Compact Performance CP system Installation and commissioning

Transcription

1 Compact Performance CP system Installation and commissioning

2 Author: Translation: Editors: Layout: Type setting: S. Breuer Douglas Smith H.-J. Drung, M. Holder Festo, Dept. PV-IDM PV-IDM Edition: 9806A Printed on 100 % recycled paper Festo AG & Co Esslingen 1998 Federal Republic of Germany The copying, distribution and utilization of this document as well as the communication of its contents to others without expressed authorization is prohibited. Offenders will be held liable for the payment of damages. All rights reserved, in particular the right to carry out patent, utility model or ornamental design registration. CP A I

3 Part no.: Title: Manual Designation: P.BE-CPSYS-GB II CP A

4 Contents Designated use V Target group VI Important user instructions VI Information on this manual VIII Product-specific terms and abbreviations X 1. System overview 1.1 Structure of CP systems CP system module functions CP fieldbus node Address range of the CP system Basic rules of addressing Address assignment after extension or conversion Fitting 2.1 Fitting the CP modules Fitting the CP fieldbus node onto a wall Fitting the CP fieldbus node onto a hat rail Mounting the node in standard housing Node in compact design Installation 3.1 General instructions on installation Connecting cable Selecting the power unit Configuring the CP system Connections on the CP fieldbus node Connecting the CP modules Connecting the operating voltage Connecting the fieldbus CP A III

5 4. Commissioning 4.1 The commissioning procedure Preparing the CP system for commissioning Saving the string assignment Reaction of the CP system when switched on Reaction of the CP system to operating faults Correcting string assignment errors A. Technical appendix A.1 Cable length and cross section A-3 A.2 Index A-7 IV CP A

6 Designated use The CP system, consisting of a CP node, CP valve terminals and CP input/output modules, referred to in the following as CP modules, is designed to be fitted into a machine or automation system. Depending on the CP node used, the system can be connected to a special fieldbus system and can be used for scanning sensor signals and for controlling pneumatic and electric actuators. The individual CP modules of the CP system are documented in specific manuals. It is absolutely essential that you observe the safety instructions listed therein, as well as the designated use of the relevant CP module. The CP modules and cables may only be used: as designated in their original condition without unauthorized modifications in faultless technical condition. If used in conjunction with commercially-available components such as sensors and actuators, the specified limit values for pressures, temperatures, electrical data, moments etc. must be observed. Please comply also with national and local safety laws and regulations. CP A V

7 Target group Important user instructions This manual is directed exclusively at technicians who are trained in control and automation technology. Danger categories This manual contains instructions on the possible dangers which may occur if the CP modules are not used correctly. These instructions are always printed in italics, are framed and signalled by pictograms. A distinction is made between the following: WARNING This means that personal injury or damage to property may occur if these instructions are not observed. CAUTION This means that damage to property may occur if these instructions are not observed. PLEASE NOTE This means that this instruction must also be observed. VI CP A

8 Pictograms Pictograms and symbols complement the danger warnings and draw attention to the nature and consequences of dangers. The following pictograms are used: Uncontrolled movements of loose tubing. Unintentional movements of the connected actuators. High voltages or undefined switching states of the electronic components which may influence connected circuits. Electrostatically vulnerable components. These will be damaged if you touch the contact surfaces. Text markings This mark indicates activities which can be carried out in any order. 1. Figures indicate activites which must be carried out in the numerical order of the figures. Hyphens indicate general items. CP A VII

9 Information on this manual This manual contains specific information on the method of operation, fitting, installation and commissioning of the CP system. Special information on commissioning, programming and diagnosis of a CP system with the fieldbus node which you are using can be found in the relevant manual for the fieldbus node. Information on further CP modules can be found in the manual for the relevant module. The following table gives a summary. VIII CP A

10 Manuals for the CP system Peripherals Manual "CP system, installation and commissioning" Contents General, basic information on operating, fitting, installing and commissioning CP systems. Manual "CP fieldbus node, programming and diagnosis" "CPV valve terminal, CPA valve terminal pneumatics" "CP modules, electronics" Contents Special information on commissioning, programming and diagnosing related to the node used. Information on fitting, installing and commissioning CP valve terminals Information on fitting, installing and commissioning CP I/O modules Fig. 0/1: Manuals on the CP system CP A IX

11 Product-specific terms and abbreviations The following product-specific terms and abbreviations are used in this manual. Term/ abbreviation O O-module CP Meaning Digital output CP output module Compact Performance CP valve terminal CPV valve terminal type 10 or CPA valve terminal type 12 CP system CP modules CP connection CP cable I I/O module I-module I/Os Node PLC/IPC String Complete system consisting of CP fieldbus node and CP modules Common term for various modules which can be incorporated in a CP system Plug or socket on the CP modules which enables the modules to be connected with the CP cable. Special cable for coupling the various CP modules Digital input Common term for the CP modules which make available digital inputs and outputs (CP input modules and CP output modules) CP input module Digital inputs and outputs CP fieldbus node with/without fieldbus connection, to which the I/O modules are connected Programmable logic controller / industrial PC Total number of I/O modules which can be connected together on a CP connection of the fieldbus node. X CP A

