Compact Performance CPV valve terminal with direct connection Electronics

Transcription

1 Compact Performance CPV valve terminal with direct connection Electronics Field bus protocols: PROFIBUS-DP, Festo, ABB CS31, SUCOnet K Direct connection type CPV..-DI01

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3 Contents and safety instructions Authors: Editors: Layout: Translations and typesetting: Uwe Reimann, Heinz Hohner H. J. Drung, M. Holder Festo AG & Co., Dept. KI-TD transline Deutschland, Dr.-Ing. Sturz GmbH printed on 100% recycled paper Edition: 9904NH (Festo AG & Co, D Esslingen, 1999) 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. CPV-DI NH I

4 Contents and safety instructions Order No Description: Description Identification: P.BE-CP-DI01-GB II CPV-DI NH

5 Contents and safety instructions Contents Intended use VII Target group VII Instructions for current manual VIII Important user information IX 1. Installation 1.1 General instructions for installation Configuring the CPV valve terminal Removing and fitting the switch module Setting the CPV valve terminal Setting the fieldbus baud rate Connecting up the fieldbus Fieldbus cable Fieldbus baud rate and fieldbus length for PROFIBUS DP Fieldbus connection Bus termination with termination resistances Optical fibre waveguide (LWL) connection for PROFIBUS DP Connection of the operating voltage Operating voltage cable Selection of the power supply unit Operating voltage connection Expansion of the CPV valve terminal CPV-DI NH III

6 Contents and safety instructions 2. Commissioning the PROFIBUS DP 2.1 Preparation of the CPV valve terminal for commissioning Switch on the operating voltages Address allocation of the CPV valve terminal General Configuration with a Siemens master COM PROFIBUS STEP 7 V4.x - HW Configurator Commissioning the CP system on the PROFIBUS DP Operation with general DP master Bus start-up Sending parametrization data Sending configuration data Request diagnostic information Cyclic exchange of data Summary of implemented functions and Service access points (SAP) Bus parameter/reaction times Transmission times on the PROFIBUS DP Data base (GSD) PROFIBUS DP diagnostics 3.1 Diagnosis with LEDs Normal operating condition Error display with the BUS/POWER LEDs LEDs for status indicator of the valve solenoid coils Error handling Diagnosis with PROFIBUS DP Diagnostic words Diagnostic information Error handling General DP master Siemens SIMATIC S5/S STEP 7 V4.x Online diagnosis via diagnostic buffer Short-circuit/overload Output module Sensor supply of an input module IV CPV-DI NH

7 Contents and safety instructions 4. Commissioning the Festo fieldbus 4.1 Preparation of the CPV valve terminal for commissioning Switch on the operating voltages Address allocation of the CPV valve terminal Configuration Configuration with the fieldbus configurator Festo fieldbus diagnostics 5.1 Diagnosis via LEDs Normal operating condition Error display with the BUS/POWER LEDs LEDs for status indicator of the valve solenoid coils Diagnosis via the fieldbus Error handling Behaviour of the CPV valve terminal caused by interference Short-circuit/overload in an output module Short-circuit sensor supply at an input module Commissioning the ABB CS Preparation of the CPV valve terminal for commissioning Switch on the operating voltages Address allocation of the CPV valve terminal General Configuration CS31 central unit as bus master T200 / 07CS61 as bus master CPV-DI NH V

8 Contents and safety instructions 7. ABB CS31 diagnostics 7.1 Diagnosis via LEDs Normal operating condition Error display of the BUS/POWER LEDs LEDs for status indicator of the valve solenoid coils Diagnosis via the fieldbus Setting the diagnostic mode Error handling Behaviour of the CPV valve terminal caused by interference Short-circuit/overload in an output module Short-circuit sensor supply at an input module Commissioning the Klöckner-Moeller SUCOnet K 8.1 Preparation of the CPV valve terminal for commissioning Switch on the operating voltages Address allocation for the CPV valve terminal CP system configuration and number of inputs/outputs Configuration for SUCOnet K Addressing inputs/outputs Diagnosis with SUCOnet K 9.1 Diagnosis via LEDs Normal operating condition Error display with the BUS/POWER LEDs LEDs for status indicator of the valve solenoid coils Diagnosis via the fieldbus Error handling Behaviour of the CPV valve terminal caused by interference Short-circuit/overload in an output module Short-circuit sensor supply at an input module A. Technical appendix A.1 Technical specifications A-3 A.2 Accessories A-5 VI CPV-DI NH

9 Contents and safety instructions Designated use This document describes the CPV valve terminal CPV- DI01, with direct interface connection, which is solely intended for use as a slave for the following fieldbuses: PROFIBUS DP Festo fieldbus ABB CS31 Klöckner Moeller SUCOnet K Only use valve terminal as follows: as designated in original condition without unauthorized modifications in perfect technical condition Specified limits for pressure, temperature, electric data, torques etc. should be observed. Note trade association regulations, technical monitoring body regulations, VDE conditions or relevant national conditions. Target group This manual is directed exclusively at technicians who are trained in control and automation technology and who have experience in installing, commissioning, programming and diagnosing slaves for the fieldbuses mentioned above. CPV-DI NH VII

10 Contents and safety instructions Information on this manual PLEASE NOTE This manual contains the software version functionality from 1.x and the hardware version from 04/98 of the CPV valve terminal with direct connection for PROFIBUS DP, Festo fieldbus, ABB CS31 and Klöckner-Moeller SUCOnet K. The current manual contains specific information regarding the installation, commissioning, programming and diagnosis of CPV valve terminals with direct connection for the fieldbuses mentioned above. Information regarding the pneumatics system can be found in the "Pneumatics system manual P.BE-CPV-...". VIII CPV-DI NH

11 Contents and safety instructions Important user instructions This manual contains instructions about possible dangers which may occur if the valve terminal is not used correctly. These instructions are always printed in italics, 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. CAUTI 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. CPV-DI NH IX

12 Contents and safety instructions 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 electric voltage or undefined voltage states of the electronic components which can affect connected circuits. Electrostatically vulnerable components. These will be destroyed if their contact surfaces are touched. Text markings This mark indicates activities which can be carried out in any order. 1. Figures indicate activities which must be carried out in the numerical order of the figures. Hyphens indicate general items. X CPV-DI NH

13 Contents and safety instructions The following product specific terms and abbreviations are used in this manual: Term/ abbreviation O OB CP CPV Direct CP System CP Connection CP Modules CP Cable I I/O Module I/Os Octet PLC/IPC Meaning Digital output Output byte Compact Performance CPV valve terminal with fieldbus direct connection Complete system consisting of CPV Direct and CP modules Socket or plug on the CP modules with which they are connected to the node by means of the CP cables Common term for the various modules which can be incorporated in a CP system Special cable for connecting the various CP modules Digital input Common term for the CP modules which provide digital inputs and outputs (CP input and CP output modules) Digital inputs and outputs Number of address words reserved by the CP system Programmable logic controller/industrial PC CPV-DI NH XI

14 Contents and safety instructions XII CPV-DI NH

15 1. Installation Chapter 1 Installation CPV-DI NH 1-1

16 1. Installation Contents 1. Installation 1.1 General instructions for installation Electronic Connection and display elements Configuring the CPV valve terminal Removing and fitting the switch module Setting the CPV valve terminal Setting the fieldbus baud rate Connecting up the fieldbus Fieldbus cable PROFIBUS DP Festo fieldbus/abb CS31/ Klöckner-Moeller SUCOnet K Fieldbus baud rate and fieldbus length for PROFIBUS DP Branch line length Fieldbus connection Screening connection Bus termination with termination resistances Optical fibre waveguide (LWL) connection for PROFIBUS DP Connection of the operating voltage Operating voltage cable Selection of the power supply unit Operating voltage connection Potential compensation Expansion of the CPV valve terminal CPV-DI NH

17 1. Installation 1.1 General instructions for installation WARNING Before starting installation or maintenance work, switch off the following: Compressed air supply Operating voltage supply for internal logics Load voltage supply valves You thereby avoid: Uncontrolled movement of loosened tubing. Unintentional movements of the connected actuators. Undefined switching states of the electronic components. CAUTI The CPV valve terminal contains components that are vulnerable to electrostatic interference. Do not touch any components Comply with the handling specifications for components vulnerable to electrostatic interference. This helps to prevent destruction of the electronics. CPV-DI NH 1-3

18 1. Installation Electronic connection and display elements The CPV valve terminal with fieldbus direct connection is fitted with the following connection and display elements: ª «ª «Bus status and power LEDs Operating voltage connection - electronic/load voltage connection CP valves Switch module Fieldbus connection CP expansion connection Switch status displays for CP valve coils Fig. 1/1: Connection and display elements 1-4 CPV-DI NH

19 1. Installation 1.2 Configuring the CPV valve terminal Removing and fitting the switch module CAUTI The switch module contains components that are vulnerable to electrostatic interference. Do not touch any components. Comply with the handling specifications for components vulnerable to electrostatic interference. The switch module must first be removed to set-up the CPV valve terminal. Figure 1/2: Removing/fitting the switch module CPV-DI NH 1-5

20 1. Installation Removing: 1. Switch off the operating voltage. 2. Unscrew the two fixing screws of the switch module. 3. Lift up the switch module. Fitting: 1. Position the switch module carefully in the cut-out. 2. Screw up the two fixing screws of the switch module. PLEASE NOTE Do not tilt the switch module during insertion. The fitting position is clearly identified by a cut-out in the housing. Ensure that the seal is fitted correctly Setting the CPV valve terminal Once removed, two DIL switches are visible in the switch module (Figure 1/5). The following parameters can be set with the DIL switches: Fieldbus protocol Configuration of the CP system Station number Diagnostic mode 1-6 CPV-DI NH

21 1. Installation Proceed as follows: 1. Switch off the operating voltage. 2. Remove the switch module (Chapter 1.2.1). 3. Set the fieldbus protocol (4x DIL, switch elements 1-2). 4. Set the configuration of the CP system (4x DIL, switch elements 3-4). 5. Assign a vacant station number to the CPV valve terminal. Set the required station number (8x DIL, switch elements 1-7). 6. Set the diagnostic mode (8x DIL, switch element 8) 7. Fit the switch module (Chapter 1.2.1). ª «ª 4x DIL switch: Settings for fieldbus protocol Settings for configuration of the CP system «8x DIL switch: Address selector switch Station number Settings diagnostic mode For addition information regarding... see following pages Figure 1/3: DIL switch in the switch module CPV-DI NH 1-7

22 1. Installation Setting the fieldbus protocol The CPV valve terminal with fieldbus direct connection is prepared for four fieldbus protocols. The protocol selection is implemented using the switch elements 1 and 2 of the 4x DIL switch. Set the required fieldbus protocol as shown in the following figure: PROFIBUS DP Festo fieldbus ABB CS31 SUCOnet K Figure 1/4: Setting the fieldbus protocol (4x DIL switch) ª Setting: Configuration of the CP system Additional CP modules can be connected to the CPV valve terminal. The CP system configuration must be set with the switch elements 3 and 4 of the 4x DIL switch according to the following figure: 1-8 CPV-DI NH

23 1. Installation Configuration of the CP system CPV valve terminal with fieldbus direct connection without expansion Number of outputs/inputs 16O Settings of the DIL switch CPV valve terminal expanded by: CP input module 16O 16I CPV valve terminal expanded by: CP valve terminal or CP output module 16O + 16O CPV valve terminal expanded by: 16O CP valve terminal/cp output module and CP input module + 16O Figure 1/5: Settings of the CP configuration (4x DIL switch) 16I PLEASE NOTE Depending on the configuration level set, the CP system assigns varying numbers of inputs and outputs or station numbers. For further information, see Chapter 1.8. CPV-DI NH 1-9

24 1. Installation «Setting the station number Set the fieldbus station number with the 8x DIL switch. PLEASE NOTE Station numbers may only be assigned once per fieldbus line. Recommendation Assign the station numbers in ascending order. Adapt the station numbers to the machine structure of the system. The following station numbers are allowed: Protocol Address designation Permissible station numbers PROFIBUS DP PROFIBUS address 0;...; 125 Festo fieldbus fieldbus address 1;...; 63 ABB CS31 CS 31 module address 0;...; 60 Klöckner Moeller SUCOnet K 2;...; CPV-DI NH

