CPX terminal. Description Electronics. System manual. Installing and. terminals. Description en 0902e [742939]

Transcription

1 CPX terminal Description Electronics System manual Installing and commissioning CPX terminals Description en 0902e [742939]

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3 Contents and general safety instructions Original en Edition en 0902e Designation P.BE CPX SYS EN Orderno E (Festo AG&Co. KG, D73726 Esslingen, Germany, 2009) Internet: E mail: service_international@festo.com The copying, distribution and utilisation of this document as well as the communication of its contents to others without expressed authorization is prohibited. Offenders will be held liable for compensation of damages. All rights are reserved, in particular the right to carry out patent, registered design or ornamental design registration. I

4 Contents and general safety instructions HARAX, INTEL, Interbus, Modbus, MOTOROLA, PROFIBUS, Push Pull, TÜV and VDE are registered trademarks of the respective trademark owners in certain countries. II

5 Contents and general safety instructions Contents Intended use Range of application and certification Target group Service Important user instructions Notes on the use of this manual VII VIII IX IX X XII 1. Overview of components Structure of the CPX terminal Mode of operation of the CPX terminal Structure of the electric CPX modules The power supply concept of the CPX terminal Commissioning, diagnosis and operational functions Assembly General instructions on assembly and dismantling Assembling electric modules with plastic interlinking blocks Replacing a complete module or interlinking block with tie rod interlinking Increasing or reducing the number of electric modules Fitting the right hand end plates with Midi/Maxi valves Assembling electric modules with metal interlinking blocks Replacing a complete module or interlinking block Fitting the CPX terminal Fitting CPX terminals without pneumatics onto a H rail Fitting CPX terminals with pneumatics onto an H rail Fitting CPX terminals with Midi/Maxi pneumatics onto an H rail Wall mounting Installation General installation instructions Connecting cable III

6 Contents and general safety instructions Configuration of the CPX bus node Configuration of the pneumatics Selecting the power supply unit Power supply of the CPX terminal Commissioning Procedure for commissioning Preparing the CPX terminal for commissioning Parameter types Possibilities of parametrisation Start up behaviour of the CPX terminal Diagnostics and error handling General notes on diagnosis On the spot diagnosis with LEDs CPX specific LEDs Diagnosis via status bits or the I/O diagnostic interface Structure of the status bits The I/O diagnostic interface Error numbers A. Technical appendix A 1 A.1 Technical data A 3 A.2 Cable length and cross sectional area A 7 B. Parameters and data of the CPX terminal B 1 B.1 Access to internal parameters and data B 3 B.2 Description of the parameters and data B 4 B.2.1 Overview of the function numbers B 5 B.2.2 System parameters B 8 B.2.3 Module parameters B 15 B.2.4 Diagnostic memory parameters B 23 B.2.5 Diagnostic memory data B 29 IV

7 Contents and general safety instructions B.2.6 System diagnostic data B 32 B.2.7 Module diagnostic data B 34 B.2.8 System data B 36 B.2.9 Module data B 42 C. General information on parametrisation C 1 C.1 Input debounce time C 3 C.2 Signal extension C 5 C.3 Influence of signal states C 8 C.3.1 Force C 11 C.3.2 Signal status in the event of a fault (Fail safe) C 15 C.3.3 Signal status in Idle status (Idle mode) C 18 C.4 Diagnostic memory C 20 C.5 Monitoring errors C 23 D. Index D 1 V

8 Contents and general safety instructions VI

9 Contents and general safety instructions Intended use CPX terminals are intended for installation in machines or automation systems. Depending on the CPX bus node used, they can be connected to a special field bus system and serve to interrogate sensor signals and to control pneumatic and electric actuators. The individual CPX modules of the CPX terminal are docu mented in specific manuals. The safety instructions listed in the manuals must always be observed and the relevant CPX module must only be used as intended. CPX modules and cables are only to be used as follows: Only in an industrial environment As intended In original status without unauthorised modifications. Only the conversions or modifications described in the documentation supplied with the product are permitted. In perfect technical condition. When used together with commercially available compo nents, such as sensors and actuators, the specified limits for pressures, temperatures, electrical data, torques etc. must be observed. Also observe the standards specified in the rele vant chapters, as well as national and local laws and technical regulations. VII

10 Contents and general safety instructions Range of application and certification The product fulfils the requirements of the EU directives and is marked with the CE marking symbol. Standards and test values, which the product must comply with and fulfil, can be found in the section Technical data". The product relevant EU directive can be found in the decla ration of conformance. Certain configurations of the product have been certified by Underwriters Laboratories Inc. (UL) for the USA and Canada. These configurations are marked as follows: ULRecognized Component Mark for Canada and the United States Note Observe the following if the UL requirements are to be complied with in your application: Rules for observing the UL certification can be found in the separate UL specific documentation. The relevant technical specifications listed there also apply here. The technical specifications in this documentation may show different values. VIII