12 1. System overview Chapter 1 System overview CP A 1-1

13 1. System overview Contents 1. System overview 1.1 Structure of CP systems CP system module functions CP fieldbus node Address range of the CP system Basic rules of addressing Address assignment after extension or conversion CP A

14 1. System overview 1.1 Structure of CP systems Festo can assist you in solving your automation tasks at the machine level by means of valve terminals. Due to their modular structure, valve terminals and I/O modules from Festo can be incorporated to the best advantage in your machines and systems. Fig. 1/1: Structure of a CP system CP A 1-3

15 1. System overview The CP system consists of individual modules which are connected by means of the CP cable. This permits a decentralized arrangement of the CP system. The compact CP valve terminals can be mounted very close to the cylinders which are to be actuated, thereby enabling short compressed air tubing to be used. Short compressed air tubing minimizes the loss of air flow and the times required for pressurizing and exhausting the tubing. This permits the use of smaller valves with sufficient flow and thereby helps to reduce costs. 1-4 CP A

16 1. System overview CP system module functions CP systems consists of the following modules: CP module CP node Function There are special CP fieldbus nodes for the various fieldbuses. They provide the connection to certain fieldbuses They offer connections for up to 4 strings to which I/O modules and valve terminals can be connected They transmit control signals to the connected modules and monitor their functioning CP valve terminals These provide various valve functions via valve plates for controlling pneumatic actuators Relay plates, pressure isolating plates and blanking plates can be used here as well Input modules There are various special designs for various types of connections. These provide inputs for connecting sensors and permit e.g. the scanning of cylinder positions Output modules These provide universally usuable electrical outputs for actuating low current consuming devices (further valves, bulbs etc.) CP A 1-5

17 1. System overview Depending on type, the CP nodes control the transfer of data to a wide variety of control systems via the various fieldbuses. Some nodes have an integrated PLC. This enables the CP system to be operated autonomously without being coupled to a fieldbus Fieldbus (incoming) Fieldbus (continuing) CP valve terminal CP input module Fig. 1/2: CP system functions Sensor Cylinder CP output module CP fieldbus node When operated with a fieldbus, the control signals arriving from the fieldbus will be sent continuously by the node to the connected CP modules. The CP modules ensure that programmed output signals are transmitted and that the appropriate valves are switched. 1-6 CP A

18 1. System overview 1.2 CP fieldbus node Designs of CP node Special CP fieldbus nodes are available for connecting a CP system to the various fieldbus systems. These are in one of the following designs: Design *) 1 2 Explanation Standard design Node in standard housing 1 with adapter 2 for connecting the four strings Compact design Extremely compact integrated version *) Diagram examples, different types of fieldbus connections CP A 1-7

19 1. System overview Layout of the CP nodes The following diagrams show the general operating, display and connecting elements of the CP nodes. PLEASE NOTE Special information on the layout of the node you are using can be found in the appropriate node manual SAVE button String error LEDs Further LEDs depending on design of node Fieldbus connection (design depending on type used, see node manual) Label fields Fuse Operating voltage connection CP connections for up to 4 strings (0...3) Fig. 1/3: General operating, display and connecting elements (fieldbus node in standard housing) CP A

20 1. System overview Operating voltage connection Fieldbus connection (design depending on type used, see node manual) Further LEDs depending on design of node CP connections for up to 4 strings (0...3) String error LEDs Label fields SAVE button Fig. 1/4: General operating, display and connecting elements (fieldbus node in compact design) CP A 1-9

21 1. System overview The CP fieldbus nodes offer connections for up to four strings. Further modules with inputs and outputs can be connected to each string CP fieldbus node Modules with outputs Modules with inputs CPV valve terminal CP input module Fig. 1/5: Principle of CP interconnection CP output module CP cable CP connection String CPA valve terminal The modules with outputs (valve terminals or output modules) are connected to the CP connections of the node. These modules have a connection for the input modules. Input modules can also be connected to the node directly CP A

22 1. System overview 1.3 Address range of the CP system Size of occupied address range Unused address range The size of the address range occupied by the CP system depends on the number of the string last used. There is a complete word (16 bits) available as address range for inputs and outputs for each string in the CP system. If the strings are assigned in ascending order without gaps, the address range for unused strings at the end of the complete address range can be used for other fieldbus stations. Other unused address ranges are reserved for later CP extensions. PLEASE NOTE Reserve sufficient address space for later extensions to your CP system. CP A 1-11

23 1. System overview The table below shows the address range depending on the last string used. Last string used Occupied address range Explanation String I/Os No CP modules are connected to strings 3, 2 and 1. 3 String I/Os No CP modules are connected to strings 3 and String I/Os No CP module is connected to string String I/Os At least 1 CP module is connected to string CP A