25 1. Installation 2 0 = = = 4 « O N 2 3 = = = = 64 «Setting the station numbers for PROFIBUS DP, ABB CS31 and SUCOnet K (8x DIL, switch elements 1-7) Setting the station numbers for Festo fieldbus (8x DIL, switch elements 1-6) Figure 1/6: Setting the station numbers The station numbers are entered with the 8x DIL switch code. station number set: 05 (= 1 + 4) station number set: 38 (= ) Figure 1/7: Example of station numbers set CPV-DI NH 1-11

26 1. Installation The following pages give an overview of the station number settings. The tables can be used for all protocols that are supported by the valve terminal. NOTE To set the station numbers for the ABB CS31 and Festo fieldbus protocols, the DIL switch elements 1-6 are sufficient. For the ABB CS31 protocol, switch element 7 must be set to. With the Festo fieldbus, switch elements 7 and 8 are used to set the baud rate. Station number Station number Figure 1/8: Setting the station numbers 0-23: Position of the DIL switch elements CPV-DI NH

27 1. Installation Station number Station number Figure 1/9: Setting the station numbers 24-67: Position of the DIL switch elements CPV-DI NH 1-13

28 1. Installation Station number Station number Figure 1/10: Setting the station numbers : Position of the DIL switch elements 1-14 CPV-DI NH

29 1. Installation Station number Station number Figure 1/11: Setting the station numbers : Position of the DIL switch elements CPV-DI NH 1-15

30 1. Installation Setting the diagnostic mode (Only for PROFIBUS DP and ABB CS31) The following diagnostics can be deactivated/activated with the switch element 8 of the 8x DIL switch: PROFIBUS DP: Device-specific diagnosis active/inactive ABB CS31: Load voltage monitoring active/inactive Diagnosis Diagnosis Figure 1/12: Setting the diagnostic mode For PROFIBUS DP: If the device-specific diagnosis is deactivated using switch element 8, diagnostic information regarding the valve terminal is not sent to the master system, e. g. output short-circuits or undervoltage of the valves (see Chapter 3.3) CPV-DI NH

31 1. Installation 1.3 Setting the fieldbus baud rate NOTE: Setting the required baud rate is only necessary for the Festo fieldbus protocol. The CPV valve terminal with fieldbus direct connection has an automatic baud rate sensor for the PROFIBUS DP (9.2 kbd-12 MBd) and SUCOnet K (187.5 kbd-375 kbd) protocols. With the ABB CS31 protocol, a constant baud rate of kbd is used. For the Festo fieldbus protocol the DIL switch elements 7 and 8 of the 8x DIL switch are used to set the baud rate. Setting the fieldbus baudrate (in kbaud) for the Festo protocol Figure 1/13: Setting the baud rate for the Festo fieldbus CPV-DI NH 1-17

32 1. Installation 1.4 Connecting the fieldbus Fieldbus cable PLEASE NOTE Note the cable specifications! During data transmission, particularly at high transmission speeds, data transmission errors, signal reflection and signal damping occurs. Both can lead to errors in transmission. Reflections may be caused by: Missing or incorrect terminating resistor. Branching Signal damping may be caused by: Transmission over great distances Unsuitable cable Information regarding the cable type can be found in the controller manual. When using the Festo IP65 plug, a cable diameter of 7-10 mm is permitted. PROFIBUS DP Use a paired, screened 2-wire cable for the fieldbus wire. Bus length Precise specifications for the bus length can be found in Chapter and in the manuals of the control system. Festo fieldbus/abb CS31/ Klöckner-Moeller SUCOnet K The cable type can be found in the PLC manual of the controller. Comply with distances and the fieldbus baud rates CPV-DI NH

33 1. Installation Fieldbus baud rate and fieldbus length for PROFIBUS DP PLEASE NOTE The CP system automatically sets itself to one of the following listed baud rates. The maximum permitted fieldbus length is dependent on the baud rate used. The table in Figure 1/14 shows the applicable baud rates. Branch line length PLEASE NOTE Comply with the maximum permitted length of the fieldbus cable when connecting the bus node via a branch line. When calculating the maximum permitted length of the fieldbus cable, take into account the sum of the branch lines. The maximum permitted length of the branch line depends on the type of cable and baud rate used. CPV-DI NH 1-19

34 1. Installation Recommendation Use a cable with a capacitance per unit length < 30 nf/km as specified below. Otherwise the cable length permitted will decrease. Baud rate (in kbaud) Fieldbus length (max.) Maximum permitted branch line m 500 m m 500 m m 100 m m 33.3 m m 20 m m 6.6 m m Figure 1/14: Max. fieldbus and branch line length for PROFIBUS DP depending on the baud rate Cable specification as per EN (cable type A): Surge impedance: Ohm (3-20 MHz) Capacitance per unit length: < 30 nf/km Loop resistance: < 110 Ohm/km Core diameter: > 0.64 mm Core cross section: > 0.34 mm CPV-DI NH

35 1. Installation Fieldbus connection PLEASE NOTE Only the Festo plug will full fill protection class IP65. The CPV valve terminal has a 9-pin Sub-D socket to connect it to the fieldbus. This connection is for the supply lead and the continuation of the fieldbus line. Use the Sub-D plug from Festo (Part-No ) to connect the CPV valve terminal. CPV-DI NH 1-21

36 1. Installation Pin Manufacturer-specific connection Festo Sub-D PROFIBUS DP Designation plug (IP65) Housing B A Cable grip n.c. n.c. RxD/TxD-P CNTR-P 1) DGND VP n.c. RxD/TxD-N n.c. Screening not connected not connected Receive/send data P Repeater control signal Data reference potential (M5V) Power supply plus (P5V) not connected Receive/send data N not connected Connection to housing 1) The repeater control signal CNTR-P is executed as a TTL signal Pin Festo fieldbus ABB CS 31 SUCOnet K Housing S+ S- Screening Bus 1 Bus 2 Shield 2) Pin numbers of the SUCOnet K interface Sub-D 9-pin 3 (T A/R A) 2) 7 (T B/R B) 2) 4 (Screening) 2) DIN (circular) 5-pin 4 (T A/R A) 2) 1 (T B/R B) 2) Housing Figure 1/15: Connection of the fieldbus interface (Looking at the socket) PLEASE NOTE Before connecting SUB-D plugs from other manufacturers: Replace the two flat screws with bolts (Festo Part-No ) CPV-DI NH

37 1. Installation PLEASE NOTE If the valve terminal is mounted on a moving machine, the fieldbus cable must be fitted with a strain relief device on the moving part of the machine. Comply with the corresponding regulations in EN Part 1. Screening connection The Festo Sub-D plug can be given a potential-isolated screening connection: Clamp the screening of the fieldbus cable under the cable grip of the Festo Sub-D plug (Figure 1/16). ª ª Screening connection, cable clip Only capacitively connected Figure 1/16: Screening connection PLEASE NOTE The cable grip in the Festo Sub-D plug is only capacitively connected internally with the metallic housing of the Sub-D plug. This prevents compensating currents from flowing via the screening of the fieldbus line (Figure 1/16). CPV-DI NH 1-23

38 1. Installation 1.5 Bus termination with termination resistances PLEASE NOTE Use a bus termination on both ends of a bus segment. This also applies when the bus connection or bus interface is at the beginning of the bus line. If the CPV valve terminal is at the end of the fieldbus system, a bus termination is necessary. Recommendation Use the SUB-D plug from Festo (Part-No ). A suitable resistance network is built into the housing of the Festo Sub-D plug. The bus termination must be manually switched with slide switches. Bus termination enabled not enabled Figure 1/17: Switch for the bus termination in the Festo Sub-D-plug 1-24 CPV-DI NH

39 1. Installation ª 390 $ Data signal 220 $ Data signal 390 $ ª «Switch in the Festo plug Pin 6 power supply Pin 5 data reference potential Figure 1/18: Circuit diagram bus termination network for line type A in compliance with EN «CPV-DI NH 1-25

40 1. Installation 1.6 Optical fibre waveguide (LWL) connection for PROFIBUS DP We recommend the optical fibre waveguide technology for transmission in environments subject to strong interference as well as for extending the transmission range when high baud rates are used. The optical fibre waveguide technology offers the following advantages: High EMC, ESD protection due to optical transmission of signals Protection against lightning Potential isolation of individual DP slaves The PROFIBUS DP interface of the node has been designed in accordance with specification EN Volume 2 and thereby supports the control of network components for optical fibre waveguides. Example for optical fibre waveguide network components: Siemens optical link module (OLM) for PROFIBUS plus Siemens optical link plug (OLP) for PROFIBUS 1-26 CPV-DI NH

41 1. Installation 1.7 Connecting the operating voltage Operating voltage cable Use an operating voltage cable with sufficient cable cross section. Avoid great distances between the power unit and the CPV valve terminal. A long operating voltage cable reduces the voltage supplied by the power unit. Calculate the suitable cable cross section and the maximum permitted cable length. The connection for the operating voltage is a plug. The pin assignments for the operating voltage connection can be found in the following pages. Use plugs for the operating voltage connection from the Festo product range that match the external diameter of the cable used (see Appendix A.2). CPV-DI NH 1-27

42 1. Installation Assembly After selecting suitable cables, connect them as follows: 1. To open the box, undo the central knurled nut. 2. Open the strain relief on the rear part of the housing. Then guide the cable through. ª ª ««Cable Housing Mains section Strain relief Figure 1/19: Box components and cable routing 1-28 CPV-DI NH

43 1. Installation 3. Isolate 5mm of the cable end and fit the strands with cable end sleeves. 4. Connect up the ends of the cables. 5. Reconnect the mains section to the box housing. Pull the cable so far back that there is no cable looped inside the housing. 6. Tighten the strain relief down firmly Selection of the power supply unit WARNING Only use power units which guarantee reliable electrical isolation of the operating voltages as per IEC 742/ EN 60742/VDE 0551 with at least 4 kv insulation resistance (Protected Extra-Low Voltage, PELV). Switch power packs are permitted if they guarantee reliable isolation as per EN 60950/ VDE Remark: By using PELV power units, protection against electric shock (protection against direct and indirect contact) in accordance with EN /IEC 204 is guaranteed on Festo valve terminals. Safety transformers with the adjacent designation must be used for supplying PELV networks. The valve terminals must be earthed in order to ensure their function (e. g. EMC). CPV-DI NH 1-29

44 1. Installation Total power consumption The power requirements of a CP system is dependent on the number of CP modules and valve coils. Recommendation Use stabilised power supply units. When selecting the power units, check that they will provide enough power. To calculate the total power required, use the following table. The following table shows the calculation of the total power consumption for a CP system. The specified values have been rounded up. Power consumption CP electronics (Pin 1) CPV valve terminal with max. 100 ma fieldbus direct interface connection CP valve terminal max. 40 ma CPA valve terminal 20 ma CP input module max. 40 ma Sensors see manufacturer data CP output module max. 40 ma Transference Power consumption valve supply (Pin 2) Power consumption of all x ma simultaneously powered valve coils 1) 1) Power consumption dependent on valve type (see specifications for valves) Total = ma = ma 1-30 CPV-DI NH

45 1. Installation Operating voltage connection The power supply is provided through a 4-pin M12 plug (see Figure 1/1). The power consumption is dependent on the type of valve terminal. The values can be found in the Pneumatics manual, P.BE-CPV-... and in the previous section. Note the following when connecting the 24 V load voltage (Pin 2): Maintain the tolerance (DC 20.4 V V). Check the 24 V load voltage for the valves while the plant is operating. WARNING Check the EMERGENCY STOP circuitry, to see which measures are required in order to place your machine/system in a safe state in the event of an EMERGENCY STOP (e. g. switching off the power supply to the valves and output modules, switching off the compressed air supply). CPV-DI NH 1-31

46 1. Installation Pin assignment of the operating voltage connections for the CPV valve terminal: «ª «DC 24 V operating voltage electronics and inputs 1) DC 24 V load voltage valves and outputs 0 V Earthing connection 1) with connected modules on the expansion connection Figure 1/20: Pin assignments operating voltage connection Potential compensation The CPV valve terminal has 2 earth connections for potential compensation: On the operating voltage connection of the CPV valve terminal. On the left end plate. ª 1-32 CPV-DI NH

