Valve terminal type 03/05 Electronics Manual Field bus connection FB14

Transcription

1 Valve terminal type 03/05 Electronics Manual Field bus connection FB14 Field bus protocols: CANopen SDS Smart Distributed System GB 9801A

2 Author: Editor: Translation: Layout: Type setting: S. Breuer, H. Hohner, H.-J.Drung H.-J. Drung, M. Holder Douglas Smith Festo, Dept. PV-IDM DUCOM Edition: January 1998 (Festo AG & Co., D Esslingen, 1998) printed on 100% recycled paper 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 registrations A I

3 Part no.: Titel: Designation: MANUAL P.BE-VIFB14-03/05-GB II 9801 A

4 Contents GENERAL SAFETY INSTRUCTIONS Designated use Target group IMPORTANT USER INSTRUCTIONS Danger categories Pictograms Instructions on this manual Service IX IX X XI XI XII XIII XV Chapter 1 Chapter 2 SYSTEM SUMMARY 1.1 SYSTEM SUMMARY 1-3 System structure 1-3 Type 03: Description of components 1-5 Type 05: Description of components 1-9 FITTING 2.1 FITTING THE COMPONENTS 2-3 Input/output modules 2-4 End plates 2-6 Hat rail clamping unit (type 03) TYPE 03: FITTING THE VALVE TERMINAL 2-9 Fitting onto a wall (type 03) 2-9 Fitting onto a hat rail (type 03) TYPE 05: FITTING THE VALVE TERMINAL 2-13 Fitting onto a wall (type 05) A III

5 Chapter 3 INSTALLATION 3.1 GENERAL CONNECTION TECHNIQUES 3-3 Selecting the field bus cable 3-4 Selecting the operating voltage cable 3-5 Connecting the cables to the plugs/sockets FIELD BUS NODE 3-8 Opening and closing the node 3-8 Configuring the valve terminal 3-11 Setting the station number with CANopen 3-12 Permitted station numbers 3-13 Setting the field bus baud rate 3-19 Setting the field bus protocol TYPE 03: CONNECTING THE OPERATING VOLTAGES 3-21 Calculating the current consumption for type Connection example (type 03) TYPE 05: CONNECTING THE OPERATING VOLTAGES 3-29 Calculating the current consumption for type Connection example (type 05) CONNECTING THE FIELD BUS 3-38 Connection instructions for CANopen 3-42 Connecting instructions for the Smart Distributed System 3-43 Terminating resistor CONNECTING THE INPUT MODULES 3-45 Pin assignment CONNECTING THE OUTPUT MODULES 3-48 Pin assignment 3-50 IV 9801 A

6 Chapter 4 COMMISSIONING 4.1 BASIC PRINCIPLES OF CONFIGURATION AND ADDRESSING 4-5 General 4-5 Switching on the operating voltage 4-6 Calculating the configuration data 4-7 Calculating the number of inputs/outputs type Calculating the number of inputs/outputs type Address assignment of the valve terminal 4-11 General type 03 and type Basic rule Basic rule Address assignment after extension/conversion 4-16 Addressing example type 03 MIDI/MAXI valves 4-19 Addressing example type 05 ISO valves BASIC PRINCIPLES OF COMMISSIONING AND DIAGNOSIS 4-21 General 4-21 Selecting the inputs/outputs 4-21 General information on CANopen 4-22 Brief summary of scope of function 4-23 Summary of object directory 4-24 Default identifier distribution 4-27 Summary of object directory 4-28 PDO communication parameter record 4-29 PDO communication mapping parameter field 4-31 Digital inputs 4-32 Digital outputs 4-32 Reaction of the digital outputs in the event of a fault 4-33 Definition of emergency object A V

7 Addressing inputs and outputs 4-36 Examples: communication process 4-38 Diagnosis of status bits 4-41 Position of the status bits BASIC PRINCIPLES OF THE SMART DISTRIBUTED SYSTEM (HONEYWELL) 4-43 General information 4-43 Commissioning 4-43 Number of inputs and outputs 4-44 Summary of implemented object models 4-45 Summary of actions 4-48 Summary of events 4-49 Assignment of SDS IDs 4-49 Diagnosis 4-50 Diagnosis via status bits 4-51 Setting the transmission mode 4-53 Bus configuration CONFIGURING/ADDRESSING THE HONEYWELL SDS PC CONTROL 4-55 General information 4-55 Settings in the Device Editor 4-55 Settings in the Tag Editor 4-58 Setting the transmission types for inputs by means of the programming software 4-60 Setting the Cyclical Timer 4-61 Diagnosis 4-63 Diagnosis via the network manager 4-63 Diagnosis via the SDS user program 4-63 Structure of the SDS diagnostic register 4-65 Diagnosis via the status bits 4-66 VI 9801 A

8 4.3.2 CONFIGURING/ADDRESSING WITH THE GE FANUC SERIES 90/ General information 4-67 Bus configuration 4-68 Assigning the I/O addresses 4-68 Diagnosis 4-73 Diagnosis via the SDS interface 4-73 Diagnosis via status bits 4-75 Chapter 5 DIAGNOSIS AND ERROR TREATMENT 5.1 SUMMARY OF DIAGNOSTIC POSSIBILITIES ON-THE-SPOT DIAGNOSIS 5-4 LED display (node) 5-4 Valves 5-8 Input/output modules TESTING THE VALVES STATUS BITS ERROR TREATMENT 5-15 Reaction to faults in the CANopen 5-16 Reaction to faults in the Smart Distributed System 5-17 Short circuit/overload at an output module A VII

9 APPENDIX A APPENDIX B TECHNICAL APPENDIX TECHNICAL SPECIFICATIONS A-3 CABLE LENGTH AND CROSS SECTION A-7 Calculating with a graph A-8 Calculating with a formula A-10 EXAMPLES OF CIRCUITRY A-12 Operating voltage connection type 03 A-12 Operating voltage connection type 05 A-13 4-input module (PNP) A-14 8-input module (PNP) A-15 4-input module (NPN) A-16 8-input module (NPN) A-17 4-output module (NPN) A-18 ACCESSORIES A-19 Bus connection A-19 INDEX VIII 9801 A

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

11 General safety instructions Target group This manual is directed exclusively at technicians who are trained in control and automation technology and who have experience in installing, commissioning, programming and diagnosing programmable logic controllers (PLC) and field bus systems. X 9801 A

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

13 General safety instructions Pictograms Pictograms and symbols supplement the danger instructions and draw attention to the consequences of dangers. The following pictograms are used: Uncontrolled movements of loose tubing. Uncontrolled movement of the connected actuators. High electric voltage or undefined switching states of the electronic components which affect the connected circuits. Electrostatically vulnerable components which will be destroyed if their contact surfaces are touched. The ISO valve terminal type 05 is very heavy. Please ensure that it is fastened correctly and see that all operating personnel wear safety shoes. XII 9801 A

14 General safety instructions Instructions on this manual The following product-specific abbreviations are used in this manual: Abbreviation Terminal Node Sub-base Single sub-base Double sub-base ISO sub-base I O I/O P module I/O module Meaning Valve terminal type 03 (MIDI/MAXI) or type 05 (ISO) with/without electrical I/Os Field bus node Pneumatic sub-base for valves for single solenoid valves type 03 (MIDI/MAXI) for double solenoid valves or mid-position valves type 03 (MIDI/MAXI) Manifold base for 4, 8 or 12 valves type 05 (ISO 5599/I, size 1 or 2) Input Output Input/output Pneumatic module in general Module with digital inputs/outputs Fig. 1: Abbreviations Valve terminal type 03/05 consists basically of the following components: the node pneumatic modules (valve sub-bases with valve and valve bridge or intermediate air supply modules). electronic modules (4 or 8-input modules, 4-output modules) A XIII

15 General safety instructions This electronics manual describes node FB14 and the input/output modules. PLEASE NOTE All information on the pneumatic modules is to be found in the Pneumatics Manual P.BE-MIDI/MAXI-03-GB or P.BE-ISO-05-GB. Valve terminals types 03/05 consist of different components: PLEASE NOTE A valve terminal with four pneumatic valve sub-bases and four input/output modules is used for the diagrams in this manual. Fig. 2: Standard fitting for the drawings XIV 9801 A

16 General safety instructions The valve terminals can be connected to the control systems of various manufacturers. This manual describes the protocols CANopen and SDS and the addressing. Interface manufacturer Controller Interface Field bus ESD GmbH Vahrenwalder Str. 205 D Hannover VME-System VME-System S5-115U U S5-95U, S5-100U VME-CAN2 VME-CAN2B CAN-CS515 CAN-CS595 Janz Computer AG Im Dörener Feld 8 D Paderborn Eberle Controls GmbH Postfach D Nürnberg VME-System VME-System PLS vario PLS 514 VMOD-ICAN2 VMOD-ICAN3 CAN 21 CAN 41 CANopen Selectron System GmbH Schupferstr. 1 D Nürnberg Selecontrol MAS IPC/PC CBI 751 PCI 517 Fig. 3: Summary of possible controllers/field bus protocols (extract) Service If you have any technical problems, please consult your local Festo Service A XV

17 General safety instructions XVI 9801 A

18 1. System summary 1. SYSTEM SUMMARY 9801 A 1-1

19 1. System summary Contents 1.1 SYSTEM SUMMARY 1-3 System structure 1-3 Type 03: Description of components 1-5 Type 05: Description of components A

20 1. System summary 1.1 SYSTEM SUMMARY System structure Festo offers a solution to automation problems at machine level with valve terminals. Valve terminals of types 03 and 05 are constructed on a modular basis and permit combinations of pneumatic and electronic modules such as the following: Industrial PC/ controller AAAA AAAAAA AAAA AAAAAA AAAA AAAAAA AAAA AAAAAA AAAA AAAAAA AAAA AAAAAA AAAAAAAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA AAAA A A AAAA AAAA AAAA AAAA A AAAAAAAAAAAAAAAAAAAAAA AAAA AAAA AAAA AAAA AAAAAAA AAAA AAAA AAAA AAAA AAAAAAA AAAAAAAAAAAAAAAAAAAAAAAA AA AAAAAAAAAAAAAAAAAAAAAA AA AAAAAAAA AA AAA AAAA AAA AAAA AAA AA AAAAAAAA AA AAA AAAA AAA AAAA AAA AA AAAAAAAA AA AAA AAAA AAA AAAA AAA AA AAAAAAAAAAAAAAAAAAAAAA AA AAAAAAAAAAAAAAAAAAAAAA AA AAAAAAAAAAAAAAAAAAAAAA AA AAAAAAA AAAAAA AA AAAAAAA AAAAAA AA AAAAAAAA AA AA AAAAAAAAA AAAAAAAAA AAAAAAAAAAAAAA Field bus Valve terminal type 03: MIDI/MAXI valves and electronic modules Valve terminal type 03: only MAXI valves Valve terminal type 05: ISO valves and electronic modules Further field bus slaves Fig. 1/1: System summary and possible variants of the valve terminals 9801 A 1-3

21 1. System summary The valve terminal with field bus connection offers the following advantages: can be fitted with digital I/Os and pneumatic valves subsequent extension/conversion possible small-scale valves can be connected to various control systems less wiring due to two-core cables clarity in system structure due to physical separation of controller and machine valves already fitted pre-wired (pilot) valve solenoid coils central compressed air supply central exhust device already tested A field bus system also offers the following advantages: fewer output modules in the controller economic data transfer over long distances high baud rate a large number of slaves can be connected error diagnosis is made easier A

