Compact performance. Elektronics manual. CPV valve terminal with field bus direct connection. Types: CPV...-DI02 PROFIBUS-DP CPV...

Transcription

1 Compact performance Elektronics manual CPV valve terminal with field bus direct connection Types: CPV...-DI02 PROFIBUS-DP CPV...-CS02 ABB CS31 Manual en 1201a [762106]

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3 Contents and general instructions Original... de Edition... en 1201a Designation... P.BE-CPV-DI02-EN Order no (Festo AG & Co. KG, D Esslingen, Federal Republic of Germany, 2012) Internet: The reproduction, distribution and utilisation of this document as well as the communication of its contents to others without express authorisation is prohibited. Offenders will be held liable for payment of damages. All rights reserved in particular the right to register patents, utility models and designs. I

4 Contents and general instructions PROFIBUS,PROFIBUS-DP,SIMATIC,SPEEDC,TORX areregisteredtrademarks of their respective trademark holders in certain countries. II

5 Contents and general instructions Contents Intended use... Target group... Service... Notes on the use of this manual... Important user instructions... VII VII VII VIII IX 1. Installation CPV-DI02 and CPV-CS General instructions on installation Electrical connecting and display elements Overview for setting the CPV Direct Setting the station number Setting the diagnostic mode (CPV-DI02) or the load voltag monitoring (CPV-CS02) Recognizing the CPI extension with the SAVE button Help table for setting the station number Connecting the field bus Field bus cable Field bus baud rate and field bus length for PROFIBUS-DP (CPV-DI02) Field bus interface Connection possibilities Bus termination with termination resistors (CPV-DI02) Connecting the power supply Cable for power supply Selecting the power unit Connecting the power supply Extending the CPV Direct Rules for extending the CPI system Preparing the CPI system for commissioning Checking the CP strings Saving the string assignment Switching-on reaction of the CPI system III

6 Contents and general instructions 1.9 Reaction of the CPI system to faults in operation Eliminating assignment faults Replacing CPI/CP modules Commissioning CPV-DI02 (PROFIBUS-DP) Preparing the CPV Direct for commissioning Switching on the power supply Address assignment of the CPV Direct Address assignment of CPI/CP modules Information on commissioning Device master file (GSD) and icon files Configuration with a Siemens master STEP 7 HW Config (up to V 5.2) preparations Station selection with STEP Configuration with STEP Tool change configuration Examples of configuration Standard configuration Tool change configuration Diagnosis CPV-DI02 (PROFIBUS-DP) Diagnosis via LEDs Normal operating status Fault diagnosis with the LEDs LEDs for status display of the valve solenoid coils Diagnosis via PROFIBUS-DP Diagnostic words Diagnosis steps Overview of the diagnostic bytes Details for standard diagnostic information Diagnosis with tool change configuration Fault treatment Siemens SIMATIC S Online diagnosis with STEP IV

7 Contents and general instructions Read out diagnostic buffer with STEP 7 (up to V 5.2) Device-related diagnosis with STEP 7 (up to V 5.2) Short circuit/overload Output module Sensor supply on one input module Commissioning CPV-CS02 (ABB CS31) Preparing the CPV Direct for commissioning Switching on the operating voltages Address assignment of the CPV Direct General data Configuration CS31 CPU as bus master Diagnosis CPV-CS02 (ABB CS31) Diagnosis via LEDs Normal operating status Fault diagnosis with the LEDs LEDs for status display of the valve solenoid coils Diagnosis via the field bus Setting the diagnostic mode Fault treatment Reaction of the CPV Direct to faults Short circuit/overload at an output module Short circuit in the sensor supply at an input module A. Technical appendix... A-1 A.1 Technical specifications... A-3 A.1.1 Common technical specifications of CPV-DI02 and CPV-CS02... A-3 A.1.2 Technical specifications for the CPV-DI02... A-5 A.1.3 Technical specifications for the CPV-CS02... A-5 A.2 PROFIBUS-DP: Commissioning with the general DP master... A-6 A.2.1 Bus start... A-6 V

8 Contents and general instructions A.2.2 Send parametriziung data... A-7 A.2.3 Check the configuration data... A-9 A.2.4 Transferring input and output data... A-10 A.2.5 Read diagnostic information... A-10 A.2.6 Implemented functions and service access points (SAP)... A-11 A.2.7 Bus parameters/reaction times... A-12 A.2.8 Transmission times on the PROFIBUS-DP... A-12 A.3 Accessories... A-13 B. Index... B-1 VI

9 Contents and general instructions Intended use The CPV valve terminals with field bus direct connection (CPV direct) described in this documentation have been designed exclusively for use as slaves on the following field buses: CPV-DI02: PROFIBUS-DP CPV-CS02: ABB CS31 Thevalveterminalmayonlybeusedasfollows: as designated in industrial applications without any modifications by the user. Only the conversions or modifications described in the documentation supplied with the product are permitted. in faultless technical condition. The maximum values specified for pressures, temperatures, electrical data, torques etc. must be observed. If additional commercially-available components such as sensors and actuators are connected, the specified limits for pressures, temperatures, electrical data, torques, etc. must not be exceeded. Please comply with national and local safety laws and regulations. If implementing an emergency stop function, note the measures listed in section Target group This manual is intended exclusively for technicians trained in control and automation technology, who have experience in installing, commissioning, programming and diagnosing slaves on the field buses named above. Service Please consult your local Festo Service if you have any technical problems. VII

10 Contents and general instructions Notes on the use of this manual Note This manual takes into consideration the functioning of the following software and hardware versions: CPV-DI02: software as from , hardware as from 0107 (for sizes CPV10 and CPV14) CPV-CS02: software as from , hardware as from 0107 (for sizes CPV10 and CPV14) This manual contains specific information on installing, commissioning, programming and diagnosing CPV valve terminals with direct connection for the field buses named. Informationonthepneumaticscanbefoundinthe Pneumatics manual P.BE-CDV-... Further information on the PROFIBUS-DP can be found in: the setting up guidelines for the PROFIBUS-DP the manuals of the master manufacturer. VIII

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

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

13 Contents and general instructions The following product-specific terms and abbreviations are used in this manual: Term/abbreviation CP cable CP function CP module CP string CP system CP valve terminal CPI function CPI connection CPI cable CPI module CPI system CPV Direct I Input module Meaning Special cable for connecting the various CPI/CP modules in a CP string. Colour: black, type KVI-CP1-... and type KVI-CP2-... Supports the CP protocol without extended functions Common term for modules without extended functions which can be incorporated in a CPI/CP system. CPI or CP modules which are connected by CPI/CP cable and which are connected to the CPX-CP interface. For reasons of simplicity, only the term CP string is used, even if it has CPI functionality. Complete electrical installation system consisting of a CP master with one or more CP strings. The system consists of CP modules (without extended functions). CPV valve terminal (type 10) or CPA valve terminal (type 12), each with CP connection (also regarded as CP modules). Basic electric unit, black. Supports the CPI protocol with extended functions Socket orplugonthecpi moduleswhichallowsthemodulestobe connected using the CPI or CP cable. Special cable for connecting the various CPI/CP modules in a CP string. Colour: white, type KVI-CP3-... Common term for modules with extended functions which can be incorporated in a CPI/CP system. Also: CPI installationsystem Complete electrical installation system consisting of a CP master with one or more CP strings. The system consists of CPI/CP modules with and without extended functions. The system need not consist exclusively of CPI modules. CPV valveterminalwithfieldbusdirect connection Digital input Input module XI

14 Contents and general instructions Term/abbreviation I/O modules I/Os O Octet Output module PLC/IPC String assignment Meaning Collective term for the modules which provide digital inputs and outputs (e.g., CPX I/O modules, CPI input modules and CPI output modules). Digital inputs and outputs Digital output Number of address words assigned by the CP system Output module Programmable logic controller/industrial PC Type and order of the CPI/CP modules connected to one or more CP strings. Tab. 0/1: Product-specific terms and abbreviations XII

15 Installation CPV-DI02 and CPV-CS02 Chapter 1 Installation CPV-DI02 and CPV-CS02 1-1

16 1. Installation CPV-DI02 and CPV-CS02 Contents 1. Installation CPV-DI02 and CPV-CS General instructions on installation Electrical connecting and display elements Overview for setting the CPV Direct Setting the station number Setting the diagnostic mode (CPV-DI02) or the load voltag monitoring (CPV-CS02) Recognizing the CPI extension with the SAVE button Help table for setting the station number Connecting the field bus Field bus cable Field bus baud rate and field bus length for PROFIBUS-DP (CPV-DI02) Field bus interface Connection possibilities Bus termination with termination resistors (CPV-DI02) Connecting the power supply Cable for power supply Selecting the power unit Connecting the power supply Extending the CPV Direct Rules for extending the CPI system Preparing the CPI system for commissioning Checking the CP strings Saving the string assignment Switching-on reaction of the CPI system Reaction of the CPI system to faults in operation Eliminating assignment faults Replacing CPI/CP modules