11 Contents and general safety instructions Target group This manual is directed exclusively at technicians trained in control and automation technology. Service Please consult your local Festo repair service if you have any technical problems. IX

12 Contents and general safety instructions Important user instructions Danger categories This manual contains instructions on the possible dangers which can occur if the product is not used correctly. These instructions are marked (Warning, Caution, etc), printed on ashaded background and marked additionally with a picto gram. A distinction is made between the following danger warnings: Warning... means that failure to observe this instruction may result in serious personal injury or material damage. Caution... means that failure to observe this instruction may result in personal injury or material damage. Note... means that failure to observe this instruction may result in material damage. The following pictogram marks passages in the text which describe activities with electrostatically sensitive devices: Electrostatically sensitive devices: inappropriate handling can result in damage to components. X

13 Contents and general safety instructions Identification of specific information The following pictograms designate texts that contain special information. Pictograms Information: Recommendations, tips and references to other sources of information Accessories: Information about necessary or useful accessories for the Festo product. Environment: Information on the environmentally friendly use of Festo products. Text designations Bullet points indicate activities that may be carried out in any order. 1. Numerals denote activities which must be carried out in the numerical order specified. Arrowheads indicate general lists. XI

14 Contents and general safety instructions Notes on the use of this manual This manual contains general basic information on the me thod of operation, on fitting, installing and commissioning CPX terminals. Special information on commissioning, parameterising and diagnosing a CPX terminal with the CPX bus node you are using can be found in the appropriate manual for the CPX bus node. Information about further CPX modules can be found in the manual for the relevant module. An overview is provided in Table0/1. Conventions The parameters and data of the CPX terminal are described in Appendix B.2. These appear in English on the handheld type CPX MMI 1. XII

15 Contents and general safety instructions Type Title Description Description Electronics Manual Electronics Software package System description" Type P.BE CPX SYS... CPX bus node" Type P.BE CPX FB... CPX I/O modules" Type P.BE CPX EA... CPX analogue I/O mo dules" Type P.BE CPX AX... "CPX CP interface" Type P.BE CPX CP.. Handheld" Type P.BE CPX MMI 1.. MPA electronics modu les" Type P.BE MPA ELEKTRONIK... CPX FEC" Type P.BE CPX FEC... FST" Overview of structure, components and mode of operation of CPX terminals; installation and commissioning instructions as well as basic principles of parametrisation Instructions on assembly, installation, commis sioning and diagnostics of the relevant bus nodes Notes on connections and instructions on fit ting, installing and commissioning input and output modules of type CPX... and the MPA, CPA and Midi/Maxi pneumatic interfaces Notes about connection types and instructions for fitting, installing and commissioning CPX analogue I/O modules Instructions on fitting, installing, commissio ning and diagnosing CP systems with the CP interface type CPX CP 4 FB Instructions for commissioning and diagnosing CPX terminals with the handheld typecpx MMI 1 Instructions on assembly, installation, commis sioning and diagnostics of the MPA pneumatic and electronic modules. Instructions for fitting, installing, commissioning and diagnosing the CPX Front End Controller. Programming in statement list and ladder diagram for the FEC Table0/1: Descriptions for the CPX terminal part 1 XIII

16 Contents and general safety instructions Type Title Description Description Pneumatics Valve terminals with MPA pneumatics" Type P.BE MPA... Valve terminals with CPA pneumatics" Type P.BE CPA... Valve terminals with Midi/Maxi pneumatics" Type P.BE Midi/ Maxi Instructions for fitting, installing, commissio ning, maintaining and converting the MPA pneumatics Instructions for fitting, installing, commissio ning, maintaining and converting the CPA pneumatics (type 12) Instructions for fitting, installing, commissio ning, maintaining and converting the Midi/ Maxi pneumatics (type 03) Table0/2: Descriptions for the CPX terminal part 2 XIV

17 Contents and general safety instructions Term/abbreviation Connection block CP CPX bus node Meaning Exchangeable housing upper part of modules with connection technology. Compact Performance Provides the connection to specific fieldbuses. Transmits control signals to the connected modules and monitors their ability to function. CPX terminal Modular, electric terminal type 50 CPX modules DIL switch Fieldbus Function modules Input module Interlinking block I I/O diagnostic interface I/O modules I/Os NBR O Output module PLC/IPC Pneumatic interface Collective term for the various modules which can be integrated in a CPX terminal. Dual in line switches consist of several logic elements with which settings can be made. Data bus via which the CPX modules communicate with each other and are supplied with the necessary operating voltage. Function modules are also known as technology modules (e.g. CPX CP interface) CPX input module Lower part of the housing of a module or block for interlinking the module electrically with the terminal Digital input The I/O diagnostic interface is a bus independent diagnostic interface at I/O level, permitting access to internal data of the CPX terminal. Common term for the CPX modules which provide digital inputs and out puts (CPX input modules and CPX output modules). Digital inputs and outputs Nitrile butadiene rubber, material for seals Digital output CPX output module Programmable logic controller/industrial PC The pneumatic interface is the interface between the modular electrical peripherals and the pneumatics. XV