47 1. Installation PLEASE NOTE Always connect the earth potential to pin 4 of the operating voltage connection. Connect the earthing connection of the left-hand end plate with low impedance (short line with large cross section) to the earth potential. The low impedance connections ensure that the housing of the valve terminal and the earthing connection on Pin 4 are at the same potential and that no compensating currents are flowing. This will avoid interference from electromagnetic sources. BUS POWER ª ««ª The load voltage can be switched separately Earthing connection on the pin 4 is designed for 3 A potential compensation PE Figure 1/21: Example of connection CPV-DI NH 1-33

48 1. Installation 1.8 Expansion of the CPV valve terminal The CPV valve terminal with fieldbus direct connection can be connected with modules of the CP system using the CP expansion connection. CP expansion connection Figure 1/22: CP expansion connection CAUTI Set the configuration of the CP system accurately with the 4x DIL switch of the switch module. This avoids any incorrect functioning of the system. Modules that are connected to the CP expansion connection are only recognised when the DIL switch is correctly set. Information for setting the DIL switch can be found in Chapter CPV-DI NH

49 1. Installation The following CP modules can be connected to the CP expansion connection: CP input module with 16 inputs, either with 8xM12 plug (Double assigned box) or 16xM8 plug (Single assigned box). CP output module with 8 outputs each with 0.5A. The power supply of the module is also via the CP expansion connection. The load voltage must be supplied separately via an M18 plug. CPV valve terminals in the 10, 14 and 18mm sizes. These are available with 4, 6 or 8 CP valve plates. CPA valve terminals in the 10 and 14 mm sizes. These are available for fieldbus connections with max. 8 double solenoid or 16 single solenoid valve plates. PLEASE NOTE The CPV valve terminal with fieldbus direct connection can be expanded by maximum: one CP input module one CP valve terminal or one CP output module CPV-DI NH 1-35

50 1. Installation CAUTI The max. cable length between the CPV valve terminal with fieldbus direct connection and the last CP module must be max. 10 m. The CP connection cables must have special electrical properties. Use only Festo CP connection cables. Festo provides pre-assembled CP connection cables. These are available in various lengths and sizes. An overview is given in Appendix A. Close any remaining open CP connections in the CP system with the seal caps provided. This meets the requirements of protection class IP 65. The following figure shows possible expansions: 1-36 CPV-DI NH

51 1. Installation Configuration of the CP system CPV Direct O-module or I -module CP valve terminal Setting of the switch elements in the 4x DIL switch ª ª ª ª «ª «ª «ª Total cable length of the CP system: maximum 10m ª «CPV valve terminal with fieldbus direct connection CP connection cable 0.5m, 2m, 5m, 8m CP input module 16 inputs (8 x M12, 16 x M8 plug) CP output module 8 outputs (8 x M12 plug) CPV or CPA valve terminal Figure 1/23: Expansion options CPV-DI NH 1-37

52 1. Installation 1-38 CPV-DI NH

53 2. Commissioning PROFIBUS DP Chapter 2 Commissioning the PROFIBUS DP CP-DI NH 2-1

54 2. Commissioning PROFIBUS DP Contents 2. Commissioning the PROFIBUS DP 2.1 Preparation of the CPV valve terminal for commissioning Switch on the operating voltages Address allocation of the CPV valve terminal General FREEZE and SYNC FREEZE SYNC Module consistency Configuration Configuration with a Siemens master COM PROFIBUS Preparations Station selection Configuration COM PROFIBUS Alternative entry via mask "Part number" Input and output addresses STEP 7 V4.x - HW Configurator Preparations Station selection and configuration Commissioning the CP system on the PROFIBUS DP Operation with general DP master Bus start-up Sending parametrization data Sending configuration data Request diagnostic information Cyclic exchange of data Summary of implemented functions and Service access points (SAP) Bus parameter/reaction times Transmission times on the PROFIBUS DP Data base (GSD) CP-DI NH

55 2. Commissioning PROFIBUS DP 2.1 Preparation of the CPV valve terminal for commissioning Switch on the operating voltages PLEASE NOTE Note the switching-on instructions in the PLC controller handbook. When the controller is switched on, it automatically implements a comparison between SET and ACTUAL configuration. For this configuration run it is important that: the specification for the fieldbus configuration are complete and correct. the power supplies to the PLC and to the fieldbus slaves are switched on either simultaneously or in the sequence specified below. Note the following points for switching on the power supply: Shared power supply Separate power supply Shared power supply for control system and all fieldbus slaves using a central power pack and/or a central switch. If the control system and fieldbus slaves have separate power supplies, switch them on in the following sequence: 1. Switch on operating voltage supply for all fieldbus slaves. 2. Switch on operating voltage supply for the controller. CP-DI NH 2-3

56 2. Commissioning PROFIBUS DP Address allocation of the CPV valve terminal The CPV valve terminal with fieldbus direct connection always uses 16 output addresses, regardless of the number of valve solenoid coils it has. This allows the later expansion of the CPV valve terminal without changing addresses. The following figure shows the addressing sequence of the individual CPV valve plates Figure 2/1: Address allocation of a CPV valve terminal 2-4 CP-DI NH

57 2. Commissioning PROFIBUS DP AB x AB x+1 A20.0 A20.1 A20.2 A20.3 A20.4 A20.5 A20.6 A20.7 A21.0 A21.1 A21.2 A21.3 A21.4 A21.5 A21.6 A21.7 AB: Output byte Figure 2/2: Address allocation of the CPV valve terminal (outputs) with examples for OB20 and OB21 CP-DI NH 2-5

58 2. Commissioning PROFIBUS DP The address allocation in the CPV valve terminal occurs from left to right and in the individual valve locations from front to back. A valve location in the CPV valve terminal always occupies 2 addresses, even when it is fitted with a reserve plate or pressure isolation plate. If a valve location is fitted with a double solenoid valve, the following allocation applies: - Pilot solenoid 14 occupies the lower-value addresses, - Pilot solenoid 12 occupies the higher-value addresses. The higher-value addresses remain unused with single solenoid valves. 2-6 CP-DI NH

59 2. Commissioning PROFIBUS DP General FREEZE and SYNC The I/O processing modes FREEZE and SYNC are supported by the CP system as per EN (DIN 19245). The method of accessing the FREEZE or SYNC command depends on the controller. Please refer to the documentation for the fieldbus module. CAUTI In the following cases, the FREEZE or SYNC mode is reset automatically: switching the CP system on/off stopping the fieldbus module. The FREEZE mode is also reset automatically in the following cases: when the bus connection to the CP system is interrupted (response monitoring active). FREEZE With this function, all the inputs of the CP system can be "frozen". The CP system then sends a constant input image of all the inputs to the master. The following FREEZE command causes the input image to be updated. The updated input image is then sent constantly to the master. Return to normal mode with the command UNFREEZE. CP-DI NH 2-7

60 2. Commissioning PROFIBUS DP SYNC This function "freezes" all the outputs of the CP system. The CP system therefore no longer reacts to modifications to the output image in the master. The following SYNC command updates and transfers the output image of the master. Return to normal mode with the command UNSYNC. Module consistency DIL switch Module consistency The CP system supports the following variants in module consistency: via the selected format (word) Configuration The position of the DIL switch in the configuration of the CP system is relevant for the necessary DP Identifier (see Chapters and 1.8). PLEASE NOTE Ensure that the DIL switches are set in compliance with the configuration of the CP system. 2-8 CP-DI NH

61 2. Commissioning PROFIBUS DP The following table shows a summary of the possible entries for the CP system: Configuration of the CP system DP identifier Comments Siemens EN50170 CPV valve terminal with fieldbus direct connection only (no expansion) ID1: 16DO ID1: digital outputs Expanded by one input module ID1: 16DO ID1: digital outputs ID2: 16DI ID2: digital inputs Expanded by one CP valve terminal or one CP output module ID1: 16DO ID2: 16DO ID1: 033 ID2: digital outputs 16 digital outputs Expanded by one CP valve terminal /CP output module and an input module ID1: 16DO ID2: 16DO ID1: 033 ID2: digital outputs 16 digital outputs Figure 2/3: Summary of entries ID3: 16DI ID3: digital inputs PLEASE NOTE Enter the identifiers in compliance with the physical sequence of the modules, starting from the CPV Direct. Example: CPV valve terminal with fieldbus direct connection and expanded by one input module. DP Identifier Comments 1 16DO 16 digital outputs 2 16DI 16 digital inputs CP-DI NH 2-9

62 2. Commissioning PROFIBUS DP 2.2 Configuration with a Siemens master PLEASE NOTE Various configuration programs are available in conjunction with a Siemens master. Observe the appropriate procedures for the configuration program used COM PROFIBUS CD ROM Preparations 1. Copy the GSD of the valve terminals into the directory \COMPB3x\GSD of the PC/programmer. The GSD can be found on the accompanying CD ROM. File: VI1000C9.GSE Further information (directories, etc.) can be found in the "readme" file in the main directory of the CD ROM. PLEASE NOTE Update the slave catalogue if copying the GSD whilst working with COM PROFIBUS. Menu: "File" - "Load GSD file" 2-10 CP-DI NH

63 2. Commissioning PROFIBUS DP Symbols 2. Bitmap files with icons of the valve terminals are available on the CD ROM to simplify configuration. Copy the file PB_DICPN.BMP into the directory \COMPB3x\BITMAPS\ of the PC/programmer. 3. In the "Busparameter" mask of the menu "Configure", edit the fields: Bus profile Baud rate Further information (directories, etc.) can be found in the "readme" file in the main directory of the CD ROM. Station selection ǻ Figure 2/4: Station selection with COM PROFIBUS CP-DI NH 2-11

64 2. Commissioning PROFIBUS DP Use the left-hand mouse button to mark the slave type "VALVES" in the slave catalogue. The slave type "VALVES" appears when the GSD has been correctly copied (see preparation step 1). ª Move the mouse to the left and click below the graphic. «The entry mask "PROFIBUS Address" will appear. Select the slave addresses identical to the selected settings of the DIL switch in the switch module (see Chapter 1.2.2) and confirm. The entry mask "Slave parameters" will appear. Select the station type "FESTO CPV DI01" and confirm with OK. The icon of the Festo valve terminal will now appear under the graphic of the master. The icon appears when the bitmap file has been correctly copied (see preparation step 3). This concludes the station selection CP-DI NH

65 2. Commissioning PROFIBUS DP Configuration COM PROFIBUS Requirements: the GSD must be in the directory of the PC/programmer the "Bus parameter" mask is edited (Bus profile, baud rate) the PROFIBUS address has been assigned (see above) the station type "FESTO CPV DI01" has been selected (see above) Configure Access the mask "Configure". 1. Double click with left-hand mouse button or click once with the right-hand mouse button on the icon of the Festo valve terminal. 2. Select "Configure" in the menu which appears. The "Configure" mask will then appear (Figure 2/5). CP-DI NH 2-13

66 2. Commissioning PROFIBUS DP Figure 2/5: Configuration with COM PROFIBUS The program has already automatically entered the DP identifiers in this mask for the 16 outputs of the CPV valve terminal. Using the column "Identifier", enter the configuration of the CP system into lines 2 and 3 (summary: see Figure 2/3) Example 1 CPV valve terminal expanded by one input module with 16 digital inputs. DP identifier Part number Comments 1 16DO automatically entered 2 16DI input module, 16 digital inputs 2-14 CP-DI NH

67 2. Commissioning PROFIBUS DP Example 2: CPV valve terminal expanded by one CPV valve terminal and one input module with 16 digital inputs. DP identifier Part number Comments 1 16DO automatically entered 2 16DO CPV valve terminal with 8 valve plates (double solenoid), 16 outputs 3 16DI input module, 16 digital inputs Alternative entry via mask "Order number" The identifiers can also be entered via a mask: 1. Mark the field "Order Number" of the relevant line. 2. Click on the button "Order No....". The "Select by Order Number" mask appears. Figure 2/6: "Selection by part number" CP-DI NH 2-15

68 2. Commissioning PROFIBUS DP 3. Mark the entry in the list that corresponds to the configuration. 4. Click on "Accept". Addressing Input and output addresses Enter the initial address of the inputs and outputs under "I Addr." or "O Addr.". Example 3: Configuration as in example 1, addresses from in/output word 42 used: DP identifier Part number Comments I-address O-address 1 16DO P DI CP-E16: 16DI P042 Example 3 - input and output addresses PLEASE NOTE When the I/O address range is marked, the function "Auto Addr." automatically assigns the free addresses of the systems with reference to the system limits. This completes the configuration/address assignment with COM PROFIBUS CP-DI NH