17 1. Installation CPV-DI02 and CPV-CS General instructions on installation Warning Before carrying out installation and maintenance work, switch off the following: the compressed air supply the operating voltage supply for the internal logics the load voltage supply for the valves. You can thereby avoid: uncontrolled movements of loose tubing uncontrolled movements of the connected actuators non-defined switching states of the electronic components. Caution The CPV valve terminal with field bus direct connection (CPV Direct) contains electrostatically sensitive components. Do not therefore touch any contacts. Observe the handling specifications for electrostatic sensitive devices. You will then prevent the electronics from being damaged. 1-3

18 1. Installation CPV-DI02 and CPV-CS Electrical connecting and display elements The following connecting and display elements can be found on the CPV Direct: Field bus connection (9-pin Sub-D socket, see section 1.3.3) 2 Underneath the removable switch cover: DIL switches and the SAVE button (see section 1.2.1) 3 Operating/load voltage connection (4-pin M12 plug, see section 1.5) 4 Power LEDs PS, PL and bus status LEDs BF, P (see section 3.1) 5 CPI extension connection (see section 1.6) 6 Switching status displays of the CP valve coils (yellow LEDs, see section 3.1.3) Fig. 1/1: Connecting and display elements on the CPV Direct 1-4

19 PS PL BF 1. Installation CPV-DI02 and CPV-CS Overview for setting the CPV Direct Fig. 1/2: Removing/fitting the switch cover DIL switch for station number and diagnostic mode 2 SAVE button 3 Cover Fig. 1/3: DIL switches and SAVE button under the switch cover 1-5

20 1. Installation CPV-DI02 and CPV-CS02 Procedure: 1. Switch off the operating voltage. 2. Unscrew the screws in the switch cover and remove the cover. 3. Set the station number and the diagnostic mode on the DIL switch (see section 1.2.2). 4. If you have connected CPI/CP modules to the CPI extension connection: read the procedure for configuring the CPI/CP modules in section Replace the switch cover. Check that the seal is seated correctly and tighten the fastening screws by hand. Note Make sure that the seal is seated correctly when you refit the switch cover. 1-6

21 1. Installation CPV-DI02 and CPV-CS Setting the station number The station number is entered coded with the 8-position DIL switch. 1 CPV-DI02: PROFIBUS address (switch elements 1 7) 2 CPV-CS02: CS31 module address (switch elements 1 6) 1 2 Fig. 1/4: Setting the station number on the CPV-DI01 or CPV-CS02 Note Station numbers may only be assigned once per field bus line. Leave DIL switch element 7 set to on the CPV-CS

22 1. Installation CPV-DI02 and CPV-CS02 Set station number: 5 Set station number: =1+4=5 Tab. 1/1: =2+4+32=38 Examples of set station numbers (binary coded) The following station numbers are permitted: Valve terminal type Protocol Address designation Permitted station numbers CPV-DI02 PROFIBUS-DP PROFIBUS address 1;...; 125 CPV-CS02 ABBCS31 CS31 module address 0;...; 60 Tab. 1/2: Permitted station numbers for PROFIBUS-DP and ABB CS31 1-8

23 1. Installation CPV-DI02 and CPV-CS Setting the diagnostic mode (CPV-DI02) or the load voltag monitoring (CPV-CS02) The following diagnosis can be deactivated with switch element 8 of the DIL switch: CPV-DI02: Device-related diagnosis CPV-CS02: Load voltage monitoring 1 DIL8: diagnosis deactivated 2 DIL8: diagnosis activated 1 2 Fig. 1/5: Setting the diagnostic mode For PROFIBUS-DP: If the device-related diagnosis is deactivated (switch element 8 to ), no device-related diagnostic information about the valve terminal will be sent to the master system, e.g. short circuit at the outputs or undervoltage of the valves (see section 3.2.2). 1-9

24 1. Installation CPV-DI02 and CPV-CS Recognizing the CPI extension with the SAVE button When the SAVE button is pressed, the CPI/CP modules connected to the CPI extension connection will be recognized automatically. 1. Prepare the connection of the CPV Direct to the power supply (see section 1.5). 2. Read the sections 1.6 Extending the CPV Direct and 1.7 Preparing the CPI system for commissioning for the exact procedure. In the tool change configuration, pressing the SAVE button is not necessary. Please refer here to section Help table for setting the station number On the following pages you will find help tables for setting the station numbers with the DIL switch. 1-10

25 1. Installation CPV-DI02 and CPV-CS02 Station no Station no reserved Tab. 1/3: Setting station numbers 0 31: position of the DIL switch elements 1-11

26 1. Installation CPV-DI02 and CPV-CS02 Station no Station no Tab. 1/4: Setting station numbers 32 63: position of the DIL switch elements 1-12

27 1. Installation CPV-DI02 and CPV-CS02 Station no Station no Tab. 1/5: Setting station numbers 64 95: position of the DIL switch elements 1-13

28 1. Installation CPV-DI02 and CPV-CS02 Station no Station no Tab. 1/6: Setting station numbers : position of the DIL switch elements 1-14

29 1. Installation CPV-DI02 and CPV-CS Connecting the field bus Field bus cable Note If installation has not been carried out correctly and if high baud rates are used, data transmission errors may occur as a result of signal reflections and attenuations. Causes of the transmission faults can be: missing or incorrect terminating resistor incorrect screening/shield connection branches transmission over long distances unsuitable cables. Observe the cable specifications. Refer to your controller manual for information on the type of cable to be used. Note If the valve terminal is fitted into a moving part of a machine, the field bus cable on the moving part must be provided with strain relief. Note the relevant regulations in IEC/DIN EN

30 1. Installation CPV-DI02 and CPV-CS02 CPV-DI02 (PROFIBUS-DP) Use a twisted, screened 2-core cable for connecting the field bus. Cable specification as per EN (cable type A): surge impedance: Ω (3 20 MHz) capacitance per unit length: < 30 nf/km loop resistance: < 110 Ω/km core diameter: > 0.64 mm core cross-sectional area: > 0.34 mm 2 Bus length Exact specifications on the bus length can be found in the next section and in the manuals for your control system. CPV-CS02 (ABB CS31) Refer to the PLC manual for your controller for the type of cable to be used. Also take into account here the distances and the field bus baud rate. 1-16

31 1. Installation CPV-DI02 and CPV-CS Field bus baud rate and field bus length for PROFIBUS-DP (CPV-DI02) Note The maximum permitted field bus segment lengths depend on the baud rate used. Note the maximum permitted segment length (cable length without repeater), if you connect the CPX terminal to a field bus segment. Avoid branch lines. The CPV-DI02 sets itself automatically to one of the following baud rates: Baud rate Maximum segment length 9.6; 19.2; kbaud 1200 m kbaud 1000 m 500 kbaud 400 m 1500 kbaud 200 m kbaud 100 m Tab. 1/7: Maximum field bus segment lengthsfor PROFIBUS-DP depending on the baud rate 1-17

32 1. Installation CPV-DI02 and CPV-CS Field bus interface There is a 9-pin Sub-D socket on the CPV Direct for connecting it to the field bus. This connection serves for the incoming and continuing field bus cable. You can connect the CPV Direct with the field bus plug from Festo type FBS-SUB-9-GS-DP-B. Note Only the Festo field bus plug complies with IP65. Before connecting field bus plugs from other manufacturers: replace the two flat screws by bolts (part no ). CPV-DI02 (PROFIBUS-DP) Pin Field bus plug IP65 PROFIBUS-DP Designation from Festo 1) Housing B A Clamp strap n.c. n.c. RxD/TxD-P CNTR-P 2) DGND VP n.c. RxD/TxD-N n.c. Screening not connected not connected Receive/transmit data P Repeater control signal 2) Data reference potential (M5V) Power supply positive (P5V) not connected Receive/transmit data N not connected Connection to functional earth (viewofsocketofthecpvdirect) 1) Type FBS-SUB-9-GS-DP-B (part no ) 2) The repeater control signal CNTR-P is in the form of a TTL signal. Tab. 1/8: Pin assignment of the field bus interface for PROFIBUS-DP (CPV-DI02) 1-18

33 1. Installation CPV-DI02 and CPV-CS02 CPV-CS02 (ABB CS31) Pin Field bus plug IP65 from Festo 1) ABB CS Housing B A Clamp strap Bus 1 Bus 2 Screening/shield (viewofsocketofthecpvdirect) 1) Type FBS-SUB-9-GS-DP-B (part no ) Tab. 1/9: Pin assignment of the field bus interfacefor ABB CS13 (CPV-CS02) 1-19

34 1. Installation CPV-DI02 and CPV-CS Connection possibilities Note Use a protective cap or blanking plug to seal unused connections. You will then comply with protection class IP65. Connection with field bus plugs from Festo Observe the fitting instructions for the field bus plug. You can connect the CPV Direct to the field bus easily with the field bus plug from Festo (type FBS-SUB-9-GS-DP-B, part no ). You can disconnect the plug from the CPV Direct without interrupting the bus cable (T-TAP function). 1 Hinged cover with display window 2 Blanking plug if connection is not used 3 Clamp strap for screening/shield connection Bus out Bus in 4 Field bus incoming (IN) AB AB 5 Switch for bus termination and continuing field bus 6 Field bus continuing (OUT) 7 Only connected capacitively Fig. 1/6: Field bus plug from Festo, type FBS-SUB-9-GS-DP-B 1-20