24 1. System overview Basic rules of addressing CP node A CP node provides four strings with a total of 64 input addresses and 64 output addresses. A string occupies 16 input addresses and 16 output addresses. The addresses are assigned fixed to the individual strings and in ascending order. String number Input addresses (E = Input) Output addresses (A = Output) 0 E0...E15 A0...A15 1 E16...E31 A16...A31 2 E32...E47 A32...A47 3 E48...E63 A48...A63 The assignment of addresses to the individual modules is therefore determined by the string to which they are connected. The addresses of an unoccupied string at the end of the complete address range can be used by other fieldbus nodes, providing this supports the fieldbus protocol used. Other unused addresses remain reserved for later extensions to the CP system. CP A 1-13

25 1. System overview CP valve terminal A CP valve terminal with CP connection always occupies 16 output addresses, irrespective of how many valve solenoid coils are fitted on it. Therefore only one valve terminal can be connected to each string. This enables the valve terminal to be extended at a later stage without the need for the address range to be shifted In the case of CPV valve terminals with 4, 6 or 8 valve locations 16 output addresses are allways assigned. With CPA valve terminals 16 output addresses are also assigned ( valve locations). Fig. 1/6: Address assignment on a CP valve terminal as an example Altogether, a maximum of 64 valve solenoid coils can be addressed per node CP A

26 1. System overview CPV valve terminal The address assignment of the CPV valve terminal is made from left to right and on the individual valve locations from the front to the rear LED row for pilot solenoid 14 LED row for pilot solenoid 12 Fig. 1/7: Example: address assignment of the CPV valve terminal 2 A valve location of the CPV valve terminal always occupies 2 addresses even when it is fitted with a blanking plate or pressure isolating plate. If a valve location is fitted with a double solenoid valve, the following assignment applies: - pilot solenoid 14 occupies the lower value address, - pilot solenoid 12 occupies the higher value address. With single solenoid valves, the higher value address remains unused. CP A 1-15

27 1. System overview CPA valve terminal A valve location occupies 1 or 2 addresses on the CPA valve terminal, depending on the manifold block Electrical bridge for single soelnoid or double solenoid valves with manual override and LEDs Electrical manifold block (EV1 or EV2) Fig. 1/8: Manifold blocks of the CPA valve terminal Manifold block Type..-EV1 Type..-EV2 Number of occupied outputs 1 output 2 outputs If a manifold block is not used (reserve plate location, pressure supply), the relevant addresses will still be assigned CP A

28 1. System overview Addresses are assigned on the CPA valve terminal from left to right and on the individual valve locations from the rear to the front. On manifold block type CPA..-EV2 the following applies: - pilot solenoid 14 occupies the lower-value address - pilot solenoid 12 occupies the higher-value address Manifold block occupies 2 addresses (type CPA..-EV2) Manifold block occupies 1 address (type CPA..-EV1) Addresses of coil 14 (lower-value address 4 5 Addresses of coil 12 (higher-value address) Reserve plate or additional pressure supply plates Fig. 1/9: Address assignment of a CPA valve terminal (example) CP A 1-17

29 1. System overview CP I/O modules Input and output modules usually occupy a complete input or output word (16 outputs or 16 inputs). Addresses are assigned from left to right and from the front to the rear Fig. 1/10: Example: address assignment with input module (type CP-E16-M8) String lengths The maximum length of a string must not exceed 10 m CP A

30 1. System overview The diagram below shows the address assignment of a CP system. 1 A0...A63 E0...E63 2 A0...A7 3 (A8...A15) 2 A16...A23 3 (A24...A31) 3 (E0...E15) 2 E16...E31 3 (A32...A47) 3 (E32...E47) 2 A48...A55 3 (A56...A63) 2 E48...E Address range occupied by the CP system Address range occupied by the module ( ) = Reserved address range A = Output E = Input Fig. 1/11: Address assignment of a CP system PLEASE NOTE Actual addressing examples for the fieldbus protocol which you are using can be found in the appropriate fieldbus node manual. CP A 1-19

31 1. System overview Address assignment after extension or conversion WARNING Please take care when modifying the string assignment of your CP system. The input and output addresses for the modules will change if you connect the modules to a different string. A special feature of the CP system is its flexibility. If the demands placed on the machine change, you can easily replace or remove modules or add further modules. The input and output addresses of already used modules will not then change, providing they remain connected to the same string. The following diagram shows as an example the new address assignment after modification of the string assignment in fig. 1/ CP A

32 1. System overview In contrast to fig. 1/11, string 0 and string 2 have been extended by the addition of extra modules. On string 0, a CPV valve terminal with 4 valve locations has been replaced by a CPV valve terminal with 8 valve locations. Please note that the assignment of the input and output addresses on strings 1 and 3 has not changed. 1 A0...A63 E0...E63 2 A0...A15 2 A16...A23 3 (A24...A31) 2 E0...E15 2 E16...E31 2 A32...A39 3 (A40...A47) 2 E32...E47 2 A48...A55 3 (A56...A63) 2 E48...E Address range occupied by the CP system Address range used by the module ( ) = Reserved address range A = Output E = Input Fig. 1/12: Extended address assignment of a CP system CP A 1-21

