Excellent communicator

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1 CPX terminal/cpi system Electrical peripherals for perfect networking Excellent communicator Highlights Modular and flexible IP65 remote I/O Decentralised and networked intelligence Minimises installation costs and increases productivity Maximum function integration for new applica tions CPX the ideal platform for electrical peripherals. Perfect as a valve terminal partner or as remote I/O: electrical, open and direct. With CPX and the CPI system, you can integrate pneumatic and elec trical control chains easily, quickly, flexibly and seamlessly into all automation concepts and company-specific standards. CPX your independent I/O platform for: A universe of possibil ities An unsurpassed variety of modules and applications CPX the new benchmark for perfecting networking thanks to: Universal communication via Fieldbus/Ethernet A choice of pneumatic platforms (valve terminals) Remote decentralised installation system CPI CPX greater economy and operational reliability through function integration, such as: Front-end control A range of scalable installation concepts Comprehensive diagnostics and condition monitoring Motion control for electric drives and servo-pneumatic drives Measuring and controlling Included in the package: advice and first-class support anywhere in the world from a strong, independent partner. Communicative, integrated and perfectly modular

2 The basis for your independent platform CPX: unique on the market when it comes to remote I/O flexibility Communication and control concepts Function integration is the way forward and valve terminals are becoming the automation platform of the 21st century. And that is exactly why an electrical platform is needed which meets all requirements with maximum modularity. Enter the CPX as remote I/O. Single-platform solutions Digital and analogue standard tasks Demanding I/O tasks Measuring tasks, e.g. for temperature, displacement, pressure and flow rate Electrical and pneumatic safety functions Diagnostics and condition monitoring Pilot or process valves Valves for cylinders, grippers, vacuum Pressure regulators for proportional control systems Servopneumatic positioning systems Electric drives and axes Positive results for you Demonstrable increase in efficiency of up to 60% Reduction in system costs by up to 20% Cycle time optimisation by 30% Reduction in flow rate/air consumption by up to 50% Maximum process reliability Comprehensive diagnostics Pages Perfect networking for universal communication Crucial factor for CPX: maximum openness to all installation, communication and control concepts. Uniform communication: with a single platform, from the control and operational level to the actuator/sensor level or field level. Integration of pneumatic and electrical control chains into all automation concepts, even company-specific ones Open to all Fieldbus protocols and Ethernet This is CPX as a remote I/O. Modbus TCP Power supply concept and zones Power supply concept for reliable operating states Highly flexible for direct machine mounting with high IP protection Up to 8 voltage zones Choice of connecting thread: M18, 7/8 or AIDA push-pull External power supply for the entire system Additional voltage zones for outputs Safer thanks to voltage zones which can be separately switched off Additional power supply and galvanic isolation of the outputs High power supply Fail-safe function built in ProfiSafe switch-off module: shuts down internal valve supply and 2 independent, safe external outputs Handheld terminal ProfiSafe switch-off module Fieldbus node Automatic earthing 24 V - Outputs 24 V - Valves 24 V - Valves - Voltage zones End plate with earthing component 24 V - Valves - Outputs 24 V - Electronics 2 - Sensors Electrical terminal CPX/Installation system CPI Subject to change 2012/02

3 Front-end control: options for electrical control Remote I/O on Fieldbus/ Ethernet Stand-alone operation (IP65/67 stand-alone control) Fieldbus remote slave Ethernet remote slave including use of IT technology Signal pre-processing Motion control for electric and servopneumatic drives Rapid data transmission and real-time capability thanks to built-in pre-processing. Pages Integrated IT saves money and can be incorporated seamlessly into host systems TCP/IP Data transfer Remote maintenance, remote diagnostics FDT/DTM Web server, OPC server Web monitor as an integrated homepage SMS text message and alarm function Maintenance tool with USB adapter for PCs An integrated diagnostics concept reduces un planned downtime by up to 35% Pages Integrated automation platform CPX with motion control I/O module Pneumatic interface e.g. valve terminals MPA or VTSA Interlinking block Control of all field devices e.g. automated process valves Technology module Electronics module Connection block Selectable and scalable: pneumatic installation concepts Centralised installation Decentralised installation with CPI Decentralised installation for upstream functions with Fieldbus Direct and/or CPI Hybrid installation Pages Incredible variety of I/O modules Limitless adaptation options Use as remote I/O Expandable to up to 10 I/O modules Up to 144 inputs locally, up to 512 decentralised System expansion to several thousand I/O Flexible adaptation with software parameterisation reduces inventory requirements Maximum modularity and flexibility 10 alternative connections in versions with IP20/IP65/IP67 quick and easy to install and compatible with companyspecific standards M8/M12/D-sub/quick connector accessories Modular system for any M8/M12 connecting cables Heavy duty, robust and reliable Choice of plastic or metal threads Perfect for direct machine mounting and adaptation to the machine concept Cable kits Choice of any cable lengths between m Adapted to all devices with M8 and M12 plug connectors Cable types: standard; suitable for use with energy chains; robotics cables Electrical terminal CPX/Installation system CPI Subject to change 2012/02 3

4 Independent platform from the controller to the front end 4 Electrical terminal CPX/Installation system CPI Subject to change 2012/02

5 *Closed-loop control without a positioner using an analogue sensor and CPX Electrical terminal CPX/Installation system CPI Subject to change 2012/02 5

6 CPX in a practical test CPX in factory and process automation Practical the best title for a technology that delivers what it promises. Even when that promise is substantial and innovative. A platform and a solution package for complex communication scenarios in automation that s how simple the future can be. CPX contributes to high-tech and reliable automation communication in factory and process automation. More than 10,000 Festo customers already depend on reliable, customised solutions, such as control cabinets, ready-to-install systems and many other applications in sectors that include: Automotive industry Printing industry Special machine construction Packaging industry Water treatment systems Biotech/pharmaceuticals Maximum functional diversity in a minimum of space, with perfectly harmonised diagnostics and condition monitoring systems on board as well. Handling applications: for loading and unloading, CPX controls a mix of technologies from standard pneumatics, servopneumatics to electric drive technology Combined motion control: CPX for open and closed-loop control of electric and pneumatic drives, with analogue and digital process sensors and vision systems, from a single station with all equipment from a single source. Adaptation to harsh environments: Festo control cabinet construction, media-resistant tubing. Pilot valves: with high flow rates, flexibility, protected environment, integratable into existing host environment: CPX offers everything on a single platform. 6 Electrical terminal CPX/Installation system CPI Subject to change 2012/02