35 1. Installation CPV-DI02 and CPV-CS02 Note The clamp strap in the field bus plug from Festo is connected internally only capacitively with the metallic housing of the Sub-D plug. This is to prevent equalizing currents flowing through the screening of the field bus cable. DIL switches With the switch in the field bus plug you can switch the following: switch setting : the bus termination is switched off and the continuing field bus cable is switched on. switch setting : the bus termination is switched on and the continuing field bus cable is switched off (see Fig. 1/7). Note Note the type designation of your field bus plug. The plug type FBS-SUB-9-GS-DP-B switches the continuing field bus cable off when the bus termination is switched on. 1-21

36 1. Installation CPV-DI02 and CPV-CS02 Connection with M12 adapter (reverse key coded) With adapter (type: FBA-2-M12-5POL-RK, part no ), you can connect the CPV Direct to the field bus via an M12 plug connector. The plug connectors have an inverted mechanical coding (reverse key or B-coded), to avoid confusion between incoming and continuing connections. You can disconnect the M12 adapter from the CPV Direct without interrupting the bus cable (T-TAP function). Connection to the field bus is made with a 5-pin M12 plug with PG9 screw connector. Use the second connection socket for the continuation of the field bus. M12 adapter (reverse key coded) Pin no VP: Supply voltage positive (P5V) 2. RxD/TxD-N: Receive/Send data N DGND: Data reference potential (M5V) 4. RxD/TxD-P: Receive/Send data P 5. FE: Functional earth Housing/thread: Screening/shield Bus in Bus out Protective cap or plug with bus termination resistor if connection is not used. Tab. 1/10: Pin assignment of the field bus interface with adapter for M12 connection, 5-pin 1-22

37 1. Installation CPV-DI02 and CPV-CS02 Connection with optical-fibre waveguides (only CPV-DI02, PROFIBUS-DP) The PROFIBUS-DP interface of the CPV-DI02 complies with specification EN and supports the controlof network components for optical-fibre waveguides. Use optical-fibre waveguides when transmission is affected by heavy interference, as well as for extending the transmission range when high baud rates are used. Example of optical-fibre waveguide network components: Siemens Optical Link Module (OLM) for PROFIBUS plus Siemens Optical Link Plug (OLP) for PROFIBUS (IP20) Harting Han-InduNet Media converter IP65 in combination with adapter cable for Festo products (optical data transmission in DESINA installation concept). 1-23

38 1. Installation CPV-DI02 and CPV-CS Bus termination with termination resistors (CPV-DI02) Note If the valve terminal is at the beginning or the end of the field bus system, a bus termination will be required. Fit a bus termination to both ends of a bus segment. Recommendation: Use the ready-to-use field bus plugs from Festo for the bus termination. A suitable resistor network is incorporated in the housing of this plug (see Fig. 1/7). Pin 6: Supply voltage 390 Ω Receive/send data P (data cable B) Pin nh 220 Ω Receive/send data N (data cable A) Pin nh 390 Ω Pin 5: Data reference potential Fig. 1/7: Circuit diagram for bus termination network (switch in Festo field bus plug set to ) (PROFIBUS-DP: for cable type A as per EN 50170) 1-24

39 1. Installation CPV-DI02 and CPV-CS Connecting the power supply Cable for power supply Use a power supply cable with sufficient cross-sectional area. Avoid long distances between the power unit and the CPV valve terminal. Long cables reduce the voltage supplied by the power unit. If necessary calculate the suitable cross-sectional area and the maximum permitted cable length. The power supply connection is in the form of a plug. The pin assignment of the plug can be found on the following pages. For connecting the power supply, use plugs from the Festo range which correspond to the outer diameter of the cable used (see appendix A.3). 1-25

40 1. Installation CPV-DI02 and CPV-CS02 1 Cable 2 Strain relief 3 Housing 4 Connecting part Fig. 1/8: Individual socket parts and cable routing Preparing When you have selected suitable cables, connect them as follows (Fig. 1/8): 1. Open the socket: Loosen the centre knurled nut. 2. Open the strain relief on the rear of the housing. Pass the cable through. 3. Remove 5 mm of the insulation from the end of the cable and fit core end sleeves. 4. Connect the conductors. 5. Replace the connecting part on the housing of the socket and screw it tight. Pull the cable back so that there are no loops inside the housing. 6. Tighten the strain relief. 1-26

41 1. Installation CPV-DI02 and CPV-CS Selecting the power unit Warning In order to provide the electric power supply, use only PELV circuits as per IEC/DIN EN (Protective Extra-Low Voltage, PELV). Take into account also the general requirements for PELV circuits as per IEC/DIN EN Use only power packswhich guarantee reliable electrical isolation of the operating voltage as per IEC/DIN EN By the use of PELV power units, protection against electric shock (protection against direct and indirect contact) is guaranteed in accordance with IEC/DIN EN (electrical equipment of machines, general requirements). The current requirement of a CP system depends on the number of CP modules and valve coils. Recommendation: Use closed-loop controlled power units. When selecting the power unit, check that it provides sufficient output. If necessary, calculate the total current requirement according to the following table. 1-27

42 1. Installation CPV-DI02 and CPV-CS02 Total current consumption The table below shows how to calculate the total current consumption for a CP system. The values specified have been rounded up. Current consumption of the CP electronics (pin 1) Sums CPV Direct CPV valve terminal CPA valve terminal CP input module Sensors CP output module max. 100 ma max. 40 ma 20 ma max. 40 ma see manufacturer specifications max. 40 ma Carry forward = ma Current consumption of the valve supply (pin 2) Current consumption of all simultaneously energized valve coils 1) x ma = ma 1) Current consumption deepnds on the valve type (see Technical Specifications of the valves in the relevant pneumatics manual). Tab. 1/11: Calculating the total current consumption 1-28

43 1. Installation CPV-DI02 and CPV-CS Connecting the power supply Warning If the valve terminal is supplied with load voltage via an output of a safety I/O module, switch-on test pulses of the safety I/O module may lead to unexpected reactions of the valve terminal. Make sure that switch-on test pulses are reliably suppressed or switched off. Power is supplied via a 4-pin M12 plug (see Fig. 1/1). Current consumption depends on the type of valve terminal. Please refer to the Pneumatics manual, P.BE-CPV-... and the previous section for the values. Observe the tolerance with the connection for the 24 V load voltage at pin 2: DC V DC. Check the 24 V operating voltage of the valves whilst the system is operating. Caution Protect the load voltage of the CPV valve coils with a max. 2 A external fuse. In this way you can avoid functional damage to the CPV Direct in the event of a short circuit. 1-29

44 1. Installation CPV-DI02 and CPV-CS02 Note Check within the framework of your EMERGENCY STOP circuit, to ascertain the measures necessary for putting your machine/system into a safe state in the event of an EMERGENCY STOP. Switching off the load voltage for the valves and output modules in the secondary circuit of the power unit. Switching off the compressed air supply for the valve terminal. Duetoenergystoredintheinputcircuitryofvalveterminals, there may be a delayed reaction of the valves when the load voltage is switched off. Take this into consideration, e.g. as follows: by using an input signal in the controller for checking whether the load voltage has been switched off. by blocking the control signal for the valves by locking the output signal with the input signal Load voltage. 1-30

45 1. Installation CPV-DI02 and CPV-CS02 Pin assignment of the power supply connection 1 1 Pin assignment 1: 24 V DC operating voltage for the electronics (and inputs, with modules connected to the extension connection) (max. 2 A) 2: 24 V DC load voltage for the valves (max. 2 A) 3: 0 V 4: Earth/ground connection Fig. 1/9: Pin assignment of the power supply connection Potential equalization The CPV valve terminal has 2 earth connections for potential equalization: on the power supply connection ontheendplate. 1-31

46 1. Installation CPV-DI02 and CPV-CS02 Note Always connect the earth potential to pin 4 of the power supply connection. Connect the earth connection of the end plate with low impedance (short cable with large cross-sectional area) to the earth potential. By means of low-impedance connections, make sure that the housing of the valve terminal and the earth connection at pin 4 have the same potential and that there are no equalizing currents. Inthisway,youwillavoidinterferencecausedbyelectromagnetic influences PS MNS 0V 2A 24 V 2A PE 2 Potential equalization 3 Load voltage can be switched off separately 4 Earth connection at pin 4 designed for 3 A Fig. 1/10: Example of connection with PELV power supply unit and potential equalization 1-32

47 1. Installation CPV-DI02 and CPV-CS Extending the CPV Direct This section is only relevant for you if you wish to connect CPI/CP modules to the CPI extension connection CPI extension connection Fig. 1/11: CPI extension connection The rules for CPI systems also apply for extending the CPV Direct (see section 1.6.1). You can connect the following CPI/CP modules to the CPI extension connection: CP input and output modules CPI input and output modules (with extended functions) CPV-SC with CPI connection CPV/CPA valve terminals with and without extended functions. 1-33

