if bent back). Please consult also the fitting instructions included with modules and components ordered at a later stage. Input/output modules Before the valve terminal is extended or converted, it must first be unscrewed and dismantled. Dismantling (see also following diagram) Loosen and remove the screws of the relevant module. The modules are now held together only by the electric plug. Carefully pull the modules away from the electric plug connectors without tilting them. Replace damaged seals

31 2. Fitting Fitting (see also following diagram) PLEASE NOTE Always place subsequently ordered modules after the the last module before the end plate. Do not fit more than 12 electronic modules. Please note also the addressing limits of your field bus protocol. Fit the modules as follows: Insert a (new) seal on the right-hand contact surface facing the node. Fit as shown in the following diagram. Seal Fastening screws max. 1 Nm Fig. 2/1: Fitting electronic I/O modules

32 2. Fitting End plates You will require a left-hand and a right-hand end plate as the mechanical conclusion of the terminal. These end plates fulfil the following functions: they comply with protection class IP 65; they contain connections/contacts for protective earthing; they contain holes for wall fitting and for the hat rail clamping unit; The right-hand end plate of the ISO valve terminal is sufficiently grounded via the screw connections and pre-fitted spring contacts of the sub-bases. There are different types of right-hand end plate for valve terminals of type 03/05. All are supplied with pre-fitted earth cables. CAUTION The right-hand end plate of valve terminal type 03 must be grounded via the earth cable before it is fitted. This is to avoid high voltages on the metal surface in the case of a fault

33 2. Fitting Earth the end plates as follows: Right-hand end plate (type 03) To earth the right-hand end plate connect the inside cable to the appropriate contacts on the pneumatic modules or on the node (see below). Left-hand end plate (type 03 and type 05) Connect the left-hand end plate by means of the ready fitted spring contacts conductively to the other components. Remarks Instructions on earthing the complete valve terminal are to be found in the chapter "Installation". The diagram below shows the fitting of both end plates. Seal Contact for PE cable Seal Factory fitted PE cable Fastening screws max. 1 Nm Fig. 2/2: Fitting both end plates (example terminal type 03)

34 2. Fitting Hat rail clamping unit (type 03) You will require the hat rail clamping unit if the terminal is to be fitted on a hat rail (support rail as per EN 50022). The hat rail clamping unit must be fastened to the rear of the end plates as shown in the diagram below. Please observe the following before fitting: the glueing surfaces must be clean (clean with spirit); Please observe the following after fitting: the flat head screws must be tightened (6). the levers must be secured with locking screws (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 Locking screw *) Different lever lengths for MIDI and MAXI Fig. 2/3: Fitting the hat rail clamping unit

35 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 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. 7.6 mm M6 Fig. 2/4: Wall fitting terminal type

36 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 will be sufficient without screws (7). If there is no hat rail clamping unit on the terminal, it can be ordered and fitted at a later stage. The use of MIDI or MAXI clamping units depends on the end plate fitted (MIDI/MAXI). Proceed as follows: Calculate the weight of the terminal (weigh or estimate). General rule: MIDI MAXI per pneumatic module 800 g 1200 g per node 1000 g 1000 g per electronic module 400 g 400 g

37 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 unlocked Hat rail clamping unit locked Retaining screw (7) Fig. 2/5: Fitting the valve terminal type 03 onto a hat rail

38 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: Sub-base *) - 4 valve locations incl. valves - 8 valve locations incl. valves - 12 valve locations incl. valves ISO size 1 ISO size 2 8 kg 14 kg 20 kg 12 kg 20 kg 28 kg per node 1 kg per electronic module 0.4 kg *) Components for vertical stacking: Please see pneumatics manual P.BE-ISO-05-GB for weights. Make sure that the fastening surface can carry this weight

39 2. Fitting Proceed as follows when fitting the terminal: Use 3 screws M10 on the adapter plate and the right-hand end plate (2) 2 screws M6 on the left-hand end plate (1) If necessary use additional fitting possibilities as follows: Fastening hole on the back of the righthand 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 the M8 thread for lifting eye bolt (e.g. transport aid for crane hooks). 1 2 M8 thread in end plate for lifting eye bolt 3 M6 M10 Fig. 2/6: Wall fitting of an ISO valve terminal type

40 3. Installation 3. INSTALLATION

41 3. Installation Contents 3.1 GENERAL CONNECTION PRINCIPLES 3-3 Cable selection 3-3 Connecting the cables to the plugs/sockets CONTROL BLOCK SB Opening and closing the control block 3-6 Structure of the control block 3-8 Diagnostic interface 3-9 Setting the baud rate 3-10 Connecting the diagnostic cable Typ 03: Connecting the operating voltages 3-12 Calculating current consumption 3-13 Operating voltage connection Typ 05: Connecting the operating voltages 3-18 Operating voltage connection 3-19 Calculating current consumption CONNECTING THE INPUT MODULES 3-25 Pin assignment CONNECTING THE OUTPUT MODULES 3-28 Pin assignment

42 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 the operating voltage for the electronic components (pin 1) the operating voltage for the outputs/valves (pin 2). You can thereby avoid: uncontrolled movements of loose tubing undesired movements of the connected actuators undefined switching states of the electronic components Cable selection The cable selection for the diagnostic interface and the operating voltage connection is described in the following sections: Diagnostic interface: Chapter 3.2, Section "Connecting the diagnostic cable" Operating voltage connection: Chapter 3.2, Section "Connecting the operating voltages" Appendix A, Section "Cable length and cross section"

43 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/output modules are in the form of sockets. The connections of the diagnostic interface and the operating voltage are in the form of plugs The pin assignment is shown in the following chapters. When you have selected appropriate cables, connect them to the plugs/sockets in accordance with steps 1-7 below. 1. Open the plugs/sockets as follows (see diagram): Mains connection socket: Insert the mains connection socket into the operating voltage connection of the valve terminal. Unscrew the housing of the socket and remove the connection part of the socket which is still inserted in the operating voltage connection. Sensor plug/diagnostic socket: Loosen the centre knurled nut

44 3. Installation 2. Open the strain relief at the rear of the housing. and push the cable through as described below (see also diagram). Cable outer diameter: PG 7: mm PG 9: mm PG 13.5: mm Plugs/sockets (straight/angled): Power supply socket: PG 7, 9 or 13.5 Sensor plug: PG 7 Bus cable socket: PG 7, 9 or 13.5 AAA AAA AAA Cable Strain relief Housing AAAAAAA AAAAAA AAAAAAA AAAAAAA AAA AAA AAA AAA AAAAAAA AAAAAA AAAAAAA AAAAAAA Connection Socket Plug Fig. 3/1: Individual plug/socket parts and cable routing 3. Remove the insulation from the last 5 mm of the cable. 4. Fit the wires with cable end sleeves. 5. Connect the ends of the conductors. 6. Replace the connection part onto the housing of the plug/socket and screw the two parts together. Pull the cable back so that it is not looped inside the housing. 7. Tighten the strain relief

45 3. Installation 3.2 CONTROL BLOCK SB-202 Opening and closing the control block 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 can thereby avoid: uncontrolled movements of loose tubing undesired movements of the connected actuators undefined switching states of the electronic components CAUTION The node contains electrostatically vulnerable components. Do not therefore touch any components Observe the regulations for handling electrostatically vulnerable components In this way you can prevent the electronic components of the node from being destroyed

46 3. Installation The following connecting and display elements are to be found on the cover of the node: Green LED Green LED Red LED AA AA AA PO WERAA RUN AA AA AA AAA RAM ERROR Plug for diagnosticinterface Operating voltage connection Red LED Fuse for operating voltage of inputs Fig. 3/2: Cover of control block PLEASE NOTE The cover is connected to the internal boards by the cables for the operating voltage connection and cannot, therefore, be removed completely. Opening Unscrew and remove the 6 Philips screws in the cover. Carefully lift up the cover, but do not damage the cables by mechanical stress. Closing Replace the cover. Push the cables for the operating voltage connection back into the housing so that they are not squashed. Tighten the Philips screws of the cover in diagonally opposite sequence