69 2. Commissioning PROFIBUS DP STEP 7 V4.x - HW Configurator CD ROM Preparations 1. Copy the data base (GSD) of the valve terminals into directory \STEP7\S7DATA\GDSD on the PC/programmer. The GSD can be found on the accompanying CD ROM. File: VI1000C9.GSE The GSD can either be copied manually into the above mentioned directory (e. g. via Windows Explorer) or loaded via the menu item "Extras" - "Install new GSD" in the mask "Hardware configuration." Further information (directories, etc.) can be found in the "readme" file in the main directory of the CD ROM. PLEASE NOTE Update the hardware catalogue if copying the GSD whilst working with STEP7. Menu in Hardware Configuration: "Extras" "Update catalogue" PLEASE NOTE From STEP7 V4.02, data base (GSD) are stored in the STEP7 project (station GSD). This may mean that the updating/ loading of new GSD will be implemented incorrectly. Please refer to STEP7 help for information on dealing with the station GSD. CP-DI NH 2-17

70 2. Commissioning PROFIBUS DP Symbols 2. Bitmap files with icons of the valve terminals are available on the CD ROM "Utilities" to simplify configuration. Copy the file PB_DICPN.BMP into the directory \STEP7\S7DATA\NSBMP of the PC/programmer. 3. Edit the mask "Properties of the DP master" Bus profile Baud rate The bitmaps can either be copied manually into the above mentioned directory or loaded via the menu item "Extras" "Install new GSD" file type "Bitmap" in HW configuration. 4. Activate the DP master in the rack CP-DI NH

71 2. Commissioning PROFIBUS DP Station selection and configuration «ª Figure 2/7: Station selection with STEP7 V4.x Hardware configuration (the masks shown here are not all seen simultaneously, see text) Click the catalogue icon. This opens the hardware catalogue. ª Mark the station type "FESTO CPV DI01" (\PROFIBUS DP\Additional FIELD DEVICES\VALVES) in the hardware catalogue with the left-hand mouse button. The slave type VALVES only appears under the folder "Additional FIELD DEVICES" when the GSD has been correctly copied (see preparation step 1). CP-DI NH 2-19

72 2. Commissioning PROFIBUS DP «Hold the left-hand mouse button pressed down and pull the cursor onto the graphic PROFIBUS line on the DP master (drag and drop). The entry mask "Properties - PROFIBUS Node" appears. Select the slave (PROFIBUS) addresses identical to the selected settings of the DIL switch in the switch module (see Chapter 1.2.2) and confirm with OK. The icon of the valve terminal will appear on the PROFIBUS line (see Figure 2/8). Figure 2/8: Configuration with STEP7 - hardware catalogue 2-20 CP-DI NH

73 2. Commissioning PROFIBUS DP Addressing Mark the symbol of the valve terminal to be configured on the graphical user interface of the HW configuration. The table in the lower screen section shows the configuration data with the columns "Module/DP"ID, "Order number", "I Address", "O Address", "Comment". In the hardware catalogue, open the directory "FESTO CPV DI01" and mark the module corresponding to the configuration of the CP system. Holding the mouse button down, drag and drop the marked module from the hardware catalogue to the next free line of the configuration table. Repeat steps 6 and 7 for further modules if necessary. PLEASE NOTE Insert the modules according to the physical sequence of the configuration into the configuration table. Modify address The I-addresses and O-addresses are automatically assigned in STEP7. To change this address assignment, follow the procedure below: Open the mask "Properties - DP slave" by double-clicking the appropriate line in the configuration table of the DP slave and modify the starting address of the inputs/outputs. CP-DI NH 2-21

74 2. Commissioning PROFIBUS DP PLEASE NOTE With the S7-400 controllers, 4 bytes of addresses are always reserved for each DP identifier. This concludes the station selection and configuration. Addressing example: Configuration of the CP system DP identifier I/O addresses (IN/OUT) 1 CPV valve terminal fieldbus direct connection 2 CPV valve terminal with 8 double solenoid valves 16DO 16DO O O21.7 O CP input module, 16 inputs 16DI I Example 3 Input and output addresses (see Figure 2/9) O O21.7 O I Figure 2/9: Example Addressing the outputs and inputs of a CP system with fieldbus direct connection in the maximum configuration 2-22 CP-DI NH

75 2. Commissioning PROFIBUS DP Commissioning the CP system on the PROFIBUS DP PLEASE NOTE Comply with the switching-on instructions in the manual for the controller. Proceed as follows: 1. Connect the fieldbus line to the fieldbus node. 2. Switch on the operating voltages: for all fieldbus slaves, for the CP system. 3. Switch on the operating voltage for the master module. Configuration run Some master systems automatically implement a comparison between SET and ACTUAL configuration (= DIL switch position) when the system is switched on. For this configuration run it is important that: The specifications on the NOMINAL configuration are complete and correct (see also section 2.1.2). The power supplies to the PLC and to the fieldbus slaves are either switched on simultaneously or in the sequence specified above. CP-DI NH 2-23

76 2. Commissioning PROFIBUS DP Recommendation Providing the safety requirements of the machine/system are fulfilled, commission the CP system with both operating voltages (pins 1 and 2), but without compressed air. This provides the option of testing without the risk of unintentional reactions. PLEASE NOTE A CP valve location occupies two addresses. The following applies: lower-value address: pilot solenoid 14 higher-value address: pilot solenoid CP-DI NH

77 2. Commissioning PROFIBUS DP 2.3 Operation with general DP master Bus start-up The Festo CP system can be controlled from any PLC, PC or industrial PC with a PROFIBUS DP module as per EN (DIN 19245). Information for the functions FREEZE, SYNC and the DP identifiers can be found in section In order to operate the CP system correctly, the DP master must perform the following functions in the sequence specified: 1. Send a parametrizing telegram 2. Send a configuration telegram 3. Request diagnostic information 4. Start useful cyclic data transmission The structure and content of the individual telegrams are described in subsequent chapters. CP-DI NH 2-25

78 2. Commissioning PROFIBUS DP Sending parametrization data The parametrizing data are transferred from the DP master to the CP system with the function Set_Prm. Bit Meaning Explanation 0 Reserved 1 2 Octet 1: Station status 3 WD_On Response monitoring of CP system on/off: logic "0": off logic "1": on 4 Freeze_Req logic "0": Freeze mode not requested by the master logic "1": Freeze mode not activated by the master 5 Sync_Req logic "0": Sync mode not requested by the master logic "1": Sync mode not activated by the master 6 Unlock_Req Bit 7 Bit 6 Explanation 7 Lock_Req 0 0 min T SDR + Slave parameters must not be overwritten 0 1 CP system released for other masters 1 0 CP system blocked for other masters 1 1 CP system released for other masters 2-26 CP-DI NH

79 2. Commissioning PROFIBUS DP Bit Meaning Explanation Octets 2 and 3: WD_Fact_1 WD_Fact_2 Range 1-255: The response monitoring time of the CP system is transferred with these two octets: T WD [s] = 10ms * WD_Fact_1 * WD_Fact_2 Octet 4: Minimum station delay responder (min T SDR) Explanation The minimum time which the CP system must wait before the reply telegram may be sent to the DP master. Octets 5 and 6: Ident_Number Explanation Transfer of the Ident number (= 00C9) of the CP system; Parametrizing telegrams to the CP system are only accepted, when the transfered and programmed Ident numbers coincide. Octet 7: Group_Ident Explanation Not supported by the CP system Octet 8-32: User_Prm_Data Explanation Not supported by the CP system CP-DI NH 2-27

80 2. Commissioning PROFIBUS DP Sending configuration data The configuration data are transferred from the DP master to the CP system with the function Chk_Cfg. Parameter summary (Chk_Cfg) Octet 1-n: DP identifier Permitted identifiers for Festo CPV valve terminals with fieldbus direct connection (see Figure 2/3): Configuration of the CP system CPV valve terminal with fieldbus direct connection only (no expansion) Expanded by one input module Octet 1: 033 Octet 2: 017 Expanded by one CP valve terminal or one CP output module Expanded by one CP valve terminal or one CP output module and one input module DP identifier decimal hex Comments Octet 1: 033 Octet 1: digital outputs Octet 1: 033 Octet 2: 033 Octet 1: 033 Octet 2: 033 Octet 3: 017 Octet 1: 021 Octet 2: 011 Octet 1: 021 Octet 2: 021 Octet 1: 021 Octet 2: 021 Octet 3: digital outputs 16 digital inputs 16 digital outputs 16 digital outputs 16 digital outputs 16 digital outputs 16 digital inputs 2-28 CP-DI NH

81 2. Commissioning PROFIBUS DP Example: Configuring a CPV valve terminal with fieldbus direction connection expanded by one input module. Octet DP identifier Comments decimal hex DO of the CPV valve terminal with fieldbus directconnection DI of the input module Request diagnostic information The diagnostic data are requested via the function Slave_Diag from the CP system. The description of this function can be found in Chapter 3.3.2, Diagnosis via PROFIBUS DP. CP-DI NH 2-29

82 2. Commissioning PROFIBUS DP Cyclic exchange of data The cyclic exchange of data is carried out with the function Data_Exchange. With this function, the output data for CP systems are transferred as an octet string of length x. The octet string length is determined by the number of identifier bytes. PLEASE NOTE With the function "Data_Exchange", the CP system expects the output information for the valves and electrical outputs. The input information is sent to the master as a reply telegram. Parameter summary (Data_Exchange) for the maximum configuration: Octet 1: O data byte_1 Bit 0: Output x *) Bit 1: Output x+1 Bit 2: Output x+2 Bit 3: Output x+3 Bit 4: Output x+4 Bit 5: Output x+5 Bit 6: Output x+6 Bit 7: Output x CP-DI NH

83 2. Commissioning PROFIBUS DP Octet 2: O data byte_2 Bit 0: Output x+8 Bit 1: Output x+9... Bit 7: Output x+15 Octet 3: I/O data byte_3 Bit 0: Input/Output y *) Bit 1: Input/Output y+1... Bit 7: Input/Output y+7 Octet 4: I/O data byte_4 Bit 0: Input/Output y+8 Bit 1: Input/Output y+9... Bit 7: Input/Output y+15 Octet 5: I/O data byte_5 Bit 0: Input/Output z *) Bit 1: Input/Output z+1... Bit 7: Input/Output z+7 Octet 6: I/O data byte_6 Bit 0: Input/Output z+8 Bit 1: Input/Output y+9... Bit 7: Input/Output z+15 *) x, y, z = Address offset of the master module CP-DI NH 2-31

84 2. Commissioning PROFIBUS DP Summary of implemented functions and Service access points (SAP) Function Available Destination SAP (DSAP) Data_Exchange Yes NIL RD_Inp Yes 56 RD_Outp Yes 57 Slave_Diag Yes 60 Set_Prm Yes 61 Chk_Cfg Yes 62 Get_Cfg Yes 59 Global_Control Yes 58 Set_Slave_Add No CP-DI NH

85 2. Commissioning PROFIBUS DP Bus parameter/reaction times Baud rate (kbaud) max T SDR (T Bit) min T SDR (T Bit) Transmission times on the PROFIBUS DP PLEASE NOTE Take into account the program cycle time of the PLC and the update time of the PROFIBUS DP. The delay time within the CP system dependends on the amount of data and therefore on the configuration of the CP system. This is: < 2 ms. The calculation of the total transmission time can be found in the controller manual. CP-DI NH 2-33

86 2. Commissioning PROFIBUS DP 2.4 Data base (GSD) Data base The CD ROM "utilities" accompanying this manual contains the data base (GSD) with the specific, legal device master data for the CP system. Further information can be found in the "readme" file on the CD ROM. The data base contains a selection of identifiers in addition to the slave-typical entries (ident number, revision, etc.). Enter the identifiers for the CP system in the same physical sequence as the modules CP-DI NH