7 Complete solution for process automation Optimised process: automating the cyclic filtration backwashing for filter cleaning process increases water production per hour. The integrated interaction of the CPX-CEC control system, with controller algorithm, CPX analogue module, MPA pilot valve, DFPB semi-rotary drive and SRAP analogue sensor box replaces a complex electrical positioner with a robust, simple and economical solution. The complete solution from a single source is the result of collaboration with Bamag in Egypt, including the control cabinet and visualisation. Advantages Robust and simple technology increases reliability In case of power failure, a pneumatic controller is available for emergency operation Complete pre-installed and tested components reduce installation time Components or complete solution from a single source reduces number of suppliers Integrated automation solution with the CPX platform simplifies engineering Extract: projects implemented Interlinked, stand-alone machine modules, feed units with a compact vision system, controlled by CPX. Alignment of pressure plates using a compact vision system and networked sensors and drives, integration into the overall system via valve terminal CPX/MPA. Automating manual workstations: typical applications for IP65-rated integrated solutions with CPX-CEC front-end controller. Laboratory automation: pneumatic and electric motion and measurement with CPX. You will find other projects related to the specific topics on the following pages. Electrical terminal CPX/Installation system CPI Subject to change 2012/02 7

8 Innovation is not a coincidence! Research for the future of automation The fact that Festo enjoys an outstanding position in indus - trial automation concepts with its integrated automation based on CPX is no coinci - dence: 8.5% of the company s turnover (2010) is invested in our research and development. Consistent innovation management ensures that products are brought to market consistently and quickly. This is why the development of the Bionic Handling Assistant was rewarded with the German Future Prize 2010 by President Wulff. We believe that part of this prize is reflected in every new product, because Festo wants every new product to be an example of optimum functionality and pioneering technology. Winner 2010 Pioneering technology. Inside: numerous innovative catalogue products, that have already proven themselves in practice. The great inspiration: bionics The Bionic Learning Network is a collaboration between Festo and leading universities, institutions and research companies. It is closely linked to the innovation processes in learning companies and also part of our commitment to technical training and education. Festo s projects are setting trends: from reliable automation to energy-efficient biomechatronnics solutions to green production. The biomechatronic footprint documents (r)evolutionary developments and improvements to mechatronic products and processes by using bionics. The line runs from the natural model to the basic technical basic principle and from bionic adaptation to the industrial application. Future gripping: flexible tripod with wide operating range. For energy-efficient sorting and movement, flexible and resilient human/machine interaction in all spatial directions. System with manual axis and adaptive gripper DHDG controlled by CPX-CEC-M1 and CoDeSys Softmotion library. 8 Electrical terminal CPX/Installation system CPI Subject to change 2012/02

9 Functional integration new horizons in automation The new portfolio with CPX With the arrival of the CPX electrical peripherals from Festo: the options for function integration on valve terminals and the CPX as a remote I/O have become virtually limitless. They drastically reduce installation costs drastically, creating single-source solutions, and minimise total costs. Single-platform solutions Digital and analogue standard tasks Demanding I/O tasks with single-channel diagnostics and parameterisation Temperature, displacement and pressure measurement Electrical and pneumatic safety functions electrical and pneumatic Integrated, comprehensive diagnostics and condition monitoring Subordinate, decentralised installation system CPI Combine this directly with the operating process elements Pilot or process valves Control valves for cylinders, grippers, vacuum Pressure regulators for pro - portional control systems Servopneumatic positioning systems Electric drives and axes For control, choose from Fieldbus/Ethernet as remote I/O or the following front-end controllers: CPX-FEC (Festo mini control system) CPX-CEC (CoDeSys control with 32 bit processor, 400MHz, CANopen master) PC Worx (controller for control environments from Phoenix Contact) Savings potential 60 % 50 % 50 % Installation time (time to market) I/O channel price Air consumption 35 % Downtime CM/diagnostics 30 % 30 % Cycle time CPi Advancing time CMPX/CMAX 20 % System costs For more about motion control and Festo s unique mechatronic port folio, go to: Electrical terminal CPX/Installation system CPI Subject to change 2012/02 9

10 Function integration 1: front-end control CPX-CEC: CoDeSys embedded controller for the CPX terminal Automation platform With CPX-CEC, the remote I/O expands into a modular PLC with IP65/67 rating. Direct machine mounting reduces installation costs and permits pre-processing or stand-alone control. The module can be used in every industry and application. It enables manual workstations, relatively small machines or interlinked standalone systems to be controlled independently. It all makes CPX into an unprecedented, standalone automation platform. Superb performance Leader in the field of intelligent embedded systems : with a 400 MHz 32 bit processor, the CPX-CEC is one of the fastest and most powerful controllers available anywhere in the world in this basic design. Summary of benefits: Better performance Reduced costs Improved cycle times More actuators can be connected Programming in a global language in accordance with IEC CoDeSys enjoys wide accept ance in the control market The CANopen Master integrated in the control system can actuate pneumatic and electric axes intelligently via Fieldbus. The comprehensive CoDeSys function library takes care of diagnostics and condition monitoring options. CoDeSys makes your life easier with simple commissioning, fast programming and parameteri - sation standardised programming of control systems to IEC standard. Also includes the new Softmotion library for motion control and interpolations up to 2.5D with the controller CPX-CEC-M1. Huge possibilities: the functions of CPX-CEC Easy control of valve terminal configurations with MPA, VTSA or CPV Connection to all Fieldbuses as remote controller and for pre-processing Control of electric drives as single axes or in synchronised multi-axis mode using CANopen Diagnostics with flexible monitoring options for pressure, flow rate, cylinder run time, air consumption, early warnings and visualisation options Control of decentralised installation systems using CPI Control of proportional pneumatic applications Servopneumatic applications AS-interface control via gateway CPI-System AS-Interface 10 Electrical terminal CPX/Installation system CPI Subject to change 2012/02