47 3. Installation Structure of the control block There are four printed circuit boards in the control block. Board 2 contains two LEDs and a plug for the diagnostic interface; board 3 contains two LEDs a switch for setting the configuration. grüne LED AA A AAA grüne LED rote LED AA AA AAA AAA rote LED Stecker für Diagnosekabel ungenutzt, müssen auf 0 stehen Platine1 1 AAA 2 AA AAA 3 AAA 4 AA AAA DIL-Schalter Platine 2 Abschirmblech Platine 4 Platine 3 Plug for operating voltage connection Fig. 3/3: Connecting, display and operating elements of the control block

48 3. Installation SF- 202 Diagnostic interface The transmission rate (baud rate) of the diagnostic interface must be set on the DIL switch. The DIL switch consists of four switch elements. These are numbered from The position "ON" is marked ON AAAAA AAAAA AAAAA AAAAA AAAAA AAAAA AAAAA AAAAA AAAAA Baud rate for RS 232 Diagnostic interface SB-202 stand alone: Unused, must be at position "ON" SF-202 master/slave: Setting the operating mode Fig. 3/4: Position and function of the DIL switch

49 3. Installation Setting the baud rate Set the baud rate on the control block so that it corresponds to the setting on the operating/programming device (PC, terminal, display). Baud rate of diagnostic interface RS 232 [Baud] DIL switch ON SB-202 stand alone only: The switch elements must be at position "ON" Fig. 3/5: Setting the baud rate Connecting the diagnostic cable In order to program the valve terminal you will require the following: PC or laptop with serial RS 232 interface (V.24) screened connecting cable (e.g. Festo diagnostic cable SB-202-BU25 or BU9) Connect the diagnostic cable as follows: Insert the 4-pin plug into the diagnostic interface of the valve terminal Connect the 25-pin or 9-pin socket to the serial RS 232 interface of your PC/laptop (COMx)

50 3. Installation If you use a different cable, please observe the following pin assignment: Pin assignment of diagnostic cable 25-pin 4-pin round plug for diagnostic interface on control block SB pin socket on PC/laptop (serial RS 232 interface/v.24) RxD 1 2 TxD TxD 2 3 RxD GND 3 7 GND Screening 4 1 Screening Pin assignment of diagnostic cable 9-pin 4-pin round plug for diagnostic interface on control block SB pin socket on PC/laptop (serial RS 232 interface/v.24) RxD 1 TxD 2 GND 3 Screening 4 3 TxD 2 RxD 5 GND Pin assignment of diagnostic interface on control block GND TxD Screening RxD Fig. 3/6: Pin assignment of diagnostic cable and interface

51 3. Installation Type 03: Connecting the operating voltages WARNING In order that the operating voltage can be isolated reliably, you must use an isolating transformer with at least 4kV isolation resistance complying with standard EN (DIN/VDE 0551). CAUTION The operating voltage supply to the outputs/valves (pin 2) must be fused externally with maximum 10 A. With external fusing you can prevent functional damage to the valve terminal in the event of a short circuit. Please observe the following before connecting the operating voltages: Calculate the total current consumption according to the following table and select a suitable power unit as well as cables with a suitable cross section. Avoid long distances between the power unit and the terminal. Also calculate the permitted distance according to Appendix A. The following general rule applies: Consumption Pin 1 = 2.2 A Pin 2 = 10 A max. Cablecross-section Distance 1.5 mm 2 8 m VB = 24 V 2.5 mm 2 14 m

52 3. Installation Calculating the current consumption type 03 The table below shows how to calculate the total current consumption for terminal type 03. The values specified have been rounded up. If you use other valves or modules, you should consult the relevant technical specifications for their current consumption. Current consumption of electronic components node type 03 and inputs (pin 1, 24 V ± 25 %) Node A Number of simultaneously assigned sensor inputs: x A + A Sensor supplies: x A (see manufacturer specifications) + A Current consumption of electronic components node and inputs (pin1) max 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 Loading current of simultaneously activated electrical outputs: x A Current consumption of outputs (pin 2) max. 10 A Total current consumption of valve terminal type A A = A + A Fig. 3/7: Calculating the total current consumption type 03 = A

53 3. Installation Operating voltage connection (type 03) The 24V operating voltages are connected at the lower left-hand edge of the control block. Operating voltage connection type 03 Fig. 3/8: Position of the operating voltage connection The following components of the valve terminal type 03 are supplied separately with + 24 V DC via this connection: the internal electronic components, PLC and inputs of the input modules (pin 1: DC + 24 V, tolerance ± 25%). the outputs of the valves and of the output modules (pin 2: DC + 24 V, tolerance ± 10%, external fuse max. 10 A required). Recommendation: Connect the operating voltage for the outputs/valves via the EMERGENCY OFF circuit or EMERGENCY OFF contacts

54 3. Installation The diagram below shows the pin assignment of the operating voltage connection. 24 V supply electronic components and inputs 1 24 V supply valves/outputs PE (protective earth connection, incoming socket) V Fig. 3/9: Pin assignment of operating voltage connection (type 03) PLEASE NOTE If there is a common power 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 whilst the system is in operation. Ensure that the operating voltage of the outputs lies within the permitted tolerance even during full operation. Recommendation: Use a closed-loop power unit. Protective earthing The valve terminal has two protective earthing connections: At the operating voltage connection (pin 4 incoming socket). At the left-hand end plate (M4 thread)

55 3. Installation PLEASE NOTE Always connect the earth cable to pin 4 of the operating voltage connection. Make sure that the housing of the valve terminal and the earth cable at pin 4 have the same potential and that no equalizing currents flow. Connect an earth cable of sufficient crosssection to the left-hand end plate if the valve terminal is not mounted on an earthed machine stand. In this way you can avoid interference due to electromagnetic sources. Connection examples (type 03) The following diagram shows the connection of a common 24V power supply for pins 1 and 2. Please note that: the supply to the outputs/valves must be fused externally with maximum 10 A against short circuit/overload. the supply to the electronic components and inputs must be fused externally with 3.15 A against short circuit/overload (recommended). the supply to the sensors is also protected via the fitted fuse (2 A). the common tolerance of DC 24 V ± 10% must be observed. when the two protective earth cables are connected, equalizing currents must be avoided, e.g. by the use of cables with suitable cross section for equipotential bonding

56 3. Installation Connecting cable for potential equalization of earthing connections AC 230 V 0 V 3.15 A Fuse for inputs/sensors (2 A) DC 24V ± 10% External fuses 10 A EMERGENCY OFF Protective earth connection pin 4 designed for 12 A Fig. 3/10: Example - connecting a common 24 V supply and both protective earth cables (type 03) Power failure bridging time for RAM memory The power failure bridging time is at least 4 hours. If the operating voltage fails at pin 1 of the operating voltage connection (control unit and inputs), all data in the program and work memory will be saved for at least 4 hours if RAMs are used. PLEASE NOTE If EEPROMs are used, the program data and the remanent operands will be saved permanently

57 3. Installation Type 05: Connecting the operating voltages WARNING In order that the operating voltage can be isolated reliably, you must use an isolating transformer with at least 4kV isolation resistance complying with standard EN (DIN/VDE 0551). 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 destroyed in the event of a short circuit

58 3. Installation Operating voltage connection type 05 The 24V operating voltages are connected at the adapter plate between the RIO node and the valves. The operating voltage connection of the RIO node and the I/O modules is supplied also via the adapter cable. Operating voltage connection type 05 Fuse for valves (4 A slow blowing) Adapter cable Fig. 3/11: Positionof the 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 electric components and the power supply to 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 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 to the EMERGENCY OFF circuit or EMERGENCY OFF contacts

59 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 whilst your system is operating. Please see that the operating voltage of the outputs lies within the permitted tolerances even during full operation. Recommendation Use a closed loop power unit. Calculate the complete current consumption according to the following table and select both a suitable power unit and cable cross section. Avoid long distances between the power unit and the terminal. Calculate the permitted distance according to Appendix A. The following rule applies for type 05: Current consumption max.*) Cable cross section Distance Pin 1 = 2,2 A 1.5 mm 2 8 m Pin 2 = 10 A 2.5 mm 2 14 m UB = 24 V *) Please note that the max. total current consumption (pins 1 and 2) is 12.2 A