87 3. PROFIBUS DP diagnostics Chapter 3 PROFIBUS DP diagnostics CP-DI NH 3-1

88 3. PROFIBUS DP diagnostics Contents 3. PROFIBUS DP diagnostics 3.1 Diagnosis with LEDs Normal operating condition Error display with the BUS/POWER LEDs Fault diagnosis with the green LED (POWER) Fault diagnosis with the red LED (BUS) LEDs for status indicator of the valve solenoid coils Error handling Diagnosis with PROFIBUS DP Diagnostic words Diagnostic options Summary of diagnostic bytes Diagnostic information Configuration station status Configuration station status Configuration station status Master address Manufacturer identifier Header device-related diagnosis Structure of device-related diagnosis Configuration of device-specific diagnosis Error handling General DP master Siemens SIMATIC S5/S Options for reading the diagnosis for S5/S STEP 7 V4.x Online diagnosis via diagnostic buffer Module information for the CP valve terminal Short-circuit/overload Output module Reset error Sensor supply of an input module Reset error/short-circuit/overload CP-DI NH

89 3. PROFIBUS DP diagnostics 3.1 Diagnosis with LEDs The light emitting diodes (LED) on the cover provide information about the operational condition of the CPV valve terminal: ª ª red LED: Bus status/error (BUS) green LED: Operating voltage display (POWER) yellow LED row for pilot solenoid 14 yellow LED row for pilot solenoid 12 Figure 3/1: LEDs of the CPV valve terminal with fieldbus direct connection CP-DI NH 3-3

90 3. PROFIBUS DP diagnostics Normal operating condition In normal operating conditions only the green power LED is lit. ( = lit; = flashes; = off) LED Colour Operating condition Error handling BUS none normal none POWER green normal none Figure 3/2: Normal operating condition Error display with the BUS/POWER LEDs Fault diagnosis with the green LED (POWER): LED Colour Operating condition Error handling POWER none operating voltage of electronics not oplied Check operating voltage connection (Pin 1) POWER green flashes rapidly Load voltage CP valves < 20.4 V Check load voltage supply (Pin 2) POWER green flashes slowly Load voltage CP valves < 10 V Check load voltage supply (Pin 2) Figure 3/3: Fault diagnosis with the green POWER LED Load voltage faults are always shown by the green LED (independent of the diagnostic mode set). When the device-specific diagnosis is activated, faults are also indicated via the fieldbus direct connection to the master PLC. 3-4 CP-DI NH

91 3. PROFIBUS DP diagnostics Fault diagnosis with the red LED (BUS): LED Colour Operating condition Error handling BUS red lit hardware fault Return for servicing BUS red flashes rapidly PROFIBUS address not allowed Correct address setting (0,...,125) BUS red flashes slowly (per second) fieldbus connection not correct. Possible causes: - station number incorrect (e.g. address is double assigned) - fieldbus module switched off or defective - interrupted, short-circuited or disturbed fieldbus connection - configuration incorrect master configuration setting in the switch module Check the... address setting fieldbus module fieldbus connection configuration of the master and the settings in the switch module BUS red off briefly switch module missing switch module defective insert switch module replace switch module Figure 3/4: Fault diagnosis with the red BUS LED CP-DI NH 3-5

92 3. PROFIBUS DP diagnostics LEDs for status indicator of the valve solenoid coils Each valve solenoid coil is indicated by a yellow LED (see Figure 3/1). These LEDs indicate the operating status of the valve solenoid coil. LED Valves Colour Switch position valve solenoid coil Error handling none basic position logic 0 (no signal) yellow Switch position or basic position logic 1 (signal on) logic 1, but: operating voltage of valve is lying below the perm. tolerance range (DC < 20.4V) or compressed air supply not correct or pilot exhaust blocked or Return for servicing Figure 3/5: LEDs for status indicator of the valve solenoid coils 3-6 CP-DI NH

93 3. PROFIBUS DP diagnostics 3.2 Error handling Any deviation of the actual configuration of the CP system from the configuration set in the switch module can lead to problems when starting the system. The following table shows the characteristics: Configuration of the CP system Deviation Characteristics > Configuration greater than position of DIL switch System is running. Excess, unconfigured modules are ignored. < Configuration smaller than position of DIL switch System is running. Implement devicespecific diagnosis (see Chapter 3.3) Figure 3/6: Characteristics of deviation between system configuration and DIL switch position CP-DI NH 3-7

94 3. PROFIBUS DP diagnostics 3.3 Diagnosis via PROFIBUS DP The CP system supports diagnostic options via the PROFIBUS in accordance with EN (DIN 19245) (The device-specific diagnosis is supported). PLEASE NOTE: The identifier or channel-related diagnosis listed in standard EN (DIN 19245) will not be supported Diagnostic words The following fault conditions of the CP system are summarised in diagnostic words and transmitted to the DP master: load voltage supply drop to valves (Pin 2) short-circuit in sensor voltage supply load voltage supply drop to output modules short-circuit/overload at the output modules interruption of the CP connection at various CP modules CP valve voltage tolerance undershot (< 20.4 V). 3-8 CP-DI NH

95 3. PROFIBUS DP diagnostics Diagnostic options The CP system acting as slave on the PROFIBUS DP offers comprehensive diagnostic options via the PROFIBUS DP. The following figure shows the necessary steps required for the diagnosis of the CP system. Only those diagnostic bits are shown which require a further diagnostic step Bit Station status 1 Device-specific diagnosis 1 is present Bit Device-specific diagnosis 1 At least one error is present Error CP string/cp valve terminal see chapter Bit Device-specific diagnosis 2 Figure 3/7: Diagnostic steps CP-DI NH 3-9

96 3. PROFIBUS DP diagnostics PLEASE NOTE Diagnostic information is only sent to the master system when the device-specific diagnosis is activated in the switch module. To do this, set the switch element 8 of the 8x DIL switch to "". When commissioning the system, it is useful in some cases to switch off the device-specific diagnosis. If the controller will not start up, try the setting "Device-specific diagnosis inactive" on the 8x DIL switch (see Chapter ) CP-DI NH

97 3. PROFIBUS DP diagnostics Diagnostic words Summary of diagnostic bytes Each bus slave is provided with various diagnostic words. The diagnostic words and their meaning in conjunction with the Festo CP system are shown in the table below. Byte (*) Octet (**) Diagnostic address Diagnostic address + 1 Octet (**) Byte (*) 0 1 Station status 1 Station status Station status 3 Master address (Diag.master_Add) Manufacturer identifier (Ident_number High-Byte 00 H) Manufacturer identifier (Ident_number Low-Byte C9 H) Header Device-related diagnosis 1 (Error summary) Device-specific diagnosis 2 (Error byte CPV Direct) always logic "0" 10 9 Contents are modified by the CP system Figure 3/8: Diagnostic words (*) = Siemens (**) = EN50170 CP-DI NH 3-11

98 3. PROFIBUS DP diagnostics Diagnostic information The following diagnostic information can be requested by the DP master from the CP system with the function Slave_Diag. The CP system replies with an octet string of length 10. The procedure for reading this diagnostic information with a SIMATIC S5/S7 system is described in Chapter Configuration station status 1 Octet 1: Station status_1 Bit Meaning Explanation 0 Diag.Station_ Non_Existent CP system can no longer/cannot yet be addressed. Possible causes: operating voltage not applied data cable interrupted interference in data cable 1 Diag.Station_Not_Ready CP system not ready for data exchange 2 Diag.Cfg_Fault The configuration data received from the master does not correspond to those recorded by the CP system. 3 Diag.Ext_Diag Device-specific diagnosis available. Possible causes: cable interrupted at I/O module short circuit/overload at electrical outputs V valves < 20.4 V V outputs < 10 V V sensor < 10 V 4 Diag.Not_Supported logic "1": Function not supported by CP system 5 Diag.Invalid_ Slave_Response Always logic "0" (set by CP system) 6 Diag.Prm_Fault Last parametrizing telegram faulty 7 Diag.Master_Lock Always logic "0" (set by CP system) Valve terminal related bits Figure 3/9: Diagnostic bits of station status_ CP-DI NH

99 3. PROFIBUS DP diagnostics Configuration station status 2 Octet 2: Station status_2 Bit Meaning Explanation 0 Diag.Prm_Req Logic "1": master must configure the CP system again 1 Diag.Stat_Diag Logic "1": master must request diagnostic data, until this bit is set to logic "0" 2 Always logic "1" (set by CP system) 3 Diag.WD_On logic "1": watchdog activated 4 Diag.Freeze_Mode logic "1": Freeze activated 5 Diag.Sync_Mode logic "1": Sync activated 6 Reserved 7 Diag.Deactivated Always logic "0" (set by CP system) Figure 3/10: Diagnostic bits of station status_2 Configuration station status 3 Octet 3: Station status_3 Bit Meaning Explanation Reserved Diag.Ext_ Diag_Overflow Always logic "0" (set by CP system) Figure 3/11: Diagnostic bits of station status_3 CP-DI NH 3-13

100 3. PROFIBUS DP diagnostics Master address Octet 4: Diag.Master_Add Explanation Figure 3/12: Diagnostic Diag. Master_Add The address of the master which parametrized the CP system is entered in this octet. Manufacturer identifier Figure 3/13: Diagnostic Ident_Number Octets 5 and 6: Ident_Number Explanation These octets contain the manufacturer identification: 00C9 H for the Festo CP system. Header device-related diagnosis Octet 7: Ext_Diag_Data (device-related diagnosis) Explanation Figure 3/14: Diagnostic Ext_Diag_Data This octet represents the header for the device diagnosis. The CP system permanently sets the value 4 in this octet, i.e. 4 octets are prepared/transmitted for "Device-specific diagnosis", incl. the header octet, independent of the CP system equipment. 3 of the 4 octets are used CP-DI NH

101 3. PROFIBUS DP diagnostics Structure of device-related diagnosis 1 Bit Meaning Explanation Octet 8: Device-specific diagnosis 1 1) 0 Common error CP system Logic "1": At least one error is present 1 not used 2 not used 3 not used 4 Common error logic "1": Error CP string/cp valve terminal 5 not used 6 not used 7 not used 1) only sent to the master PLC, when the device-specific diagnosis is activated in the switch module. Figure 3/15: Diagnostic bits of device-related diagnosis 1 CP-DI NH 3-15

102 3. PROFIBUS DP diagnostics Configuration of device-specific diagnosis 2 Bit Meaning Explanation Octet 9: Device-specific diagnosis 2 0 E Off logic "1": CP connection interrupted at output module 1 E On logic "1": CP connection interrupted at input module 2 Short-circuit/overload logic "1": short circuit/overload at output module 3 U Off logic "1": load voltage drop at output module 4 U Sen logic "1": Short-circuit/overload sensor supply <10 V 5 U Val logic "1": Power supply valve coils <20.4 V 6 U Load logic "1": Power supply valve coils <10 V 7 Ex not used Figure 3/16: Diagnostic bits for device-specific diagnosis CP-DI NH

103 3. PROFIBUS DP diagnostics 3.4 Error handling In the case of the following faults, the reaction of the CP system depends on the configured reaction of the master module. telegram failure master stop interruption in bus cable Depending on the setting or the configuration, all the outputs (valves and electrical outputs) will be switched off or maintain their status. WARNING Make sure that the valves and outputs are reset after rectifying the above mentioned faults. Dangerous situations can arise if the valves and outputs are not reset after one of the above faults. PLEASE NOTE Single solenoid valves move to the basic position. Double solenoid valves remain in the current position. If mid-position functions are implemented by CP valves, they will move to defined positions (pressioned, exhausted, blocked) CP-DI NH 3-17

104 3. PROFIBUS DP diagnostics General DP master Siemens SIMATIC S5/S7 Use the function Set_Prm to determine the watchdog time (WD_Fact_1, Octet 2, WD_Fact_2, Octet 3). In the case of a fault, e. g. a bus failure, the CP system will switch off all valves and electrical outputs after the parametrized time. These controllers can be used to set the reaction of the CP system to the faults named (for details, see controller manual). Almost all configuration programs contain the function "Response monitoring". For the operating modes named, the specified time corresponds to the drop-off time of the valves and the electrical outputs. Further details on response monitoring can be found in the appropriate manuals CP-DI NH