22 1. System summary Type 03: Description of components Valve terminal type 03 consists of individual modules. Each module is assigned with different functions as well as different connecting, display and operating elements. These are summarized in the diagram below Figure Module 1 Node FB14 2 Electronic modules (input/output modules), fitted with digital inputs (modules with 4 or 8 inputs) digital outputs (modules with 4 outputs) 3 End plate left with opening for additional earth/ground connection 4 Pneumatic MIDI, MAXI modules (sub-bases) fitted with S-valves: 5/2-way solenoid valves 5/2-way double solenoid valves 5/3-way mid-position valves (exhausted, pressurized, blocked) blanking plates S = auxiliary pilot air 5 Pneumatic MIDI, MAXI modules: pressure supply with integrated exhaust (MIDI) intermediate pressure supply with integrated exhaust (MIDI) pressure supply adapter with/without regulator (MIDI MAXI) additional pressure supply (MAXI) 6 End plate right, depending on size of last sub-base with either: common pneumatic tubing and integrated regulator for 5 bar auxiliary pilot air (non-regulated auxiliary pilot air is not permitted) common pneumatic tubing connections, but without regulator without common tubing connections (only MAXI) Fig. 1/2: Modules of the valve terminal type A 1-5

23 1. System summary The following connecting, display and operating elements are to be found on the electronic modules: O4 O4 I4 I Figure Meaning Output socket for electrical output Yellow LED (status display per output) Red LED (error display per output) Input socket for one electrical input Green LED (per input) Input socket for two electrical inputs Two green LEDs (one LED per input) Node with LEDs and field bus connection detailed description in chapter "Installation" End plate right Fuse for inputs/sensors Operating voltage connection Fig. 1/3: Display and operating elements on the electronic modules A

24 1. System summary The connecting, display and operating elements shown below are to be found on the pneumatic MIDI modules type Figure Meaning Node with LEDs and field bus connection, detailed description in chapter "Installation" Yellow LEDs Manual override for valve solenoid coils Valve location inscription field Unused valve location with blanking plate Common tubing connections Work connections (per valve) Fuse for inputs/sensors Operating voltage connection Fig. 1/4: Operating, display and connecting elements 9801 A 1-7

25 1. System summary The following connecting, display and operating elements are to be found on the pneumatic MAXI modules type Figure Meaning Node with LEDs and field bus connection, detailed description in the chapter "Installation" Yellow LEDs (per valve solenoid coil) Manual override (per valve solenoid coil) Valve location inscription field (designation labels) Unused valve location with blanking plate Common tubing connections Work connections (2 per valve, one above the other) Regulator for limiting the pressure of the auxiliary pilot air Common tubing connection Exhaust connections Fig. 1/5: Operating, display and connecting elements of the MAXI modules type A

26 1. System summary Type 05: Description of components Valve terminal type 05 consists of individual modules. Each module is assigned with different functions as well as different connecting, display and operating elements. These are summarized in the diagram below Figure Module 1 Node FB14 2 Electronic modules (input/output modules), fitted with digital inputs (modules with 4 or 8 inputs) digital outputs (modules with 4 outputs) 3 End plate left with opening for additional earthing connection 4 Pneumatic modules (manifold sub-bases) fitted with: Pneumatic valves with hole pattern as per ISO 5599/I - Pneumatic single solenoid valves - Pneumatic double solenoid valves - Pneumatic mid-position valves Components for vertical linking (pressure regulator intermediate plate, throttle plate, etc.) Blanking plates 5 Adapter plate for ISO sub-base (manifold sub-bases) as per ISO 5599/I sizes 1 and 2 6 End plate right with fitting holes and thread for M8 ring screws (for transport) Fig. 1/6: Modules of valve terminal type A 1-9

27 1. System summary The connecting, display and operating elements shown below are to be found on the pneumatic ISO modules type Figure Module 1 Node with LEDs and field bus connection, detailed description in the chapter "Installation" 2 Fuse for inputs/sensors 3 Adapter plate 4 Operating voltage connection for terminal type 05 5 Fuses for valves 6 Valve location inscription field 7 Yellow LEDs (per pilot solenoid coil) 8 Manual override (per pilot solenoid coil, either pushing or locking) 9 External control connection 10 Common pneumatic tubing connections 11 Work connections (per valve) 12 Adapter cable for operating voltage supply to node and I/O modules Fig. 1/7: Operating, display and connecting elements of ISO modules type 05 The electronic modules have already been described in the section "Description of components type 03." A

28 1. System summary Incoming field bus Continuing field bus 1 Node 4 2 A A AA AA 1 2, 4 = Compressed air = Work air Electrical signal flow Fig. 1/8: Function summery of valve terminal type 03/05 The node controls the following functions: connection of the terminal to the field bus module of your control system and to further field bus slaves via the field bus interface adaption of the field bus baud rate and protocol to the control system control of data transfer to/from the field bus module of your control system internal control of the terminal 9801 A 1-11

29 1. System summary The input modules process the input signals (e.g. from sensors) and transmit these signals via the field bus to the controller. The output modules are universal electrical outputs and control low current consuming devices, e.g. further valves, lights etc.. The pneumatic modules provide the following: common channels for supply air and exhaust electrical signals from all solenoid valve coils Work connections 2 and 4 have been provided for each valve location on the individual pneumatic modules. The common channels in the pneumatic end plate or special intermediate supply modules are used to supply the valves with compressed air and to vent the exhaust and pilot exhaust air. Futher modules for intermediate air supply are also available, e.g. in order that different working pressures can be used or that MIDI/MAXI valves or ISO valves can be fitted on a node. Further information on their use can be found in the pneumatics manual for your valve terminal. Only the electronic modules and the node are described here A

30 2. Fitting 2. FITTING 9801 A 2-1

31 2. Fitting Contents 2.1 FITTING THE COMPONENTS 2-3 Input/output modules 2-4 End plates 2-6 Hat rail clamping unit (type 03) TYPE 03: FITTING THE VALVE TERMINAL 2-9 Fitting onto a wall (type 03) 2-9 Fitting onto a hat rail (type 03) TYPE 05: FITTING THE VALVE TERMINAL 2-13 Fitting onto a wall (type 05) A

32 2. Fitting 2.1 FITTING THE COMPONENTS WARNING Before fitting the components, switch off the following: the compressed air supply the power supply for the outputs (pin 2) the power supply for the electronic components (pin 1) You can thereby avoid: uncontrolled movements of loose tubing undesired movements of the connected actuators undefined switching states of the electronic components CAUTION The valve terminal components contain electrostatically vulnerable elements. Do not therefore touch any contact surfaces on the side plug connectors of the components. Please observe the instructions for handling elements liable to damage by electrostatic charges. You thereby avoid destroying the valve terminal components A 2-3

33 2. Fitting PLEASE NOTE Treat all the modules and valve terminal components with great care. Pay special attention to the following: Screw connections must not be distorted or subjected to mechanical stress. The screws must fit exactly (otherwise the threads will be damaged). The specified torques must be observed. The modules must be aligned correctly (IP 65). The contact surfaces must be clean (avoid leaks and faulty connections). The contacts of type 03-MIDI valve solenoid coils must not be bent (they are not resistant to bending in alternate directions, i.e. they will break off if bent backwards). Please observe also the fitting instructions enclosed with modules and components ordered at a later date. Input/output modules Before the valve terminal can be extended or converted, it must first be dismantled. Dismantling (see also following diagram) Remove completely the screws of the relevant modules. The modules are now held together only by the plug connectors. Pull the modules carefully and without tilting away from the plug connectors. Replace any seals which are damaged A

34 2. Fitting Fitting (see also following diagram) PLEASE NOTE Modules ordered at a later date should be placed, where possible, after the last module before the end plate. Do not fit more than 12 electronic modules. Fit the modules as follows: Fit a (new) seal on the right-hand contact surface facing the node. Then fit the module as shown in the diagram below. Seal Fastening screws max. 1 Nm Fig. 2/1: Fitting the electronic I/O modules 9801 A 2-5

35 2. Fitting End plates A left-hand and a right-hand end plate are required as a mechanical termination of the valve terminal. These end plates fulfil the following functions: They comply with protection class IP 65. They contain connections/contacts for the protective earth cable. They contain openings for fitting onto walls and onto the hat rail clamping unit. The right-hand end plate of the ISO terminal is connected conductively via screw connectors and ready fitted spring contacts to the manifold sub-base. It is therefore sufficently earthed. There are different designs of right-hand end plate for terminal type 03 (MIDI/MAXI). Each design has a ready fitted protective earth cable. CAUTION Before operating terminal type 03, you must earth the right-hand end plate by means of the protective earth cable. This is to avoid high voltages on the metal surface if there is a technical fault A

36 2. Fitting Earth the end plates as follows: Right-hand end plate (type 03) In order to earth the right-hand end plate, connect the cable fitted inside to the appropriate contacts on the pneumatic modules or node (see following diagram). Left-hand end plate (types 03 and 05) Connect the left-hand end plate conductively to the other components by means of the ready fitted spring contacts. Please note: Instructions on earthing the complete valve terminal are to be found in the chapter "Installation". The following diagram shows how both end plates are fitted. Seal Contact for protective earth cable Seal Fastening screws max. 1 Nm Pre-fitted protective earth cable Fig. 2/2: Fitting the end plates (example terminal type 03) 9801 A 2-7

37 2. Fitting Hat rail clamping unit (type 03) If the valve terminal is to be fitted onto a hat rail (support rail as per EN 50022), you will require a hat rail clamping unit. The hat rail clamping unit is fastened to the back of the end plates as shown in the diagram below. Before fitting ensure that: the fastening surfaces are clean (clean with spirit); the flat head screws are tightened (6). After fitting ensure that: the levers are secured with a locking screw (7). 1 Self adhesive rubber foot 2 Clamping elements 3 Left-hand lever *) 4 Right-hand lever *) 5 O-ring 6 Flat head screw 7 Retaining screw *) Different lever lengths with MIDI and MAXI Fig. 2/3: Fitting the hat rail clamping unit A

38 2. Fitting 2.2 TYPE 03: FITTING THE VALVE TERMINAL Fitting onto a wall (type 03) WARNING In the case of long terminals, use additional support brackets approx. every 200 mm. You thereby avoid: overloading the fastening eyes on the end plates the terminal sagging natural resonances Proceed as follows: Calculate the weight of the terminal (weigh or estimate). General rule: MIDI MAXI Per pneumatic module 800 g 1200 g per node 1000 g 1000 g Per electronic module 400 g 400 g Make sure that the fastening surface can support this weight A 2-9

39 2. Fitting Fasten the terminal with four M6 screws as shown below (fitting position as desired). Use spacers if necessary. 7.6 mm M6 Fig. 2/4: Fitting terminal type 03 on a wall Fitting onto a hat rail (type 03) The terminal is suitable for fitting onto a hat rail (support rail as per EN 50022). For this purpose there is a guide groove on the rear of all modules for hanging the terminal on the hat rail. CAUTION Fitting onto the hat rail without the hat rail clamping unit is not permitted. If the terminal is fitted in a sloping position or is subjected to vibration, protect it against slipping and use the screws supplied (7) to protect it against unintentional loosening/ opening A

40 2. Fitting PLEASE NOTE If the terminal is fitted in a horizontal position and is not subjected to vibration, the fastening of the hat rail clamping unit will be sufficient without the screws (7). If your terminal does not have a hat rail clamping unit, this can be ordered and fitted at a later date. Whether MIDI or MAXI clamping units are to be used depends on the end plates (MIDI/MAXI). Proceed as follows: Calculate the weight of the terminal (weigh or estimate). General rule: MIDI MAXI Per pneumatic module 800 g 1200 g Per node 1000 g 1000 g Per electronic module 400 g 400 g Make sure that the fastening surface can support this weight A 2-11

41 2. Fitting Fit a hat rail (support rail as per EN x15; width 35 mm, height 15 mm). Fasten the hat rail to the fastening surface at least every 100 mm. Hang the terminal onto the hat rail. Secure the terminal on both sides against tilting or slipping with the hat rail clamping unit (see diagram below). If the terminal is fitted in a sloping position or is subjected to vibration, use two screws (7) to protect the hat rail clamping unit against unintentional loosening/opening. Valve terminal type 03 Hat rail clamping unit Locking screw (7) Fig. 2/5: Fitting terminal type 03 onto a hat rail A