11 Control concepts with CPX-CEC The following basic control concepts can be implemented by combining CPX-CEC with the CPX terminal platform: Stand-alone operation as a front-end controller or programmable valve terminal for direct machine mounting Fieldbus remote controller (combination with Fieldbus nodes for Interbus, Profibus-DP, CANopen, DeviceNet or CC-Link) as the pre-processing unit for decentralised, stand-alone subsystems Remote Ethernet controller as pre-processing unit for decentralised, stand-alone subsystems with use of IT technology CPX-CEC variants: CPX-CEC: with RS232, compatible with CPX-FEC CPX-CEC-C1: with CANopen master CPX-CEC-M1: with CANopen master and CoDeSys Softmotion library Limitless expansion to form an automation platform Immensely powerful and with IP65/67 protection With the CPX-CEC controller as a CANopen master, you can expand CPX with up to 127 additional CPX terminals, motor controllers and many more CANopen stations and implement several thousand I/O.** CPX thus becomes an immensely powerful automation platform, with IP65/67-rated protection. **Depends on a number of para meters, such as: size of the user program, re quired cycle time, baud rate, distance, etc. An example: With 1500 I/Os each, CAN open requires about 3 ms bus cycle time; with I/Os about 30 ms. These figures are still real-time capable for the pneumatic systems. A selection of completed projects Diagnostics and condition monitoring in pneumatic (sub-)systems Fast and simple implementation of diagnostic functions, enhanced energy efficiency, process optimisation for customer projects, or support in air consumption measurement and system analysis it s all pos - sible with the software library for the range of CoDeSys control systems from Festo. Readymade software components support the monitoring of pressure, flow rates and air consumption. Further diagnostic functions include: Standard functions mean/maximum values Counting functions Time functions, e.g. travel times Switching times of actuators Diagnostics of, e.g. wear or leak detection CoDeSys can also be used to interpret the information acquired. Detailed diagnostics and plausibility checks (If-Then analyses) are possible, as is integration into SCADA systems via an OPC server. Electrical terminal CPX/Installation system CPI Subject to change 2012/02 11

12 Function integration 2: motion control Control: the individual modules Motion control with CPX-CEC-C1 Program, automate, benefit all in compliance with IEC Directly mounted on the machine as an intelligent remote I/O terminal in IP65/IP67, CPX-CEC is ideally adapted to the CPX terminal and decentralised control tasks in the machine. Comprehensive CoDeSys function library Integrated CANopen master for several thousand I/O Motion control with up to 31 asynchronous electric drives Advantages Reduced installation costs Improved cycle times Significant increase in functionality CPX-CEC-C1 CoDeSys controller with CANopen master for multiple asynchronous axes decentralised control in the field. CPX-CEC-C1 as master: controls electric axes, swivel and gripper units on loading and unloading stations and links them with existing processes. Motion control with CPX-CEC-M1 As for CPX-CEC-C1, plus CoDeSys Softmotion library. This enables the controller to perform a 2.5 dimensional interpolation for up to 8 synchronous, electrically movable axes. Flexible electronic camming functions included. Benefits Economical open and closed loop control The only fully integrated automation platform in the world in IP65: for standard pneumatics, proportional pneumatics, servopneumatics, electric drives and sensors CPX-CEC-M1 with additional CoDeSys Softmotion library for 2.5 dimensional interpolation in the field. 70 picks/min! And high precision: the high-speed T-gantry. Complete control using CPX-CEC-M1. Electric multi-axis controller CPX-CMXX The IP65-rated electric multiaxis controller uniformly parameterises up to 8 electric drives, thus simplifying control operations: through simple multi-axis movement, point to point, synchronously. Handling with CPX-CMXX controller can be incorporated into existing processes. Benefits Faster cycles thanks to simply coordinated multi-axis movements Simple and quick installation/ parameterisation with the Festo Configuration Tool (FCT) No need to program the logic program and telegram structure for coordination of the individual axes Stand-alone control with CPX: complex and synchronous handling functions including pneumatics and electrics based on front-end control. 12 Electrical terminal CPX/Installation system CPI Subject to change 2012/02

13 Fieldbus gateway CPX-CM-HPP The Fieldbus gateway with the Festo Handling and Positioning Profile (FHPP) for economical control of up to 4 electric drives, standard or 8 in system. Benefits High flexibility: all electric drive units from Festo integrated in Fieldbus/ Ethernet Simplified engineering Reduced complexity Faster commissioning CPX-MMI CPX-Terminal FHPP-Profile (CAN-Bus) SFC-LAC SFC-DC CMMx-xx MTR-DCI ELGL-LAS EGC EGC Convenient positioning with individual electric axes with full diagnostic functionality: ideal for the CPX-CM-HPP module. Smart Soft Stop electric endposition controller CPX-CMPX Developed from the SPC11: CPX-CMPX. Makes for faster cycle times by up to 30% on up to 8 drives and 30% less air consumption than comparable standard pneumatic components: the CPX-CMPX electronic end-position cushioning with drive-dependent strokes of up to 2 m. Benefits Fast, vibration-free travel between two (fixed) stops Increased cylinder service life Highly dynamic movement of loads up to 300 kg Auto-Teach through the pressure sensors of the proportional valve VPWP CMPX Proportional valve VPWP DGPIL linear drive Opening machine safety guards quickly and gently: a typical application for Smart Soft Stop end-position controller CPX-CMPX. On request also with protective circuit to EN ISO Servopneumatic position controller for pneumatic drives CPX-CMAX One of a kind: the CPX-CMAX, developed from the SPC200, controls the positioning of various pneumatic drive families, linear or rotational, with IP65 rating, on up to 8 drives per CPX terminal. Benefits Travel speeds up to 3 m/s Acceleration values up to 30 m/s² with precision ± 0.2 mm For loads of 1 kg to 300 kg 64 configurable positioning records can be started via Fieldbus Robust and convenient positioning in the range to +/- 0.2 mm with simultaneous force control in the current position for gluing, welding etc. Tile production: robust positioning and minimal vibrations with changing loads, with CPX-CMAX servopneu - matics. Electrical terminal CPX/Installation system CPI Subject to change 2012/02 13