105 3. PROFIBUS DP diagnostics Two types of error response for the control system can be set: the controller switches to the operating mode "STOP" when an error occurs (hard error characteristics) or the controller remains in the operating mode "RUN" when an error occurs (soft error characteristics). Control system Module Meaning STOP RUN SIMATIC S5 with IM 308C OB23 OB24 reaction to QVZ with direct peripheral access reaction to QVZ with peripheral access via process image default default OM is programmed OM is programmed OB35 reaction to PEU default OM is programmed SIMATIC S7/M7 OB82 reaction to a devicespecific diagnosis OB86 reaction to failure of a DP slave QVZ: Acknowledgment delay OB: Organization module PEU: Periphery unclear Figure 3/17: Error response of the control system default default OM is programmed OM is programmed Further details on the control system can be found in the appropriate manuals. CP-DI NH 3-19

106 3. PROFIBUS DP diagnostics Options for reading the diagnosis for S5/S7 Diagnosis for PROFIBUS DP is supported in the various control systems by function modules. These read the slave diagnosis and write them to a data range of the user program. Control system SIMATIC S5 with IM 308C SIMATIC S5 with S5-95U/DP-Master SIMATIC S5 with SF 50/DP-Master Function module FB 192 "IM 308C" FB 230 "S_DIAG" FB 230 "S_DIAG" SIMATIC S7/M7 SFC 13 "DP NRM_DG" See... Manual "Decentralized peripheral system ET 200" Manual "Decentralized peripheral system ET 200" Manual "Programmable valve terminal with SB/SF 50" Referencemanual "System and standard functions" Figure 3/18: Options for reading the diagnosis for S5/S7 Manufacturer Siemens Siemens Festo Siemens Example for a STEP 7 user program: STL Explanation CALL SFC 13 REQ := TRUE Read request LADDR := W#16#03FE Pointer on diagnostic address, e.g d = 03FE h (s. Mask "DP slave properties" in HW configuration) RET_VAL := MW100 when errors occur, output error code RECORD := P#M110.0 WORD 5 Pointer at start of the data range for diagnosis and length of diagnostic data BUSY := M10.0 Reading terminated Figure 3/19: Example 3-20 CP-DI NH

107 3. PROFIBUS DP diagnostics 3.5 STEP 7 V4.x Online diagnosis via diagnostic buffer The diagnostic buffer of STEP7 offers the possibility of displaying diagnostic events of the S7 system in the sequence in which they occur. ª «Figure 3/20: Online diagnosis via diagnostic buffer (for explanations, see text) CP-DI NH 3-21

108 3. PROFIBUS DP diagnostics Direct diagnostic events in connection with CP valve terminals could be: Decentralized periphery: station failure - communication between slave and master interrupted Module disturbed - see device-specific diagnosis Change of operating condition from START to RUN (set/actual difference present) - configuration data of CP valve terminal do not coincide with the periphery - CP valve terminal has incorrect DIL settings Requirements The hardware configuration must be accessed Proceed as follows (Figure 3/20): Switch from offline to online. ª Use the right-hand mouse key to mark the CPU in the rack. Click "Module Information" in the menu which appears. «The window "Module Information" now appears. Select the rider "Diagnostic buffer." Mark the event and read the details on the event. These will give you more information on how to proceed further and are dependent on the S7 controller used CP-DI NH

109 3. PROFIBUS DP diagnostics Module information for the CP valve terminal Mark the CP valve terminal instead of the CPU. Further information regarding the condition of the CP system can be read from the window "Module Information". CP-DI NH 3-23

110 3. PROFIBUS DP diagnostics 3.6 Short-circuit/overload Output module If there is a short-circuit or overload: All digital outputs of the output module are switched off the green LED "Diag" on the output module will flash rapidly the Bit short-circuit/overload in octet 9 "Device-specific diagnosis 2" is set to logic "1". PLEASE NOTE The outputs cannot be used until the short-circuit or overload is eliminated and the error reset. Reset error In order to reset the error, the 8 outputs must be reset. The following options are available: Options Explanation set all outputs of the output module to logic "0" (RESET) or interrupt CP connection to CP output module briefly or interrupt operating voltage of the CP system briefly manually or automatically in the program - outputs on the output module are automatically reset - all outputs of the CP system are automatically reset Figure 3/21: Online diagnosis via diagnostic buffer (explanation see text) The outputs can then be used again. If the short-circuit still exists, the outputs will be switched off again CP-DI NH

111 3. PROFIBUS DP diagnostics Sensor supply of an input module If there is a short-circuit, overload or voltage error in the sensor supply: the sensor supply to all the inputs of a module will be switched off the green LED "Diag" on the input module will flash rapidly the error Bit USen in octet 9 "Device-specific diagnosis 2" is set to logic "1". PLEASE NOTE: The inputs cannot be used until the short-circuit or overload is eliminated and the error reset. Reset error/short-circuit/overload In order to reset the error the following options are available: briefly interrupt the CP connection on the CP input module. or briefly interrupt the operating voltage of the CP system on the field bus node. The inputs can then be interrogated again. If the shortcircuit still exists, the error message will appear again. CP-DI NH 3-25

112 3. PROFIBUS DP diagnostics 3-26 CP-DI NH

113 4. Commissioning the Festo fieldbus Chapter 4 Commissioning the Festo fieldbus CP-DI NH 4-1

114 4. Commissioning the Festo fieldbus Contents 4. Commissioning the Festo fieldbus 4.1 Preparation of the CPV valve terminal for commissioning Switch on the operating voltages Address allocation of the CPV valve terminal Configuration Configuration with the fieldbus configurator Addressing CP-DI NH

115 4. Commissioning the Festo fieldbus 4.1 Preparation of the CPV valve terminal for commissioning Switch on the operating voltages PLEASE NOTE Note the switching-on instructions in the PLC controller manual. When the controller is switched on, it automatically implements a comparison between the SET and ACTUAL configuration. For this configuration run it is important that: the specification for the fieldbus configuration are complete and correct. the power supplies to the PLC and to the fieldbus slaves are either switched on simultaneously or in the sequence specified below. Note the following points for switching on the power supply: Shared power supply Separate power supply Shared power supply for control system and all fieldbus slaves using a central power pack and/or a central switch. If the control system and fieldbus slaves have separate power supplies, switch them on in the following sequence: 1. Switch on operating voltage supply for all fieldbus slaves. 2. Switch on operating voltage supply for the controller. CP-DI NH 4-3

116 4. Commissioning the Festo fieldbus Address allocation of the CPV valve terminal The CPV valve terminal with fieldbus direct connection always uses 16 output addresses, regardless of the number of valve solenoid coils it has. This allows for the later expansion of the CPV valve terminal without changing addresses. The following figure shows the addressing sequence of the individual CPV valve plates Fig. 4/1: Address allocation of a CPV valve terminal 4-4 CP-DI NH

117 4. Commissioning the Festo fieldbus The address allocation on the CPV valve terminal occurs from left to right and on the individual valve locations from front to back AWn.x AWn.x+1 A1.0.0 A1.0.1 A1.0.2 A1.0.3 A1.0.4 A1.0.5 A1.0.6 A1.0.7 A1.1.0 A1.1.1 A1.1.2 A1.1.3 A1.1.4 A1.1.5 A1.1.6 A1.1.7 AW: n: x: Output word Slave number Word (8 Bits) Figure 4/2: Address allocation of the CPV valve terminal (outputs) with examples for slave No. 1 CP-DI NH 4-5

118 4. Commissioning the Festo fieldbus A valve location in the CPV valve terminal always occupies 2 addresses, even when it is fitted with a reserve plate or pressure isolation plate. If a valve location is fitted with a double solenoid valve, the following allocation applies: - Pilot solenoid 14 occupies the lower-value addresses, - Pilot solenoid 12 occupies the higher-value addresses. The higher-value addresses remain unused with single solenoid valves. 4-6 CP-DI NH

119 4. Commissioning the Festo fieldbus 4.2 Configuration PLEASE NOTE The CP modules always use 16 outputs and/or 16 inputs, independent of the configuration and type of the module (inputs, outputs, valves). The position of the DIL switch in the configuration of the CP system is relevant for the number of the reserved I/O addresses and station numbers (see Chapters and 1.8) PLEASE NOTE Ensure that the DIL switches in the switch module are set in compliance with the configuration of the CP system. If the set configuration is greater than the real configuration, an error message (ACP) is initiated. CP-DI NH 4-7

120 4. Commissioning the Festo fieldbus Configuration with the fieldbus configurator Procedure The fieldbus configurator in the FST software provides support during compilation of the set point configuration. The menu control and operation of the FST software is described in the relevant FST handbook of the PLC. 1. Enter the fieldbus address of the fieldbus slave (CP system). 2. Select type of fieldbus slave ("Valve terminal 10" for CP system). 3. Enter number of assigned inputs/outputs byte-wise under IW and OW. PLEASE NOTE The entry mask of the fieldbus configurator shows IW and OW on the monitor. This stands for input words and output words, each with 8 Bits. For each module, enter 2 IW or 2 OW (16 inputs or 16 outputs). PLEASE NOTE With a Festo fieldbus master, it is possible to configure the CP system with a set/actual comparison. An existing fieldbus configuration is then loaded into the master. 4-8 CP-DI NH

121 4. Commissioning the Festo fieldbus Figure 4/4: Example Configuring with FST 200; Select CP system from slave list Figure 4/5: Example Configuring with FST 200; Enter number of IW or OW CP-DI NH 4-9

122 4. Commissioning the Festo fieldbus Addressing PLEASE NOTE Addressing of the CP system occurs byte-wise via the Festo fieldbus. Note the difference compared to word-wise addressing of other fieldbus slaves. Addressing inputs/outputs Example The following example shows the addressing of the inputs/outputs with the CPV valve terminal expanded by a CP valve terminal and an output module (fieldbus address of the CP system: 3). Master: Festo SF3 Configuration with FST200: 2 IW and 4 OW CP system fieldbus address: 3 ª «ª «O O3.0.7 O O3.2.7 I I3.0.7 O O3.1.7 O O3.3.7 I I3.1.7 CPV valve terminal with Festo fieldbus direct connection CPV valve terminal with 8 valve plates CP input module with 16 inputs Figure 4/3: Example Addressing with Festo fieldbus 4-10 CP-DI NH

123 5. Festo fieldbus diagnostics Chapter 5 Festo fieldbus diagnostics CP-DI NH 5-1

124 5. Festo fieldbus diagnostics Contents 5. Festo fieldbus diagnostics 5.1 Diagnosis via LEDs Normal operating condition Error display with the BUS/POWER LEDs Fault diagnosis with the green LED (POWER): Fault diagnosis with the red LED (BUS) LEDs for status indicator of the valve solenoid coils Diagnosis via the fieldbus Error handling Behaviour of the CPV valve terminal caused by interference Short-circuit/overload in an output module Reset error Short-circuit sensor supply at an input module Reset error/short-circuit/overload CP-DI NH

125 5. Festo fieldbus diagnostics 5.1 Diagnosis via LEDs The light emitting diodes on the cover of the CPV valve terminal provide information about the operational condition of the CPV valve terminal: ª red LED: Bus status/error (BUS) ªgreen LED: Operating voltage display (POWER) yellow LED row for pilot solenoid 14 yellow LED row for pilot solenoid 12 Figure 5/1: LEDs of the CPV valve terminal with fieldbus direct connection CP-DI NH 5-3

126 5. Festo fieldbus diagnostics Normal operating condition In normal operating conditions only the green power LED is lit. ( = lit; = flashes; = off) LED Colour Operating condition Error handling BUS none normal none POWER green normal none Fig. 5/2: Normal operating condition Error display with the BUS/POWER LEDs Fault diagnosis with the green LED (POWER): LED Colour Operating condition Error handling POWER none operating voltage of electronics not opplied Check operating voltage connection (Pin 1) POWER green flashes rapidly load voltage CP valves < 20.4 V Check load voltage supply (Pin 2) POWER green flashes slowly load voltage CP valves < 10 V Check load voltage supply (Pin 2) Fig. 5/3: Fault diagnosis with the green POWER LED Load voltage faults are always shown by the green LED. 5-4 CP-DI NH

127 5. Festo fieldbus diagnostics Fault diagnosis with the red LED (BUS): LED Colour Operating condition Error handling BUS red lit hardware fault Return for servicing BUS red flashes rapidly fieldbus address not allowed Correct address setting (1,...,63) BUS red flashes slowly (per second) fieldbus connection not correct. Possible causes: - Station number not correct (e.g. address is double assigned) - fieldbus module switched off or defective - interrupted, shortcircuited or disturbed fieldbus connection - configuration incorrect master configuration <> settings in the switch module Check the... address setting fieldbus module fieldbus connection configuration of the master and settings in the switch module BUS red off briefly switch module missing switch module defective insert switch module replace switch module Fig. 5/4: Fault diagnosis with the red BUS LED: CP-DI NH 5-5