42 2. Fitting 2.3 TYPE 05: FITTING THE VALVE TERMINAL Fitting onto a wall (type 05) WARNING In the case of long terminals with several I/O modules, use additional support brackets approximately every 200 mm. You thereby avoid: overloading the fastening eyes on the left-hand end plate the terminal sagging (I/O side) natural resonances Proceed as follows: Calculate the weight of the terminal (weigh or estimate). General rule: Sub-base *) - 4 valve locations with valves - 8 valve locations with valves - 12 valve locations with valves ISO Size 1 8 kg 14 kg 20 kg ISO Size 2 12 kg 20 kg 28 kg Per node 1 kg 1 kg Per electronic module 0.4 kg 0.4 kg *) Components for vertical linking: For weight see Pneumatics Manual P.BE-ISO-05-GB. Make sure that the fastening surface can support this weight A 2-13

43 2. Fitting Fasten the terminal as follows: with three M10 screws on the adapter plate and on the right-hand end plate (2); with two M6 screws on the left-hand end plate (1). If necessary, use the following additional fastening methods: the opening on the bottom of the right-hand end plate with an M10 thread ("blind hole" 3); the support bracket for the I/O modules (see fitting instructions with support bracket). The terminal can be fitted in any position. If necessary, use spacers and the thread for an M8 ring screw (transport aid). 1 2 Thread for M8 ring screw (for transport) 3 M6 M10 Fig. 2/6: Fitting an ISO terminal type 05 on wall A

44 3. Installation 3. INSTALLATION 9801 A 3-1

45 3. Installation Contents 3.1 GENERAL CONNECTION TECHNIQUES 3-3 Selecting the field bus cable 3-4 Selecting the operating voltage cable 3-5 Connecting the cables to the plugs/sockets FIELD BUS NODE 3-8 Opening and closing the node 3-8 Configuring the valve terminal 3-11 Setting the station number with CANopen 3-12 Permitted station numbers: 1;...; Setting the field bus baud rate 3-19 Setting the field bus protocol Type 03: Connecting the operating voltages 3-21 Calculating the current consumption for type Connection example (type 03) Type 05: Connecting the operating voltages 3-29 Calculating the current consumption for type Protective earthing 3-35 Connection example (type 05) Connecting the field bus 3-38 Connection instructions for CANopen 3-42 Connecting instructions for the Smart Distributed System 3-43 Terminating resistor CONNECTING THE INPUT MODULES 3-45 Pin assignment CONNECTING THE OUTPUT MODULES 3-48 Pin assignment A

46 3. Installation 3.1 GENERAL CONNECTION TECHNIQUES WARNING Before installation or maintenance work is carried out, the following must be switched off: the compressed air supply the power supply to the electronic components (pin 1) the power supply to the outputs/valves (pin 2). You thereby avoid: uncontrolled movements of loose tubing undesired movements of the connected actuators undefined switching states of the electronic components 9801 A 3-3

47 3. Installation Selecting the field bus cable A twisted, screened 4-core cable should be used as the field bus cable. PLEASE NOTE You must refer to the PLC manual for your controller to see which type of cable you should use. Also take into account the distance and the field bus baud rate selected. The table below shows the approximate values for the maximum distances depending on the baud rate selected. Precise specifications are to be found in the manuals for your control system. Baud rate Maximum distance Max. branch length 1000 kbaud m 0.3 m 500 kbaud m 0.75 m - 3 m 125 kbaud 500 m 3 m 20 kbaud 1000 m 7.5 m Not all the baud rates named can be used with all PLCs, controllers or PCs/IPCs. Please note also any restrictions of the maximum branch length A

48 3. Installation Selecting the operating voltage cable Several parameters must be taken into consideration when the operating voltages are connected. Further information can be found in subsequent chapters. Chapter 3: Section: Chapter 3: Section: Installation "Connecting the operating voltages" - Calculating the current consumption - Type of power unit - Cable length and cross section Installation "Connecting the field bus" - Calculating the current consumption bus interfaces - Cable length and cross section Appendix A: Cable length and cross section - Calculating the length and cross section with a table - Calculating with a graph 9801 A 3-5

49 3. Installation Connecting the cables to the plugs/sockets CAUTION The position of the pins is different depending on whether they are in the form of plugs or sockets. The connections of the input and output modules are in the form of sockets. The connections of the field bus interface and tf the operating voltage are in the form of plugs. The pin assignment can be found in the chapters which follow. When you have selected suitable cables, connect them according to steps Open the plugs/sockets as follows (see diagram): Power supply socket Insert the power supply socket into the operating voltage connection on the valve terminal. Unscrew the housing of the socket and remove it. The socket remains inserted in the operating voltage connection. Sensor plug and field bus socket Unscrew the centre knurled nut. 2. Open the strain relief on the rear part of the housing. Pass the cable through as shown in the diagram below A

50 3. Installation Cable outer diameter PG7: mm PG9: mm PG13.5: mm Plugs/sockets (straight or angled) power supply socket: PG7, 9 or 13.5 sensor plug: PG7 bus cable socket: PG9 AAAA AAAA Cable Strain relief Housing AAAAAAA AAAA AAA AAAAAAA AAAAAAA AAA AAA AAA AAA AAAAAAA AAAA AAA AAAAAAA AAAAAAA Connecting part Socket Plug Fig. 3/1: Individual plug/socket parts and cable routing 3. Remove 5 mm of insulation from the end of the cable. 4. Fit the strands with cable end sleeves. 5. Connect the ends of the cables. 6. Close the strain relief again and screw the housing back onto the socket. Pull the cable back so that it is not looped inside the housing. 7. Tighten the strain relief A 3-7

51 3. Installation 3.2 FIELD BUS NODE Opening and closing the node WARNING Before installation or maintenance work is carried out, the following must be switched off: the compressed air supply the operating voltage supply to the electronic components (pin 1). the operating voltage supply to the outputs/valves (pin 2). You thereby avoid: uncontrolled movements of loose tubing undesired movements of the connected actuators undefined switching states of the electronic components A

52 3. Installation CAUTION The valve terminal node contains electrostatically vulnerable components. Do not therefore touch any components. Observe the regulations for dealing with electrostatically vulnerable components. In this way the electronic components of the node will not be destroyed. The following connecting and display elements are to be found on the cover of the node. Green LED Green LED Plug for field bus cable A A MOD/NET AAAPOWERAAA STATUS AAA BUS AAA ERROR POWER BUS Red LED Green LED Operating voltage connection Fuse for operating voltage of inputs Fig. 3/2: Cover of node 9801 A 3-9

53 3. Installation PLEASE NOTE The cover is connected to the internal printed circuit boards by means of the operating voltage cable. It cannot, therefore, be removed completely. Opening Unscrew and remove the 6 Philips screws in the cover. Carefully lift up the cover. Do not damage the cable through mechanical stress. Closing Replace the cover. Place the operating voltage cables back into the housing so that they are not clamped. Tighten the Philips screws in the cover in diagonally opposite sequence A

54 3. Installation Configuring the valve terminal There are four printed circuit boards in the node. Board 2 contains two LEDs and a plug for the field bus cable; board 3 contains two LEDs and switches for setting the configuration. Green LED Green LED Plug for field bus cables AAA AAA AA AA AA AA A AA AA AA AA AA AA A A A A A A A A A A Green LED Red LED Address selector switch (station number) A A A A Baud rate Protocol Board 1 Screening AAA AA A AA Board 4 Board 2 Board 3 Flat plug for operating voltage connection Fig. 3/3: Connecting, display and operating elements of the node 9801 A 3-11

55 3. Installation Setting the station number with CANopen You can set the station number of the valve terminal with the two address selector switches on board 3. The switches are numbered from The arrow on the address selector switches indicates the tens or units figures of the station number set Address selector switch UNITS figure 9 Address selector switch TENS figure Fig. 3/4: Address selector switch PLEASE NOTE Station numbers may only be assigned once per CANopen interface. Recommendation Assign the station numbers in ascending order and, if necessary, select them to suit the machine structure of your system A

56 3. Installation Permitted station numbers: 1;...; 98 PLEASE NOTE Observe any limitations concerning the station numbers as stipulated by the CAN master and your controller. Proceed as follows: 1. Switch off the operating voltage. 2. Assign an unused station number to the valve terminal. 3. Use a screwdriver to set the arrow of the relevant address selector switch to the units or tens figure of the desired station number. Example UNITS TENS Setting with field bus address: 05 UNITS TENS Setting with field bus address: 38 Fig. 3/5: Examples of address settings 9801 A 3-13

57 3. Installation Setting/saving the station number with the Smart Distributed System, Honeywell PLEASE NOTE With the Smart Distributed System protocol the station number set must always be an odd number. If the valve terminal detects an even station number when the station number is saved, this will automatically be corrected to the next lower odd number. Valve terminals which only have inputs cannot be addressed. The station number can be set with the following devices: Handheld Activator for Honeywell Smart Distributed System or a suitable Smart Distributed System Master. With this protocol, it is not necesary to set the station number by means of the address selector switches A

58 3. Installation The station number (= SDS-ID) is stored in a non-volatile memory in the field bus node of the valve terminal. The station number can be modified at any time. The station number last entered remains stored in the node. Assigning station numbers with the valve terminal Valve terminal Assigned station numbers max. 32 outputs (valves/electrical outputs) max. 28 inputs and max. 32 outputs One Two n = odd n = odd n + 1 is assigned automatically by valve terminal Example: Setting and saving the station number with the Honeywell Handheld Activator 1. Supply the valve terminal with 24 V. Connect the bus connection of the valve terminal with the Handheld Activator. 2. Switch on the Activator. Wait until the following menu appears: F1 - Select Device F2 - Data / Function F3 - Test F4 - Bus Status 9801 A 3-15

59 3. Installation 3. Press key F1 - Select Device. The following menu will appear: Address: NONE F1 - Select Device F2 - Change Address F3 - Options Press key F1- Address: NONE. The following menu will appear: -- Select Device -- Address: NONE Enter: STAT Å ì ESC <Digit> ENT Press the STAT key. The Activator will now search for the station number of the valve terminal. When you commission the valve terminal for the first time, station number 125 will appear, otherwise the last station number saved. You can transfer the station number found with ENTER. You can continue the search with A

60 3. Installation Now enter the new station number. PLEASE NOTE Always label the field bus node with the last saved station number. You can then be sure that, in the event of the fieldbus node being replaced, the station number is known and can be loaded into the new node. Protocol Baud rate Max. number of valve terminals Permitted statíon numbers Honeywell Smart Distributed System Up to 500 kbaud 64 0;...; 126 Over 500 kbaud 32 Fig. 3/6: Summary of possible station numbers 9801 A 3-17

61 3. Installation Besides the address selector switch there is also a DIL switch in the node. The following functions can be set on this DIL switch: the field bus baud rate the field bus protocol. The DIL switch consists of four switch elements. These are numbered from 1 to 4. The position ON is marked. AAA AA AA AA AA AA AA AA AA AAA AA AA AAA AA AAA AA AA ON AA AA AA AA AA ON Field bus baud rate Field bus protocol Fig. 3/7: Position of the DIL switch A

62 3. Installation Setting the field bus baud rate PLEASE NOTE Set the field bus baud rate of the valve terminal so that it corresponds to that set on the master interface. Protocol Smart Distributed System Field bus baud rate [kbaud] automatic setting of baud rate CANopen 20 kbaud 125 kbaud 500 kbaud 1000 kbaud ON Fig. 3/8: Setting the field bus baud rate 9801 A 3-19

63 3. Installation Setting the field bus protocol Set switch elements 3 and 4 to the desired protocol: Protocol CANopen Smart Distributed System DIL switch settings Reserved Reserved ON ON ON ON ON Fig. 3/9: Setting the field bus protocol A

64 3. Installation TYPE 03: CONNECTING THE OPERATING VOLTAGES WARNING Use only power units which guarantee reliable electrical isolation of the operating voltages in accordance with IEC 742/EN with at least 4 kv isolation resistance. Switch power packs are permitted, providing they guarantee reliable electrical isolation as per EN CAUTION The operating voltage supply to the outputs/valves (pin 2) must be fused externally with max. 10 A. The external fuse prevents the valve terminal from being damaged in the event of a short circuit A 3-21