60 3. Installation Calculating the current consumption type 05 The following table shows the calculation of the total current consumption for the ISO terminal type 05. The values are rounded up. If you use other valves or modules, you should consult the appropriate technical specifications for their consumption. Current consumption of electronic components node type 05 and inputs (pin 1, 24 V ± 25 %) Node A Number of simultaneously occupied sensor inputs: x A + A Sensor supplies: x A (see manufacturer specifications) + A Current consumption of electronic components, node and inputs (pin 1) max. 2.2 A = A A Current consumption of outputs type 05 (pin 2, 24 V ± 10 %) Number of valve coils (simultaneously under power): x A + A Number of simultaneously activated electric outputs: x A + A Load current of simultaneously activated electric outputs x A + A Current consumption of outputs (pin 2) max. 10 A = A + A Total current consumption of valve terminal type 05 = A Fig. 3/12: Calculating the total current consumption type

61 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 PE 3 (protective earth connection, leading socket) 0 V Fig. 3/13: Pin assignment of the operating voltage connection Protective earthing The valve terminal has two protective earth connections: on the operating voltage connection (pin 4, leading socket) on the left-hand end plate (M4 thread). 2 PLEASE NOTE Always connect the earth cable to pin 4 of the operating voltage connection. Make sure that the housing of the valve terminal and the earth cable at pin 4 have the same potential and that no equalizing currents flow. Connect an earth cable of sufficient crosssection to the left-hand end plate if the valve terminal is not mounted on an earthed machine stand. In this way you can avoid interference due to electromagnetic sources

62 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 must be fused externally with 3.15 A against short circuit/overload (recommended) that the operating voltage of the sensors is protected also by the fitted fuse (2 A) that the operating voltage of the valves is protected also by the fitted fuse (4 A, slow blowing) the common tolerance of DC 24 V ± 10% must be observed the operating voltage supplied of the node is 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

63 3. Installation Fuse for inputs/sensors (2A) Operating voltage connection Fuse for valves (4 A, slow blowing) Connected adapter cable Connecting cable for potential compensation of earth connections AC 115V 230V DC 24V ± 10% 0 V 3.15 A 24 V External fuses 10 A Emergency off Earth cable connection pin 4 designed for 12.2 A Fig. 3/14: Example - connecting a common 24V supply and both earth cables (type 05) Power failure bridging time for RAM memory The power failure bridging time is at least 4 hours. If the operating voltage fails at pin 1 of the operating voltage connection (control unit and inputs), all data in the program and work memory will be saved for at least 4 hours if RAMs are used. PLEASE NOTE If EEPROMs are used, the program data and the remanent operands will be saved permanently

64 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 can thereby avoid: uncontrolled movements of loose tubing undesired movements of the connected actuators undefined switching states of the electronic components

65 3. Installation Four or eight inputs are available on the input modules of the valve terminal for user applications. The inputs have positive logic (PNP inputs). Input module 4-inputs Input module 8-inputs Sockets each with one digital input INPUT Green LED Sockets each with two digital inputs INPUT One green LED for each digital input Fig. 3/15: Digital input modules (4/8 inputs) Recommendation for 8-input modules: Use the Festo duo-cable to connect two sensors via one plug at low costs

66 3. Installation Pin assignment The diagram below shows as an example the pin assignment of all the inputs. Pin assignment 4 inputs LED Pin assignment 8 inputs LED free + 24 V V Input Ix 0 Input Ix V V Input Ix 0 1 free + 24 V V Input Ix+1 1 Input Ix V V Input Ix free + 24 V V Input Ix+2 2 Input Ix V V Input Ix free + 24 V V Input Ix+3 3 Input Ix V V Input Ix Fig. 3/16: Input module: pin assignment 4/8 inputs

67 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 can thereby avoid: uncontrolled movements of loose tubing undesired movements of the connected actuators undefined switching states of the electronic components

68 3. Installation There are four transistor outputs on the output modules of the valve terminal for user applications. These outputs have positive logic (PNP outputs). Output module (4 outputs) Yellow LED per output Red LED per output Sockets each with one digital output OUTPUT Fig. 3/17: Digital output module (4 outputs)

69 3. Installation Pin assignment The diagram below shows as an example the pin assignment of all the outputs. Pin assignment 4 outputs LED free 0 V 2 3 free 1 4 Output Ox 0 free 0 V 2 3 free 1 4 Output Ox+1 1 free 0 V 2 3 free 1 4 Output Ox+2 2 free 0 V 2 3 free 1 4 Output Ox+3 3 Fig. 3/18: Output module: pin assignment 4 outputs

70 4. Commissioning/programming 4. COMMISSIONING AND PROGRAMMING

71 4. Commissioning/programming Contents 4.1 BASIC PRINCIPLES OF CONFIGURA- TION AND ADDRESSING 4-4 General 4-4 Calculating the configuration data 4-4 Calculating the number of inputs/outputs Type Type Address assignment of the valve terminal 4-7 Basic rule Basic rule Basic rule Address assignment after extension/conversion 4-12 Examples of addressing Type 03 MIDI/MAXI valves 4-15 Type 05 ISO valves 4-16 Addressing with FST202C FIRST STEPS WITH FST 4-20 Prerequisites 4-20 On-line operation 4-22 Create allocation list 4-24 Load programs 4-25 Creating EEPROM 4-27 Boot mode 4-30 Auto mode PROGRAMMING 4-32 Programming with FST 202C 4-32 Structuring 4-32 Operators, command set 4-34 Operands 4-37 Function modules

72 4. Commissioning/programming 4.4 PROGRAMMING TECHNIQUES 4-44 Task structure of the operating system 4-44 Program processing 4-44 Multitasking process 4-47 Module processing 4-48 Program and data backup 4-53 Program memory RAM 4-54 Program memory EEPROM 4-55 Programming EEPROM 4-57 Boot mode and automode PRACTICAL APPLICATIONS 4-59 Control of a station 4-59 Basic stand-alone control 4-60 System operation with ABG 4-61 System operation with ABG Emulator as commissioning aid 4-67 Display and operate software package

73 4. Commissioning/programming 4.1 BASIC PRINCIPLES OF CONFIGURATION AND ADDRESSING General Before programming you must create an allocation list of all the connected inputs/outputs. This allocation list will simplify addressing or programming. Addressing the valve terminal requires a very exact procedure, as different specifications are sometimes required for each terminal on account of the modular structure. Please note here the specifications in the following sections. SF- 202 Calculating the configuration data The programmable valve terminal can control up to 48 inputs and outputs, whereby a different number of I/Os are assigned per module. The following table shows the I/Os required for each module. Module type Number of assigned I/Os *) S valve sub-base (type 03) 2 outputs D valve sub-base (type 03) ISO sub-base (type 05) - 4 valve locations - 8 valve locations - 12 valve locations Output module (4 digital outputs) Input module (4 digital inputs) Input module (8 digital inputs) 4 outputs 8 outputs 16 outputs 24 outputs 4 outputs 4 inputs 8 inputs *) The I/Os are assigned automatically within the terminal, irrespective of whether an input/output is actually used. Fig. 4/1: Number of I/Os assigned per module

74 4. Commissioning/programming Calculating the number of inputs/outputs (type 03) Copy the table for further calculations. Note the different way of calculating the number of outputs for type 03 and type 05. Table for calculating the inputs/outputs (type 03) INPUTS 1. Number of 4-input modules 4 Σ I 2. Number of 8-input modules 8 + Σ I Total number of inputs to be configured (SB-202: max. 48 SF-202: max. 32) Σ I OUTPUTS 3. Number of S sub-bases (type 03) 2 Σ O 4. Number of D sub-bases (type 05) 4 + Σ O Intermediate sum of = Σ O 5. Check that the sum of is divisible by 4 without remainder. This is necessary because of the 4-bit orientated internal addressing of the terminal. A distinction must be made between the following cases: a) If divisible by 4 without remainder then continue with 7 b) If this is not the case, round up (+2 O) + 2O 6. Number of electronic 4-output modules 4 + Σ O Total number of outputs to be configured (SB-202: max. 48 SF-202: max. 32) = Σ O Fig. 4/2a: Calculating the number of inputs/outputs (type 03)