48 1. Installation CPV-DI02 and CPV-CS02 Caution The max. cable length between the CPV Direct and the last CPI/CP module must not exceed 10 m. The CP connecting cables must have special electrical properties. Therefore always use Festo CP connecting cables. Ready-to-use CP connecting cables are available from Festo. These are available in various lengths and designs. } Seal unused CP connections of your CP system with the relevant seal provided. In this way you will comply with protection class IP

49 1. Installation CPV-DI02 and CPV-CS Rules for extending the CPI system The CPI system supports a different number of modules per CP string, depending on the type of CP master and on the CPI/CP modules connected. TheCPVDirectisaCPImaster. Modules can be placed in two different groups: CPI modules (with extended functions) CP modules (without extended functions) Rules and properties CPI system CPI master CPI modules Max. 4 modules on the CP string Max. 32 inputs and 32 outputs (per CP string) The sequence of the modules within the CP string is optional A mixture of CPI/CP modules is possible on CPI masters: Only one CP input module is possible at the end of a string Only one CP valve terminal 2) or one CP output module 2) is possible per CP string. Unused locations on the CP string can be filled with CPI modules 1) Incoming and continuing interface on all CPI modules (input modules, output modules) and valve terminals with CPI connection 1) With extended functions 2) Without extended functions Tab. 1/12: Rules for extending the CPI system Note Irrespective of the type of CPI/CP modules, not more than 32 inputs and 32 outputs may be connected (sum of all modules on a CP string). This means that a CP string can be extended by maximum 2 CP valve terminals with CPI ability, as CP valve terminals always occupy 16 output addresses. 1-35

50 1. Installation CPV-DI02 and CPV-CS02 CPI master X X X X X X X I X X I X VI/O X: Any CPI module or CP valve terminal with CPI ability (max. 2 valve terminals possible) I: CP input module VI/O: CP valve terminal or CP output module grey = CPI modules/valve terminals with extended functions Fig. 1/12: Examples of extending a CPI system 1-36

51 1. Installation CPV-DI02 and CPV-CS02 CP string without CPI output module with max. one CP valve terminal type Maximum sensor current consumption of the CPI modules on the CP string 1) Maximum string length with CPI cable, type KVI-CP V val = V V val = 20.4 V 16 valves 2) 8valves 3) CPV10-.../CPA A 10 m 10 m 10 m CPV14-.../CPA A 10 m 10 m 10 m CPV A 10 m 10 m 10 m V val = 20.4 V 16 valves 4) 1.0 A 10 m 10 m 10 m 5) 8m 6) 1.5 A 10 m 10 m 10 m 5) 5m 6) 1) Maximum sensor supply current used 2) Rated voltage or undervoltage of -10 %, 16 valve solenoid coils switched simultaneously (high current phase) 3) Rated voltage or undervoltage of -15 %, 8 valve solenoid coils switched simultaneously (high current phase) 4) Rated voltage or undervoltage of -15 %, 16 valve solenoid coils switched simultaneously (high current phase) 5) Valve terminal installed in each case at start of string 6) Valve terminal installed in each case at end of string Tab. 1/13: Permitted string lengths with CPI cables, type KVI-CP depending on the CP valve terminal used and on the sensor current consumption CP string without CP valve terminal, with a maximum of one CPI output module, type Maximum sensor current consumption of the CPI modules on the CP string 1) CP-A04-M12-CL 0.5 A 10 m CP-A08...-M A 10 m 1) Maximum sensor supply current used Maximum string length with CP cable, type KVI-CP Tab. 1/14: Permitted string lengths with CP cables, type KVI-CP depending on the CPI output module used and on the sensor current consumption 1-37

52 1. Installation CPV-DI02 and CPV-CS Preparing the CPI system for commissioning This section is only relevant for you if you have connected CPI/CP modules to the CPI extension connection. Note Do not yet connect the CPV Direct to a higher-order controller for preparing commissioning. You will thus avoid addressing faults which may occur in variousfieldbussystemswhenaddressrangesaremodified during operation Checking the CP strings Preparations Before commissioning a CPV Direct with CPI extensions, you should first prepare each individual CPI system for commissioning. Proceed as follows: 1. Check the pneumatic tubing of the valve terminals with the aid of the manual override (see pneumatics manual). 2. Check the complete electric circuitry of the CPI system. 3. Save the current string assignment of the CPI system as the nominal assignment, as described in section

53 1. Installation CPV-DI02 and CPV-CS Saving the string assignment Warning Be very careful if the string assignment of your CPI system is modified at a later stage: After saving the string assignment, check the address assignments of your CPI system before starting user programs. You will then avoid addressing faults in the case of incorrectly fitted CPI modules. String assignment The CPV Direct saves the type and the sequence of the connected CPI modules for the CP string (string assignment). The saved string assignment enables the CPV Direct to avoid faults in connecting, and thus addresssing. It checks automatically to see if the current string assignment is the same as the saved assignment. A distinction is made here between the following test phases: testing during the start-up phase (see section 1.8) testing during operation (see section 1.9). When the status LEDs on all the CPI modules light up, the CPI system is prepared for commissioning. You can now commission the CPI system. 1-39

54 1. Installation CPV-DI02 and CPV-CS02 Saving the string assignment The desired string assignment is generated and saved for commissioning. In this way the appropriate addresses are assigned to the connected CPI modules. Save the string assignments as follows: 1. Leave the power supply for the CPV Direct switched off for thetimebeing. 2. Make sure that the CPI cables are fastened properly with the union nut. 3. Switch on the power supply for the CPV Direct and, if necessary, for the CPI/CP modules with load voltage connection. The fault LED P on the CPV Direct will flash if CPI/CP modules are connected or if the string assignment is modified. 4. Use a small screwdriver or similar tool to press the SAVE button for at least 1 s (see section Fig. 1/3). This will save the current string assignment as the nominal string assignment in the CPV Direct. The fault LED Pno longer flashes. The status LEDs of all the recognized CPI/CP modules light up. 5. Power / Note After saving the string assignment, check the address assignments of your CPI system before starting user programs. 1-40

55 1. Installation CPV-DI02 and CPV-CS Switching-on reaction of the CPI system When the power supply is switched on, the CPV Direct ascertains automatically the current string assignment. It also ascertains which CPI/CP modules are connected to the string extension. If the current assignment is the same as the saved assignment, the CPV Direct will switch automatically to the readyto-operate status. The PS/PL LEDs of the CPV Direct as well as the status LEDs on the connected CPI/CP modules light up. If the current assignment is not the same as the saved assignment, the fault LED P on the CPV Direct will flash. In this case the CPI system is not ready to operate. You then have the following possibilities of restoring the readiness to operate: eliminate assignment faults manually or replace individual CPI modules (see section 1.9) save the current assignment as the nominal assignment (see section 1.7.2). Detailed instructions on diagnosing the CPV Direct using the LEDs can be found in section

56 1. Installation CPV-DI02 and CPV-CS02 Switch on the power supply CP string: Register module types No Module types: Set = Actual? CP configuration fault Fault LEDP flashes Yes No Save button pressed? Ye s String assignment save Fault LED P off CPI system ready to operate (permanent I/O update) Initial commissioning (commissioning with modified configuration) Normal operation Fig. 1/13: Switching-on reaction of the CPI system 1-42

57 1. Installation CPV-DI02 and CPV-CS ReactionoftheCPIsystemtofaultsinoperation Warning Undesired activation of actuators An incorrect status of the valves and outputs can lead to dangerous situations. Make sure that valves and outputs are put into a safe state when faults occur. If there is a fault on the CP string during operation, e.g. due to cable fracture, etc., this will be displayed on the CPV Direct by the diagnostic LED of the string extension (P). The status LED on the relevant module goes out. All modules working without faults remain ready to operate. Detailed instructions on diagnosing the CPV Direct using the LEDs can be found in section Eliminating assignment faults In order to eliminate assignment or connection faults of the CPI system: 1. Switch off the power supply for the CPV Direct. 2. Restore the saved assignment by connecting the appropriate CPI/CP modules with the CPV Direct. 3. Switch on the power supply for the CPV Direct again. 1-43

58 1. Installation CPV-DI02 and CPV-CS Replacing CPI/CP modules Note Replacing a CPI/CP module with a CPI/CP module of a different type or replacing several CPI/CP modules will require new commissioning and new saving of the string assignment (see section 1.7). In order to replace a single CP module, proceed as follows: 1. Switch off the power supply for the CPV Direct. 2. In the case of CPI/CP output modules and valve terminals on the CP string concerned: switch off the following sources of energy: the compressed air supply to the valve terminal the operating voltage supply for the CPI/CP output module. 3. Disconnect all connecting cables and, if necessary, also the tubing. 4. Connect all the cables and, if applicable, the tubing with the new module ofthesametype. 5. Now connect the new module ofthesametypeto the same string. 6. In the case of CPI/CP output modules and CP valve terminals: switch on the operating voltage supply or the compressed air supply again. 7. Switch on the power supply for the CPV Direct again. 8. Check the addresses of the CPI system. 1-44