128 5. Festo fieldbus diagnostics LEDs for status indicator of the valve solenoid coils Each valve solenoid coil is indicated by a yellow LED (see Figure 5/1). These LEDs indicate the operating status of the valve solenoid coil. LED Valves Colour Switch position valve solenoid coil Error handling none basic position logic 0 (no signal) yellow Switch position or basic position logic 1 (signal on) logic 1, but: Operating voltage of valves is below the perm. tolerance range (DC < 20.4V) or Compressed air supply not O.K. or Pilot exhaust blocked or Return for servicing Fig. 5/5: LEDs for status indicator of the valve solenoid coil 5-6 CP-DI NH

129 5. Festo fieldbus diagnostics 5.2 Diagnosis via the fieldbus A Festo PLC can be used to directly evaluate all diagnostic information. An error list is provided in the master. This error list records and constantly updates all the diagnostic bits. The following errors are recognised by the CP system: Diagnostic bit KCP U Val U Tol U Sen U Off KZ/Ü ACP Fig. 5/6: Summary of diagnostic bits Meaning CP system not ready (during the start-up phase) Configuration error in the fieldbus master Load voltage drop CP valves < 10.4 V CPV Direct CP valve terminal in the expansion Undervoltage CP valves < 20.4 V CPV Direct CP valve terminal in the expansion Short-circuit sensor supply at the CP input module Load voltage drop at the CP output module Short-circuit/overload CP output module Connection to a CP module in the expansion interrupted CP input module CP output module CP valve terminal The diagnostic byte is interrogated via the function module 44 or in the command interpreter (CI). Further information can be found in the PLC manual of the controller. CP-DI NH 5-7

130 5. Festo fieldbus diagnostics 5.3 Error handling Behaviour of the CPV valve terminal caused by interference Behaviour caused by interference in the control system: The CP valves and any other electric outputs present are switched off if there are errors or interference after the following times: Baud rate (kbaud) Switch off time s s ms ms Figure 5/3: Switch off time for CP valves and outputs caused by interference (dependent on the baud rate) PLEASE NOTE If the outputs are reset after PLC stop, fieldbus interruption or interference, note the following: single solenoid valves return to basic position double pilot valves remain in current position mid-position valves return to middle position (depending on valve type) pressioned, exhausted or blocked. 5-8 CP-DI NH

131 5. Festo fieldbus diagnostics Short-circuit/overload in an output module If there is a short-circuit or overload: all digital outputs of the module are switched off the green LED "Diag" on the output module will flash rapidly the Bit short-circuit/overload (KZ/Ü) of the diagnostic byte is set to "logic 1". PLEASE NOTE The outputs cannot be used until the short circuit or overload is eliminated and the error reset. Reset error In order to reset the error, the 8 outputs must be reset. The following options are available: Options set all outputs of the output module to logic "0" (RESET) or briefly interrupt CP connection on the CP output module or briefly interrupt operating voltage of the CPV direct Explanation manually or automatic in the program outputs on the output module are automatically reset all outputs of the CP system are automatically reset Subsequently, the outputs can be set to "logic 1". If the short-circuit still exists, the outputs will be switched off again. CP-DI NH 5-9

132 5. Festo fieldbus diagnostics Short-circuit sensor supply at an input module If there is a short-circuit, overload or voltage error in the sensor supply: the sensor supply to all the inputs of a module will be switched off the green LED "Diag" on the input module will flash rapidly the error bit in the diagnostic byte is set to logic "1". PLEASE NOTE The inputs cannot be used until the short-circuit or overload is eliminated and the error reset. Reset error/short-circuit/overload In order to reset the error, the following options are available: briefly interrupt the CP connection on the CP input module. or briefly interrupt the operating voltage of the CPV direct. The inputs can then be interrogated again. If the shortcircuit still exists, the error message will appear again CP-DI NH

133 6. Commissioning the ABB CS31 Chapter 6 Commissioning the ABB CS31 CP-DI NH 6-1

134 6. Commissioning the ABB CS31 Contents 6. Commissioning the ABB CS Preparation of the CPV valve terminal for commissioning Switch on the operating voltages Address allocation of the CPV valve terminal General Configuration CS31 central unit as bus master T200 / 07CS61 as bus master CP-DI NH

135 6. Commissioning the ABB CS Preparation of the CPV valve terminal for commissioning Switch on the operating voltages PLEASE NOTE Note the switching-on instructions in the PLC controller manual. When the controller is switched on, it automatically implements a comparison between the SET and ACTUAL configuration. For this configuration run it is important that: the specification for the fieldbus configuration are complete and correct. the power supplies to the PLC and to the fieldbus slaves are switched on either simultaneously or in the sequence specified below. Note the following points for switching on the power supply: Shared power supply Separate power supply Shared power supply for control system and all fieldbus slaves using a central power pack and/or a central switch. If the control system and fieldbus slaves have separate power supplies, switch them on in the following sequence: 1. Switch on operating voltage supply for all fieldbus slaves. 2. Switch on operating voltage supply for the controller. CP-DI NH 6-3

136 6. Commissioning the ABB CS Address allocation of the CPV valve terminal The CPV valve terminal with fieldbus direct connection always uses 16 output addresses, regardless of the number of valve solenoid coils it has. This allows for the later expansion of the CPV valve terminal without changing addresses. The following figure shows the addressing sequence of the individual CPV valve plates Figure 6/1: Address allocation of a CPV valve terminal 6-4 CP-DI NH

137 6. Commissioning the ABB CS31 The address allocation in the CPV valve terminal occurs from left to right and in the individual valve locations from front to back on,00 on,01 on,02 on,03 on,04 on,05 on,06 on,07 on,08 on,09 on,10 on,11 on,12 on,13 on,14 on,15 n: Station number Figure 6/2: Address allocation of the CPV valve terminal (outputs) A valve location in the CPV valve terminal always occupies 2 addresses, even when it is fitted with a reserve plate or pressure isolation plate. If a valve location is fitted with a double solenoid valve, the following allocation applies: - Pilot solenoid 14 occupies the lower-value addresses, - Pilot solenoid 12 occupies the higher-value addresses. The higher-value addresses remain unused with single solenoid valves. CP-DI NH 6-5

138 6. Commissioning the ABB CS General A CP system can be fitted with a varying number of inputs/outputs. The addressing of the CPV valve terminal with ABB CS31 direct connection is based on the specifications of the CS31 system bus. The following applies for the CP system: 16 inputs or 16 outputs occupy a CS31 bus address. Even an incomplete 16 group occupies a full CS31 bus address. The following applies when a CP system is connected to the ABB Procontic T200: The address designation of the inputs and outputs is different from that of a CS31 central unit. The appropriate module identifiers must be entered in the configuration table of the T200. PLEASE NOTE Select the range n = for the addresses in the CPV valve terminal. This also allows a CP valve terminal or CP output module connected to an expansion connection to be addressed. PLEASE NOTE Note that, depending on the configuration, the CP system can occupy one or two station numbers. 6-6 CP-DI NH

139 6. Commissioning the ABB CS Configuration PLEASE NOTE The CP modules always use 16 outputs and/or 16 inputs, independent of the configuration and type of the module (inputs, outputs, valves). The position of the DIL switch in the configuration of the CP system is relevant for the number of the reserved I/O addresses and station numbers (see Chapters and 1.8) PLEASE NOTE Ensure that the DIL switches in the switch module are set in compliance with the configuration of the CP system. If the set configuration is greater than the real configuration, an error message (BE) is initiated. CP-DI NH 6-7

140 6. Commissioning the ABB CS CS31 central unit as bus master The CP system with ABB CS 31 direct connection offers max. 32 outputs (valves or digital outputs) and max. 16 inputs. The following figure shows an address summary. CP system Signal designation when a CS31 central unit is used Configuration Outputs/inputs Outputs Inputs CPV valve terminal with ABB CS31 direct connection CP expansion module: CP valve terminal or CP output module 16O On,00... On,15 32O On+1,00... On+1,15 CP input module 16I In,00... In,15 n = station number set Figure 6/3: Configuration options and addresses for a CS31 central unit The CS31 central unit determines the configuration of the CS31 system during switch on and does not need to be set. PLEASE NOTE The system flag KW 00,09 can be used to block program processing until the specified number of I/O modules (incl. CP system) are present on the CS31 system bus. 6-8 CP-DI NH

141 6. Commissioning the ABB CS31 Example: Addressing in a CS31 central unit In the CPV valve terminal with fieldbus direct connection, station number 20 is set. The CPV valve terminal is expanded by a CPV valve terminal and a CP input module and occupies two CS31 bus addresses (station numbers). ª «ª «O20,00...A20,15 O21,00...A21,15 CPV valve terminal with ABB CS31 direct connection CPV valve terminal with 8 valve plates CP input module with 16 inputs Figure 6/4: Example Addressing in a CS31 central unit I20,00...I20,15 CP-DI NH 6-9

142 6. Commissioning the ABB CS T200 / 07CS61 as bus master Four CS31 system buses can be connected to the T200 station. The coupler 07CS61 closest to the T200 central unit has the line No. 1, the downstream buses have line numbers 2, 3 and 4. Example: Signal designation A 1.20,05 indicates: Line 1, CS31 bus address 20, output 05. During the program generation, the central unit must be informed which line configuration is present. To do this, enter the relevant module identifiers into the configuration table using the programming system (e.g. 07 PC 332). The following table shows a summary. Configuration of the CP system Module identifier with coupler 07CS61 Outputs Signal designation Inputs CPV valve terminal with ABB CS31 direct connection (CPV Direct) CPV Direct + CP input module O16 OL.n,00... OL.n,15 IO16 OL.n,16... OL.n,31 IL.n,00... IL.n,15 CPV Direct + CP valve terminal or CP output module O16 O16 OL.n,00... OL.n,15 OL.n+1,00... OL.n+1,15 CPV Direct + CP input module + CP valve terminal or CP output module IO16 O16 OL.n,16... OL.n,31 OL.n+1,00... OL.n+1,15 IL.n,00... IL.n,15 L: Line number n: station number set Figure 6/5: Summary of module identifiers 6-10 CP-DI NH

143 6. Commissioning the ABB CS31 Example: Addressing in a T200 central unit with coupler 07CS61 (Line 1): In the CPV valve terminal with fieldbus direct connection, station number 12 is set. The CPV valve terminal is expanded by a CPV valve terminal and a CP input module and occupies two CS31 bus addresses (station numbers). ª «O1.12,16...O1.12,31 O1.13,00...O1.13,15 I1.12,00...I1.12,15 ª «CPV valve terminal with ABB CS31 direct connection CPV valve terminal with 8 valve plates CP input module with 16 inputs Figure 6/6: Example Addressing in a T200 central unit CP-DI NH 6-11

144 6. Commissioning the ABB CS CP-DI NH

145 7. ABB CS31 diagnostics Chapter 7 ABB CS31 diagnostics CP-DI NH 7-1

146 7. ABB CS31 diagnostics Contents 7. ABB CS31 diagnostics 7.1 Diagnosis via LEDs Normal operating condition Error display of the BUS/POWER LEDs Fault diagnosis with the green LED (POWER): Fault diagnosis with the red LED (BUS): LEDs for status indicator of the valve solenoid coils Diagnosis via the fieldbus Example 1 central unit 07KR Example 2: Coupler 07CS Setting the diagnostic mode Error handling Behaviour of the CPV valve terminal caused by interference Short-circuit/overload in an output module Reset error Short-circuit sensor supply at an input module Reset error/short-circuit/overload CP-DI NH

147 7. ABB CS31 diagnostics 7.1 Diagnosis via LEDs The light emitting diodes on the cover of the CPV valve terminal provide information about the operational condition of the CPV valve terminal: ª ª red LED: Bus status/error (BUS) green LED: Operating voltage display (POWER) yellow LED row for pilot solenoid 14 yellow LED row for pilot solenoid 12 Figure 7/1: LEDs of the CPV valve terminal with fieldbus direct connection CP-DI NH 7-3