33 1. System overview 1-22 CP A

34 2. Fitting Chapter 2 Fitting CP A 2-1

35 2. Fitting Contents 2. Fitting 2.1 Fitting the CP modules Fitting the CP fieldbus node onto a wall Fitting the CP fieldbus node onto a hat rail Mounting the node in standard housing Node in compact design CP A

36 2. Fitting 2.1 Fitting the CP modules WARNING Before starting with the fitting, switch off the following: the compressed air supply to all CP valve terminals the power supply to all output modules the power supply to the node. You thereby avoid: uncontrolled movements of loose tubing unintentional movements of the connected actuators undefined switching states of the electronic components. All CP modules are suitable for fitting onto a wall or a hat rail. PLEASE NOTE The maximum length of a string must not exceed 10 m. CP A 2-3

37 2. Fitting Dimensions for wall fitting Fitting onto a hat rail The dimensions of the threaded holes in the CP fieldbus node can be found in the following chapter; the dimensions of the various modules can be found in the manual for the relevant module. Information on fitting the fieldbus node can be found in chapter 2.3; information on fitting the various modules onto a hat rail can be found in the manual for the relevant module. 2-4 CP A

38 2. Fitting 2.2 Fitting the CP fieldbus node onto a wall The CP nodes can be fastened to a flat surface by means of the four holes on the left and right-hand edges of the node housing. Proceed as follows: 1. Fasten the node with 4 screws as shown in the diagram below. Use screws with the following threads: M6 thread for node in standard housing M4 thread for node in compact design 2. Tighten the screws in diagonally opposite sequence. 144 mm 62 mm 110 mm mm Fig. 2/1: Fitting the CP node onto a wall CP A 2-5

39 2. Fitting 2.3 Fitting the CP fieldbus node onto a hat rail CP nodes in the standard housing and in compact design are suitable for fitting onto a hat rail (mounting rail as per EN 50022) Mounting the node in standard housing On the rear of the standard housing there is a guide groove for hanging the node onto a hat rail. You will also require the hat rail clamping unit. PLEASE NOTE If your node does not have a hat rail clamping unit, it can be ordered and fitted later. 2-6 CP A

40 2. Fitting Fitting the hat rail clamping unit The hat rail clamping unit must be fastened to the rear of the end plate. Proceed as follows: Fasten the hat rail clamping unit in the sequence shown in the diagram below Fit as follows: Rubber foot (self-adhesive) Clamping elements Lever (left or right) O-ring Flat head screw Retaining screw Fig. 2/2: Fitting the hat rail clamping unit CP A 2-7

41 2. Fitting Before fitting the rubber feet (1), make sure that the contact surfaces are clean (use spirit). After fitting make sure that: - the flat head screws are tightened (Fig. 2/2, item 5). - the lever is secured with the retaining screw (item 6). Fitting onto a hat rail CAUTION Fasten the node to the hat rail with a hat rail clamping unit. If the node is fitted on a sloping surface or is subjected to vibration, the hat rail clamping unit must also be protected against slipping and against unintentional opening/closing with the screws (6) intended for this purpose. PLEASE NOTE If the node is fitted in a horizontal position and if the load is at rest, the hat rail clamping unit can be secured without screws (6). 2-8 CP A

42 2. Fitting Proceed as follows: 1. Make sure the fastening surface can support the weight of the node. 2. Fit a hat rail (mounting rail as per EN x15; width 35 mm, height 15 mm). 3. Fasten the hat rail to the supporting surface at least every 100 mm. 4. Hang the node on the hat rail. Fasten the node on both sides with the hat rail clamping unit to protect it against tipping or slipping (see diagram below). Fig. 2/3: Fitting onto a hat rail CP A 2-9

43 2. Fitting 5. If the hat rail clamping unit is subjected to vibration or if it is fitted on a slope, protect it against unintentional loosing/opening with two screws as shown in Fig. 2/2, item CP A

44 2. Fitting Node in compact design PLEASE NOTE In order to fit the node onto a hat rail you will require fastening kit CP-TS-HS35. This kit contains 2 fastenings, 2 M4x12 screws and 2 washers. Proceed with the fitting as follows: 1. Make sure that the fastening surface can support the weight of the node. 2. Fit a hat rail (mounting rail as per EN x15; width 35 mm, height 15 mm). 3. Fasten the hat rail to the support surface at least every 100 mm. 4. Let both fixtures snap into the hat rail (see Fig. 2/4). 5. Screw the housing onto the fixture with the screws provided, as shown in the diagram below. 6. Tighten the screws. The fixture and the housing will then be clamped tight on the hat rail. CP A 2-11