59 Commissioning CPV-DI02 (PROFIBUS-DP) Chapter 2 Commissioning CPV-DI02 (PROFIBUS-DP) 2-1

60 2. Commissioning CPV-DI02 (PROFIBUS-DP) Contents 2. Commissioning CPV-DI02 (PROFIBUS-DP) Preparing the CPV Direct for commissioning Switching on the power supply Address assignment of the CPV Direct Address assignment of CPI/CP modules Information on commissioning Device master file (GSD) and icon files Configuration with a Siemens master STEP 7 HW Config (up to V 5.2) preparations Station selection with STEP Configuration with STEP Tool change configuration Examples of configuration Standard configuration Tool change configuration

61 2. Commissioning CPV-DI02 (PROFIBUS-DP) 2.1 Preparing the CPV Direct for commissioning Switching on the power supply Note Please observe also the switching-on instructions in the manualforyourplc. When the controller is switched on, it will automatically carry out a comparison between the NOMINAL and the ACTUAL configurations. It is important for this configuration run that: the specifications for the field bus configuration are complete and correct. the power supplies for the programmable logic controller and for the field bus slaves are switched on either simultaneously or in the sequence indicated below. Please note the following when switching on the power supply: Common supply Separate supply Common power supply for the control system and all field bus slaves via a central power unit or a central switch. If there is a separate supply for the control system and for the field bus slaves, the power should be switched on in the following sequence: 1. the operating voltage supply for all field bus slaves 2. the operating voltage supply for the controller. 2-3

62 2. Commissioning CPV-DI02 (PROFIBUS-DP) Address assignment of the CPV Direct The CPV Direct always occupies 16 output addresses, irrespective of the number of valve solenoid coils fitted on it. This enables the CPV Direct to be extended at a later stage without the need to shift the addresses. The following diagram shows the addressing sequence of the individual CPV valve plates Fig. 2/1: Address assignment of the CPV Direct A valve location on the CPV Direct always occupies 2 addresses, even if it is fitted with a blanking plate or pressureseparator plate. If a valve location is fitted with a doublesolenoid valve, the following applies: pilot solenoid coil 14 occupies the less significant address pilot solenoid coil 12 occupies the more significant address. With single-solenoid valves the higher-value address remains unused. 2-4

63 2. Commissioning CPV-DI02 (PROFIBUS-DP) Addresses are assigned from left to right on the CPV Direct and from the front to the rear on the individual valve locations OB x OB x+1 O20.0 O20.1 O20.2 O20.3 O20.4 O20.5 O20.6 O20.7 O21.0 O21.1 O21.2 O21.3 O21.4 O21.5 O21.6 O21.7 OB: Output byte Fig. 2/2: Address assignment of the CPV Direct (outputs) with examples for OB20 and OB21 2-5

64 2. Commissioning CPV-DI02 (PROFIBUS-DP) Address assignment of CPI/CP modules CPI/CP modules Tab. 2/1 provides an overview of the assigned addresses for the various CPI/CP modules (as at 2011). Assigned I/O on CPV-DI Type CPI-capable 1) CPI masters 1) I O CPI/CP input modules CP-E08-M8-CL CP-E08-M12-CL CP-E16-KL-CL CP-E08-M12-EL CP-E16-M8-EL CP-E32-M8-EL CP-E16-M8 CP-E16N-M8 CP-E16-M8-Z CP-E16-M12x2-5POL CP-E16N-M12x2 CP-E16-KL-IP20-Z Yes Yes Yes Yes Yes Yes No No No No No No 8I 8I 16 I 16 I 16 I 32 I 16 I 16 I 16 I 16 I 16 I 16 I CPI/CP output modules CP-A04-M12-CL CP-A08-M12-EL-Z CP-A08-M12-5POL CP-A08N-M12 Yes Yes No No 8O 8O 16 O 16 O CPI/CP valve terminals CPV...-CPI CPV-SC-CPI CPV...-GE-FB-4 CPV...-GE-FB-6 CPV...-GE-FB-8 CPA10/14-IFB-CP Yes Yes No No No No 16 O 16 O 16 O 16 O 16 O 16 O 1) with extended functions Further CPI modules and CPI-capable valve terminals in preparation. Tab. 2/1: Assigned I/Os of the CPI/CP modules 2-6

65 2. Commissioning CPV-DI02 (PROFIBUS-DP) Information on commissioning FREEZE and SYNC The operating modes FREEZE and SYNC are supported by the CP system in accordance with EN The method of accessing the FREEZE and SYNC commands depends on the controller used. Please refer here to the documentation for your field bus module. Caution The operating mode FREEZE or SYNC will be reset automatically: when the CP system is switched on/off when the field bus module stops. Only the operating mode FREEZE will be reset automatically: when the bus connection to the CP system is interrupted (response monitoring active). FREEZE command All the outputs of the CPI system will be frozen. The CPV Direct now sends a constant image of all the inputs to the master. With each further FREEZE command, the input image is updated and sent again to the master. Return to normal operation: UNFREEZE command SYNC command All the outputs of the CPI system will be frozen. The CP system now no longer reacts to modifications to the output image in the master. With each further SYNC command, the output image will be updated and transferred. Return to normal operation: UNSYNC command 2-7

66 2. Commissioning CPV-DI02 (PROFIBUS-DP) Module consistency The CP system supports the following variants of module consistency: over the selected format (word) The following table provides an overview of the possible DP identifiers for the CPV-DI02: CPV and extension DP identifier Comment Siemens EN CPV-DI02 (without extension) ID: 16DO ID: 21 h /33 d 16 digital outputs/valve coils of the CPV Extension: 8 digital inputs ID: 8DI ID: 10 h /16 d e. g. CPI/CP input modules Extension: 16 digital inputs ID: 16DI ID: 11 h /17 d Extension: 24 digital inputs ID: 24DI ID: 12 h /18 d Extension: 32 digital inputs ID: 32DI ID: 13 h /19 d Extension: 8 digital outputs ID: 8DO ID: 20 h /32 d e. g. CPI/CP output modules, CP valve Extension: 16 digital outputs ID: 16DO ID: 21 h /33 d terminals Extension: 24 digital outputs ID: 24DO ID: 22 h /34 d Extension: 32 digital outputs ID: 32DO ID: 23 h /35 d Extension: Tool change configuration (32 digital inputs and outputs) ID: 32DX ID: 33 h /51 d see section Tab. 2/2: Overview of DP identifiers for various extensions to the CPV-DI02 Note Enter the identifiers corresponding to the physical sequence of the modules on the CP extension string, starting with the CPV-DI

67 2. Commissioning CPV-DI02 (PROFIBUS-DP) 2.2 Device master file (GSD) and icon files In order to configure the CPV Direct with a PC/programmer, you will require the appropriate GSD file. In addition to the slave-typical entries (Ident. number, Revision, etc.), the device master file (GSD) also contains a selection of identifiers. Reference sources Current GSD files can be found on the Festo Internet pages under: GSD files You will require one of the following files for the CPV Direct: CPV_0A35.GSD (german Version) or CPV_0A35.GSE (international version) Icon files You will find icon files to represent the valve terminal in your configuration software under the above-mentioned Internet address. Normal operating status Diagnostic case Special operating status File: Pbdicpin.dib File: Pbdicpid.dib File: Pbdicpis.dib Tab. 2/3: Icon files for configuration software 2-9

68 2. Commissioning CPV-DI02 (PROFIBUS-DP) 2.3 Configuration with a Siemens master Note Various configuration programs are available for use in conjunction with a Siemens master. Please observe the relevant procedure for your configuration program. The following sections describe as an example the main configuration steps with the STEP 7 software. It is assumed that the reader is already familiar with the information in the manual for the STEP 7 software. Information on operation with general DP masters can be found in appendix A STEP 7 HW Config (up to V 5.2) preparations GSD 1. Copy the GSD of the valve terminal into the directory...\step7\s7data\gsd on your PC/programmer. File: CPV_0A35.GS* (Reference sources for the GSD see section 2.2) The GSDs can either be: copied manually into the above mentioned directory (e.g.withwindowsexplorer)or loaded via the menu [Options] [Install new GSD]. Note Update the hardware catalogue if you copy the GSD during work with STEP 7. Menu in HW Config: [Options] [Update catalogue] 2-10

69 2. Commissioning CPV-DI02 (PROFIBUS-DP) Note As from STEP 7 V4.02, GSDs are stored within the STEP 7 project (station GSD). This can cause the updating/reading of new GSD files to appear as if incorrect. Please inform yourself about handling the station GSD files in the STEP 7 help. 2. Process the dialogue window Properties PROFIBUS Baud rate Profile Icons 3. Copy the icon files (see section 2.2) for the CPV Direct into directory...\step7\s7data\nsbmp on your PC or programmer. The icon files can either be: copied manually into the above named directory or loaded via the menu [Options] [Install new GSD] file type Bitmap files in HW Config. 4. Insert a DP master system: Right-hand mouse click on DP under CPU in the rack. Click on [Add master system] in the context menu. The line of the DP master system will be displayed. 2-11