18 Contents and general safety instructions Term/abbreviation Status bits Technology modules Meaning Internal inputs that supply coded common diagnostic messages Function modules are also known as technology modules (e.g. CPX CP interface) Table0/3: Product specific terms and abbreviations XVI

19 Overview of components Chapter 1 1 1

20 1. Overview of components Contents 1. Overview of components Structure of the CPX terminal Mode of operation of the CPX terminal Structure of the electric CPX modules The power supply concept of the CPX terminal Commissioning, diagnosis and operational functions

21 1. Overview of components 1.1 Structure of the CPX terminal CPX terminals consist of electric and pneumatic modules for controlling pneumatic actuators and low current consuming electric devices (further valves, bulbs, etc.). They are usually placed decentrally directly on the machine or system. Design variants CPX terminals are available in plastic version (type CPX...) and in metal version (type CPX M...) with various different functions. They can be fitted with different electric and pneu matic modules (valves) in accordance with the customer s wishes. The equipment fitted on the CPX terminal in this man ual may therefore differ from the equipment you are using Electric modules (electric side) 2 Pneumatic modules (pneumatic side); optional Fig.1/1: Structure of a CPX terminal with CPA pneumatics (example in plastic version) 1 3

22 1. Overview of components Fieldbus connection CPX terminals with fieldbus connection permit communica tion with remotely situated higher order control systems. CPX terminals are constructed on a modular basis and can consist of the following modules, for example: Modules Brief description CPX bus node for connecting to higher order control systems via the fieldbus; Connections depend on the design of the CPX bus node CPX Front End Controller for control ling pneumatic and electric actua tors; communication via Ethernet (web server, e mail, Modbus TCP, EasyIP etc.) CPX I/O modules for evaluating pro cess signals; Selectable connection technology (M12 connections here) CPX CP interface for connecting de centrally arranged CP I/O modules and CP valve terminals (technology module) Tab.1/1: Electrical modules of a CPX terminal (examples in plastic version) 1 4

23 1. Overview of components Modules Brief description Pneumatic interface for connecting the modular electrical peripherals of type50 (CPX) to valve terminals of type32 (MPA) Pneumatic interface for connecting the modular electrical peripherals of type50 (CPX) to VTSA/ISO valves (type44) Pneumatic interface for connecting the modular electrical periphery type50 (CPX) to valve terminals of type03 (Midi/Maxi). Pneumatic interface for connecting the modular electrical peripherals of type50 (CPX) to valve terminals of type12 (CPA) Tab.1/2: Pneumatic interface modules for CPX terminals 1 5

24 1. Overview of components Modules Brief description MPA VTSA Midi/Maxi ÌÌÌÌ ÌÌÌÌ Ì Ì ÌÌ ÌÌ ÌÌÌ CPA Tab.1/3: Valve terminal pneumatics for CPX terminals The electric and pneumatic side of the CPX terminal can be adapted to various requirements. The electric side can be fitted with various electric CPX modules, e.g.a CPX bus node, digital and analogue CPX I/O modules etc. (see Tab.1/1). 1 6

25 1. Overview of components The pneumatic side can be fitted with pneumatics of type MPA, VTSA, Midi/Maxi or CPA (see Tab.1/3). Different sizes of valves are possible here. Pneumatic modules are not abso lutely necessary. CPX terminals can consist exclusively of electric modules. If pneumatic modules are to be used, the pneumatic interface appropriate to the pneumatics in ques tion is required (see Tab.1/2) Mode of operation of the CPX terminal 1 Fieldbus incoming Fieldbus continuing 3 Compressed air supply 4 Supply air (2/4) 5 CPX bus node Fig.1/2: Function overview of CPX terminal (here with MPA pneumatics) 1 7

26 1. Overview of components CPX bus node The node point of a CPX terminal with fieldbus connection is the CPX bus node, which controls the following functions: The connection of the terminal to the relevant field bus The control of data transfer to/from the field bus module of your control system Read and write access (depending on the CPX bus node) to system relevant parameters and diagnostic data (access to internal data and parameters) Internal control of the terminal CPX bus nodes provide the connection to certain fieldbuses, pass control signals on to the other CPX modules and monitor their ability to function. Basic settings for fieldbus communi cation can usually be made by DIL switch directly on the CPX bus node. Detailed information on the CPX bus node you are using can be found in the manual for the relevant CPX bus node. CPX Front End Controller (CPX FEC) The CPX Front End Controller can be used together with a CPX bus node or independently of a CPX bus node. It offers the following functions, for example: Independent control of the CPX valve terminal (Stand Alone) Communication via Ethernet (e.g. web server, e mail, EasyIP) Ethernet slave function (via Modbus TCP) Communication via fieldbus (only in conjunction with the appropriate CPX bus node) 1 8