45 2. Fitting Fixture Hat rail Node housing M4x12 screw Washer Fig. 2/4: Fitting onto a hat rail Proceed as follows when dismantling: 1. Loosen the screws. 2. Remove the housing. 3. Prize the fixture out of the hat rail with a screwdriver Fixture Screwdriver Fig. 2/5: Dismantling the fixture 2-12 CP A

46 3. Installation Chapter 3 Installation CP A 3-1

47 3. Installation Contents 3. Installation 3.1 General instructions on installation Connecting cable Selecting the power unit Configuring the CP system Connections on the CP fieldbus node Connecting the CP modules Connecting the operating voltage Connecting the fieldbus CP A

48 3. Installation 3.1 General instructions on installation WARNING Before undertaking installation or maintenance work, switch off: the compressed air supply the power supply to the CP fieldbus node (pins 1 and 2) the power supply to the CP output modules. You thereby avoid: uncontrolled movements of loose tubing unintentional movements of the connected actuators. undefined switching states of the electronic components. CP A 3-3

49 3. Installation Connecting cable CP cable Fieldbus cable Operating voltage cable The CP cable (type KVI-CP-1-...) from Festo is used for connecting the CP modules to a string. For all other connections, you can use self-assembled cables. Please observe the instructions in the sections which follow. Use a cable which is suitable for your fieldbus system. Refer to the manual for your fieldbus node or controller for the appropriate type of cable. Take into account the distance and the fieldbus baud rate. Use a cable with suitable cross section for the operating voltage supply. Avoid long distances between the power unit and the CP node. Long cables reduce the voltage supplied by the power unit. If necessary, calculate the suitable cross section and the maximum permitted cable length according to the formula in Appendix A. 3-4 CP A

50 3. Installation Preparing the connecting cable CAUTION The respective pin positions on the plug connector and on the socket connector are different. The connections for sensors and actuators on the input and output modules are in the form of sockets. Pin assignment see manual "CP modules." The connections on the fieldbus interface and for the operating voltage are in the form of plugs. Pin assignment of the fieldbus interface see manual "CP fieldbus node." The pin assignment of the operating voltage connection can be found in the chapters which follow. Use Festo plugs and sockets which correspond to the outer diameter of the cables you are using. Cable diameter Type of plug/socket mm PG mm PG mm PG13.5 Connection Type of plug/socket Mains socket PG7, 9 or 13.5 Fieldbus cable socket *) PG7, 9 or 13.5 *) The plug for the fieldbus connection depends on the node used (see node manual) CP A 3-5

51 3. Installation Preparing the cable When you have selected a suitable cable, connect it as follows: 1. Open the plug/socket as follows: Mains power socket. Insert the mains power socket into the operating voltage connection on the valve terminal. Unscrew the housing of the socket. Then remove the terminal of the socket which is still inserted in the operating voltage connection. Fieldbus socket and sensor plug (only with PG...): Loosen the centre knurled nut Cable Strain relief Housing Plug Terminal Socket Fig. 3/1: Plug/socket components and cable gland CP A

52 3. Installation 2. Open the strain relief on the rear of the housing and pass the cable through as follows. 3. Strip 5 mm from the end of the cables and fit ferrules into the strands. 4. Connect the ends. 5. Insert the terminal back into the housing of the plug/socket. Pull the cable through as far as possible so that it is not looped inside the housing. 6. Tighten the strain relief. CP A 3-7

53 3. Installation Selecting the power unit WARNING Use only power packs which guarantee reliable electrical isolation of the operating voltages as per IEC 742/EN 60742/VDE 0551 with at least 4 kv isolation resistance. Switch power packs are permitted, providing they guarantee reliable isolation as per EN 60950/VDE The current consumption of a CP system depends on the number and type of components connected. Recommendation. Use a closed-loop power unit. When selecting the power unit, check that it has sufficient output. Calculate the total current consumption according to the following table. Connect the operating voltage for the valve coils (pin 2) via EMERGENCY STOP. Calculating the current consumption The following table shows how to calculate the complete current consumption for a CP system. The values specified have been rounded up. Please refer to the appropriate technical specifications for the current consumption of the valves and modules. 3-8 CP A

54 3. Installation Current consumption at pin 1 of CP fieldbus node Current consumption of CP fieldbus node Maximum current consumption of electronic components (internal electronic components of all CP modules) Current consumption of all connected sensors (see manufacturer specifications) 250 ma +560 ma + A Sum of current consumption at pin 1 = A A Current consumption at pin 2 of CP fieldbus node Current consumption of all valve coils supplied simultaneously with power 1) A Sum of current consumption at pin 2 = A + A Current consumption at pin 1 of output modules Current consumption of all simultaneously actuated electrical outputs (internal consumption at logic 1) 2) Load current of simultaneously actuated outputs x A + A Sum of current consumption of outputs = A + A Total current consumption of the CP system = A 1) Current consumption depends on valve type (see technical specifications for valves) 2) Internal consumption at logic 1 (see technical specifications for output module) PLEASE NOTE Select a power unit which has sufficient output for further extensions to the CP system. CP A 3-9