65 3. Installation The 24V operating voltages are connected at the lower left-hand edge of the node. AA AA POWER A AAABUS POWER AA MOD/NET AA STATUS AA AA ERROR BUS Operating voltage connection Fig. 3/10: Position of the operating voltage connection A

66 3. Installation The following elements of the valve terminal are supplied with + 24 V DC operating voltage via this connection: the internal electronic components and the inputs of the input modules (pin 1: + 24 V DC, tolerance ± 25%). the outputs of the valves and the outputs of the output modules (pin 2: + 24 V DC, tolerance ± 10%, external fuse max. 10 A required). Recommendation: Connect the operating voltage for the outputs/valves via the EMERGENCY STOP circuit. PLEASE NOTE If there is a common voltage supply for pin 1 (electronic components and inputs) and pin 2 (outputs/valves) the lower tolerance of ±10% for both circuits must be observed A 3-23

67 3. Installation Check the 24 V operating voltage for the outputs whilst your system is operating. Please ensure that this voltage lies within the permitted tolerances even during full operation. Recommendation Use a closed loop power unit. Calculate the complete current consumption in accordance with the following table and then select a suitable power unit and cable cross section. Avoid long distances between the power unit and the terminal. Calculate the permitted distance in accordance with Appendix A. The following general rule applies to type 03: Supply voltage Cable cross section Distance Pin 1 Pin 2 VO = 2.2 A = 10 A = 24 V 1.5 mm 2 8 m 2.5 mm 2 14 m A

68 3. Installation Calculating the current consumption for type 03 The table below shows how to calculate the total current consumption for terminal type 03. The values quoted have been rounded up. If other valves or modules are used, you should consult the appropriate technical specifications for their current consumption. Current consumption of electronic components on node type 03 and inputs (pin 1, 24 V ± 25 %) Node Number of simultaneously occupied sensor inputs: x0.010 A A A Sensor supplies: x A (see manufacturer specifications) + A Current consumption of electronic components on the node and inputs (pin 1) max. 2.2 A = A A Current consumption of outputs type 03 (pin 2, 24 V ± 10 %) Number of MIDI valve coils (simultaneously under power): x A + A Number of MAXI valve coils (simultaneously under power): x A + A Number of simultaneously activated electrical outputs: x A + A Load current of simultaneously activated electrical outputs: x A + A Current consumption outputs (pin 2) max. 10 A = A + Total current consumption of valve terminal type 03 = A A Fig. 3/11: Calculating the total current consumption type A 3-25

69 3. Installation The following diagram shows the pin assignment of the operating voltage connection. 24 V supply to electronic components and inputs 24 V supply to valves and outputs PE (protective earth connection, incoming contact) 0 V Fig. 3/12: Pin assignment of the operating voltage connection (type 03) Protective earthing The valve terminal has two protective earth connections as follows: on the operating voltage connection (pin 4 incoming contact) on the left-hand end plate (M4 thread) A

70 3. Installation PLEASE NOTE Always connect the earth/ground cable to pin 4 of the operating voltage connection. Ensure that the valve terminal housing and the protective earth conductor at pin 4 have the same voltage and that no equalizing currents flow. Connect a protective earth conductor with sufficient cross section to the left-hand end plate if the valve terminal is not fitted on an earthed machine stand. You can thereby avoid: interference from electromagnetic sources. Connection example (type 03) The following diagram shows the connection of a common 24 V supply for pins 1 and 2. Please note that: the supply to the outputs/valves must be protected against short circuit/overload with an external fuse max. 10 A; the supply to the electronic components and inputs must be protected against short circuit/overload with an external 3.15 A fuse (recommendation); 9801 A 3-27

71 3. Installation the common tolerance of 24 V DC ± 10 % must be observed; equalizing currents must be avoided when both earth cables are connected, e.g. by the use of cables with suitable cross section as voltage compensation Connecting cable for voltage compensation of earth connections AC 0 V 24 V 3,15 A Fuse for inputs to sensors (2 A) DC 24V ± 10% External fuses 10 A EMERGENCY STOP Earth cable connection pin 4 designed for 12 A Fig. 3/13: Example connecting a common 24V supply and both earth cables (type 03) A

72 3. Installation TYPE 05: CONNECTING THE OPERATING VOLTAGES WARNING Use only power units which guarantee reliable electrical isolation of the operating voltages in accordance with IEC 742/EN with at least 4 kv isolation resistance. Switch power packs are permitted, providing they guarantee reliable electrical isolation as per EN CAUTION The operating voltage supply to the outputs (pin 2) must be fused externally with max. 10 A. The external fuse prevents the terminal from being damaged in the event of a short circuit A 3-29

73 3. Installation The 24 V operating voltages are connected on the adapter plate between the node and the valves. The node and the I/O modules are supplied with current via the adapter cable. Operating voltage connection type 05 Fuses for valves (4 A slow blowing) Adapter cable Fig. 3/14: Position of the operating voltage connection type A

74 3. Installation The following elements of valve terminal type 05 are supplied with +24 V DC operating voltage via this connection: the internal electronic components and the inputs of the inputs modules (pin 1: + 24 V DC, tolerance 25 %, external fuse max A recommended). the outputs of the valves and the outputs of the output modules (pin 2: + 24 V DC, tolerance 10 %, external fuse max. 10 A slow blowing required). Recommendation Connect the operating voltage for the outputs/valves via the EMERGENCY STOP circuit or EMERGENCY STOP contacts. PLEASE NOTE If there is a common voltage supply for pin 1 (electronic components and inputs) and pin 2 (outputs/valves), the lower tolerance of 10% for both circuits must be observed A 3-31

75 3. Installation Check the 24 V operating voltage of the outputs whilst your system is operating. Please ensure that this voltage lies within the permitted tolerances even during full operation. Recommendation Use a closed loop power unit. Calculate the complete current consumption in accordance with the following table and then select a suitable power unit and suitable cable cross section. Avoid long distances between the power unit and the terminal. Calculate the permitted distance in accordance with Appendix A. The following general rule applies to type 05: Supply max.*) Cable cross section Distance Pin 1 = 2.2 A 1.5 mm 2 8 m Pin 2 = 10 A 2.5 mm 2 14 m VO = 24 V *) Please observe the maximum total current consumption (pins 1 and 2) of max A A

76 3. Installation Calculating the current consumption for type 05 The table below shows how to calculate the total current consumption for ISO terminal type 05. The values quoted have been rounded up. If other valves or modules are used, you should consult the appropriate technical specifications for their current consumption. Current consumption of electronic components node type 05 and inputs (pin 1, 24 V ± 25 %) Node Number of simultaneously occupied digital sensor inputs: x A A A Sensor supplies: x A (see manufacturer specifications) + A Current consumption of electronic components node and inputs (pin 1) max. 2.2 A A = A Current consumption of outputs type 05 (pin 2, 24 V ± 10 %) Number of pilot valve solenoids (max. 12 solenoids simultaneously under power): x A + A Number of simultaneously activated electrical outputs: x A Load current of simultaneously activated electrical outputs: x A + A + A Current consumption of outputs (pin 2) max A = A + Total current consumption of valve terminal type 05 = A A Fig. 3/15: Calculating the total current consumption type A 3-33

77 3. Installation The following diagram shows the pin assignment of the operating voltage connection on the adapter plate. 24 V supply to electronic components and inputs 24 V supply to valves and outputs PE (protective earth connection, incoming contact) 0 V Fig. 3/16: Pin assignment of operating voltage connection (type 05) A

78 3. Installation Protective earthing The valve terminal has two protective earth connections as follows: on the operating voltage connection (pin 4 incoming contact) on the left-hand end plate (M4 thread). PLEASE NOTE Always connect the earth/ground cable to pin 4 of the operating voltage connection. Ensure that the valve terminal housing and the protective earth conductor at pin 4 have the same voltage and that no equalizing currents flow. Connect a protective earth conductor with sufficient cross section to the left-hand end plate if the valve terminal is not fitted on an earthed machine stand. You can thereby avoid: interference from electromagnetic sources A 3-35

79 3. Installation Connection example (type 05) The following diagram shows the connection of a common 24 V supply for pins 1 and 2. Please note that: the outputs must be protected against short circuit/overload with an external slow-blowing fuse of max. 10 A; the electronic components and inputs must be protected against short circuit/overload with an external 3.15 A fuse (recommendation); the sensors must be additionally protected with the (2 A) fuse fitted; the valves must be additionally protected with the 4 A slow-blowing fuse fitted; the common tolerance of 24 V DC ± 10% must be observed; the node must be supplied with power via the adapter cable; equalizing currents must be avoided when both earth cables are connected, e.g. by means of cables with suitable cross section as a voltage compensation A

80 3. Installation Operating voltage connection Fuse for valves (4 A) Connected adapter cable Connecting cable for voltage compensation of earth connections AC DC 24V ± 10% 0 V 24 V external fuses 10 A 3.15 A EMERGENCY STOP Earth connection pin 4 designed for 12 A Fig. 3/17: Example connecting a common 24V supply and both earth cables (type 05) 9801 A 3-37

81 3. Installation CONNECTING THE FIELD BUS There is a field bus plug on the node for connecting the valve terminal to the field bus. The two bus cables, the voltage supply cables (+24V and 0V) for the bus interface and the cable screening are all connected to this plug. The hardware basis of the bus interface is formed by the CAN bus. A typical feature of this bus interface is that it is supplied with voltage via the field bus plug. The bus should be connected via a branch line by means of a 5-pin M12 socket with PG9 screw connector. These can be ordered from Festo (type FBSD-GD-9-5POL, part no ). Alternatively, you can use the bus cables of other manufacturers (see Appendix A, Accessories). PLEASE NOTE Consult the manual for your PLC to ascertain the T-adapter and the maximum branch line length which are permitted for your controller. Appendix A contains a summary of suitable installation accessories. The diagram overleaf shows the main bus connection A

82 3. Installation Voltage supply for bus interface Field bus Screening Branch line AA AA AA AA A A T-adapter +24 V 0 V AA AA AA A Bus Fig. 3/18: Structure of bus interface 9801 A 3-39

83 3. Installation Current consumption of all bus interfaces Number of Festo valve terminals connected * 50 ma A Current consumption of the remaining field bus interfaces A Current consumption of sensor inputs/sensor supply via the bus A Total current consumption of all bus interfaces A Avoid long distances between the bus voltage supply and the bus slaves. If necessary, calculate the permitted distance (see also Appendix A). PLEASE NOTE Bus slaves of different manufacturers have different tolerances in respect of the interface supply. Take this into consideration when planning the bus length. The following applies to FESTO valve terminals: Vmax = 25V Vmin = 11.5V A

84 3. Installation CAUTION Please observe the correct polarity when connecting the field bus interface. Connect the screening. The diagram below shows the pin assignment of the field bus interface. Connect the field bus cables to the terminals of the bus cable socket. Please observe also the connection instructions in the other diagrams as well as the instructions in the PLC manual for your controller. GND bus Data + (CAN_H) +24V bus Data - (CAN_L) Screening 1MΩ 220 nf internal RC network Node housing Fig. 3/19: Pin assignment of the field bus interface 9801 A 3-41

85 3. Installation Connection instructions for CANopen PLEASE NOTE You must check the connection assignment of the CANopen interface in the manual for your controller. Connect the field bus cable of your control system to the field bus interface of the valve terminal as follows: PLC/PC/IPC plug assignment Valve terminal pin assignment of the field bus interface View Pin Signal destination 1 * * * 9 CAN_L CAN_GND CAN_SHLD GND CAN_H CAN_V+ Data-/CAN_L Pin 5 GND bus Pin 3 Screening Pin 1 Data+/CAN_H Pin V bus Pin 2 * nc = Not connected Fig. 3/20: Pin assignment as per DS A