75 4. Commissioning/programming Calculating the number of inputs/outputs (type 05) Copy the table for further calculations. Please observe that the calculation of outputs differs for type 03 and type 05. Table for calculating the number of inputs/outputs (type 05) INPUTS 1. Number of 4-input modules 4 Σ I 2. Number of 8-input modules 8 + Σ I Total sum of inputs to be configured (SB-202: max. 48 SF-202: max. 32) = Σ I OUTPUTS 3. ISO sub-base modules for 4 valve locations 8 O 8 valve locations 16 O 12 valve locations 24 O Σ O 4. Number of electronic output modules 4 = Σ O Total sum of outputs to be configured (SB-202: max. 48 SF-202: max. 32) = Σ O Fig. 4/2b: Calculating the number of inputs/outputs (type 05)

76 4. Commissioning/programming Address assignment of the valve terminal The address assignment of the outputs of a modular valve terminal depends on the equipment installed. The terminal can be equipped in the following ways: valves and digital I/O modules valves only digital I/O modules only The rules described overleaf apply to the address assignment of these fitting variants. This is followed by a detailed example for terminals type 03 and type 05. PLEASE NOTE If two addresses are occupied for a valve location, the following assignment applies: lower-value address pilot solenoid 14 higher-value address pilot solenoid 12 There is a Festo software package which ascertains and prints out the addressing of a terminal (depending on equipment fitted). Please ask your Festo technician

77 4. Commissioning/programming Basic rule 1 With mixed fitting, the address assignment of the following is taken into account: valves digital I/O modules 1. Outputs The address assignment of the outputs does not depend on the inputs. 1.1 Address assignment of the valves Addresses should be assigned in ascending order without gaps Counting begins on the node from left to right S sub-bases always occupy 2 addresses D sub-bases always occupy 4 addresses ISO valve locations always occupy 2 adr. Max. 26 valve solenoid coils can be adr. 1.2 Rounding up to 4 bits; two cases are distinguished: a) If the number of valve addresses is divisible by 4 without remainder, continue with 1.3. b) If this is not the case, rounding must be made to 4 bits because of the 4 bit orientated addressing. The 2 bits thus rounded in the address range cannot be used 1.3 Address assignment of the output modules After the (rounded 4-bit) addressing of the valves, the digital outputs are addressed Addresses should be assigned in ascending order without gaps Counting begins on the node from right to left. Counting on the individual modules is from top to bottom. Digital O-modules always occupy 4 addresses

78 4. Commissioning/programming 2. Inputs The address assignment of the inputs does not depend on the outputs. 2.1 Address assignment of input modules Addresses should be assigned in ascending order without gaps. Counting on the node is from right to left. Counting begins on the node from top to bottom. 4-input modules occupy 4 addresses. 8-input modules occupy 8 addresses. When the operating voltage is switched on, the valve terminal recognizes automatically all available pneumatic modules (Type 03: max. 13 modules, type 05: 4, 8 or 12 valve locations) and digital input/output modules. It also assigns the appropriate addresses. If a valve location is not used (blanking plate) or if a digital input/output is not connected, the appropriate address is nevertheless assigned

79 4. Commissioning/programming The diagram below shows as an example the address assignment with mixed fitting. I module 4 inputs I module 8 inputs O module 4 outputs O module 4 outputs SINGLE sub-base DOUBLE sub-base DOUBLE sub-base Double sub-base Round up Fig. 4/3: Address assignment of a valve terminal with digital I/Os Notes on Fig. 4/3 If single valves are fitted to double subbases, four addresses will be reserved for valve solenoid coils; the higher address in each case cannot be used (see address 3). If unused valve locations are fitted with blanking plates, the addresses will still be reserved (see addresses 12, 13). Because of the 4-bit orientated addressing of the modular valve terminal, rounding is always made to the full four bits (unless the fitting already uses all 4 bits). Two addresses cannot therefore be used (see addresses 14, 15)

80 4. Commissioning/programming Basic rule 2 If only valves are fitted, the address assignment is as described in basic rule 1. PLEASE NOTE Maximum 26 valve solenoid coils can be addressed. There is no rounding of the last two positions on the valve side. Basic rule 3 If only electrical I/Os are used, the address assignment is always as described in basic rule 1. PLEASE NOTE Counting begins immediately to the left of the node. There is no rounding of the last two positions on the valve side. Maximum 48 digital outputs/inputs can be addressed. SF- 202 Basic rule 4 For SF-202 only. Please unfold for page 4-10 Please unfold for page

81 4. Commissioning/programming Address assignment after extension/conversion A special feature of the modular valve terminal is its flexibility. If the demands placed on the machine change, the fittings of the valve terminal can also be changed. CAUTION If the valve terminal is subsequently extended or converted, the input/output addresses may be shifted. This applies in the following cases: If one or several pneumatic modules is/are subsequently fitted/removed (type 03). If a pneumatic module with single valves is replaced by a new module with double valves or vice versa (type 03). If additional input/output modules are inserted between the node and existing input/output modules. If existing 4-input modules are replaced by 8-input modules or vice versa. PLEASE NOTE The addressing limit of 48 inputs and outputs must be observed if the terminal is extended or converted

82 4. Commissioning/programming Using the standard fitting in the previous diagram, this diagram shows the modifications to the address assignment when an extension is made. Input module 4 inputs Input module 8 inputs Output module 4 outputs Output module 4 outputs S valve sub-base D valve sub-base D valve sub-base D valve sub-base POWER SUPPLY D valve sub-base S valve sub-base No rounding Fig. 4/4: Address assignment of a valve terminal after extension/conversion Notes on Fig. 4/4 Pressure supply modules and intermediate supply modules do not occupy any addresses

83 4. Commissioning/programming Example of addressing type 03 MIDI/MAXI valves 4-input module 8-input module 4-output moduleh 4-output moduleh Double sub-base Double sub-base Double sub-base Double sub-base Single sub-base Double sub-base Round up PLEASE NOTE If a valve location occupies two addresses, the assignment is as follows: low value addresses pilot solenoid coil 14 higher value addresses pilot solenoid coil 12 Fig. 4/5: Address assignment of a valve terminal type 03 (MIDI/MAXI valves) E5a 4-15

84 4. Commissioning/programming Example of addressing type 05 ISO valves 4-input module 8-input module 4-output module 4-output module Double sub-base Double sub-base Double sub-base Single sub-base Double sub-base Double sub-base Double sub-base Single sub-base Do not round up PLEASE NOTE If a valve location occupies two addresses, the assignment is as follows: low value addresses pilot solenoid coil 14 higher value addresses pilot solenoid coil 12 Fig. 4/6: Address assignment of a valve terminal type 05 (ISO valves) 4-16 E5a

85 4. Commissioning/programming Addressing with FST 202C PLEASE NOTE There is a Festo software package which ascertains and prints out the addressing of a terminal (depending on equipment fitted). Please ask your Festo technician. SF- 202 The programmable valve terminal SB-202 contains maximum 48 inputs and outputs. These are addressed by the FST 202C with 8 input and output words each with 8 bits. Non available inputs are "logic 0" here. The following tables show the assignment of the I/Os between the terminal and the FST; once as a complete table and once by means of an example (standard fitting). PLEASE NOTE If two addresses are occupied for a valve location, the following assignment applies: lower-value address pilot solenoid 14 higher-value address pilot solenoid