14 Function integration 3: measuring and controlling Extremely easy in the future: measurement and control Up until now, measuring and controlling were separate subsections of automation, which could only be implemented with complex and usually external solutions. The incredible variety of I/O modules, coupled with technology modules for measuring and controlling pressures and pneumatic or electric drives, make measuring and controlling simple. Another feature which makes the CPX electrical peripherals so universal and unique. Measuring and controlling: the individual modules High-resolution analogue input module with four 16-bit inputs CPX-4AE-U-I Extremely flexible for demanding tasks in factory and process automation, for example, in level measurement, pressure measurement and distance measurement. Numbers technical functions configurable, limit monitoring, diagnostics and the following measuring ranges per channel: Bipolar Unipolar ma ma V V V ma V Advantages Powerful and usable everywhere. Economical: numerous signal types integrated into a single module Safety thanks to standard overload protection Reduced downtimes due to comprehensive channelspecific diagnostics Analogue module integrated into field with high protection class Powerful and usable everywhere. The 16-bit input module as part of a modular system. Demanding solutions for factory and process automation through to integrated complete solution including open and closed-loop control on the CPX platform Measuring module CPX-CMIX-M1-1 Turns pneumatic cylinders into sensors, and is unique worldwide, due to its completely digital data acquisition* and data transmission. Repetition accuracy of ±0.01 mm and the integration of both analogue and digital transducers. Benefits Space and time-saving: retracting/advancing and measuring in one work step Reduced cycle time; strokedependent triggering of subsequent process steps Improvements in quality: process steps are measured and documented Faster and more reliable commissioning, due to harmonised system More communicative and more productive: due to optimised cycle times, because subsequent process steps can be triggered in an optimal way depending on the stroke More efficient: Y-stroke lowering and measuring at the same time. For cylinders with an integrated displacement encoder. *Depending on the measuring system 14 Electrical terminal CPX/Installation system CPI Subject to change 2012/02

15 Analogue input modules for 4 thermoelements or RTD temperature sensors CPX-4AE-TC/CPX-4AE-T Whether in process automation or in manufacturing processes, the new temperature sensor modules are designed for: Thermoelements of types B, E, J, K, N, R, S and T (-270 C to 1820 C) RTD temperature sensors PT 100, PT 200, PT 500, PT 1000, Ni 100, Ni 120, Ni 500, Ni 1000 (-200 C to 850 ) Advantages Reduced downtimes due to channel-oriented diagnostics Reduced channel costs due to 4 channels per module Avoids expensive sensors with integrated signal converters Reduced system costs thanks to simple function integration in Fieldbus/Ethernet networks Integrated temperature detection with CPX in control cabinet or field. Analogue input module with 4 pressure sensors CPX-4AE-P The new pressure sensor modules offer extreme function integration in a tiny space, and with IP65 protection. They greatly simplify installation in the field, and make engineering far easier. Advantages Parameterisation, commissioning, evaluation as an absolute value in mbar, psi, kpa without conversion highly economical Parameterisable pressure sensor with 4 relative pressure measurements or 2 differential pressure measurements. Versions for bar or vacuum bar. No need for external sensors means a great reduction in installation effort and space requirement Pre-assembled and tested unit Channel-oriented diagnostics for reduced downtimes Pressure sensor module CPX-4AE-P Low-cost: replacing individual sensors in the field reduces installation time. Proportional-pressure regulator VPPM on CPX/MPA The proportional-pressure regulator VPPM for reliable and precise closed-loop control. It has preselectable presets plus multi-sensor control and can be integrated into the electrical terminal CPX/MPA, VPPM permits many additional diagnostic functions and variable pressure zones. Benefits Reliable and trouble-free pressure regulation and diagnostics via Fieldbus/Ethernet Efficient: up to 8 VPPM per valve terminal CPX/MPA, can be expanded subsequently Reliable: pressure is maintained if the supply voltage or bus communication fails Economical: long service life, 100% tested and preassembled units Energy-efficient, as control is local Proportional-pressure regulator VPPM on CPX/MPA Controlled and documented quality, flexible batch change when welding plastic tanks with closed-loop control technology and sensors on CPX/MPA. Electrical terminal CPX/Installation system CPI Subject to change 2012/02 15

16 Function integration 4: diagnostics and condition monitoring For perfect process reliability the diagnostics and condition monitoring package with CPX Integrated diagnostics concept reduces unplanned downtime by up to 35%. CPX integrates internal diagnostics and condition monitoring functions. The respective valve terminals, such as types MPA or VTSA, have superb communications capabilities thanks to the integrated serial interface or a Fieldbus module from the CPX series. Everything that is necessary for internal diagnostics and condition monitoring down to individual channel level. The same goes for process diagnostics, as shown on the previous pages with CPX-CEC and connected sensors or with compact vision systems. Convenient integration of diagnostic data into your HOST environments thanks to integrated IT services. Depending on the Fieldbus system used and your control/ visualisation system, the CPX diagnostic data can be transferred and integrated seamlessly. Defined diagnostic modules ensure easy engineering. Our manuals and technology brochures for all Fieldbus systems provide a detailed guide: Profibus/Profinet brochure DeviceNet/EtherNet/IP brochure CANopen/EtherCAT/ Modbus/TCP brochure In addition, our new support portal on the Internet provides professional help with device files, drivers, firmware issues etc.: Three error modes for simple detection Current errors LED-supported diagnostics provides rapid, immediate assist - ance. A CPX-MMI reports locally in normal text, while Fieldbus or Ethernet transmits details at channel level for process visualisation. Future errors These will hopefully not even occur, thanks to automatic condition monitoring for preventive maintenance and numerical data and warning messages at channel level, e.g. for up to 128 solenoid coils. Random errors/history More rapidly analysed and detected thanks to a diagnostic trace which automatically stores the 40 most recent errors. No need for timeconsuming investigations, even for sporadic errors. Undervoltage per module Electronics -25% Load -10%/valves -25% Emergency off 10 V Short circuit can be selected For each channel For each module For each valve Error memory Last 40 messages With a time stamp Recognises sporadic errors Condition monitoring Setpoint specification for each valve Monitoring of downstream processes/mechanical systems Preventive diagnostics/ maintenance Wire break can be selected For each channel For each module For each valve Upper/lower limit value For each analogue channel Voltage Current Temperature Pressure Undervoltage for each valve manifold Auxiliary power supply to valves monitored separately Load/valves -25% Implemented with ease with Festo. On request, we offer complete project implementation for diagnostics/condition monitoring in pneuma tic (sub-) systems, based on CPX-CEC. 16 Electrical terminal CPX/Installation system CPI Subject to change 2012/02