86 3. Installation Connecting instructions for the Smart Distributed System PLEASE NOTE Always check the pin assignment of the Smart Distributed System interface in the manual for your controller. Connect the field bus cable of your control system to the field bus interface of the valve terminal as follows: Plug assignment SDS interface Valve terminal pin assignment of the field bus interface View Pin Signal destination 1 * * 5 * 6 * 7 8 * 9 CAN_L GND CAN_H V+ Data-/CAN_L Pin 5 GND bus Pin 3 Screening Pin 1 Data+/CAN_H Pin V bus Pin 2 * nc = Not connected Fig. 3/21: Pin assignment (Honeywell IPC) 9801 A 3-43

87 3. Installation Terminating resistor If the valve terminal to be connected is at the end of the field bus line, a terminating resistor (120 Ohm, 0.25 Watt) must be fitted in the socket of the field bus cable. Adaption is necessary. Fitting the terminating resistor 1. Connect the wires of the resistor together with those of the field bus cable between the wires Data + (pin 4) and Data - (pin 5) of the bus cable socket. PLEASE NOTE To guarantee reliable contact, we recommend that the wires of the resistor and those of the bus cable be crimped together in common end sleeves. 120Ω Fig. 3/22: Pin assignment of the field bus interface 2. Fit the bus cable socket to the field bus plug A

88 3. Installation 3.3 CONNECTING THE INPUT MODULES WARNING Before installation or maintenance work is carried out, the following must be switched off: the compressed air supply the operating voltage supply to the electronic components (pin 1). the operating voltage supply to the outputs/valves (pin 2). You thereby avoid: uncontrolled movements of loose tubing undesired movements of the connected actuators undefined switching states of the electronic components Four or eight inputs are available for the user on the input modules of the valve terminal. The input modules have the following switching logic depending on their type: Input module type INPUT INPUT-N Switching logic PNP (positive) NPN (negative) 9801 A 3-45

89 3. Installation Input module 4 inputs Input module 8 inputs Socket with one digital input each Green LED Socket with two digital inputs each One green LED each per digital input Fig. 3/23: Digital input modules (4/8 inputs) Recommendation for the 8-input modules: Use the Festo DUO cable in order to connect two sensors with one plug A

90 3. Installation Pin assignment The following diagram shows the pin assignment of all inputs. Pin assignment 4 inputs LED Pin assignment 8 inputs LED free V Input 0 V 0 Ix V 1 4 Input Ix + 24 V 1 4 Input Ix 1 free V Input 0 V 1 Ix V 1 4 Input Ix V 1 4 Input Ix+2 3 free V Input 0 V 2 Ix V 1 4 Input Ix V 1 4 Input Ix+4 5 free V Input 0 V 3 Ix V 1 4 Input Ix V Fig. 3/24: Input modules: pin assignment (4/8 inputs) 1 4 Input Ix A 3-47

91 3. Installation 3.4 CONNECTING THE OUTPUT MODULES WARNING Before installation or maintenance work is carried out, the following must be switched off: the compressed air supply the operating voltage for the electronic components (pin 1) the operating voltage for the outputs/valves (pin 2) You thereby avoid: uncontrolled movements of loose tubing undesired movements of the connected actuators undefined switching states of the electronic components A

92 3. Installation Four transistor outputs are available for the user on the output modules of the valve terminal. The outputs have positive logic (PNP outputs). Output module (4-outputs) Yellow LED per output Red LED per output Socket with one digital output each Fig. 3/25: Digital output module (4-outputs) 9801 A 3-49

93 3. Installation Pin assignment The diagram below shows the pin assignment of all outputs. Pin assignment 4 outputs LED free V free Output Ox free V free Output Ox+1 free V free Output Ox+2 free V 3 free 1 4 Output Ox+3 Fig. 3/26: Output modules: pin assignment (4 outputs) A

94 4. Commissioning 4. COMMISSIONING 9801 A 4-1

95 4. Commissioning Contents 4.1 BASIC PRINCIPLES OF CONFIGURATION AND ADDRESSING 4-5 General 4-5 Switching on the operating voltage 4-6 Calculating the configuration data 4-7 Calculating the number of inputs/outputs type Calculating the number of inputs/outputs type Address assignment of the valve terminal 4-11 General type 03 and type Basic rule Basic rule Address assignment after extension/conversion 4-16 Addressing example type 03 MIDI/MAXI valves 4-19 Addressing example type 05 ISO valves A

96 4. Commissioning 4.2 BASIC PRINCIPLES OF COMMISSIONING AND DIAGNOSIS 4-21 General 4-21 Selecting the inputs/outputs 4-21 General information on CANopen 4-22 Brief summary of scope of function 4-23 Summary of object directory 4-24 Default identifier distribution 4-27 Summary of object directory 4-28 PDO communication parameter record 4-29 PDO communication mapping parameter field 4-31 Digital inputs 4-32 Digital outputs 4-32 Reaction of the digital outputs in the event of a fault 4-33 Definition of emergency object 4-35 Addressing inputs and outputs 4-36 Examples: communication process 4-38 Diagnosis of status bits 4-41 Position of the status bits A 4-3

97 4. Commissioning 4.3 BASIC PRINCIPLES OF THE SMART DISTRIBUTED SYSTEM (HONEYWELL) 4-43 General information 4-43 Commissioning 4-43 Number of inputs and outputs 4-44 Summary of implemented object models 4-45 Summary of actions 4-48 Summary of events 4-49 Assignment of SDS IDs 4-49 Diagnosis 4-50 Diagnosis via status bits 4-51 Setting the transmission mode 4-53 Bus configuration CONFIGURING/ADDRESSING THE HONEYWELL SDS PC CONTROL 4-55 General information 4-55 Settings in the Device Editor 4-55 Settings in the Tag Editor 4-58 Setting the transmission types for inputs by means of the programming software 4-60 Setting the Cyclical Timer 4-61 Diagnosis 4-63 Diagnosis via the network manager 4-63 Diagnosis via the SDS user program 4-63 Structure of the SDS diagnostic register 4-65 Diagnosis via the status bits CONFIGURING/ADDRESSING WITH THE GE FANUC SERIES 90/ General information 4-67 Bus configuration 4-68 Assigning the I/O addresses 4-68 Diagnosis 4-73 Diagnosis via the SDS interface 4-73 Diagnosis via status bits A

98 4. Commissioning 4.1 BASIC PRINCIPLES OF CONFIGURATION AND ADDRESSING General Before commissioning or programming, you should first compile a configuration list of all the connected field bus slaves. On the basis of this list you can: make a comparison between the ACTUAL and NOMINAL configurations in order to ascertain if there are any incorrect connections. access these specifications during the syntax check of a program, in order to avoid addressing errors. The valve terminal must be configured very accurately, since different configuration specifications may be required for each terminal due to the modular structure. Please observe here also the specifications in the following sections A 4-5

99 4. Commissioning Switching on the operating voltage PLEASE NOTE Observe also the switching-on instructions in the PLC manual for your controller. When the controller is switched on, it automatically carries out a comparison between the NOMINAL and ACTUAL configurations. The following points are important for the configuration: The specifications on configuration must be complete and correct. The power supplies to the PLC and to the field bus slaves must be switched on either simultaneously or in the sequence specified below. Please observe also the following points when switching on the power supplies: Common supply. If the control system and all the field bus slaves have a common power supply, they should be switched on with a common central power unit or switch. Separate supply. If the control system and the field bus slaves have separate power supplies, they should be switched on in the following sequence: 1. first the field bus slaves 2. then the control system A

100 4. Commissioning Calculating the configuration data Before configuring, calculate the exact number of inputs/outputs available. A modular valve terminal consists of a number of I/Os which differs depending on the type of valve terminal. PLEASE NOTE The terminal makes available four status bits for diagnosis via the field bus. These are always assigned automatically within the terminal when there are input modules. The status bits occupy four additional input addresses A 4-7

101 4. Commissioning The following table shows the number of I/Os required for each module for configuration. Module type Number of assigned I/Os *) Single sub-base (type 03) 2O Double sub-base (type 03) ISO manifold sub-base (type 05) - 4 valve locations - 8 valve locations - 12 valve locations Output module (4 digital outputs) Input module (4 digital inputs) Input module (8 digital inputs) 4O 8O 16O 24O 4O 4I 8I Status bits**) 4I *) The I/Os are assigned automatically in the terminal irrespective of whether an input/output is actually used. **) The status bits are assigned automatically in the terminal as soon as there are input modules. Fig. 4/1: Number of assigned I/Os per module A

102 4. Commissioning Calculating the number of inputs/outputs type 03 Copy this table for further calculations and ascertain the number of inputs/outputs. Table for calculating the inputs/outputs type 03 INPUTS 1. Number of 4-input modules 4 Σ E 2. Number of 8-input modules 8 + Σ E 3. The 4 status bits are assigned internally automatically by the terminal. They must be treated like inputs and added to the intermediate sum. + 4E Total sum of inputs to be configured = OUTPUTS Σ E 4. Number of single sub-bases type Number of double sub-bases type Σ Σ A A Intermediate sum of = Σ A 6. Check whether sum of can be divided without remainder. This check is necessary because of the 4-bit orientated internal addressing of the terminal. Different cases: a) If divisible by 4 without remainder continue with point 7. b) If not round up (+ 2 outputs) + 2A 7. Number of electrical 4-output modules 4 + Σ A Total sum of outputs to be configured = Σ A Fig. 4/2: Calculating the number of inputs/outputs type A 4-9

103 4. Commissioning Calculating the number of inputs/outputs type 05 Copy this table for further calculations. Table for calculating the number of inputs/outputs type 05 INPUTS 1. Number of 4-input modules 4 Σ E 2. Number of 8-input modules 8 + Σ E 3. The 4 status bits are assigned internally automatically by the terminal. They must be treated like inputs and added to the intermediate sum. + 4E Total sum of inputs to be configured = Σ E OUTPUTS 4. ISO manifold sub-base for: 4 valve locations 8O 8 valve locations 16O 12 valve locations 24O 5. Number of electrical 4-output modules 4 + Σ Σ A A Total sum of outputs to be configured = Σ A Fig. 4/3: Calculating the number of inputs/outputs type A

104 4. Commissioning Address assignment of the valve terminal General type 03 and type 05 The address assignment of a modular valve terminal depends on the equipment fitted on the terminal. A distinction must be made between the following equipment fitted: valves and digital I/O modules valves only digital I/O modules only The basic rules described overleaf apply to the address assignment of these fitting variants. PLEASE NOTE If two addresses are assigned for one valve location, the following applies: Lower-value address pilot solenoid 14 Higher-value address pilot solenoid A 4-11

105 4. Commissioning Basic rule 1 With mixed fitting, consideration is given to the address assignment of the valves, the digital I/O modules and the status bits. 1. Outputs: The address assignment of the outputs does not depend on the inputs. 1.1 Address assignment of the valves: Addresses should be assigned in ascending order without gaps. Counting begins on the node from left to right. Single sub-bases always occupy two addr. Double sub-bases always occupy four addr. ISO valve locations always occupy two addr. Maximum 26 valve solenoid coils can be addressed. 1.2 Rounding up to 4 bits, different cases: a) If the number of valve addresses can be divided by 4 without remainder, continue with point 1.3. b) If the number of valve addresses cannot be divided by 4 without remainder, the number must be rounded up to 4 bits because of the 4-bit orientated addressing. The 2 bits thus rounded up cannot be used. 1.3 Address assignment of the output modules: The digital outputs are addressed after the (rounded up 4-bit) addresses of the valves. Addresses should be assigned in ascending order without gaps. Counting begins on the node from right to left. Counting on the individual modules is from top to bottom. Digital output modules always occupy 4 addresses A