55 3. Installation Configuring the CP system CP systems can be coupled to various fieldbuses. The coupling is made via the CP node which has been adapted to suit the appropriate fieldbus. CP nodes usually support various fieldbus protocols and baud rates for the appropriate fieldbus. The various settings must be made with the DIL switch on the node. Settings on the node The following settings are possible depending on the CP node used: Fieldbus baud rate Fieldbus address Valve terminal test On the compact design nodes, the DIL switches are situated behind an easily accessible cover; on nodes in standard design, you must open the housing in order to set the DIL switch. Information on the procedure as well as on the setting possibilities can be found in the manual "CP fieldbus node." 3-10 CP A

56 3. Installation 3.2 Connections on the CP fieldbus node CP fieldbus nodes have the following connections: fieldbus connection (design depends on type) operating voltage connection earth/ground connection CP connections Earth/ground connection Fieldbus connection (design depends on type used, see node manual) Operating voltage connection CP connections for up to 4 strings (0...3) Fig. 3/2: Connections on the CP fieldbus node 3 CP A 3-11

57 3. Installation Connecting the CP modules WARNING Use the special CP cable (type KVI-CP-1-...) from Festo for connecting the CP modules to a string. Please note that the total length of the cable must not exceed 10 m. You thereby avoid: errors in data exchange between the node and the connected CP modules. CP connections There are four CP connections on the node for strings Modules with a total of 16 inputs and 16 outputs can be connected to each CP connection. If required, a maximum of one module with outputs (valve terminal or output module) can be connected to the CP connections. These modules have a CP connecting socket for coupling to an input module. Input modules can also be connected directly to the CP connecting socket of the node. The output addresses occupied by this string then remain unused CP A

58 3. Installation Valve terminal and input module on string 0 Output module and input module on string 1 Input module on string 2 CP connection (plug) CP cable CP connections (sockets) CP node Fig. 3/3: Connecting possibilities of the CP modules (example) 3 CP A 3-13

59 3. Installation Connecting CP modules 1. Check which address range is intended for the CP module (see chapter 1). 2. Connect the CP module with the CP cable to the string which provides this address range. 3. Fasten the plug and socket of the CP cable with the union nut. This will guarantee electrical contact. 4. With the aid of the labels (type IBS 6x10 or IBS 9x20), mark the string to which the module is connected. In this way you can avoid mistakes when repair and maintenance work are carried out at a later stage Connecting the operating voltage The following components are supplied with + 24 V DC operating voltage via the operating voltage connection on the node. the internal electronic components of the node and of the connected CP modules including the sensors connected to the input modules (pin 1: + 24 V DC, tolerance + 10/ - 15 %). valve coils of the valve terminals (pin 2: + 24 V DC, tolerance + 10/- 15 %) CP A

60 3. Installation Recommendation Connect the operating voltage for the valve coils (pin 2) via EMERGENCY STOP. PLEASE NOTE: Check whether a pressure switch-off is also necessary for EMERGENCY STOP on your machine/system. The output modules have an additional operating voltage connection for supplying the connected actuators. Here as well, the operating voltage should be connected via the EMERGENCY STOP contact. The diagram below shows the pin assignment of the operating voltage connection on the node V supply for electronic components/inputs 24 V supply for valves 0 V PE (protective earth, leading contact) Fig. 3/4: Pin assignment of operating voltage connection on the node CP A 3-15

61 3. Installation Protective earth The node has two protective earth connections: on the operating voltage connection (pin 4 leading contact). on the node housing (earthing connection see Fig. 3/2). PLEASE NOTE Always connect a protective earth conductor to pin 4 of the operating voltage connection. Make sure that the housing of the node and the protective earth conductor at pin 4 have the same potential and that there are no equalizing currents. Connect a protective earth conductor with sufficient cross section to the earth/ground connection marked with if the node is not mounted on an earthed machine stand. You thereby avoid: interference due to electromagnetic sources. Check the 24 V operating voltage of the outputs while your system is operating. Make sure that the operating voltage of the outputs remains within the permitted tolerances, even when the machine is working at full load CP A

62 3. Installation Connection example Please observe the following if there is a common 24 V supply for pins 1 and 2: Maintain the common tolerance of 24 V DC + 10/ - 15 %. When connecting the two protective earth conductors, avoid equalizing currents, e.g. by using cables of sufficient cross section as equipotential bonding. 1 AC 230 V 0 V 24 V DC 24 V Connecting cable for equipotential bonding of the earth/ground connections Protective earth connection pin 4 designed for 12 A The 24 V supply for the valves can be switched off separately. Fig. 3/5: Example connecting a common 24 V supply and both protective earth conductors 3 CP A 3-17

63 3. Installation Connecting the fieldbus Before you connect the fieldbus cable, you should first prepare the CP system for commissioning on the fieldbus (see chapter 4). PLEASE NOTE A description of the fieldbus of your node can be found in the appropriate manual for the CP fieldbus node CP A