17 Diagnostics options in the Festo valve terminal range CPX-4DE CPX-8DE CPX-16DE CPX-L-16DE CPX-8DE-D CPX-16DE-D CPX-4DA CPX-8DA/8DA-H CPX-8DE-8DA CPX-L-8DE-8DA CPX-2AE-U-I CPX-4AE-U-I CPX-4AE-I CPX-4AE-P CPX-4AE-TC/T CPX-2AA-U-I VTSA MPA-L MPA-S/MPA-F MPA diagnostics Pressure sensor MPA Digital I/O Analogue I/O Pneumatics Undervoltage Short circuit signal U Short circuit supply Wire break I I I Lower limit Upper limit Parameterisation errors Condition monitoring Sensor overload Measuring range exceeded No diagnostics Module-oriented diagnostics Module/channel-oriented diagnostics U = Voltage I = Current input T = Temperature DE = Digital input DA = Digital output AE = Analogue input AA = Analogue output For details of further, specific diagnostic options for pressure and displacement measurement, for all electrical and servopneumatic axes or our proportional pneumatics, and for motion and control, refer to the relevant catalogue pages and manuals in the electronic catalogue. Electrical terminal CPX/Installation system CPI Subject to change 2012/02 17

18 Universal communication via Fieldbus and Ethernet Simple and reliable: communication on all levels With the special functions that are possible with no problems using CPX, the modular electric terminal will quickly establish itself as a new standard in industrial communication. With the huge range of modules available with CPX, these advantages are easy to implement. Not least of which is independent and flexible communication via Fieldbus/Ethernet anywhere in the world, and from the management level to the field level. Without this, comprehensive diagnostics, for example, would be impossible. Status byte and diagnostic status interface CPX provides comprehensive diagnostic information. If this is not supported by the fieldbus or host system used, parts of the information can also be transmitted within the process data, thus facilitating partial readout of the data. Device status/diagnostics via online diagnostics with Rockwell RSNetworx. Fail-safe/fault mode Ideal for risk management: safety-critical processes can be planned precisely with fail-safe or fault mode because the behaviour of outputs during a bus interruption can be defined in advance (e.g. OFF or Hold Last State). This function is available for Profibus, DeviceNet, Ethernet/IP, Profinet and EtherCat. Defining fail-safe/fault mode with Rockwell RSNetworx. 18 Electrical terminal CPX/Installation system CPI Subject to change 2012/02

19 Parameterisation via PLC/ fieldbus Depending on the fieldbus, a start-up configuration can be defined for each field device and loaded via the fieldbus after power-on. Benefits Uniform user interface in the PLC In the event of a fault the field device easily replaced and can be parameterised with the old values This function is available for Profibus, DeviceNet, CANopen, Ethernet/IP and ProfiNet. Festo valve terminals configured and parameterised with Siemens STEP 7. Modular device configuration This function makes modular devices such as CPX and other subsystems easier to configure. Benefits Clear configuration Differentiated planning, also with different data types Simple parameterisation This function is available for Profibus, DeviceNet, CANopen and ProfiNet. Address reservation This function is device and fieldbus-dependent. Address reservation can be used to apply a single, uniform PLC program on differently configured machines and field devices. Currently this design is supported by CANopen via Specific Object. Modular device configuration with Siemens STEP 7. If you connect a subordinate CPI system to the CPX terminal, you can use it to carry out address reservation by allocating the fourth string first. Electrical terminal CPX/Installation system CPI Subject to change 2012/02 19

20 Specific versions for integrated automation CPX for special tasks and environments CPX as remote I/O Plastic Electric function integration: Digital and analogue I/O functions, always completely pre-assembled and function tested, IP65 or IP20 Choice of communication protocols for Fieldbus and industrial Ethernet, plus choice of bus connection technologies Pre-processing possible thanks to integrated CoDeSys control Pressure sensors integrated Safety engineering integrated (electrically isolated supply to outputs, multiple voltage zones, ProfiSafe switch-off module) Comprehensive diagnostic concept with condition monitoring, contigious integration of data into other HOST systems All I/O functions in one pro - duct comprehensive parameterisation options for ideal production process design in the field CPX as remote I/O Plastic CPX with IP20 connection technology for control cabinet applications CPX as remote I/O Metal Electric function integration: Modular I/O system, completely in metal Individually expandable I/O modules 8xM12 for 16 inputs per module with single-channel diagnostics 8 high-current outputs and 2A per output with single-channel diagnostics Sturdy connection technology M12 Connection technology for Fieldbus and power optionally to AIDA specifications* for the automotive industry or industry standard 7/8 All CPX functions available mixture of plastic and metal modules possible CPX as remote I/O Metal Remote I/O in extra sturdy metal housing, individually expandable I/O modules * AIDA = Automation Initiative of German Domestic Automobile Manufacturers CPX with servopneumatics Servopneumatic function integration Minimum configuration with bus connection/control system, controller and small number of I/O for interaction Up to 8 axes possible motion control complete solution in IP65 Soft stop function with electronic end position control for pneumatic drives Servopneumatic positioning and force control in one CPX with servopneumatics CPX as comprehensive motion control system with servopneumatics Motion control in IP65, direct in the application 20 Electrical terminal CPX/Installation system CPI Subject to change 2012/02