86 Inputs Outputs Terminal FST 202C Terminal FST 202C I0.0 I0.1 I0.2 I0.3 I0.4 I0.5 I0.6 I0.7 I1.0 I1.1 I1.2 I1.3 I1.4 I1.5 I1.6 I1.7 I2.0 I2.1 I2.2 I2.3 I2.4 I2.5 I2.6 I2.7 I3.0 I3.1 I3.2 I3.3 I3.4 I3.5 I3.6 I3.7 I4.0 I4.1 I4.2 I4.3 I4.4 I4.5 I4.6 I4.7 I5.0 I5.1 I5.2 I5.3 I5.4 I5.5 I5.6 I O0.0 O0.1 O0.2 O0.3 O0.4 O0.5 O0.6 O0.7 O1.0 O1.1 O1.2 O1.3 O1.4 O1.5 O1.6 O1.7 O2.0 O2.1 O2.2 O2.3 O2.4 O2.5 O2.6 O2.7 O3.0 O3.1 O3.2 O3.3 O3.4 O3.5 O3.6 O3.7 O4.0 O4.1 O4.2 O4.3 O4.4 O4.5 O4.6 O4.7 O5.0 O5.1 O5.2 O5.3 O5.4 O5.5 O5.6 O5.7 Fig. 4/7: Addressing the inputs and outputs with FST 202C VISB - 03/05 4. Commissioning/programming

87 4. Commissioning/programming I module 4 inputs I module 8 inputs O module 4 outputs O module 4 outputs SINGLE DOUBLE DOUBLE DOUBLE Round up Inputs Outputs Outputs Terminal FST Terminal FST Terminal FST I0.0 I0.1 I0.2 I0.3 I0.4 I0.5 I0.6 I0.7 I1.0 I1.1 I1.2 I O0.0 O0.1 O0.2 O0.3 O0.4 O0.5 O0.6 O0.7 O1.0 O1.1 O1.2 O1.3 O1.4* O1.5* O1.6** O1.7** * Blanking plate (unused) ** cannot be used (rounded) Fig. 4/8: Example - addressing the standard fitting O2.0 O2.1 O2.2 O2.3 O2.4 O2.5 O2.6 O

88 4. Commissioning/programming 4.2 FIRST STEPS WITH FST A program must always be commissioned in RAM. If there is a failure of the operating voltage during commissioning, the following will apply: The information will be stored in RAM for at least 4 hours. In most cases, commissioning can therefore be completed. The programs are still available on the PC and must be reloaded if the information is lost. Fast and reliable commissioning can be made with the Festo programming software FST 202C. This is installed on a personal computer which is then connected to the programmable valve terminal by means of the diagnostic cable KDI-SB202-Bu25 or -Bu9 (RS232 interface). SF- 202 Prerequisites When the programmable valve terminal has been fully connected, commissioning can be started. Software-Tools FESTO Software-Tools Fig. 4/9: Software and PC for commissioning 4-20 E5a

89 4. Commissioning/programming The installation and operation of the software package is described in detail in the appropriate manual. Please consult this manual for more information on the FESTO software tools (FST). The following sections show only the most important steps in commissioning. The programming software responds with the following picture when accessed. Fig. 4/10: Title mask of programming software E5a 4-21

90 4. Commissioning/programming The programming software FST 202C contains the following functions, amongst others: Programming in STL Programming in LDR Setting and resetting individual outputs On-line operation When you select the operating mode on-line, the following mask appears: Fig. 4/11: Selection mask for ON-LINE operation This initial mask shows the configuration of the control unit and the amount of free memory space. With key F1 you can access the menu for bit-by-bit switching on/off (setting/resetting) of the outputs (display FPC-Info) E5a

91 4. Commissioning/programming Display FPC-Info: The status of the inputs/outputs is shown as follows in this menu. Fig. 4/12: Switching on/off the outputs bit-by-bit Switching the outputs on/off: WARNING When the system is switched on, the outputs react immediately to the entry on the screen. Make sure that there is no danger to human beings or to the machine when the outputs are switched on/off. Activate bit-by-bit entry with the TAB key ( I). Select the relevant output with the cursor keys or with the mouse. Set, reset or switch over the relevant output with the keys F1 to F3. E5a 4-23

92 4. Commissioning/programming Create allocation list The function "allocation list" can be found in the utility programs of the FST202C. The allocation list is an assignment list in which the logical outputs (operands for valves and electrical outputs) are assigned with their mechanical functions. The allocation list will be required later for creating the program. It facilitates programming and enables documentation to be clear and complete. Recommendation: Create an allocation list for all projects. Fig. 4/13: Allocation list editor of the FST 4-24 E5a

93 4. Commissioning/programming Load programs Programs for the programmable valve terminal are grouped together as a project in the FST 202C and loaded into the terminal via the RS-232 interface. The individual steps are shown below. A detailed description is to be found in the FST 202C user manual. Proceed as follows: Use the cursor keys or the mouse to select the function Load project under project management and activate the function with ENTER or double click. Fig. 4/14: Select load project E5a 4-25

94 4. Commissioning/programming In the following mask select the individual programs or modules which are to be loaded into the programmable valve terminal. Fig. 4/15: Selection of programs to be loaded Start loading the programs with key F1. When programs have been newly created or modified, they must then be translated into machine code. When all programs are in machine code, the FST 202C loads them into the valve terminal. When loading is complete, the message "Loading complete" appears E5a

95 4. Commissioning/programming Creating EEPROM When a program has been loaded and tested, it is copied into the EEPROM, whereby commissioning is concluded. The controller can now function reliably and free of maintenance. For this purpose, the program is first read and then stored as a file on the hard disc of the computer. Proceed as follows: Use the cursor keys or the mouse to select the function Read controller under Utilities and activate the function with ENTER or double click. Fig. 4/16: Read controller The FST 202C then reads the whole program, including the contents, from the controller and stores it as a file. E5a 4-27

96 4. Commissioning/programming When reading is complete, the file contents can be loaded into the EEPROM. Programming the EEPROM is incorporated into the Program call as an individual utility program. The installation routine writes the entries correctly into the configuration file. Proceed as follows: Use the cursor keys or the mouse to select and activate the function Program call under Utilities. Use the cursor keys or the mouse to select and activate the function EEPROM programming under Program call. Fig. 4/17: Program call EEPROM 4-28 E5a

97 4. Commissioning/programming The EEPROM programmer then responds with the mask shown below. Proceed as follows: Start programming with key F4. Fig. 4/18: Input message of EEPROM programmer E5a 4-29

98 4. Commissioning/programming Boot mode When the EEPROM has been programmed, the next booting from the EEPROM is usually desired (boot mode). The FST 202C asks whether or not this is to be done and the question must be answered with Yes. Fig. 4/19: Conversion of boot mode to EEPROM mode The transfer of the boot mode to EEPROM is shown on the mask illustrated below. Fig. 4/20: Boot mode converted to EEPROM mode 4-30 E5a

99 4. Commissioning/programming Auto mode As the last step in commissioning, you can determine whether or not the programmable valve terminal is to start processing the program automatically when the operating voltage is applied (auto mode: ON). The program with the lowest number will be started (usually program 0). Proceed as follows: Select ON-LINE menu Select auto mode with key F5 Answer the question "Automode on/off?" with Y (=Yes). Fig. 4/21: Conversion to auto mode Commissioning is then concluded. E5a 4-31

100 4. Commissioning/programming 4.3 PROGRAMMING SF- 202 Programming with the FST 202C The programming languages Statement list (STL) and Ladder diagram (LDR) can be used for creating the user programs and program modules. The programming conditions, the programming languages and programming techniques are described in the manuals: FESTO Software Tools Statement list for the FPC 202C Manual FST 202C FESTO Software Tools Ladder diagram for the FPC 202C Manual FST 202C The following sections give a brief summary of the most important steps in programming and draw attention to special features of the programmable valve terminal. Structuring The programmable valve terminal makes the following aids available for structuring a program or project: 8 programs 8 program modules 3 function modules For ease of programming and to relieve the user programs, frequently required command structures can be programmed in program modules (subprograms). Program modules and function modules differ depending on whether they are to be programmed by the user himself or whether they are already defined in the operating system