70 2. Commissioning CPV-DI02 (PROFIBUS-DP) Station selection with STEP Fig. 2/3: Station selection with STEP 7 HW Config (the windows displayed are not all visible at the same time, see text) 1. If the hardware catalogue is not open: click on the catalogue icon (see Fig. 2/3 1 ). The hardware catalogue will be displayed. 2-12

71 2. Commissioning CPV-DI02 (PROFIBUS-DP) 2. Open the following folder in the hardware catalogue: \PROFIBUS-DP\Additional Field Devices\Valves. The folder Valves is displayed when you copy the GSD (see step 1 of the preparations). Pull the station type Festo CPV-DI02 onto the line of the DP master system 2. The dialogue window Properties PROFIBUS interface will be displayed Select the PROFIBUS address identical to the selected setting on the DIL switch in the switch module (see section 1.2.2) and close with OK. The icon of the valve terminal will be displayed on the line of the DP master system. 4. If necessary, process the dialogue window Properties DP slave 4: Double-click on the icon of the valve terminal. 2-13

72 2. Commissioning CPV-DI02 (PROFIBUS-DP) Configuration with STEP Fig. 2/4: Configuration with STEP 7 HW Config (example for adding one CP input module with 16 inputs, explanations see text) 1. Click on the icon of the valve terminal to be configured in the HW Config 1. The configuration table will be displayed under the rack Open the module Festo CPV-DI02 (folder\profibus- DP\ Additional Field Devices\Valves\...) in the hardware catalogue

73 2. Commissioning CPV-DI02 (PROFIBUS-DP) Basic configuration The CPV-DI02 valve terminal always occupies 16 output addresses. Carry out first a configuration of the basic device as follows. 3. Pull the entry Base: 16DO onto the 1st. line of the configuration table Pullthemodulesontothenextfreelineintheconfiguration table according to the extension of your CPV Direct. Assign the starting address in the window Properties DP slave 5. Note Pull the modules into the configuration table according to the physical sequence of the extensions of your CPI system. Modifying the address The addresses are assigned automatically. Double click on the relevant line in the configuration table and modify the starting address of the inputs/outputs in the window Properties DP slave. Note With S7-400 controllers, up to 4 bytes of addresses are reserved for each DP identifier, depending on the version status. This concludes the station selection and configuration. 2-15

74 2. Commissioning CPV-DI02 (PROFIBUS-DP) Tool change configuration With the tool change configuration you can commission modules without new configuration on the CP extension connection. In the tool change configuration, pressing the SAVE button is not necessary. The tool change configuration is useful if various extensions are connected in turn to the CP...-SC-DP during operation. 1 2 Fig. 2/5: Tool change configuration 2-16

75 2. Commissioning CPV-DI02 (PROFIBUS-DP) Procedure: 1. Carry out the basic configuration Pull the entry Tool change O/I:32/32 out of the hardware catalogue onto the 2nd. line of the configuration table 2. Addressing and function With the tool change configuration the maximum possible 32 inputs and 32 outputs will be assigned, irrespective of whether these are used or not. The addresses are assigned without gaps, module after module in ascending sequence. Please take this into account when programming the controller. Caution Communication via the PROFIBUS-DP will start in any case, even if the addresses are used incorrectly. The system does not check in the tool change configuration which modules are actually connected. After changing the string assignment, evaluation of input signals can appear to be defective if inputs are read which are no longer present in the string assignment. After changing the string assignment (e.g. with fewer modules): Ensure that only the addresses of the modules actually connected to the CP string are processed by the controller. The same applies to outputs. Note the example in Tab. 2/8. Device Assigned I/Os Addressing CPV basic device 16 O Output byte0 1 CPI extension 32 I Input byte O Output byte 2 5 Tab. 2/4: I/O assignment for tool change configuration 2-17

76 2. Commissioning CPV-DI02 (PROFIBUS-DP) Configuration Advantages Disadvantages Standard configuration Tool change configuration Good diagnostic possibilities Protection against confusion of the modules on the CP string Modifications to the CP extension string are possible without new configuration. Can be configured Modifications to the CP extension string must be configured again. Limited diagnostic possibilities (see section 3.2.5) Address assignment of the change configurations must be carried out very carefully. Tab. 2/5: Advantages and disadvantages of the tool change configuration 2-18

77 2. Commissioning CPV-DI02 (PROFIBUS-DP) 2.4 Examples of configuration Standard configuration The following table shows three examples of configuration and addressing extensions on the CPI extension connection of a CPV-DI02. No. Standard configuration DP identifiers Addressing 1 16DO 1) O20.0 O21.7 8DI I20.0 I20.7 CPV-DI02 + CP-E08-M12-CL 2 16DO 1) O20.0 O21.7 8DO O22.0 O22.7 CPV-DI02 + CP-A04-M12-CL+ CP-E08-M12-CL 8DI I20.0 I DO 1) O20.0 O21.7 8DI I20.0 I20.7 8DI I21.0 I21.7 CPV-DI02 + 4x CP-E08-M12-CL 8DI I22.0 I22.7 8DI I23.0 I23.7 1) CPV-DI02 Basic configuration Tab. 2/6: Examples of standard configuration and addressing a CPV-DI02 with different CPI extensions 2-19

78 2. Commissioning CPV-DI02 (PROFIBUS-DP) Tool change configuration The following table shows the same CPI extensions as Tab. 2/6, but this time with the tool change configuration. Inthis way you can connect the extensions 1, 2 or 3 without a new configuration. Tool change configuration DP identifiers Assigned addresses 16DO 1) O20.0 O I20.0 I DX I20.0 I23.7 O22.0 O O22.0 O22.3 I20.0 I20.7 O20.0 O I20.0 I20.7 I21.0 I21.7 I22.0 I22.7 I23.0 I23.7 Addresses used 1 CPV-DI02 + CP-E08-M12-CL 2 CPV-DI02 + CP-A04-M12-CL+ CP-E08-M12-CL 3 CPV-DI02 + 4x CP-E08-M12-CL 1) CPV-DI02 Basic configuration Tab. 2/7: Different extensions with tool change configuration (compare with example in Tab. 2/6) 2-20

79 2. Commissioning CPV-DI02 (PROFIBUS-DP) Note The following example makes clear that with the tool change configuration you must be very careful, especially in using the input and output addresses. Explanation of the example In configuration 1 in Tab. 2/8 a lamp is connected to the 2nd. output module as a signal generator. In configuration 2 an actuator is connected to the 2nd. output module. In both cases address O23.7 is used. Take into account in the controller that the lamp now lies at address O25.7 and an actuator at O23.7. Tool change configuration DP identifiers Assigned addresses O22.0 O22.7 O23.0 O DO 1) O20.0 O O DX I20.0 I23.7 O22.0 O25.7 O22.0 O22.7 O23.0 O23.7 O24.0 O24.7 O25.0 O25.7 O20.0 O Addresses used O23.7 O CPV-DI02 + 2x CP-A08-M12-CL 2 CPV-DI02 + 4x CP-A08-M12-CL 1) CPV-DI02 Basic device Tab. 2/8: Example of a tool change configuration which requires special attention with the addressing (see text above) 2-21

80 2. Commissioning CPV-DI02 (PROFIBUS-DP) 2-22

81 Diagnosis CPV-DI02 (PROFIBUS-DP) Chapter 3 Diagnosis CPV-DI02 (PROFIBUS-DP) 3-1

82 3. Diagnosis CPV-DI02 (PROFIBUS-DP) Contents 3. Diagnosis CPV-DI02 (PROFIBUS-DP) Diagnosis via LEDs Normal operating status Fault diagnosis with the LEDs LEDs for status display of the valve solenoid coils Diagnosis via PROFIBUS-DP Diagnostic words Diagnosis steps Overview of the diagnostic bytes Details for standard diagnostic information Diagnosis with tool change configuration Fault treatment Siemens SIMATIC S Online diagnosis with STEP Read out diagnostic buffer with STEP 7 (up to V 5.2) Device-related diagnosis with STEP 7 (up to V 5.2) Short circuit/overload Output module Sensor supply on one input module

83 3. Diagnosis CPV-DI02 (PROFIBUS-DP) 3.1 Diagnosis via LEDs The LEDs on the cover indicate the operating status of the CPV Direct LED PS: Power System : Operating voltage supply for the electronics and sensors LED PL: Power Load : Load voltage supply for valves (and valves/outputs in the CP extension string) 2 LED BF: Bus fault/status LED P: Other fault messages 3 Yellow LEDs for pilot solenoids 12 and 14 Fig. 3/1: LEDs on the CPV Direct Normal operating status Only the green Power LED and the yellow LEDs of the pilot solenoids light up in the normal operating status. lights up; flashes; off 3-3