148 7. ABB CS31 diagnostics Normal operating condition In normal operating conditions only the green power LED is lit. ( = lit; = flashes; = off) LED Colour Operating condition Error handling BUS none normal none POWER green normal none Figure 7/2: Normal operating condition 7-4 CP-DI NH

149 7. ABB CS31 diagnostics Error display of the BUS/POWER LEDs Fault diagnosis with the green LED (POWER): LED Colour Operating condition Error handling POWER none operating voltage of electronics not opplied Check operating voltage connection (Pin 1) POWER green flashes rapidly load voltage CP valves < 20.4 V check load voltage supply (Pin 2) BUS red lit POWER green flashes slowly load voltage CP valves < 10 V Check load voltage supply (Pin 2) BUS red lit Figure 7/3: Fault diagnosis with the green POWER and red BUS LEDs Load voltage faults are always shown by the green and red LEDs (independent of the diagnostic mode set). When the device-specific diagnosis is activated, faults are also indicated via the fieldbus direct connection to the master PLC. CP-DI NH 7-5

150 7. ABB CS31 diagnostics Fault diagnosis with the red LED (BUS): LED Colour Operating condition Error handling BUS red flashes rapidly - Station number incorrectly (> 60) set Correct station number (0,...,60) BUS red flashes slowly (per second) - Address setting incorrect e.g. double assigned - CPV valve terminal not initialized yet BUS red lit - load voltage drop in the CPV Direct 1) - load voltage drop in the CP valve terminal of the expansion 1) - load voltage drop CP output module 1) Correct station number Start bus Check power supply Check power supply Check power supply - Undervoltage of valves in the CPV Direct 1) - undervoltage of CP valves < 20.4 V (in the expansion) 1) - short-circuit/overload CP output module - short-circuit sensor supply CP input module - Connection to a CP module interrupted - CP input module - CP output module - CP valve terminal Check power supply Check power supply Rectify shortcircuit/overload Rectify shortcircuit/overload Restore connection 1) These error displays can be switched off using the diagnostic mode settings. They are however then not transmitted to the CS31 master (see section 1.2.2). Figure 7/4: Fault diagnosis with the red BUS LED 7-6 CP-DI NH

151 7. ABB CS31 diagnostics LEDs for status indicator of the valve solenoid coils Each valve solenoid coil is indicated by a yellow LED (see Figure 7/1). These LEDs indicate the operating status of the valve solenoid coil. LED Colour Switch position valve solenoid coil Error handling none basic position logic 0 (no signal) yellow Switch position or basic position logic 1 (signal on) logic 1, but: Operating voltage of valves is below the perm. tolerance range (DC < 20.4V) or Compressed air supply not O.K. or Pilot exhaust blocked or Return for servicing Figure 7/5: LEDs for status indicator of the valve solenoid coils CP-DI NH 7-7

152 7. ABB CS31 diagnostics 7.2 Diagnosis via the fieldbus The CPV valve terminal with ABB CS31 direct connection behaves like a binary input/output module on the ABB CS31 system bus. All central units and couplers implement the general monitoring of the CS31 system bus, e.g. total failure of peripheral modules. The central units and couplers interrogate the diagnostic messages prepared by the CPV valve terminal. The relevant ABB manuals apply for all central units and couplers. The following figures show examples of diagnostic options relating to: central unit 07KR91 T200 with coupler 07CS61 PLEASE NOTE Several CP diagnostic messages are summarised into collective signals in the ABB CS31 protocol. 7-8 CP-DI NH

153 7. ABB CS31 diagnostics Example 1 central unit 07KR91 The entries of the CPV valve terminal in the error flag words have the following meaning: FK3 = small error FK4 = warning M255,10 M 255,13 M 255,14 MW 255,00 MW 255,08 ª MW 255,01 MW 255,09 ª «MW 255,02 MW 255,10 «MW 255,03 MW 255,11 MW 255,04 MW 255,12 MW 255,05 MW 255,13 MW 255,06 MW 255,14 MW 255,07 MW 255,15 Error recognition/meaning in Festo CP systems 15 D = CPV valve terminal not connected ª Type of device: 2 D = Binary outputs (CPV Direct without expansion or expanded by a CP valve terminal/cp output module) 4 D = Binary inputs/outputs (CPV Direct expanded by an input module) «Group No. (station number set, decimal) 1 D = internal module error (in the CP system) undervoltage valves 20.4V load voltage drop (CP output module, CP valve terminal) short-circuit sensor supply 2 D = wire break, connection interrupted to CP output module / CP input module / CP valve terminal 4 D = overload/short-circuit of electrical output Channel No. In connection with CPV valve terminals is always 0! Figure 7/6: Example 07KR91 Meaning of ABB error flags in Festo CP systems CP-DI NH 7-9

154 7. ABB CS31 diagnostics Example 2: Coupler 07CS61 The diagnostic information from the CPV valve terminal is entered in the following error flags: Line 1: MW4104,04 Line 2: MW4105,12 Line 3: MW4107,04 Line 4: MW4108,12 They have the following meaning: Error code 0000 No error 1111 Module (CPV valve terminal) separated from bus 0100 Overload (at least one electric output module short circuited/overloaded) 0010 Wire break (Connection to CP output module/cp valve terminal or CP input module interrupted) 0001 Internal error in the CP system Undervoltage valves in CPV Direct < 20.4 V load voltage drop CP valve terminal in the expansion load voltage drop CP output module < 10 V sensor supply CP input module short-circuited Channel No. always 0! 1 = Input/output module always 1 in connection with CPV valve terminals Station address set 0 = Binary module Figure 7/7: Example 07CS61 Meaning of ABB error flags in Festo CP systems (see Figure 7/2) 7-10 CP-DI NH

155 7. ABB CS31 diagnostics 7.3 Setting the diagnostic mode The following error messages can be switched off with the switch element 8 of the 8x DIL switch in the switch module (see Chapter 1.2.2): Load voltage drop of the CPV valve terminal with ABB CS31 direct connection of the CP valve terminal in the expansion of the CP output module in the expansion The following table shows the behaviour of the diagnostic LEDs or the error flags with active/inactive load voltage monitoring: Monitoring active Monitoring inactive BUS LED lit off POWER LED flashes 1) flashes 1) Error flags set reset 1) only with load voltage faults in the CPV Direct Figure 7/8: Diagnostic mode settings Behaviour of LEDs and error flags CP-DI NH 7-11

156 7. ABB CS31 diagnostics 7.4 Error handling Behaviour of the CPV valve terminal caused by interference Behaviour caused by interference in the control system: The CP valves and any other electric outputs present are switched off if there are errors or interference after 250 ms. PLEASE NOTE If the outputs are reset after PLC stop, fieldbus interruption or interference, note the following: single solenoid valves return to basic position double pilot valves remain in current position mid-position valves return to middle position (depending on valve type) pressioned, exhausted or blocked CP-DI NH

157 7. ABB CS31 diagnostics Short-circuit/overload in an output module If there is a short-circuit or overload: all digital outputs of the module are switched off the green LED "Diag" on the output module will flash fast the corresponding diagnostic bit is set. PLEASE NOTE The outputs cannot be used until the short-circuit or overload is eliminated and the error reset. Reset error In order to reset the error, the 8 outputs must be reset. The following options are available: Options set all outputs of the output module to logic "0" (RESET) or briefly interrupt CP connection on the CP output module or briefly interrupt operating voltage of the CPV direct Explanation manually or automatic in the program outputs on the output module are automatically reset all outputs of the CP system are automatically reset Subsequently, the outputs can be set to "logic 1". If the short-circuit still exists, the outputs will be switched off again. CP-DI NH 7-13

158 7. ABB CS31 diagnostics Short-circuit sensor supply at an input module If there is a short-circuit, overload or voltage error in the sensor supply: the sensor supply to all the inputs of a module will be switched off the green LED "Diag" on the input module will flash fast the error bit in the diagnostic byte is set to logic "1". PLEASE NOTE The inputs cannot be used until the short circuit or overload is eliminated and the error reset. Reset error/short-circuit/overload In order to reset the error the following options are available: Briefly interrupt the CP connection on the CP input module. or briefly interrupt the operating voltage of the CPV direct. The inputs can then be interrogated again. If the short circuit still exists, the error message will appear again CP-DI NH

159 8. Commissioning the SUCOnet K Chapter 8 Commissioning the Klöckner-Moeller SUCOnet K CP-DI NH 8-1

160 8. Commissioning the SUCOnet K Contents 8. Commissioning the Klöckner-Moeller SUCOnet K 8.1 Preparation of the CPV valve terminal for commissioning Switch on the operating voltages Address allocation for the CPV valve terminal CP system configuration and number of inputs/outputs Configuration for SUCOnet K Addressing inputs/outputs Addressing the inputs and outputs with master PS CP-DI NH

161 8. Commissioning the SUCOnet K 8.1 Preparation of the CPV valve terminal for commissioning Switch on the operating voltages PLEASE NOTE Note the switching-on instructions in the PLC controller manual. When the controller is switched on, it automatically implements a comparison between the SET and ACTUAL configuration. For this configuration run it is important that: the specification for the fieldbus configuration are complete and correct. the power supplies to the PLC and to the fieldbus slaves are switched on either simultaneously or in the sequence specified below. Note the following points for switching on the power supply: Shared power supply Separate power supply Shared power supply for control system and all fieldbus slaves using a central power pack and/or a central switch. If the control system and fieldbus slaves have separate power supplies, switch them on in the following sequence: 1. Switch on operating voltage supply for all fieldbus slaves. 2. Switch on operating voltage supply for the controller. CP-DI NH 8-3

162 8. Commissioning the SUCOnet K Address allocation for the CPV valve terminal The CPV valve terminal with fieldbus direct connection always uses 16 output addresses, regardless of the number of valve solenoid coils it has. This allows for the later expansion of the CPV valve terminal without changing addresses. The following figure shows the addressing sequence of the individual CPV valve plates Figure 8/1: Address allocation of a CPV valve terminal 8-4 CP-DI NH

163 8. Commissioning the SUCOnet K The address allocation in the CPV valve terminal occurs from left to right and in the individual valve locations from front to back %SD %SD %SD %SD %SD %SD %SD %SD %SD %SD %SD %SD %SD %SD %SD %SD Figure 8/2: Address allocation of the CPV valve terminal (outputs), example: Station number 2, Module 1 CP-DI NH 8-5

164 8. Commissioning the SUCOnet K A valve location in the CPV valve terminal always occupies 2 addresses, even when it is fitted with a reserve plate or pressure isolation plate. If a valve location is fitted with a double solenoid valve, the following allocation applies: - Pilot solenoid 14 occupies the lower-value addresses, - Pilot solenoid 12 occupies the higher-value addresses. The higher-value addresses remain unused with single solenoid valves. 8-6 CP-DI NH

165 8. Commissioning the SUCOnet K 8.2 CP system configuration and number of inputs/outputs PLEASE NOTE The CP system permanently occupies 32 inputs and 32 outputs within the PLC, independent of the configuration and type of module (inputs, outputs, valves) and independent of the DIL switch settings for the configuration of the CP system. The settings of the CP system configuration with the SUCOnet protocol only relate to checking the connected expansion modules. The position of the DIL switch in the configuration of the CP system is relevant (see Chapters and ). and 1.8) The CP system itself always occupies 32 I/O. PLEASE NOTE Ensure that the DIL switches in the switch module are set in compliance with the configuration of the CP system. CP-DI NH 8-7

166 8. Commissioning the SUCOnet K The following table shows the different options: Configuration of the CP system CPV valve terminal with SUC- Onet K direct connection (CPV Direct) CPV Direct + CP input module CPV Direct + CP valve terminal or CP output module CPV Direct + CP input module + CP valve terminal or CP output module Outputs Number of Inputs 16O 16O 16O 16O 16O 16O Figure 8/3: Number of inputs/outputs for the configuration options 16I 16I 8-8 CP-DI NH

167 8. Commissioning the SUCOnet K 8.3 Configuration for SUCOnet K The following module type is required for the CPV valve terminal with SUCOnet K direct connection and any eventual expansions: SIS-K-06/07 (SUCOnet K slave with max. 32 inputs and 32 outputs). A topology configurator from Klöckner-Moeller is available for configuring the bus slave. The following figure shows the configuration entries for a CP system with SUCOnet K direct connection in connection with a PS4-201 as the master. Figure 8/4: Example - Configuration of PS4 CP-DI NH 8-9