101 4. Commissioning/programming Both types of modules can be accessed from within an active program. When the modules have been fully processed, the accessing program continues at the point at which it was interrupted. Program modules Program modules can be created with the FESTO programming software in statement list or ladder diagram or as a text module with the text display editor. In certain cases, program modules can also be obtained from the factory. Maximum eight such modules can be stored in the user memory of the programmable valve terminal. Function modules Function modules are part of the operating system and are supplied by the factory. The operating system of the programmable valve terminal can manage maximum 256 (0 to 255) function modules. At present three modules have been predefined. They are stored in the operating system EPROM. When a program or a project has been planned and structured, progamming can be started. The following are required here: operators/command set operands (remanent, non remanent) function modules These are described briefly overleaf

102 4. Commissioning/programming Operators, command set Depending on the programming language selected (STL or LDR), different operators must be used for creating the program. The permitted operators (command set) are listed below. STEP IF THEN OTHRW NOP CFMn CMPn JMP TO SET RESET LOAD SWAP SHL For sequencing programs a symbolic step mark is permitted Initiation of a conditional part Initiation of an executive part, if the condition is fulfilled under IF. Initiation of an alternative executive part, if the condition is not fulfilled under IF. Non-operation, must be in the IF part. Substitute symbol in executive part. Call up function module (CFM0... CFM255) Call up program module (CMP0... CMP7) Jump to step mark, instructions follow in an executive part. One bit operands are set to logic ONE, timer, counter or programs are started. Instruction follows in an executive part. Memory command. One bit operands are set to logic ZERO. Timer, counter or programs are stopped. Instruction follows in an executive part. Memory command. With this command one and multi-bit operands and constants are loaded in the accumulator. In the multi-bit accumulator higher and lower value bytes are exchanged. In the multi-bit accumulator all bits are moved one position to the left. Bits forced out at the left are lost. Fig. 4/22a: Operators of the programmable valve terminal

103 4. Commissioning/programming SHR ROL ROR PSE BID DEB In the multi-bit accumulator all bits are moved one position to the right. Bits forced out at the right are lost. In the multi-bit accumulator all bits are rotated anti-clockwise; the last bit becomes the first, the last but one becomes the last, etc. In the multi-bit accumulator all bits are rotated in a clockwise direction; the first bit becomes the last, the second becomes the first etc. Initiates a change of processor, is used to terminate the program. Converts the contents of the multi-bit accumulator from dual to decimal code. Converts the contents of the multi-bit accumulator from decimal to dual code. ( Open brackets. Start of a collection of several instructions + Arithmetical instruction for addition, also as a sign for constants. - Arithmetical instruction for subtraction * Arithmetical instruction for multiplication / Arithmetical instruction for division < Arithmetical comparison (less than...) <= Arithmetical comparison (less than or equal to... ) = Arithmetical comparison (equal to...) => Arithmetical comparison (equal to or greater than... ) > Arithmetical comparison (greater than...) <> Arithmetical comparison (unequal to... ) ) Close brackets, End of collection of several instructions AND Logical instruction for bit-by-bit AND operation Fig. 4/22b: Operators of the programmable valve terminal

104 4. Commissioning/programming OR EXOR TO SHIFT INC DEC WITH N CPL INV Logical command for bit-by-bit OR operation Logical command for bit-by-bit exclusive OR operation Transfers in combination with LOAD operand 1 to operand 2 Exchanges the subsequent one bit operand with the value in the one-bit accumulator Multi-bit operands are increased in value by 1 (incremented) Multi-bit operands are decreased in value by 1 (decremented) when modules are called this is used to introduce parameter transfer (CMP... WITH) Negation: negates operands, i.e. they are interrogated to logic ZERO Complements multi-bit operands according to the second complement method Complements multi-bit operands according to the first complement method Fig. 4/22c: Operators of the programmable valve terminal If STL is used as the programming language, all the commands can be used. If LDR is used as the programming language, some commands cannot be used or only in another form. All arithmetical operations are made in boxes. The exact syntax is described in detail in the relevant FST 202C manual

105 4. Commissioning/programming Operands The table below contains the operands managed by the operating system of the FPC 202C. They can be addressed with the statement list and ladder diagram. RAM mode Whilst the program is running, all operands in RAM (remanent RAM) can be used. If the operating voltage fails, all the operands will still be available in RAM for at least 4 hours. EEPROM mode Some of the operands will be copied into the EEPROM (remanent EEPROM) if the boot mode "EEPROM mode" has been set. The remainder will be lost after 4 hours (non remanent). The following tables summarize the: available operands remanent operands. Operands Number Designation Parameter Comment Inputs Input words Outputs Output words Flag Flag words Init flag I IW O OW F FW FI {0-7}.{0-7} {0-7} {0-7}.{0-7} {0-7} {0-15}.{0-15} {0-15} 1 Single-bit operand, assignment depends on configuration Multibit operand Single-bit operand, assignment depends on configuration Multibit operand Single-bit operand 16 flag words each with 16 flags Multibit operand Single-bit operand, FI only with LDR Fig. 4/23a: Operands available with the programmable valve terminal

106 4. Commissioning/programming Operands Number Designation Parameter Comment Counters 32 C {0-31} Single-bit operand Counter preselects Counter words CP CW {0-31} {0-31} Multibit operand Multibit operand Timers 32 T/TE/TA {0-31} Single-bit operand, all timers can be programmed as impulse timer T, with LDR also as switchon delay timer TE, switch-off delay timer TA Timer preselects Timer words TP TW {0-31} {0-31} Multibit operand Multibit operand Registers 64 R {0-63} Multibit operand Errors 1 E 1 Single-bit operand Error word 1 EW 1 Multibit operand Programs 8 P {0-7} Single-bit operand Program modules Function modules Special operands 8 CMP {0-7} Create on PC in STL or LDR 3 CFM See section "Function modules" 40 FU {0-23} and {32-47} in operating system EPROM Multibit operand Fig. 4/23b: Operands available in the programmable valve terminal PLEASE NOTE Not all inputs and outputs physically exist nor can they be connected

107 4. Commissioning/programming Operands Designation/ parameter RAM Remanent EEPROM Flags F F15.15 F F15.15 Flag words FW0... FW15 FW2... FW15 Counters C0... C31 C0... C31 C0... C15 Counter preselects CP0... CP31 CP0... CP31 CP0... CP15 Counter words CW0... CW31 CW0... CW31 CW0... CW15 Timers T/TA/TE non remanent Timer preselects TP0... TP31 TP0... TP31 TP0... TP15 Timer words TW0... TW31 non remanent Registers R0... R63 R0... R63 R0... R30 Errors E E, + Error word EW EW Programs P P Program modules CMP CMP Function modules CFM CFM Special operands FU0... FU23 non remanent FU32... FU47 non remanent Fig: 4/24: Remanent/non remanent operands

108 4. Commissioning/programming Remarks on the special operands: The special operands FU0 to FU23 have not yet been defined. They can be used as freely-available 16-bit registers. They are not remanent in any operating mode. The special operands FU32 to FU47 serve as transfer or return parameters with program and function modules. They are available twice because the programmable valve terminal can process two programs simultaneously with two tasks. Each task has a group of transfer parameters

109 4. Commissioning/programming Function modules FN/CFM 0 Delete internal operands Entry format STL THEN CFM 0 WITH <P1> Parameter P1: Mode (0...3) (see below) P1 has the following meaning: 0: Delete all registers, flags, timers and counters 1: Delete all registers 2: Delete all flags 3: Delete all timers and counters Comment Parameter P1 can be a constant (e.g. V3) or a variable (e.g. R33). Return parameter Case 1 P1 (FU32) = {-1} Processing successful Case 2 P1 (FU32) = {0} Processing incorrect P2 (FU33) = {error number}

110 4. Commissioning/programming FN/CFM 1 Locate short circuit Entry format STL CFM 1 Parameter No parameter Comment: When called, the first short-circuited electrical output sends a return signal. Return parameter: Case 1 P1 (FU32)= {-1} Processing successful P2 (FU33)= {-1} No short circuit or no output available P3 (FU34)= without meaning Case 2 P1 (FU32)= {-1} Processing successful P2 (FU33)= Word number P3 (FU34)= Bit number of the first short circuited output Case 3 P1 (FU32)= {0} Processing incorrect P2 (FU33)= {error number}

111 4. Commissioning/programming FN/CFM 2 Indirect setting/resetting of local outputs Entry format STL THEN CFM 2 WITH <P1>, <P2>, <P3> Parameter P1 = {0, 1} P2 = {0... 7} P3 = {0... 7} The parameters have the following meaning: P1 = 0: Reset output = 1: Set output P2 = Word number of output P3 = Bit number of output Return parameter Case 1 P1 (FU32) = {-1} Processing successful Case 2 P1 (FU32) = {0} Processing incorrect P2 (FU33) = {error number} The function modules are suitable for diagnosis and error treatment. Further details are to be found in Chapter 5 "Diagnosis and error treatment."