106 4. Commissioning 2. Inputs The address assignment of the inputs does not depend on the outputs. 2.1 Address assignment of the input modules: Addresses should be assigned in ascending order without gaps. Counting begins on the node from right to left. Counting on the individual modules is from top to bottom. 4-input modules occupy 4 addresses. 8-input modules occupy 8 addresses. 2.2 Status bits The address assignment of the status bits depends on the equipment fitted on the inputs and on the configuration. The following rule applies: The status bits are only available when input modules are connected to the terminal and when at least 8 inputs are configured in the PLC. Addressing. The status bits are transferred to the four highest-value positions of the configured address range. When the operating voltage is switched on, the valve terminal automatically recognizes all the available pneumatic modules (type 03: max. 13 modules; type 05: 4, 8, 12 valve locations) and digital input/output modules and assigns the appropriate addresses. If a valve location is not used (blanking plate) or if a digital input/output is not connected, the relevant address will still be occupied A 4-13

107 4. Commissioning The diagram below shows the address assignment with mixed fitting. 4-input module 8-input module 4-output module 8-output module Single sub-base Double sub-base Double sub-base Double sub-base Round up Fig. 4/4: Address assignment of a valve terminal with digital I/Os (example type 03) Remarks on the diagram If single solenoid valves are fitted onto double sub-bases, four addresses will be reserved for valve solenoid coils; the higher address in each case then remains unused (see address 3). If unused valve locations are fitted with blanking plates, the addresses will still be occupied (see addresses 12, 13). Due to the 4-bit orientated addressing of the modular valve terminal, the address of the last valve location is always rounded up to four full bits (unless the equipment fitted already uses the four full bits). This means that two addresses cannot be used (see addresses 14, 15) A 4-14

108 4. Commissioning Basic rule 2 If only valves are used, the address assignment will always be as described in basic rule 1. PLEASE NOTE Maximum 26 valve solenoid coils can be addressed. There is no rounding up of the last two positions on the valve side. Valve terminals without input modules do not require a configuration for inputs. The status bits are not therefore available. Basic rule 3 If only electrical I/Os are used, the address assignment will always be as described in basic rule 1. PLEASE NOTE Counting begins immediately to the left of the node. There is no rounding up of the last two positions on the valve side. Please unfold for page A

109 4. Commissioning Address assignment after extension/ conversion A special feature of the modular valve terminal is its flexibility. If the demands placed on the machine change, then the equipment fitted on the terminal can also be modified. CAUTION If extensions or conversions are made to the terminal at a later stage, this may result in a shifting of the input/output addresses. This applies in the following cases: if one or more pneumatic modules is/are fitted/removed at a later stage (type 03). if a pneumatic module with single valves is replaced by a new module with double valves or vice versa (type 03). if additional input/output modules are inserted between the node and existing input/output modules. if existing 4-input modules are replaced by 8-input modules or vice versa. If the configuration of the inputs is changed, the addresses of the status bits will always be shifted A

110 4. Commissioning The diagram below shows the modifications to the address assignment if the standard fitting in the previous diagram is extended. 4-input module 8-input module 4-output module 4-output module Single sub-base Double sub-base Double sub-base Double sub-base SUPPLY Double sub-base Single sub-base Do not round up Fig. 4/5: Address assignment of a valve terminal after extension/conversion Please note: Air supply modules and intermediate air supply modules do not occupy any addresses A 4-17

111 4. Commissioning Addressing example type 03 MIDI/MAXI valves 4-input module 8-input module 4-output module 4-output module Double sub-base Double sub-base Double sub-base Double sub-base Single sub-base Double sub-base Round up Please note: If a valve location occupies two addresses, the following applies: Lower-value address pilot solenoid 14 Higher-value address pilot solenoid 12 Fig. 4/6: Address assignment of a valve terminal type 03 (MIDI/MAXI valves) 9801 A 4-19

112 4. Commissioning Addressing example type 05 ISO valves 4-input module 8-input module 4-output module 4-output module Double valve Double valve Double valve Single valve Double valve Double valve Double valve Single valve Do not round up Please note: If a valve location occupies two addresses, the following applies: Lower-value address pilot solenoid 14 Higher-value address pilot solenoid 12 Fig. 4/7: Address assignment of a valve terminal type 05 (ISO valves) A

113 4. Commissioning 4.2 BASIC PRINCIPLES OF COMMISSIONING AND DIAGNOSIS General This chapter describes the configuration and addressing of a valve terminal on a CANopen Interface or CANopen master. The following standards have been taken into account: DS 301 DSP 401 DS DS 207 Draft Standard 301 concerns the communications profile based on CAL Draft Standard Proposal 401 defines the device profiles for input/output CAN Application Layer CAL In order to understand this chapter, the user should be familiar with CANopen and the specifications DS 301 and DSP 401. Selecting the inputs/outputs PLEASE NOTE The sum of the input bytes must not exceed 8 bytes (60 inputs + 4 status bits) and 8 output bytes (64 outputs). The number of inputs and outputs is different due to the modular structure of the valve terminal. The number of input bytes and/or output bytes which actually exist on the valve terminal can be read via the appropriate index A 4-21

114 4. Commissioning General information on CANopen CANopen devices have an object directory which provides access in a standardized manner to all important node parameters. You can configure a CANopen system mainly by accessing the object directory of the individual nodes. The access mechanism is made available by Service Data Objects (SDOs). There are two different communication mechanisms in a CANopen system. "Process Data Objects (PDOs) serves for the fast transfer of processing data and is transmitted by simple CAN messages without protocol overhead and in the broadcast procedure. Process Data Objects can be transmitted event-controlled, synchronous to a system time interval or on demand. Die Service Data Objects (SDO) forms a point-to-point conection and permits access to every entry in the object directory of a node A

115 4. Commissioning Brief summary of scope of function Module states and boot up after communication profile DS 301 All the entries in the communication part of the object directory are included A service data object for read/write access to the object directory A process data object for access to digital input/outputs PDO-COB identifier for read/write access can be selected individually PDO transmission types for read/write access can be set separately as asynchronous (255), synchronous cyclic (1-240), synchronous acyclic (0) as per DS 301 PDO emergency telegram for error message to the master Synchronous mode Node guarding All COB-IDs of the implemented functions (except for SDO) can be selected separately in the object directory via SDO transfer, both for sending and for receiving Default setting of all identifiers as per DS 301 and the node address 9801 A 4-23

116 4. Commissioning Summary of object directory The following table shows the implemented objects of the Festo valve terminal. The table is based on DS 301 (Draft Standard Proposal): Index (hex) Objects E Communication part of the object directories 1400 Communication parameter for receive PDO 1600 Mapping parameter for receive PDO (variable mapping not implemented) 1800 Communication parameter for send PDO 1803 Communication parameter for emergency PDO 1A00 Mapping parameter for send PDO (variable mapping not implemented) 1A03 Mapping parameter for emergency PDO (variable mapping not implemented) 6000 Input array 6200 Output array 6206 Fault mode array for the output lines 6207 Fault state array for the output lines A

117 4. Commissioning COB identifier The Festo valve terminal with CANopen represents a "minimum capability device" (minimum device). The PDO-COB identifier can be selected individually for read and write access. Bit 10 Bit 7 Bit 6 Bit 0 Function code Module-ID Fig. 4/9: Structure of COB identifier Max. 127 slaves can be controlled with the module-id. Addresses from can be set with the address selector switches of the valve terminal. Address 99 is reserved for the self test. Address 00 is not valid. The address is also referred to as station number, MAC-ID or "MESSAGE-ID." Example: COB-ID for valve terminal. Set address (rotary switch): 10D. Bit 10 Bit 7 Bit 6 Bit Function code Module-ID Fig. 4/10: Structure of COB identifier for valve terminal no A 4-25

118 4. Commissioning Switch-on reaction of the valve terminal Status diagram of the Festo valve terminal Switch on 4 [cs=82h] 4 [cs=82h] Hardware initialization Communication initialization [cs=80h] Pre-Operational Operational [cs=01h] 5 [cs=81h] 5 [cs=81h] Fig. 4/11: Status diagram of the valve terminal Status transfer Designation Description of the status transfers Command specifier (CS) Function 1 Automatic initialization after switching on 2 Start_remote_Node_Indication 01H Start valve terminal Release outputs Start PDO transmission 3 Enter_Pre_Operation_ State 80H Stops PDO transmission; SDO remains active 4 Reset_Communication_ Indication 82H Reset communication functions 5 Reset_Node_Indication 81H Reset module including application A

119 4. Commissioning Peer-to-Peer Objects Object Name Object designation Function code (binary) CMS priority group Value range of COB identifier with Festo valve terminals SYNC D 80H Default identifier distribution The following table shows the identifier distribution. EMER- GENCY Send PDO Receive PDO Send SDO Receive SDO Node guarding For high-priority processes e.g. voltage failure , 1 129D to 226D 081H 0E2H , 2 385D to 482D 181H 1E2H D to 610D 201H 262H D to 1506D 581H 5E2H , D to 1634D 601H 662H D to 1890D 701H 762H 9801 A 4-27

120 4. Commissioning Summary of object directory The communication part of the objects contains the following objects. Values and examples refer to module-id = 1. Index (hex) Object name symbolic Communication profile Object designation Object type Object attributes Values/ subindex Explanation of values 1000 VAR Device type U32 ro = Device profile for I/O module x: 0300 = Digital inputs and digital outputs exist 1001 VAR Manufacturer error field U8 ro xx 00 = No error 81 = Generic manufacturer error 1002 VAR Predef_status U32 ro Not defined 1003 ARRAY Predef_error field [2] 1004 ARRAY No. of PDOs [3] supported 1005 VAR COB Id SYNC message U16 ro "0"= 0x xx "1"= xx xx U32 ro "0"= "1"= "2"= Number of errors Standard error field 2023 = Short circuit/ overload 2033 = Valve voltage < 21.6 V 3033 = Valve voltage > 10 V 2031 = Sensor voltage < 10 V No. of transmit PDOs No. of receive PDOs No. of syn. transmit PDOs No. of syn. receive PDOs No. of asyn transmit PDOs No. of asyn. receive PDOs U32 rw = Device supports SYNC message. Does not generate SYNC message = Default COB-ID VAR Communication cycle period U32 rw = 10 sec U = unsigned, ro = read only, rw = read write Table continued on next page A

121 4. Commissioning Table continued Index (hex) Object name symbolic Communication profile Object designation 1007 VAR Synchronous window length 1008 ARRAY Manufacturer device name 1009 ARRAY Manufacturer hardware version Object type Object attributes Values/ subindex Explanation of values U32 rw Without function String FB14 String min A ARRAY Manufacturer software version String E 31 V B VAR Node-ID U32 ro Node address 100C VAR Guard time U16 rw E8 03 e.g ms 100D VAR Lifetime factor U8 rw 03 Life time for the node guarding protocol 100E VAR Nodeguard_id U32 rw Nodeguard identifier U = unsigned, ro = read only, rw = read write PDO communication parameter record The following object directory is defined in the "Receive" PDO communication parameter. Values and examples refer to module-id = 1. Index (hex) Object name symbolic Communication profile Object designation 1400 RECORD Communication parameter for receive PDO Object type PDOComm parameter Object attributes Values/ subindex rw "0"=02 "1"= "2"=xx Default = FF Explanation of values = No. of entries = COB-ID module-id = transmission type 01 = async. FF= acyc. async A 4-29

122 4. Commissioning The following object directory is defined in the "Transmit" PDO communication parameter. Values and examples refer to module-id = 1. PLEASE NOTE With transmission type "synchronous", the parameter (01...F0) specifies the number of SYNC messages which must be received until the send PDO is transmitted. Index (hex) Object name symbolic Communication profile Object designation Communication parameter for send PDO 1803 RECORD 4. Communication parameter for send PDO Object type PDOComm parameter PDOComm parameter Object attributes Values/ subindex rw "0"=02 "1"= "2"=xx Default = FF rw "0"=02 "1"= "2"=FE Explanation of values = No. of entries = COB-ID module-id transm. type 00 = acyclic synch. 01-F0 = synch. FF = acyclic asynch. = No. of entries = COB-ID 80 + module-id = transmission type asynch. (not changeable) A