21 CPX with motion control Function integration of electric drive technology: Minimum configuration with choice of bus connection, motion controller CPX-CMXX and small number of I/O with controller CPX-CEC (MC integrated) and small number of I/O As gateway with CPX-CM-HPP module and bus connection Maximum expansion up to 8 axes (synchronous, inter - polated) or 31 axes (asynchronous) possible Any combination with I/O functions and pneumatics for optimum integrated automation in the field CPX with motion control Motion controller in control cabinet and motion controller on CPX either in the field or in the control cabinet CPX as decentralised installation system CPI Function integration of decentralised I/O: Perfect decentralisation and scaling, of I/O Perfect decentralisation of pneumatics and integration into one system Create perfect synergies with the central CPX terminal and all additional functions More information about CPI can be found on pages CPX as decentralised installation system CPI Very compact automatic assembly machines often require small I/O modules and decentralised valve terminals perfectly integrated into the CPX terminal by the decentralised installation system CPI. CPX and rapid tool changing on a robot With Fast Start-Up and Quick Connect on CPX. When robots change complex tools, they often have their own intelligence and/or bus connection. If you look at the time a Fieldbus station takes to set the first output after Power on CPX is usually faster than others. With Profinet, Profibus and DeviceNet these times are significantly less than 1 sec for the CPX terminal.* *Other Fieldbuses on request Electrical terminal CPX/Installation system CPI Subject to change 2012/02 21

22 Unlimited pneumatics: CPX with valve terminals Ideal for CPX: valve terminals MPA or VTSA Two perfect companions for CPX: valve terminals MPA or VTSA Each has its own profile and its own advantages. One is highly communicative thanks to serial communication; the other has greater pneumatic flexibility than any standards-based valve terminal before it. Both represent the ideal add-on for perfect integration in pneumatic and electrical networks. CPX/MPA Serial communication for comprehensive diagnostics Technical features: Unique worldwide: serial linking, consistent communication down to the valve Metal manifold block Up to 64 valve positions or 128 solenoid coils Up to 8 voltage zones on one valve terminal for greater safety, reliability and efficiency Space-saving in the control cabinet Reliable and feedback-free switching of pilot valves/ process actuators Standard air qualities: with 40 μm grade of filtration, filtered, lubricated, unlubricated or inert gases Choice of platforms: MPA-S up to 700 l/min flat design, perfect for CPX with integrated proportional pneumatics MPA-F up to 900 l/min up to 40% greater flow rate, greater capacity for simultaneous valve switching MPA-L up to 360 l/min polymer manifold block, expandable in single steps The perfect integrator of systems and functions: From the individual valve to the valve terminal with multipin connectors or fieldbus/ Ethernet Reduction in channel cost by up to 50% with maximum function integration at the same time A world first: MPA-VPPM pressure regulator propor tional technology on the fieldbus for robust closed-loop control Integrated pressure sensors optimise your process documentation Large choice of components for vertical stacking Comprehensive diagnostics Meets every need: for more information see pages CPX/MPA with function integration MPA on AS-interface MPA-VPPM with function integration: proportional pneumatics MPA on CPI system MPA-L with polymer manifold block MPA-F with high flow rate 22 Electrical terminal CPX/Installation system CPI Subject to change 2012/02

23 CPX/VTSA built-in flexibility and a variety of sizes Technical features: Unique worldwide: 4 different valve sizes (18, 26, 42 and 52 mm) on one valve terminal, without adapter plates Pneumatic and electrical power supply for up to 32 valves Flexible and highly modular ideal for special purpose machines or changing applications Standards-based valves and sub-bases to ISO and ISO with electrical contacting in the sub-base VTSA-F: standard valves, subbases with 40% more flow Reliable: valves, outputs and logic voltage can be switched off separately Electrical connection - Multi-pin with pre-assembled cable or terminal strip (Cage Clamp) - Control block via CPX - AS-interface - Individual connection Extensive vertical stacking: Controllers, flow control valves, shut-off plates for versatile pneumatic solutions Vertical pressure shut-off plate for hot swap : maintenance or repair of a valve in operation, without shutting off the pressure Pressure regulator plates: Standard regulator A, B, AB Reversible A/B regulator on the pressure regulator plate for fine adjustment and up to 50% more venting, as venting not done via pressure regulator Festo with VTSA: More built-in safety for systems and machines with VTSA Solution ready for installation on a valve terminal On/off and soft-start valves for greater process reliability during switch-on Multiple voltage zones on one valve terminal Switching position sensing for increased reliability, e. g. for press control (one/two channel) Special valves for pneumatic manual clamping devices, lifting cylinders and rotary cylinders ProfiSafe switch-off module: shuts down internal valve supply and 2 independent, safe external outputs Switchable pilot air: protection against unwanted system restarts up to max. PL d in compliance with EN Optional non-return valves, also activated by the pilot air valve, allow pneumatic stopping of two channels CPX/VTSA with function integration VTSA with integrated multi-pin plug connection (cable or terminal strip) and Safety@Festo CPX metal and VTSA with max. flow rate and connection technology in accordance with AIDA* * Automation Initiative of German Domestic Automobile Manufacturers CPX/VTSA with function integration up to ISO size 2 (52 mm) VTSA on AS-interface VTSA-F with high flow rate MPA and VTSA two products that deserve a closer look: Valve terminal MPA brochure ISO valve terminal VTSA brochure Electrical terminal CPX/Installation system CPI Subject to change 2012/02 23