64 4. Commissioning Chapter 4 Commissioning CP A 4-1

65 4. Commissioning Contents 4. Commissioning 4.1 The commissioning procedure Preparing the CP system for commissioning Saving the string assignment Reaction of the CP system when switched on Reaction of the CP system to operating faults Correcting string assignment errors CP A

66 4. Commissioning 4.1 The commissioning procedure In order to avoid connecting and addressing errors, you should proceed with commissioning in steps. The diagram below shows the individual steps: Step 1 Check the valve/cylinder combinations Step 2 Save the string assignment of the CP system Step 3 Check the address assignment (if necessary by means of LEDs, without actuators connected) Step 4 Commission the complete system PLC/IPC (higher-order PLC/IPC depending on node design) Fig. 4/1: Steps in commissioning } see CP valve terminal, pneumatic components see sections 4.2 and see CP fieldbus node, programming and diagnosis CP A 4-3

67 4. Commissioning 4.2 Preparing the CP system for commissioning WARNING Leave the fieldbus unconnected while you are commissioning the CP system. You thereby avoid: addressing errors which arise due to modification of the address ranges with various fieldbus systems while they are operating. Preparations Before commissioning a fieldbus system with CP node, you should first prepare each individual CP system for commissioning. Proceed as follows: 1. Check the pneumatic tubing of the CP valve terminals with the aid of the manual override (see pneumatics manual). 2. Check the complete electrical circuitry of the CP system. 3. Save the current string assignment of the CP system as the nominal assignment, as described in the following section. 4-4 CP A

68 4. Commissioning Saving the string assignment WARNING If you later modify the string assignment of your CP system: Check the address assignment of your CP system after saving the string assignment and before starting any user programs. You thereby avoid: addressing errors with incorrectly installed CP modules. String assignment Saving the string assignment Each string, and therefore each module connected to a string, is assigned a fixed address range (see chapter 1). The assignment of strings and modules, accomplished with CP cables, is known as the string assignment. In order to prepare for commissioning, you must create and save the desired string assignment. The appropriate addresses are then assigned to the connected CP modules. PLEASE NOTE Non-assigned strings are saved as string assignments at the factory. CP A 4-5

69 4. Commissioning Save the string assignment as follows: 1. Check that the CP modules are connected to the string which provides the intended address range (see also chapter 1). 2. Check also that the modules are correctly marked and that the CP cables are correctly fastened with the union nut. 3. Now switch on the operating voltage. The status LEDs on the CP modules and the LEDs on the strings to which CP modules are connected, or where the string assignment has been modified, will now flash. 4. Now take a pen or other pointed object and press the SAVE button on the fieldbus node. The current string assignment will then be saved as the nominal assignment and the appropriate addresses assigned to the CP modules. 5. Check to see that the status LEDs on the modules light up and that the string LEDs on the node are out (see also section 4.5). If this is the case, all the CP modules are ready to operate and the saved string assignment is identical to the current string assignment. 4-6 CP A

70 4. Commissioning Test phases With the aid of the saved string assignment, the CP node helps to avoid connecting errors and therefore addressing errors. It checks automatically whether the current string assignment corresponds to the saved string assignment. A distinction is made here between the following test phases: test during the power-up phase (see section 4.3) test during operation (see section 4.4). If the status LEDs on all the CP modules light up, the CP system is prepared for commissioning. Now you can commission the CP system on the fieldbus. Different procedures are necessary for commissioning the various fieldbus systems. Explanations on this can be found in the manual for the CP fieldbus node. CP A 4-7

71 4. Commissioning 4.3 Reaction of the CP system when switched on When the voltage supply is switched on, the node ascertains the current string assignment automatically. It ascertains, one after the other, which CP modules are connected to which strings. If the current assignment corresponds to the saved assignment, the fieldbus node will switch immediately to ready status. The status LEDs on the modules will then light up, thereby indicating readiness to operate (see Fig. 4/2). If the current assignment does not correspond to the saved assignment, the LED of the relevant string will flash on the fieldbus node. The status LEDs on the modules will also flash. In this case, the CP system is not ready to operate. PLEASE NOTE If several strings do not match, their string LEDs will flash one after the other. 4-8 CP A

72 4. Commissioning The ready status can be restored in one of the following ways: by eliminating assignment errors manually by saving the current assignment as the nominal assignment (see section 4.2.1). Eliminating assignment errors manually Restore the saved assignment by connecting the node with the appropriate modules again. If the current assignment is now correct again, the CP node will switch automatically and immediately to ready status. CP A 4-9

73 4. Commissioning Power-up Registering of current string assignment Yes Current string assignment = Saved string assignment? CP system ready 2) No LED on relevant string flashes SAVE button pressed? Manual error elimination possible No Yes Current string assignment is saved 1) 1) Due to saving the string assignment, the scope of data for fieldbus communication may also be changed. 2) If the address range is saved by saving the string assignment when the power supply is switched on, it may be necessary to switch on the power supply again (see manual "CP node"). Fig. 4/2: Reaction of the CP system when switched on 4-10 CP A