112 4. Commissioning/programming 4.4 PROGRAMMING TECHNIQUES This chapter deals with some special features of the operating system which are of assistance in clarifying complex procedures and which enable programs to be optimally organised. A section on data saving concludes this chapter. SF- 202 Task structure of the operating system The operating system of the programmable valve terminal is capable of multi-tasking, i.e. several tasks can be carried out parallel. Of the 8 user programs in the controller two can be processed simultaneously. The calling program and the program called up are active, all other programs are passive. Program processing Start a program (preferably P0) using the RUN command or automode. P0 P1 P2 P3 P4 P5 P6 P7 active passive passive passive passive passive passive passive Fig: 4/25: Program start Recommendation: Use Program no. 0 as organisation program P0 for the following tasks: Starting and stopping other programs General monitoring

113 4. Commissioning/programming Note: In this case further programs should only be started from P0, otherwise P0 itself will be stopped and general monitoring will become ineffective. From the active program 0 a second program, for example P4, can be called up: before: P0 P1 P2 P3 P4 P5 P6 P7 active passive passive passive passive passive passive passive call P4 after: P0 P1 P2 P3 P4 P5 P6 P7 active passive passive passive active passive passive passive parallel program processing P0 and P4 Fig. 4/26: Parallel program processing 1 Both user programs are now processed alternately. With compiled programs, the processing change takes place after a complete cycle. The cycle consists of the following: with LDR a program cycle (= complete LDR program) with STL a program step (from STEP... to STEP...)

114 4. Commissioning/programming A maximum of two programs can be processed simultaneously. If an additional program is called up from one of the active programs, the calling program and the newly set program run parallel, the third is automatically stopped. before: P0 P1 P2 P3 P4 P5 P6 P7 active passive passive passive active passive passive passive call P7 after: P0 P1 P2 P3 P4 P5 P6 P7 active passive passive passive passive passive passive active parallel program processing P0 and P7 Fig. 4/27: Parallel program processing

115 4. Commissioning/programming Multi-tasking The operating system of the programmable valve terminal is designed for multi-tasking, enabling the processor to process several tasks simultaneously. Two of these tasks are available to the user. Tasks are always changed with an STL program before the commands STEP and Processor change. With an LDR program the task change always takes place at the end of the program. The two active programs are processed alternately. Only one program can be processed at one time. Program x STEP 1 Program y STEP 1 STEP 2 STEP 2 STEP 3 STEP 3 Fig. 4/28: Program processing Step 1 of program y is processed first, if step 1 of program x has been run through once. This change over between programs is known as task changeover. Processing takes place so quickly that it appears to occur simultaneously

116 4. Commissioning/programming Module processing Process diagram The programmable valve terminal works with process diagram. At the start of the processing cycle all the states of the inputs are read (process diagram inputs, PAE), then the program is processed and finally the outputs are set or reset depending on the processing result (process map outputs, PAA). Module in LDR/STL without STEP Calling a program module or function module is interpreted as if a subprogram were being called. When the program module or function module has been fully processed, the user program is continued from the point at which it was interrupted. This applies to: modules in LDR modules in STL without step

117 4. Commissioning/programming PAE Process diagram read inputs P0 (task 0) P3 (task 1) IF THEN CMP1 WITH.. IF THEN... Module 1 IF THEN... IF THEN... Additional programs or modules IF THEN... PAA Process diagram write outputs Fig. 4/29: Module in LDR/STL without STEP

118 4. Commissioning/programming Module in STL with STEP As with the STEP command within a program, a task change is carried out within the module prior to this command. As a result the entire program from which the module is called ceases to be processed until the module has been processed. PAE PAE Process diagram read inputs B...C P0 (Task 0) P3 (Task 1) A Module 1 IF THEN CMP1 WITH... IF THEN... B C C STEP IF THEN... STEP IF THEN... STEP IF THEN... A B Change task Change task PAA PAA Process diagram write outputs Fig. 4/30: Module in STL with STEP

119 4. Commissioning/programming Module for character output With the output of texts via the serial interface, a similar response is produced as with the modules in STL with STEP. The calling program is then interrupted. This is an important point to remember when planning the program. PAE PAE Process diagram read inputs B... G P0 (Task 0) P3 (Task 1) IF THEN CMP1 WITH... IF THEN... A B C D E F G Module 1 (character) A B C D E F G Change task Change task PAA PAA Process diagram write outputs Fig. 4/31: Module processing for character output

120 4. Commissioning/programming Remarks on previous diagram: An assembler module compiled with the aid of the display editor is called up from a program. This is the task to be processed. The module transfers a character to the interface driver (UART) and then carries out a change of task. This prevents the whole process from coming to a halt until output of the text is completed. However, the calling program will not be processed further until the text has been output completely. At a transmission rate of 9600 baud this is approximately 1ms per character. With a text of 50 characters this gives an interruption time of 50 ms for the calling program. It is essential to take this into account when planning the program

121 4. Commissioning/programming Program and data backup The programmable valve terminal is provided with a main memory in the form of a static RAM. When the program is being processed it must be in RAM during run time. Internal operands too, such as register, flag, counter etc. are filed in RAM. Programs can be backed up if they are programmed and stored in a permanent EEPROM. The EEPROM programming is supported by the utilities program for EEPROM programming via the function Program call-up of the FST 202C. With the boot mode RAM or EEPROM you can later specify whether or not the data and programs are to be transferred when the controller is switched on, either: directly from RAM or from EEPROM and copied into RAM

122 4. Commissioning/programming Program memory RAM The RAM is permanently soldered onto the PC board. The program memory serves simultaneously as the main memory. The RAM has a capacity of 32 KByte, of which approximately 26 KByte is available as program memory. In this operating mode all internal function units are remanent. Reaction to power failure: 1. If the operating voltage fails for less than 4 hours, all data and programs will be retained in RAM. 2. If the operating voltage fails for longer than 4 hours, all data and programs in RAM will be lost

123 4. Commissioning/programming Program memory EEPROM In addition to the RAM, a permanent EEPROM is installed for data backup. The EEPROM does not lose any data if there is an operating voltage failure and can be programmed several times with the FST 202C. All programs are therefore retained. Of the internal operands, only those designated as "remanent EEPROM" are protected against power failure. RAM Power on EEPROM Program Programming with FST max times Program Operands Remanent operands Remanent Power on Power off times Fig. 4/32: Memory management system in EEPROM operation

124 4. Commissioning/programming Remarks: EEPROM can be programmed maximum times using FST 202C. Usually the EEPROM is programmed when commissioning has been completed. Commissioning takes place in RAM. The contents of the RAM will be retained for at least 4 hours even without a battery. If the data are lost, they can be loaded again from the PC. If there is a failure in the operating voltage, the remanent operands and current auto mode will be "rescued" in EEPROM. This requires a programming procedure. The special memory management system enables these programming procedures to be repeated times, e.g. with 50 interruptions to the operating voltage daily the EEPROM will have a life of 17 years. Once the maximum number of programming cycles has been reached (FST programming , interrupted operating voltage ), the fault message 8 "EEPROM defective or missing" appears and the red LED fault indicator will light up