123 4. Commissioning PDO communication mapping parameter field PLEASE NOTE Variables mapping is not supported. "Receive" PDO mapping parameter: Index (hex) Object name symbolic Communication profile Object designation 1600 ARRAY Mapping parameter for receive PDO Object type PDOComm parameter Object attributes ro Values/ subindex "0"= 0x "1"= "2"= "3"= "4"= "5"= "6"= "7"= "8"= Explanation of values = No. of available output bytes = O O 0.7 = O O 1.7 = O O 2.7 = O O 3.7 = O O 4.7 = O O 5.7 = O O 6.7 = O O 7.7 "Transmit" PDO mapping parameter: Index (hex) Object name symbolic Communication profile Object designation 1A00 ARRAY Mapping parameter for send PDO 1A03 ARRAY Mapping parameter for emergency PDO Object type PDOComm parameter PDOComm Parameter Object attributes ro Values/ subindex "0"= 0x "1"= "2"= "3"= "4"= "5"= "6"= "7"= "8"= ro 0 =07 1 = Explanation of values = No. of available input bytes = I I 0.7 = I I 1.7 = I I 2.7 = I I 3.7 = I I 4.7 = I I 5.7 = I I 6.7 = I I 7.7 = No. of bytes = Manufacturer error field Emergency error code = Reserved 9801 A 4-31

124 4. Commissioning Digital inputs Festo supports the "INPUT ARRAY" and "OUTPUT ARRAY" for the 8-bit commands. The following tables apply: Index (hex) Object name symbolic Communication profile Object designation 6000 ARRAY Read state 8 input lines[9] Object type Object attributes Values/ subindex Unsigned 8 ro 0 = 0x "1" =xx "2" =xx "3" =xx "4" =xx "5" =xx "6" =xx "7" =xx "8" =xx Explanation of values = No. of available input bytes = I I 0.7 = I I 1.7 = I I 2.7 = I I 3.7 = I I 4.7 = I I 5.7 = I I 6.7 I I 7.7 Digital outputs Index (hex) Object name symbolic Communication profile Object designation 6200 ARRAY Write state 8 output lines[9] Object type Object attributes Values/ subindex Unsigned 8 rw 0 = 0x "1" = xx "2" = xx "3" = xx "4" = xx "5" = xx "6" = xx "7" = xx "8" = xx Explanation of values = No. of available output bytes = O O 0.7 = O O 1.7 = O O 2.7 = O O 3.7 = O O 4.7 = O O 5.7 = O O 6.7 = O O A

125 4. Commissioning Reaction of the digital outputs in the event of a fault Festo supports the "FAULT MODE ARRAY" for the 8-bit commands. The following tables apply: Index (hex) Object name symbolic Communication profile Object designation 6206 ARRAY Fault mode 8 output lines[9]. Define masking Object type Object attributes Values/ subindex Unsigned 8 rw "0"= 0x "1" = xx "2" = xx "3" = xx "4" = xx "5" = xx "6" = xx "7" = xx "8" = xx Default value: FF Explanation of values = No. of available output bytes = Masking O O 0.7 = Masking O O 1.7 = Masking O O 2.7 = Masking O O 3.7 = Masking O O 4.7 = Masking O O 5.7 = Masking O O 6.7 = Masking O O A 4-33

126 4. Commissioning Festo supports the "FAULT STATE ARRAY" for the 8-bit commands. The following tables apply: Communication profile Index (hex) Object name symbolic Object designation Object type Object Values/ attributes subindex Explanation of values 6207 ARRAY Fault state 8 output lines[9] Set masking Unsigned 8 rw "0"= 0x "1" = xx "2" = xx "3" = xx "4" = xx "5" = xx "6" = xx "7" = xx "8" = xx Default value: 00 = No. of available output bytes = Fault state O O 0.7 = Fault state O O 1.7 = Fault state O O 2.7 = Fault state O O 3.7 = Fault state O O 4.7 = Fault state O O 5.7 = Fault state O O 6.7 = Fault state O O 7.7 PLEASE NOTE With index 6206, you can determine the outputs which are to assume a default status in the event of an error. With index 6207, you can determine the status which the outputs are to assume in the event of an error A

127 4. Commissioning Definition of emergency object Festo supports a "PDO Emergency Object" as per DS 401 (see diagram). The PDO object is sent by the valve terminal in the following cases: undervoltage at valves and outputs < 21.6 V undervoltage at valves and outputs < 10 V short circuit/overload at an output undervoltage at sensor supply < 10 V The emergency PDO is sent when a fault occurs and when the fault has been eliminated. Byte Byte 7 Emergency Error code 2320 = SC/O 3320 = Vval < 21,6 V 3330 = Voff < 10 V 3120 = Vsen > 10 V Error register 00 = no error 81 = Generic and Manufacturer error Manufacturer specific error field (reserved) Fig. 4/12: Definition of Emergency Object 9801 A 4-35

128 4. Commissioning Addressing inputs and outputs PLAESE NOTE Observe also the basic addressing rules at the beginning of the chapter. I I 3.7 I I 3.3 I I 2.7 I I 1.7 I I 0.7 O 1.4; O 1.7 O 0.0 O 0.1 O 0.3; O 0.2 O 0.5; O 0.4 O 0.7; O 0.6 O 1.1; O 1.0 (free due to rounding) Fig. 4/13: Assignment of inputs/outputs The following table shows the assignment of all the inputs and outputs: A

129 4. Commissioning Valve terminal inputs Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 Byte 0 I0.7 I0.6 I0.5 I0.4 I0.3 I0.2 I0.1 I0.0 Byte 1 I1.7 I1.6 I1.5 I1.4 I1.3 I1.2 I1.1 I1.0 Byte 2 I2.7 I2.6 I2.5 I2.4 I2.3 I2.2 I2.1 I2.0 Byte 3 I3.7 I3.6 I3.5 I3.4 I3.3 I3.2 I3.1 I3.0 Byte 4 I4.7 I4.6 I4.5 I4.4 I4.3 I4.2 I4.1 I4.0 Byte 5 I5.7 I5.6 I5.5 I5.4 I5.3 I5.2 I5.1 I5.0 Byte 6 I6.7 I6.6 I6.5 I6.4 I6.3 I6.2 I6.1 I6.0 Byte 7 I7.7 I7.6 I7.5 I7.4 I7.3 I7.2 I7.1 I7.0 Valve terminal outputs Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 Byte 0 O0.7 O0.6 O0.5 O0.4 O0.3 O0.2 O0.1 O0.0 Byte 1 O1.7 O1.6 O1.5 O1.4 O1.3 O1.2 O1.1 O1.0 Byte 2 O2.7 O2.6 O2.5 O2.4 O2.3 O2.2 O2.1 O2.0 Byte 3 O3.7 O3.6 O3.5 O3.4 O3.3 O3.2 O3.1 O3.0 Byte 4 O4.7 O4.6 O4.5 O4.4 O4.3 O4.2 O4.1 O4.0 Byte 5 O5.7 O5.6 O5.5 O5.4 O5.3 O5.2 O5.1 O5.0 Byte 6 O6.7 O6.6 O6.5 O6.4 O6.3 O6.2 O6.1 O6.0 Byte 7 O7.7 O7.6 O7.5 O7.4 O7.3 O7.2 O7.1 O7.0 Fig. 4/14: Assignment of inputs/outputs 9801 A 4-37

130 4. Commissioning Examples: communication process All the examples refer to module-id = 1, i.e. the set valve terminal address 1. Example 1: Signal change 0 1 input 0 PLC PC IPC COB-ID 181 Data values in hex Fig. 4/15: Signal change at input 0 When there is a signal change, the valve terminal automatically sends the status of the inputs (send PDO). In the example only input 0 is at "log. 1." Example 2: Set output 0 of the valve terminal PLC PC IPC COB-ID 201 Data values in hex Fig. 4/16: Output 0 (set 1st. valve) In order to set valves and outputs on the valve terminal, the receive PDO must be sent by the master. In the example only output 0 is set. Any outputs already set will be reset A

131 4. Commissioning Example 3: Read object 1000H, subindex 0 (device type: device profile, device equipping). PLC PC IPC COB-ID Initiate Domain Upload Request Initiate Domain Upload Response Index Index Sub-Index Sub-Index Data*) Data *) Values in hex *) with 4 data bytes Fig. 4/17: Read object 1000H In order to read objects of a valve terminal, the send SDO must be loaded with the Upload command, the index and the subindex. The valve terminal then sends the number of data bytes, the index, the subindex and the data bytes A 4-39

132 4. Commissioning Example 4: Write object 100CH, subindex 0 (Guard time). COB-ID Initiate Domain Download Request Index Sub-Index Data *) PLC PC IPC B 0C F C xx xx xx xx Initiate Domain Upload Response Index Sub-Index Data*) Values in hex *) with 2 data bytes xx = Value not defined Fig. 4/18: Write object 100CH In order to write objects of a valve terminal, the receive SDO must be loaded with the Download command, the index, the subindex and the value. The valve terminal then sends as acknowlegement the index, the subindex and a data byte A

133 4. Commissioning Diagnosis of status bits The status bits signalize internal errors in the valve terminal. The following errors are recognized: Undervoltage at valves/outputs < 21.6V Undervoltage at valves/outputs < 10V Short circuit/overload of an electrical output Undervoltage in sensor supply < 10V Further information can be found in chapter 5 "Diagnosis and error treatment" (chapter 5.3 Status bits). The status bits are treated and transferred like inputs. They always occupy the four highestvalue addresses/bits of the available address range. If the inputs of the input addresses/bits thereunder are not used, the valve terminal will set them to "logic zero." PLEASE NOTE The status bits always increase the number of inputs by 4 and, therefore, also the sum of any input bytes. Example: Valve terminal fitted with 32 inputs. The number of available input bytes is then: 5 input bytes (28 inputs + 4 status bits) A 4-41

134 4. Commissioning Position of the status bits The addresses of the status bits in the address range of a valve terminal (depending on the extent to which the valve terminal is equipped) are shown in the following table: Valve terminal equipment None Available address range No address range for inputs Addresses of the status bits No status bits available up to 4 inputs I I 0.3 I I 0.7 up to 12 inputs I I 1.3 I I 1.7 up to 20 inputs I I 2.3 I I 2.7 up to 28 inputs I I 3.3 I I 3.7 up to 36 inputs I I 4.3 I I 4.7 up to 44 inputs I I 5.3 I I 5.7 up to 52 inputs I I 6.3 I I 6.7 up to 60 inputs I I 7.3 I I A

135 4. Commissioning 4.3 BASIC PRINCIPLES OF THE SMART DISTRIBUTED SYSTEM (HONEYWELL) General information PLEASE NOTE When using the valve terminal on the Honeywell Smart Distributed System (SDS), observe the instructions on setting the station number (see chapter 3). Commissioning Carry out the following steps in order to commission the system: Step Activity 1 Setting the protocol Remove the cover of the node Set the protocol (Smart Distributed System) Replace the node cover and screw it tight 2 Setting the station number Connect the Handheld Activator to the valve terminal Apply 24 V DC to the valve terminal Switch on the Handheld Activator Select the menu <Select Device> Select the valve terminal <F1-Select Device> Press <ENT> to enter the station number found (station number 125 is set when system is supplied) The station number must be an odd number Enter new station number <F2 Change Address>. Press: <ENT>. Label the valve terminal with the station number 3 If necessary, set transmission mode (un/solicited mode, cyclical timer) 4 Connect valve terminal to the field bus Carry out bus configuration If necessary, carry out I/O test Fig. 4/19: Commissioning steps 9801 A 4-43

136 4. Commissioning Number of inputs and outputs PLEASE NOTE The maximum equipment fitted onto the valve terminal with the SDS protocol is: max. 4 bytes outputs (32 valve coils and/or electrical outputs). max. 4 bytes inputs (28 electrical inputs + 4 status bits) The following equipment can be fitted: Valve terminal equipment *) System configuration Outputs Inputs Up to 8 outputs 8 Up to 16 outputs 16 Up to 32 outputs 32 Up to 8 outputs and 4 inputs 8 8 Up to 16 outputs and up to 12 inputs Up to 32 outputs and up to 28 inputs *) further variants of equipment are possible Fig. 4/20: Examples: Variants of equipment A