84 3. Diagnosis CPV-DI02 (PROFIBUS-DP) LED Colour Operating status Fault treatment PS green lights up Power supply for the electronics/ sensors OK PL green lights up Power supply for the valves/ outputs OK BF off No bus fault P off No other fault Tab. 3/1: Normal operating status Fault diagnosis with the LEDs Fault diagnosis with the LED PS The green LED PS ( Power System ) indicates faults in the operating voltage supply. LED Colour Operating status Fault treatment PS off Operating voltage for electronics not applied Check operating voltage supply (pin 1) PS green flashes slowly Operating voltage for the electronics. 18 V PS green lights up Operating voltage for the electronics is applied Tab. 3/2: Fault diagnosis with the green LED PS 3-4

85 3. Diagnosis CPV-DI02 (PROFIBUS-DP) Fault diagnosis with the LED PL The green LED PL ( Power Load ) indicates faults in the load voltage supply. LED Colour Operating status Fault treatment PL off Load voltage for valves/outputs not applied Check load voltage supply (pin 2) PL green flashes fast Load voltage of CP valves of the CPV Direct V PL green flashes slowly Load voltage of the CP valves/ outputs in the CPI extension string V Check load voltage supply of the CPI extension string (pin 2) PL green lights up Load voltage for CP valves/ outputs is applied Tab. 3/3: Fault diagnosis with the green LED PL Load voltage faults are always displayed with the LED PL (irrespective of the diagnostic mode set). If the device-related diagnosis is activated, faults will also be sent to the master PLC via the field bus. 3-5

86 3. Diagnosis CPV-DI02 (PROFIBUS-DP) Fault diagnosis with the LED BF The red LED BF ( Bus fault ) indicates the bus fault or bus status. LED Colour Operating status Fault treatment BF off Normal operating status BF red flashes fast PROFIBUS address not permitted Correct address setting (1;...; 125) BF red flashes slowly (1-second intervals) Field bus connection not OK. Possible causes: Station number not correct (e.g. address assigned twice) Field bus module switched off or defective Interrupted, short-circuited or faulty field bus connection Faulty PROFIBUS configuration Check the... address setting field bus interface field bus connection the configuration of the master and that in the CPV Direct and, if necessary, carry out new recognition (see section 1.2.4) BF red lights up Hardware fault Servicing required Tab. 3/4: Fault diagnosis with the red LED BF 3-6

87 3. Diagnosis CPV-DI02 (PROFIBUS-DP) Fault diagnosis with the LED P Thered LED P (other fault) indicates CPI system faults or other faults. LED Colour Operating status Fault treatment P off Normal operating status P red flashes fast CP string faults: Deviation of nominal status actual status of the CP configuration CP configuration not permitted Check the CP configuration and, if necessary, carry out new recognition (see section 1.2.4) Alternative: Use the tool change configuration P red flashes slowly (1-second intervals) Periphery fault in the CP string: Themodulehasadiagnostic fault (short circuit, overload,...) Check the modules in the CP string for diagnosis (see section 3.2) P red lights up Module failure in the CP string: Cable interrupted or short circuit If the LEDs PS/PL are out: there is a hardware fault Check CPI cables Servicing required Tab. 3/5: Fault diagnosis with the red LED P 3-7

88 3. Diagnosis CPV-DI02 (PROFIBUS-DP) LEDs for status display of the valve solenoid coils There is a yellow LED for every valve solenoid coil (see Fig. 3/1). This LED indicates the switching status of the valve solenoid coil. LED Colour Switch position Valve solenoid coil Meaning off Normal setting Logical 0 (no signal) yellow lights up Switch position or Normal setting Logical1(signalpresent) Logical 1 but: the load voltage of the valves lies below the permitted tolerance range ( V DC) or compressed air supply not OK or pilot exhaust blocked or servicing required Tab. 3/6: LEDs for the status display of the valve solenoid coils Note If there is no valve solenoid coil, the assigned LED will not show control of the output. 3-8

89 3. Diagnosis CPV-DI02 (PROFIBUS-DP) 3.2 Diagnosis via PROFIBUS-DP The CP system supports diagnostic possibilities via the PROFIBUS as per EN The device-specific diagnosis is supported. Note The identifier-related or channel-related diagnosis listed in EN is not supported Diagnostic words The following fault states of the CPI system are grouped into diagnostic words and passed on to the DP master: failure of the load voltage supply for the valves (pin 2) short circuit in sensor power supply failure of load voltage at the output modules short circuit/overload on the output modules interruption of the CPI connection on various CPI modules lower voltage tolerance limit of CP valves exceeded ( V). 3-9

90 3. Diagnosis CPV-DI02 (PROFIBUS-DP) Diagnosis steps The CP system offers extensive diagnostic possibilities via the PROFIBUS-DP. The diagram below shows you the steps required for diagnosing the CPI system. Only the diagnostic bits, which require a further diagnostic step, are represented. Note The diagnostic information is only sent to the master if the device-related diagnosis is activated (DIL switch element 8 at, see section 1.2.3) Bit Station status 1 CPV Direct is without power or the bus plug is not inserted. The configuration of the modules (see section 2.3) for the CPI extension string does not correspond to the configuration saved in the CPV Direct (see SAVE button in sections and 1.6). Fig. 3/2: First diagnostic step 3-10

91 3. Diagnosis CPV-DI02 (PROFIBUS-DP) In the following only those diagnostic bits, which require further diagnostic steps, are represented Bit Station status 1 There is a device-related diagnosis Bit Device-related diagnosis 1 (see Tab. 3/12) Thereisatleastonefault. Fault CP string/cp valve terminal see Tab. 3/13 and Tab. 3/14 Bit Device-related diagnosis 2 3 Fig. 3/3: Further diagnostic steps In order to commission your system, it may be useful in some cases to switch off the device-related diagnosis (DIL switch element 8 at, see section 1.2.3). 3-11

92 3. Diagnosis CPV-DI02 (PROFIBUS-DP) Overview of the diagnostic bytes Diagnostic words Several diagnostic words are provided for each bus slave. The diagnostic words and their meaning for CP systems from Festo are shown in the following table: Byte * Octet ** Diagnostic address Diagnostic address + 1 Octet ** Byte * 0 1 Station status 1 Station status Station status 3 Master address (Diag.Master_Add) Manufacturer s code (Ident_number High byte 0A h ) Manufacturer s code (Ident_number Low byte 35 h ) Header Device-related Diagnosis 1 (overview of faults) Device-related Diagnosis 2 (fault byte CPV Direct) bold = Contents modified by the CPI system * = Siemens ** = EN Identification byte of the diagnosis 10 9 Tab. 3/7: Overview of diagnostic bytes: Standard diagnostic information 3-12

93 3. Diagnosis CPV-DI02 (PROFIBUS-DP) Details for standard diagnostic information The following diagnostic information can be requsted by the DP master from the CPI system via the function Slave_Diag. The CPI system replies with an octet string of length 10. The procedure for reading out this diagnostic information with a SIMATIC S5/S7 system is described in section Octet 1: Station status_1 Bit Meaning Explanation 0 Diag.Station_Non_Existent CPI system no longer/not yet addressable. Possible causes: Operating voltage not applied Data cable interrupted Fault in data cable 1 Diag.Station_Not_Ready CPI system not yet ready for data exchange 2 Diag.Cfg_Fault The configuration data received from the master do not agree with those ascertained by the CPI system. 3 Diag.Ext_Diag There is a device-related diagnosis. Possible causes: Cable fracture on input/output module Short circuit/overload at electric outputs or sensor supply for inputs V valves V V outputs. 10 V V sensor. 10 V 4 Diag.Not_Supported 1 = CPI system does not support the function requested 5 Diag.Invalid_Slave_Response always 0 (set by CPI system) 6 Diag.Prm_Fault Last parametrizing telegram faulty 7 Diag.Master_Lock always 0 (set by CPI system) bold = valve terminal related bits Tab. 3/8: Diagnostic bits station status

94 3. Diagnosis CPV-DI02 (PROFIBUS-DP) Octet 2: Station status_2 Bit Meaning Explanation 0 Diag.Prm_Req 1 = The master must configure the CPI system again 1 Diag.Stat_Diag 1 = The master must request diagnostic data until this bit is set to 0 2 always 1 (set by CPI system) 3 Diag.WD_On 1 = Response monitoring/watchdog activated 4 Diag.Freeze_Mode 1 = FREEZE activated 5 Diag.Sync_Mode 1 = SYNC activated 6 reserved 7 Diag.Deactivated always 0 (set by CPI system) bold = valve terminal related bits Tab. 3/9: Diagnostic bits of station status 2 Octet 3: Station status_3 Bit Meaning Explanation 0 6 reserved 7 Diag.Ext_Diag_Overflow always 0 (set by CPI system) Tab. 3/10: Diagnostic bits of station status

95 3. Diagnosis CPV-DI02 (PROFIBUS-DP) Further octets Octets 4 7: Overview Octet Designation Explanation 4 Diag.Master_Add Master address: The address of the master, which parametrized the CPI system, is entered in this octet. 5 6 Ident_number Manufacturer identification: These octets contain the manufacturer identification: 0A35 h for the CPV Direct. 7 Ext_Diag_Data (device-related diagnosis) Header device-related diagnosis Length of the device-related diagnosis: 10 bytes Tab. 3/11: Overview of octets