24 Perfect platform for all installation concepts Four principles four times the choice Your system concept defines the ideal valve terminal solution thanks to CPX CPX realises the principle of freedom of choice. It is suitable for every design, from electrical peripherals to industrial communication platforms. With decentralised and distributed designs, it s integrated in CPI. Three steps to making the right choice: [A] You define the machine and installation concept. [B] You check for the requirements of your industry: machine concept, electrical installation, special applications [C] You select the right valve terminal based on function and performance. Industrial Industrial Ethernet Ethernet Feldbus Feldbus Industrial Ethernet Feldbus Industrial Ethernet AS-Interface Industrial Ethernet Feldbus P P t t P P t t Centralised installation Decentralised installation system Decentralised installation for upstream functions (Fieldbus Direct) Hybrid installation system (centralised/decentralised) Control of several drives and functions via one valve terminal Short control loop system (extending over only a few meters) Typical number of I/O between 16 and 128 Advantages Up to 60% more efficient thanks to function integration Channel costs reduced by up to 50% Up to 40% better power density Individual functions on a small valve terminal Installation-saving hybrid cable for data and power, for connecting up to 16 modules via Fieldbus nodes Typical number of I/O between 16 and 512 Advantages Cycle times shortened by up to 30% thanks to very short tubing lengths Space reduced by up to 70% Air consumption reduced by up to 50 % Small valve terminals with directly integrated Fieldbus connections or AS-interface components For repositioning, loading and unloading outside the machine Ideal for tools on robots or handling systems, upstream stoppers and deflectors Typical number of I/O between 4/8 and 32 (48) Advantages All the advantages of decentralised installation Graduated granulation Comprehensive diagnostics and condition monitoring for each slave Only available from Festo! Comprehensive combination of individual systems can be expanded as required Ideal in a control cabinet or on a control cabinet wall. Advantages Best mix Short cycle times and high machine performance System costs reduced by up to 20 % in terms of TCO 24 Electrical terminal CPX/Installation system CPI Subject to change 2012/02

25 In focus: CPI system with CPX a new benchmark for decentralised concepts 3x3 platforms for economical automation Decentralised installation with CPI for shorter distances and cycle times Very short cycle times, expansion from purely decentralised networking through to hybrid concepts: CPX reinforces the arguments in favour of CPI as a decentralised installation concept: Control of up to 512 drives via 4 CPX-CP installation strings and 16 modules Optimised installation Optimised combination Benefit from combination You can achieve an optimum technical and economic solution by mixing decentralised and centralised installation principles. Choose from: 3 master platforms 3 valve terminal platforms 3 I/O module platforms 3 master platforms The following master platforms are perfect for different kinds of applications: Small, up to 32 I/O: Fieldbus Direct Medium, up to 128 I/O: CPI system up to IP65/67 for direct machine mounting Large, up to 512 I/O: CPX system as a centralised/ decentralised hybrid system. Temperature detection, pressure sensors and proportional pneumatics included on request. 3 valve terminal platforms CPV flow rates up to 1600 l/min CPV-SC compact but big on efficiency MPA high performance in pneumatics 3 I/O module platforms On-site: I/O modules CL Minimum dimensions for installation directly on sensors and actuators, e.g. for electronics and light assembly industry. Sturdy I/O modules RL Tough aluminium housing. Suitable for repairs, electronics can be replaced. Triple-optimised: EL I/O modules Compact, sturdy, ec onomical I/O concepts Electrical terminal CPX/Installation system CPI Subject to change 2012/02 25

26 Modules for maximum applications One terminal complete with remote I/O many modules It is the only way to achieve maximum connectivity and crucial for the future of automation. That is the reason for the modular variety of the CPX electrical peripherals. Technical data Electrical system Power supply - Electronics plus sensors 24 V, max. 16 A - Actuators plus valves 24 V, max. 16 A Power supply connection M18: 4-pin, 7/8 : 4 or 5-pin AIDA push-pull Current consumption Depending on system configuration Mechanical components Grid dimension 50 mm Module dimensions 50 x 107 x 50 mm (W x L x H) including interlinking module Connection technology Choice of 10 connection technologies/ip20 and IP65/67 protection Environment Protection class as per EN PWIS classification Module types: bus node CPX-FB6 CPX-FB11 CPX-FB13 CPX-FB14 CPX-FB23 CPX-FB32 CPX-FB33 CPX-M-FB34 CPX-M-FB35 CPX-FB38 CPX-FEC [T05] CPX-FEC [T03] CPX-CEC CPX-CEC-C1/CPX-CEC-M1 CPX-M-SF34/CPX-M-SF35 The table below lists the possibilities module by module. See for yourself the potential that CPX provides for pneumatic and electrical engineering. IP20/IP65/IP67 depending on connection technology used PWIS-free Interbus DeviceNet Profibus DP CANopen CC link Ethernet/IP Profinet (2xM12) Profinet (2xRJ45, CU) Profinet (2xSCRJ, FO) EtherCat (2xM12) Ethernet: Modbus TCP Front-end controller Festo FST Ethernet: Modbus TCP, EasyIP Front-end controller CoDeSys with serial interface, Ethernet: Modbus TCP server, Easy IP Front-end controller CoDeSys with CANopen Master, Ethernet: Modbus TCP server, Easy IP. M1: with CoDeSys Softmotion library for motion control up to 2.5D PC Worx controller with Profinet, for Phoenix Contact automation environments SF34: (2xRJ45, CU); SF35 (2xSCRJ, FO) Digital I/O modules CPX-16DE 16 inputs (PNP) CPX-16DE-D 16 inputs (PNP) + channel diagnostics CPX-L-16DE-16-KL-3POL 16 inputs (PNO) 16x terminal strips, 3-pin CPX-8DE 8 inputs (PNP) CPX-4DE 4 inputs (PNP) CPX-4DA 4 outputs (PNP/1 A) CPX-8DE-8DA 8 inputs (PNP) plus 8 outputs (PNP/0.5 A) CPX-L-8DE-8DA-16-KL-3POL 8 inputs (PNP) plus 8 outputs (PNP/0,25A), 16x terminal strips, 3-pin CPX-8DE-D 8 inputs (PNP) + channel diagnostics CPX-8NDE 8 inputs (NPN) CPX-8DA 8 outputs (PNP/0,5 A) CPX-8DA-H 8 high-current outputs (PNP/2.0 A) CPX-FVDA-P ProfiSafe switch-off module for valve voltage and 2 additional independent outputs (PNP) Analogue I/O modules CPX-2AE 2 inputs (0/ ma, V) CPX-2AA 2 outputs (0/ ma, V) CPX-4AE-I 4 inputs (signal detection/0/4...20ma) CPX-4AE-U-I 4 inputs, 16-bit (0/ ma, ±20 ma, 0 10 V, ±10 V, ±5V) CPX-4AE-TC 4 inputs (temperature detection thermocouples/-270 C to 1820 C) CPX-4AE-T 4 inputs (temperature detection temperature sensors/-200 C to 850 C) CPX-4AE-P 4 inputs as integrated pressure sensor module, 4 absolute/2 differential pressures, versions for and bar Technology modules CPX-CMXX CPX-CM-HPP CPX-CMPX CPX-CMAX CPX-CMIX-M1-1 CPX-CP-4-FB Pneumatic interface VMPA-FB-EPL-... VMPAF-FB-EPL-... VMPAL-EPL-... VABA-S6-1-X1 /-X2 Electric multi-axis controller, up to 8 axes synchronously Field bus gateway, up to 2x4 axes asynchronously Soft Stop electronic end-position controller, up to 8 pneumatic drives Servopneumatic position controller, up to 8 pneumatic drives Measuring module for cylinders with displacement measurement system Interface for the decentralised installation system up to 512 (4x128) I/O MPA with max. 128 solenoid coils MPA-F A with max. 128 solenoid coils MPA-L with max. 32 solenoid coils VTSA with max. 32 solenoid coils CPX terminal for optimum integration into control concepts from leading manufacturers (e.g. Siemens S7, Allen Bradley, Beck IPC, Mitsubishi, Rockwell Automation) Fieldbus utilities (GSD, EDS), 26 Electrical terminal CPX/Installation system CPI Subject to change 2012/02