137 4. Commissioning Attribute ID Function 0 Network Data Descriptor Summary of implemented object models The table below shows all the implemented attributes of the input object of the valve terminal (as per Multiple Binary Input Object profile = station address n+1). Variable type Size Number Read/ Write Value U Byte 3 r (15, 31) 1) 1 Baud rate U Byte 1 r 0 2 Object type U Byte 2 r Partner ID no. U Word 1 r Logical address list U Byte? r SDS-ID -1 2) 5 Unused 6 Un/solicited mode Byte 1 rw 1 (default) 7 Software version ASCII Undefined 12 r V2.0 (or higher) 8 Diagnostic error counter U Byte 1 r 9 Diagnostic error register U = unsigned; r = read only; rw = read/write U Long Word 1 r 1) Depends on equipment fitted on valve terminal. The valve terminal selects the number automatically. 2) Related to station number n+1 Fig. 4/21: Summary of implemented attributes (input model) 9801 A 4-45

138 4. Commissioning Attribute ID Function Variable type Size Number Read/ Write Value 10 Cyclic timer U Word 1 rw 0 11 Serial number U Long 1 r Individual 12 Data Code ASCII Undefined 4 r 3497 (or higher) 13 Catalog listing ASCII Undefined 32 r IFB Partner name ASCII Undefined 32 r FESTO 15 Component tag name ASCII Undefined 32 rw VALVE TERMINAL 16 Unused 17 Unused 18 Input variable Boolean Undefined 8 1 [16] [32] r Status of inputs U = unsigned; r = read only; rw = read/write 1) Depends on equipment fitted on valve terminal. The valve terminal selects the number automatically. 2) Related to station number n+1 Fig. 4/21a: Summary of implemented attributes (input model) Continued The following table shows all the implemented attributes of the output object of the valve terminal (as per Multiple Binary Output Object profile = station address n) A

139 4. Commissioning Attribute Function ID 0 Network Data Descriptor Variable type Size Number Read/ Write Value U Byte 3 r (15, 31) 1) 1 Baud rate U Byte 1 r 0 2 Object type U Byte 2 r Partner ID no. U Word 1 r Logical address list U Byte? r SDS-ID -1 2) 5 Unused 6 Unused 7 Software version ASCII Undefined 12 r V2.0 (or higher) 8 Diagnostic error U Byte 1 r counter 9 Diagnostic error U Long Word 1 r register 10 Unused 11 Serial number U Long 1 r Individual 12 Data code ASCII Undefined 4 r 3497 (or higher) 13 Catalog listing ASCII Undefined 32 r IFB Partner name ASCII Undefined 32 r FESTO 15 Component tag name ASCII Undefined 32 rw VALVE TERMINAL 16 Unused 17 Unused 18 Output variable Boolean Undefined 8 1 [16] [32] r Status of outputs U = unsigned; r = read only; rw = read/write 1) Depends on equipment fitted on valve terminal. The valve terminal selects the number automatically. 2) Related to station number n Fig. 4/22: Summary of implemented attributes (output model) 9801 A 4-47

140 4. Commissioning Action ID Function Summary of actions The table below shows all the implemented actions of the valve terminal (as per Multiple Binary Input or Output Object profile). Request Data parameters Request Data parameter type Response Data parameters 0 No operation None None 1 Change address New address device ID partner ID serial no. U 8 U 8 U 16 U 32 None 2 Self test None None 6 Clear all errors None None 8 Enroll logical device 53 Read primitive tag None Serial no. partner ID Attribute ID U 8 Attribute ID primitive tag 57 Password Password code U 8*N None U = unsigned; r = read only; rw = read/write Fig. 4/23: Summary of implemented actions Response Data parameter type U 16 U 32 U 8 U A

141 4. Commissioning Summary of events The table below shows all the implemented events of the valve terminal (as per Multiple Binary Input or Output Object profile). Event ID Function 0 Diagnostic event counter 6 Update input state 1) Output Data parameters Counter value U 8 Attribute ID data Output Data parameter type U 8 U 8 7 Noop 1) U = unsigned 1) Only valve terminal with inputs and outputs Fig. 4/24: Summary of implemented events Assignment of SDS IDs The table below shows the assignment of the object IDs and attribute IDs to the SDS IDs: Valve terminal Output equipment Only outputs SDS ID n * ) object ID 0 attribute ID 19 max. 28 inputs and max. 32 outputs SDS ID n * ) object ID 0 attribute ID 19 Input SDS ID n+1 *) object ID 0 attribute ID 18 Only inputs Not possible *) SDS ID n stands for the stored station number in the valve terminal. Fig. 4/25: Assignment of the SDS IDs 9801 A 4-49

142 4. Commissioning Diagnosis PLEASE NOTE The controllers offer very different diagnostic possibilities. Details can be found in the manual for your interface or control system and in the following chapter. The Festo valve terminal supports the following functions: - Diagnostic error counter - Diagnostic error register. The number of set bits in the error register is shown in the error counter. In addition to the SDS-typical error codes, the error register also contains valve terminal specific error messages A

143 4. Commissioning The table below shows the assignment of the valve terminal specific bits in byte 2 of the diagnostic error register. Bytes 3 and 4 are not assigned. Bit Function Meaning 0 Reserved 1 Reserved 2 Short circuit/ over load 3 Reserved Short circuit/overload of an electrical output 4 VSen Undervoltage in sensor supply (< 10 V) 5 VVal Undervoltage in valve supply (< 21.6 V) 6 Voff Undervoltage in valve supply (< 10 V) 7 Reserved Fig. 4/26: Valve terminal specific error messages In addition, the Festo valve terminal provides status bits for diagnostic purposes, irrespective of the control system used. Diagnosis via status bits PLEASE NOTE The status bits are only available if inputs are fitted A 4-51

144 4. Commissioning The status bits signalize internal errors of the valve terminal. The following errors are recognized: undervoltage at valves/outputs < 21.6 V undervoltage at valves/outputs < 10 V short circuit/overload at an electrical output undervoltage in sensor supply < 10 V Further details can be found in chapter 5.4, Status bits. PLEASE NOTE The status bits are treated and transferred like inputs. They always occupy the four highest value addresses/bits of the configured address range. If the inputs of the input addresses/bits thereunder are not used, the valve terminal will set them to logic zero." Valve terminal equipment The status bits occupy the following address range depending on the equipment fitted on the valve terminal: Configured address range Available input addresses Addresses of the status bits No inputs Up to 4 inputs 1 byte / 8 inputs Up to 12 inputs 2 bytes / 16 inputs Up to 28 inputs 4 bytes / 32 inputs Fig. 4/27: Position of status bits A

145 4. Commissioning Setting the transmission mode PLEASE NOTE Undertake all settings via the user program. In this way you can be sure that a new node will automatically be set correctly after servicing. The Festo valve terminal is set at the factory as follows: Unsolicited mode (attribute ID 6 = 1). Cyclical timer = 0 (attribute ID 10 = 0) The following transmission modes of the valve terminal inputs can be set with the Handheld Activator: Solicited mode: inputs are interrogated by the master Unsolicited mode: event-controlled transmission of status modifications Cyclic mode: cyclic transmission of the valve terminal inputs. The repetition time results from: (set value) * 10 ms. The value 0 deactivates this mode. All three transmission modes can be combined. Further information can be found in the documentation for your control system A 4-53

146 4. Commissioning Set the transmission mode with the Handheld Activator as follows: 1. Connect the Activator to the valve terminal. 2. Activate function F1 - Select Device (2x). Select the valve terminal. Enter the address of the input object to be modified. Transfer this with ENT. 3. Press ESC (= return to input starting menu). 4. Activate F2 - Data / Function. 5. Activate F3 - Direct Access 6. Enter The set Un/Solicited mode will appear, e.g Press the PROG key. Set the desired mode: 0 = Solicited mode 1 = Unsolicited mode 9. Transfer the mode with ENT. 10. Press ESC (= return to main menu). The Cyclical timer is set accordingly. Select attribute 10 (instead of attribute 6). Bus configuration The SDS bus configuration is different for each system. The following examples show two bus configurations for the most common SDS control systems A

147 4. Commissioning CONFIGURING/ADDRESSING THE HONEYWELL SDS PC CONTROL General information PLEASE NOTE The following information refers to the special settings required when the Honeywell SDS PC is used in conjunction with a Festo valve terminal. Configuration must be made with a special Honeywell program. Details on installing and operating this program can be found in the relevant Honeywell documentation. The SDS device address (SDS-ID) must be the same as the station number stored in the valve terminal. Settings in the Device Editor PLEASE NOTE If certain device types are not available in your control system, contact your control system supplier. He will supply you with the necessary updates A 4-55

148 4. Commissioning Enter the following with the Device Editor: Device name Device type SDS device address Festo valve terminals require specific entries both for outputs and inputs Configuring Festo valve terminals as: - 8; 16 or 32 input bits and - 8; 16 or 32 output bits Fig. 4/28: Select device and device type for Festo valve terminals A

149 4. Commissioning Activate the button "Configure". Then assign an SDS device address (SDS-ID) to each device (see also chapter 3) )Valve terminals with outputs occupy one SDS Device Address (n = odd number) Valve terminals with outputs and inputs occupy two SDS Device Addresses (n and n+1) Fig. 4/29: Assigning the SDS device address The assignment of device, device type and SDS device address is then concluded A 4-57

150 4. Commissioning Settings in the Tag Editor PLEASE NOTE Declare the inputs and outputs of the valve terminal in bits. In this way, the valve coils and the return messages from the sensors can be addressed more easily in the sequence program. Enter symbolic names for the inputs or outputs of the valve terminal as follows: 1. Device : select the SDS-ID for the valve terminal to be configured. 2. "Type": select "Input bit" 3. "Tag : enter a symbolic name for each I/O listed under "Point" A

151 4. Commissioning The example shows the configuration of the valve terminal inputs. The outputs must be configured in the same way. 1 1 Symbolic name for each bit Fig. 4/30: Entries in the Tag Editor 9801 A 4-59

152 4. Commissioning Setting the transmission types for inputs by means of the programming software You can set the transmission type for inputs with the function Attribute Editor during the network test. Example: SDS ID of the valve terminal Mode selcetion: 0 = Solicited Mode 1 = Unsolicited Mode Fig. 4/31: Setting the Un/Solicited Mode A

153 4. Commissioning Setting the Cyclical Timer SDS ID of the inputs of the valve terminal Refresh time of inputs: 0 = Inactive n = Refresh time n * 10 ms Fig. 4/32: Setting the Cyclical Timer Settings can also be made via the user program (function I/O Special Function Selection or SDS Attribute Write, see appropriate documentation) A 4-61

154 4. Commissioning Recommendation: Enter the necessary settings via the user program. During servicing, these settings will be transferred automatically. Example: Activate SDS driver Activate Write Device Select SDS ID of the inputs of the valve terminal Attribute 6: Un/Solicited Mode Mode 0 or 1 via variable Fig. 4/33: Setting the Un/Solicited Mode via the user program A

155 4. Commissioning Diagnosis The following possibilities of diagnosis are available: Diagnosis via the network manager Diagnosis via the SDS user program Diagnosis via the status bits Diagnosis via the network manager Faulty slaves can be localized with the function Network Status and Diagnostics in the network manager. To improve diagnosis you should make a list of all the attributes. Attribute 9 (SDS Diagnostic Register ) contains valve terminal specific error messages in addition to SDS specific error messages. Diagnosis via the SDS user program The SDS Diagnostic Error Counter (attribute 8) and the SDS Diagnostic Error Register (attribute 9) can be downloaded from the user program with the function I/O Special Function Selection A 4-63

156 4. Commissioning Example: Activate SDS driver Activate Device Diagnostic Select SDS ID Diagnostic bytes 0 and 1 Diagnostic bytes 2 and 3 Fig. 4/34: Download SDS diagnostic register The low and high integer variables contain valve terminal specific error mesages in addition to SDS specific error messages A