96 3. Diagnosis CPV-DI02 (PROFIBUS-DP) Structure of device-related diagnosis Octet 8: Device-related diagnosis 1 *) Bit Meaning Explanation 0 Common fault in the CPI system 1 = There is at least one fault 1 not used 2 not used 3 not used 4 Common fault 1 = Fault CP string/cp valve terminal 5 not used 6 not used 7 No I/O data exchange Actual configuration Nominal configuration in the CP string (carry out recognition with SAVE button see 1.2.4) *) Is sent to the master PLC only if the device-related diagnosis is activated with the DIL switch. Tab. 3/12: Diagnostic bits of device-related diagnosis 1 Octet 9: Device-related diagnosis 2 Bit Meaning Explanation 0 Error output 1 = CPI connection interrupted at output module 1 Error input 1 = CPI connection interrupted at input module 2 Short circuit/overload 1 = Short circuit/overload at the output module 3 V out 1 = Load voltage failure at output module 4 V sen 1 = Short circuit/overload in sensor supply. 10 V 5 V val 1 = Load voltage of valve coils V 6 V load 1 = Load voltage of valve coils. 10 V 7 Ix 1= Otherfault Tab. 3/13: Diagnostic bits of device-related diagnosis

97 3. Diagnosis CPV-DI02 (PROFIBUS-DP) Octet 10: Device-related diagnosis 3 Bit Meaning Explanation 0 Diagnosis CPV Direct 1 = CPV Direct (basic device) signals diagnosis 1 Diagnosis in the CP string 1 = 1st. module in the CP string signals diagnosis 2 Diagnosis in the CP string 1 = 2nd. module in the CP string signals diagnosis 3 Diagnosis in the CP string 1 = 3rd. module in the CP string signals diagnosis 4 Diagnosis in the CP string 1 = 4th. module in the CP string signals diagnosis 5 7 reserved Tab. 3/14: Diagnostic bits of device-related diagnosis 3 Octets 11 16: Overview Octet Designation Explanation 11 Fault number Fault number of CPV Direct basic device 12 Fault number Fault number for 1st. module in the CP string 13 Fault number Fault number for 2nd. module in the CP string 14 Fault number Fault number for 3rd. module in the CP string 15 Fault number Fault number for 4th. module in the CP string 16 reserved Tab. 3/15: Overview of octets

98 3. Diagnosis CPV-DI02 (PROFIBUS-DP) Overview of the most important fault numbers No. Operating status Eliminating faults 0 No fault 2 Short circuit/overload in sensor supply (SCS) or at output (SCO) 5 Undervoltage in the power supply (load supply for outputs/valves, sensor supply for input modules with additional supply) Eliminate short circuit/overload Eliminate the undervoltage in the relevant power supply 11 Short circuit/overload at the valve Check valve 12 Pilot valve function warning Recommendation: Replace the valve 13 Wire fracture at valve (openload) Check valve 14 Valve: switching counter, limit value exceeded 34 Incorrect string assignment ascertained during operation (e.g. CPI module failed or CPI cable defective) More than one module failed during operation modules are no longer recognized. 35 The string assignment when the power supply is switched on is not the same as the saved string assignment or an incorrect module is recognized during operation. 36 Short circuit in CP string (24 V el/sen or 24 V val ) Communication on CP string interrupted Recommendation: Replace the valve Check CP strings (CPI modules and CPI cables), if necessary replace CPI modules or CPI cables Switch power supply off and then on again. If fault still occurs, check and, if necessary, replace CPI cables and CPI modules Check CP strings (CPI modules and CPI cables), if necessary replace CPI modules or CPI cables With correct string assignment: the string assignment must be saved Check string assignment, if necessary replace CPI module Check CP strings, if necessary replace CPI cable Tab. 3/16: Overview of the most important fault numbers from Tab. 3/

99 3. Diagnosis CPV-DI02 (PROFIBUS-DP) Diagnosis with tool change configuration In the tool change configuration only a simple diagnostic message is output for the CP string via the channel-related diagnosis. (Information on the tool change configuration see section ) Note In the tool change configuration the diagnostic information for all modules in the CP string is entered in the 2nd. diagnostic byte. No information is given as to which module registers the fault. Note the module LEDs in the CP string for ascertaining the exact location of the fault. Value Fault type (standard) Value Fault type (Festo) Periphery fault in the tool change configuration Tab. 3/17: Diagnosis with tool change configuration The diagnostic information of the CPv-DI01 basic device is normally entered in the 1st. diagnostic byte in the tool change configuration. 3-19

100 3. Diagnosis CPV-DI02 (PROFIBUS-DP) 3.3 Fault treatment With the following faults, the reaction of the CPI system depends on the configured reaction of the master module: telegram failure master stop interruption in the bus cable. Depending on the setting or configuration, all the outputs (valves and electric outputs) will be switched off or retain their status. Warning Make sure that valves and outputs are put into a safe state if the faults named occur. An incorrect status of the valves and outputs can lead to dangerous situations. Note Pleasenotethefollowingiftheoutputsareresetafter PLC stop, field bus interruption or fault: Single-solenoid valves move to the basic position. Double-solenoid valves remain in the current position. Mid-position valves move to the mid-position (depending on valve type: pressurized, exhausted or blocked). 3-20

101 3. Diagnosis CPV-DI02 (PROFIBUS-DP) Siemens SIMATIC S7 With these controllers, you can determine the reaction of the CPI system to the faults named above. Almost all configuration programs contain the function Response monitoring. For the operating modes named, the specified time corresponds to the drop-out time of the valves and electric outputs. You can set two types of fault reactions of the control system: Hard fault reaction: the controller switches to the operating mode STOP when a fault occurs. Soft fault reaction: the controller remains in the operating mode RUN when a fault occurs. Control system Module Meaning STOP RUN SIMATIC S7/M7 OB82 Reaction to a device-related diagnosis default OB is programmed OB86 Reaction to failure of a DP slave default OB is programmed QVZ: OB: PEU: quitting delay organisation module periphery not clear Tab. 3/18: Fault reactions STOP and RUN with S7 Further details on response monitoring can be found in the relevant controller manuals. 3-21

102 3. Diagnosis CPV-DI02 (PROFIBUS-DP) Possibilities for downloading the diagnosis for S7 The diagnosis for PROFIBUS-DP is supported in the different control systems by means of function modules. These download the slave diagnosis and write it into a data range of the user program. Control system Function module See... Manufacturer SIMATIC S5 with S5-95U/DP master FB 230 S_DIAG ET 200 Decentral Periphery System manual Siemens SIMATIC S7/M7 SFC 13 DP NRM_DG System and Standard Functions reference manual Siemens Tab. 3/19: Possibilities for downloading the diagnosis for S7 Example for a STEP 7 user program: STL Explanation CALL SFC 13 REQ:=TRUE Read request LADDR:=W#16#03FE Pointer at diagnostic address, e.g d = 03FE h ( Properties DP slave see mask in HW Config) RET_VAL:=MW100 When faults occur, output fault code RECORD:=P#M110.0 WORD 5 Pointer at start of data range for diagnosis and length of diagnostic data BUSY:=M10.0 Read procedure finished Fig. 3/4: Example 3-22

103 3. Diagnosis CPV-DI02 (PROFIBUS-DP) 3.4 Online diagnosis with STEP 7 Direct diagnostic events in conjunction with the CP valve terminal can be: decentral periphery station failure communication between slave and master interrupted module faulty (see device-related diagnosis Tab. 3/12 and Tab. 3/13) change of operating status from START to RUN (nominal/actual difference exists) configuration data of the valve terminal do not match the periphery valve terminal has incorrect DIL setting Read out diagnostic buffer with STEP 7 (up to V 5.2) The diagnostic buffer of STEP 7 offers the possibility of displaying diagnostic events of the S7 system in the sequence in which they occur. Requirement: HW Config has been accessed. Proceed as follows (see Fig. 3/5): 1. Switch from offline to online Click with the right-hand mouse button on the CPU in rack Click on [Module information...] in the context menu shown. The window Module information will then appeart Click on the register Diagnostic buffer Click on the event and read the details 5. Here you will find more detailed information on proceding further, depending on the S7 controller used. 3-23

104 3. Diagnosis CPV-DI02 (PROFIBUS-DP) Fig. 3/5: Online diagnosis via the diagnostic buffer (explanation see text) 3-24

105 3. Diagnosis CPV-DI02 (PROFIBUS-DP) Device-related diagnosis with STEP 7 (up to V 5.2) You can display fault messages of the device-related diagnosisviathewindow Moduleinformation (seefig.3/6): 1. Click with the right-hand mouse key on the icon of the valve terminal Click on [Module information...] in the context menu shown. The window Module information will be displayed. 3. Read the diagnostic information Fig. 3/6: Device-related diagnosis with STEP 7 (explanation see text) 3-25