27 Services and support for more added value Support over the entire value added chain Services Our services support you every step of the way, from planning to operation, and make the process faster, more reliable and more efficient. They also cut your forecast total costs. Engineering The optimum CPX solution right from the word go Procurement service Simplified procurement and logistics Commissioning service Know-how on request: fast installation, fast connection, fast commissioning After-sales services Reliable operation of your CPX solution Engineering Procurement Assembly/commissioning Operation Reduction in costs Reduction in time Process reliability Ready-to-install solutions tailored If you want just a little more individuality, Festo is the perfect choice. Our customised solutions meet all current and future market requirements. As always, pneumatics, electrical engineering, motion and networking are all provided by a single source. Build it yourself? Have it built! The decision is yours. But Bear in mind that complete systems can save you up to 50%. With ready-to-install systems you no longer need to undertake complex working processes. We design, procure, compile, test and deliver. We can also assemble and commission your system on request. You concentrate on your core tasks; that not only saves time and money, but brings maximum reliability with regard to function and optimal settings. We offer: Engineering Documentation Assembly Testing and test runs Initial start-up Servicing during the operating phase Ready-to-install handling systems, controlled by valve terminals, designed, installed and tested. Guaranteed perform ance and function. Just connect and it s ready to go. Ready-to-install control cabinets with remote I/O and valve terminals give you a total solution, either stand-alone or with a Fieldbus connection to your host system. Ready-to-install mounting plates: complete solutions for a machine unit on the Fieldbus. Customised solutions Optimised and individualised Fieldbus solutions: Electrical Pneumatic Mechatronic Integrated into machine profiles Individual solutions: On integrated blocks On printed circuit boards Modular control units Safety guards New: CPX hood CAFC-X1-GAL ATEX made simple with no control cabinet. Up to 70% more economical than conventional solutions. Electrical terminal CPX/Installation system CPI Subject to change 2012/02 27

28 A universe of possibilities made for the future Highly communicative the independent platform for three levels Maximum economy 1. Benefit from the new portfolio with CPX in on a single platform Digital and analogue standard tasks Demanding I/O tasks with single-channel diagnostics and parameterisation Temperature, displacement and pressure measurement Safety functions electrical and pneumatic Integrated, comprehensive diagnostics and condition monitoring Subordinate, decentralised installation system with CPI 2. Combine this directly with the operating process elements Create perfect solution packages with Festo for increased productivity, safety and reliability: Standard pneumatics, gripping, vacuum Pilot or process valves Control valves for cylinders, grippers, vacuum Pressure regulators for pro - portional control systems and pressure sensors Servopneumatic positioning systems Electric drives and axes (motion control) Quality management and part/position sensing with Festo s Compact Vision System 3. For control, choose from fieldbus/ethernet or the following front-end controllers: CPX-FEC (Festo mini control system) CPX-CEC (CoDeSys control with 32 bit processor, 400 MHz, CANopen master) PC Worx (controller for control environments from Phoenix Contact) An energy-efficient design of pneumatic systems and subsystems can save energy and gain cycle time. The best possible mix of technologies can be both technically and economically beneficial. It all adds up to a wholesale reduction in total cost of ownership (TCO). Perfect combinations for a host of industries and applications Comprehensive diagnostics CPX/MPA serial communication for a comprehensive diagnostics concept CPX goes motion control actuation of up to eight electric and servo pneumatic axes, with IP65 rating CPX/VTSA solid metal version for electrical and pneumatic systems, with integrated safety functions Another advantage: comprehensive support services for maximum performance Consultation Software support for design and commissioning eplan macros New: FluidDraw Professional the intuitive circuit diagram software for electrics and pneumatics, with complete integration of all Festo modular products Commissioning service, and much more You won t find a greater concentration of diagnostics for electrical, pneumatic and motion control systems: Internal device diagnostics: optional single-channel diagnostics and condition monitoring for all I/Os and valves CoDeSys front-end controller CPX-CEC as an integrated controller for process diagnostics in a complete pneumatic (sub-)system On request: complete project implementation by Festo Comprehensive IT services for communication and seamless integration into exist ing host systems 28 Electrical terminal CPX/Installation system CPI Subject to change 2012/ en 2012/02