74 4. Commissioning 4.4 Reaction of the CP system to operating faults If there is a fault on a CP module during operation, e.g. due to cable fracture etc., the LED on the appropriate string of the fieldbus node will light up. The status LED on the relevant module will go out. All modules which function faultlessly remain ready to operate. You can now restore the defective connection during operation, or replace the defective module without affecting operation of the other modules in the other strings. When the connection is restored or after replacement, the ready status of the relevant module will be restored automatically. CP A 4-11

75 4. Commissioning Fault, CP connection interrupted String error LED lights up; non-affected modules are still active. Has error been eliminated manually? No Yes No Have not more than 1 I-module and 1 O-module/valve terminal been replaced? 1) (max. 2 modules) Yes Failed CP modules are not operated. Switch on again. 2) String error LED is switched off. Failed CP modules are operated again. 1) Only modules of the same type on a single string can be replaced simultaneously during operation. 2) The operating voltage must be switched on again to resume operation. Fig. 4/3: Reaction to faults in the system 4-12 CP A

76 4. Commissioning Replacing modules during operation WARNING Check whether the organisational concept of your machine/system permits the replacement of modules during operation. Make sure that modules are not separated from a string and then connected to another string during operation. Use the labels (type IBS 6x10 or IBS 9x20), to mark modules unambiguously. You thereby avoid: an incorrect string assignment ascertained by the node and then displayed when the operating voltage is switched back on. CP A 4-13

77 4. Commissioning Please observe the following rules: Basic rules Only modules of the same type can be replaced during operation. Replace I-module by I-module of same type (replacement of CP-E16-M8 by CP-E16-M12x2 is not permitted during operation) Replace O-module by O-module Replace valve terminal by valve terminal of the same type (valve type and number of valves must correspond). Replacement by another module type (e.g. O-module by valve terminal) will be interpreted by the node as a user error. In this case therefore, the ready status will not be restored to the relevant module during operation. Replacement possibilities During operation, a maximum of one I-module and one module with outputs (O-module or valve terminal) may be separated from the CP system or replaced at the same time, e.g.: one I-module and one valve terminal or one I-module and one O-module CP A

78 4. Commissioning If more than the above-mentioned modules are separated from and then connected again to the CP system simultaneously, there is a danger of a connection error (reversal of module connections). Operation of these modules is not, therefore, resumed while the system is operating. In this case, the operating voltage must be switched on again. The test will now run through the power-up phase and assignment errors will be displayed accordingly. Proceed as follows when replacing a module: 1. With output modules and valve terminals: Switch off: - the compressed air supply to the valve terminal - the operating voltage supply to the O-module. 2. Loosen all connecting cables and, if necessary, all tubing. 3. Connect all the cables and, where appropriate, tubing with the same type of new module. 4. With output modules and valve terminals: Switch on the operating voltage supply and the compressed air supply again. 5. Now reconnect the same type of new module to the same string. CP A 4-15

79 4. Commissioning 4.5 Correcting string assignment errors With the four string LEDs on the node and the status LEDs on the CP modules, you can check the string assignment of the CP system. The LEDs have the following meanings: String LEDs on node LED is out LED lights up LED flashes Status LEDs on the CP modules LED is out LED lights up LED flashes Meaning No error ascertained in string assignment Incorrect string assignment ascertained during operation or CP connection interrupted Incorrect string assignment ascertained when operating voltage is switched on Meaning Operating voltage not applied or no connection to node or incorrect string assignment ascertained during operation Operating voltage applied Test phase after power-up or error in supply e.g. short circuit/overload or incorrect string assignment when operating voltage is switched on Error treatment None Correct string assignment or check CP cable Check CP connection or string assignment 1) Error treatment Check CP connection and operating voltage connection on node (pin 1) or correct string assignment None None or eliminate error or check string assignment 1) 1) When the string assignment has been modified (CP modules added or removed), you must save the new string assignment by pressing the SAVE button on the node (see section 4.2.1) CP A

80 4. Commissioning Correct the string assignment as follows: Use the string LEDs to ascertain on which strings there is an assignment error. Check whether the correct modules or module types are connected to these strings. Replace defective modules or defective CP cables. If the node ascertains an incorrect string assignment during the power-up phase, the status LEDs of all the connected modules will flash. Modules of which the status LED does not flash, are not ready to operate. There is a non-permitted string assignment, for example, or the connection to the node is interrupted. In this case, create a permitted string assignment or check the connection to the node. CP A 4-17

81 4. Commissioning If you wish to correct a string assignment error by saving the string assignment: PLEASE NOTE When you have saved the string assignment, check the address assignment of your CP system before you start user programs. You thereby avoid: addressing errors due to incorrectly installed CP modules CP A

82 A. Technical appendix Appendix A Technical appendix CP A A-1

83 A. Technical appendix Contents A. Technical appendix A.1 Cable length and cross section A-3 A.2 Index A-7 A-2 CP A