125 4. Commissioning/programming Programming EEPROM Programming of the EEPROMs is controlled by the FST 202. The FST functions Load Program or Load Project always use the RAM. On completion of the program/project the following procedure must be adopted: Activate FST function read controller The entire contents of the RAM are transferred to the PC and filed in the current project path under the name "3Z0C00V1". Select EEPROM programming on the FST function program call. Press function key F4, program EEPROM The contents of "3Z0C00V1", previously filed on the PC, will be loaded into the EEPROM of the programmable valve terminal. Use function key F3, to set boot mode, EEPROM operation. The screen will show the number of completed programming procedures of the EE- PROM. Boot mode and auto mode The boot mode determines which program memory is to be processed (RAM or EE- PROM). Once the operating voltage supply has been switched on, the auto mode function determines whether or not the existing program in the selected program memory is to be processed

126 4. Commissioning/programming Boot mode EEPROM PLEASE NOTE: Data in RAM is overwritten. When the operating voltage supply is switched on the entire contents of the EEPROM (programs and remanent operands) are copied into RAM. Note: When programs are loaded from the FST 202C into the programmable valve terminal, the following message appears on the screen: "Warning: With POWER ON data from the EEPROM is loaded. Boot mode RAM No copying process takes place when the unit is switched on. Automode When the operating voltage supply is switched on in Automode ON, the program with the lowest number is started. Response of programmable valve terminal when project/program is loaded When project/program is loaded, the programmable valve terminal switches all outputs off and stops the program processing

127 4. Commissioning/programming 4.5 PRACTICAL APPLICATIONS The programmable valve terminal is designed to handle a wide range of different control tasks, e.g.: As part of an extensive control system with higher order control. For independent control with user-friendly operations by means of keyboard and text display. Control of a station Using the two electrical inputs and two electrical outputs the programmable valve terminal can be operated as a subsystem (slave). Parts control Release for run completed Error message I8 I8 I4 O4 Fig. 4/33: Programmable valve terminal as slave in a control system The main controller (master) starts the programs filed in the programmable valve terminal and receives an acknowledgement of completion (or an engaged signal if the sequence is still running)

128 4. Commissioning/programming The extra inputs are available for additional information, for example, parts control. Using the second output the programmable valve sensor terminal can supply information about a specific situation to the higher order controller. Separate connection of the operating voltage for the valves enables the higher order controller to shut down the valves of the programmable valve terminal in an emergency. Basic stand-alone control Keys and display units can be connected to the electrical inputs and outputs for simple operation of small, stand-alone devices or machines. Start Error Start Stop EMERGENCY OFF EMERGENCY OFF pin 2 Operation Fig. 4/34: Simple operation with push buttons

129 4. Commissioning/programming System operation with ABG With the display and control unit E.ABG it is easy to work with operating mode selection, manual operation of control elements and input for time and quantity values. AAAA AAAA AAAA AAAAAAA AAAA AAAA AAAA AAAA AA AAAA AAAA AAAA AAAA AA AAAA AAAA AAAA AAAA AA AAAA AAAA AAAA AAAAAAA AAAA AAAA AAAA AAAA AAAAA AAAA A AAAA A AAAAA AAAAA AAAA A AAAA A AAAAA AAAAA AAAA A AAAA AAAAA AAAA AAA AAA AAAA AAAAA AAAA A AAAA AAAAA AAAAA AAAA A AAAA A AAAAA AAAAA AAAA A AAAA A AAAAA AAAAA AAAA AAAAA AAAA A AAAA AAAA AAAA AAAA AAAA A AAAA A AAAAA AAAA AAAA A AAAA A AAAAA AAAA AAAA A AAAA AAAAA AAA AAA AAAA AAAA AAAA A AAAA AAAAA AAAA AAAA A AAAA A AAAAA AAAA AAAA A AAAA A AAAAA AAAA AAAA AAAAA AAAAA Fig. 4/35: Display and operating unit E.ABG The display and operating unit ABG has an LCD display with 2 x 16 characters and a keypad with 16 keys. The ABG is connected to the diagnostic interface of the programmable valve terminal. Software links to user programs are made using the program module, the parameters of which can be specified, and which displays the function keys on flags, and which files the numerical keys in a multi-bit function unit

130 4. Commissioning/programming The functions Start and Stop can be controlled from the keyboard or through the inputs. The EMERGENCY STOP switch is always connected, as a hardware-related function, to the programmable valve terminal via pin 2. AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAA AAA AAAAAA AAA AAA AAAAAA AAA AAA AAAAAA AAA AAA AAAAAA AAA AAA AAA AAA AAA AAAAAA AAA AAA AAAAAA AAA AAA AAA AAA AAA AAAAAA AAA AAA AAA AAA V.24/RS232 Bild 4/36: Operating the system with ABG

131 4. Commissioning/programming The display in the ABG is programmed via the FST display editor, which offers very simple and easy-to-use programming of the texts. Fig. 4/37: Text programming with FST Display Editor Standard operation is available on diskette. This standard operation is written in STL and can easily be adapted to the requirements of a particular system. See overleaf for further details about standard software

132 4. Commissioning/programming System operation with ABG-2 With the display and operating unit E.ABG-2 it is easy to work with a selection of operating modes, manual operation of the control elements and input of time and quantity values. AAAA AAAA AAAA AAAA AAAA AAAA AAAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAAA AAAA AAAAAAAAAAAAAAAAAAA AAAA AAAAAAAAAAAAAA AAAA AAAA AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA AAAAA AAAA AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA AAAAA AAAA AAAA AAAAAAAAAAAAAA AAAA AAAAAAAAAAAAAA AAAA AAAA AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA AAAAA AAAA AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA AAAAA AAAA AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA AAAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA Fig. 4/38: Display and operating unit E.ABG-2 The display and operating unit E.ABG-2 has a fluorescent tube with 2 x 20 characters and a keyboard with 20 keys and 20 LEDs. The keys and LEDs may be allocated as required. Exchangeable inscription labels can be used to assign a text to each key. The ABG-2 is connected to the diagnostic interface of the programmable valve terminal. A program module, the parameters of which can be specified, and which displays all keys and LEDs on flags, is used for the software link to the user program

133 4. Commissioning/programming The functions Start and Stop can be activated via the keyboard or through the inputs. The EMERGENCY STOP switch is always connected through pin 2 to the programmable valve terminal as part of the hardware. AAAA AAAA AAAA AAAAAAA AAAA AAAA AAAA AAAAAAA AAAA AAAA AAAA AAAAAAA AAA AAA AAA AAA AAA AAA AAA AAAAAAAAA AAA AAA AAA AAA AAA AAA AAA AAAAAAAAA AAA AAA AAA AAA AAA AAA AAA AAAAAAAAA AAA AAA AAA AAA AAA AAA AAA AAAAAAAAA V.24/RS232 Fig. 4/39: Operating the system with ABG

134 4. Commissioning/programming The FST display editor is used for programming the display in ABG-2. It permits very simple and easy-to-use programming of the texts. Fig. 4/40: Text programming with FST Display Editor Standard operation is available on a diskette. This standard operation is written in STL and can easily be adapted to the requirements of a particular system. Additional details about standard software are given overleaf

135 4. Commissioning/programming Emulator as commissioning aid While commissioning is taking place the PC is linked with the programmable valve terminal by means of the serial interface, enabling programs to be loaded and the program sequence to be followed. V.24/RS232 Fig. 4/41: PC connection during commissioning It may be necessary to control the content of multibit function units or the status of single bit function units or to alter them. In this case control via ABG or ABG-2 is interrupted. The entries required by ABG-x can still be made by emulators, which offer software simulation of the operating and display units. Depending on the program in use, the appropriate emulator is loaded as a background program into the PC memory. The key combination ALT F10 is then used to call up the emulator and the ABG-x appears on the screen

136 4. Commissioning/programming Fig. 4/42: Emulator for the ABG All outputs of the programmable valve sensor terminal are then show in the ABG display on the PC screen. All permissible entries normally via the function keys are interpreted as outputs of the ABG-x by the programmable valve terminal. When the entries have been completed, press ESC to quit the emulator. The FST 202C will then be available for normal use

137 4. Commissioning/programming Fig. 4/43: Emulator for the ABG-2 With the ABG-2 the LEDs are additionally emulated, with the circle symbol for the LED changing (0 = LED out, X = LED alight)