27 1. Overview of components CPX I/O modules Processing signals can be evaluated with the CPX I/O mod ules. Input modules provide inputs for connecting sensors and enable cylinder positions to be scanned, for example. Output modules provide universally usable electric outputs for controlling low current consuming devices (further valves, bulbs, etc.). Note Including the CPX bus node, a maximum of10 electric CPX modules plus a pneumatic interface are permitted on the electric side. The CPX I/O modules have various types of connections. The connections are on a sub base which can be removed from the module. This offers the following advantages: The CPX terminal can be fitted with the desired con nections. It can be adapted easily to various applica tions and operating conditions. When servicing is required, the electronics of the I/O modules can be replaced without the need to dis mantle the CPX terminal, or to loosen individual con nections on the I/O modules. The following types of connection can be used: M12 connection, 5 or 8 pin M8 connection, 3 or 4 pin Terminal strips, 16 pin Sub D connection, 25 pin HARAX connection, 4 pin Further information on the CPX I/O modules can be found in the manual CPX I/O modules", type P. BE CPX EA

28 1. Overview of components CPX CP interface The CPX CP interface serves for connecting decentrally ar ranged CP modules (CP valve terminals and CP I/O modules). It transmits control signals to the connected CP modules and monitors their ability to function. Maximum 128 external I/Os are possible per CPX CP interface. Detailed information on the CPX CP interface can be found in the manual for the CPX CP interface type P. BE CPX CP... Pneumatic interface If the CPX terminal is to be fitted with valves, a pneumatic interface will be required (see Tab.1/2). The pneumatic inter face is the interface between the electric and pneumatic pe ripherals. It forms the mechanical connection between the pneumatic and electric modules and transmits the electric signals. The CPX pneumatic interface is mounted on the right hand side of the last electric module. Pneumatic interfaces can be used for e.g.: Pneumatics of type MPA (maximum 128solenoid coils) Pneumatics of type VTSA (maximum 32solenoid coils) Pneumatics of type Midi/Maxi (maximum 26solenoid coils) Pneumatics of type CPA (maximum 22solenoid coils) 1 10

29 1. Overview of components Pneumatic interface for MPA pneumatics Pneumatic interfaces for VTSA pneumatics, Midi/Maxi pneumatics or CPA pneumatics The pneumatic interface for MPA pneumatics provides the mechanical and electrical connection to the MPA pneumatic modules. Therefore, from the point of view of the CPX termi nal, the MPA pneumatic interface does not count as an elec tric module. Instead, the individual MPA pneumatic modules each represent an electric module with digital outputs for triggering the integrated valves. From a technical point of view, the pneumatic interfaces for VTSA pneumatics, Midi/Maxi pneumatics or CPA pneu matics represent electrical modules with a variable (configu rable) number of digital outputs for activating the integrated valves. Detailed information on the CPX pneumatic interfaces and MPA pneumatic modules can be found in the manual for the CPX I/O modules of type P. BE CPX EA... Valve terminal pneumatics The valve terminal pneumatics provide the following: Common channels for supply and exhaust air Electric signals for all valve solenoid coils Working lines 2 and 4 are provided for each valve position on the individual pneumatic modules. The valves are supplied with compressed air via the common channels or via special supply modules. Both the air and auxiliary pilot air from the valves are also exhausted via these common channels. Further modules for pressure supply are also available, e.g. in order to permit work to be carried out with different work pressures. 1 11

30 1. Overview of components CPX terminals without pneumatics CPX terminals without pneumatic modules possess an end plate instead of the pneumatic interface. This design provides digital and analogue inputs and outputs on the relevant fieldbus. A maximum of 10 electric modules (including the CPX bus node) are permitted on a CPX terminal. 1 CPX bus node 2 I/O modules Right end plate 4 Left end plate X 1 X 3 X 1 X 3 X 1 X 3 X 2 X 4 X 2 X 4 X 2 X Fig.1/3: CPX terminal as fieldbus I/O slave 1 12

31 1. Overview of components Valve terminal pneumatics of type MPA MPA pneumatics consist of serially linked MPA pneumatic modules. From a technical viewpoint, the MPA pneumatic modules in a CPX terminal represent digital output modules for controlling the integrated valves (valve solenoid coils). The pneumatic interface for MPA pneumatics provides the mechanical and electrical connection to the MPA pneumatic modules. CPX terminals with MPA pneumatics can be expanded as fol lows: CPX terminal with MPA pneumatics Number of valve positions 1) Load voltage supply for the valves via... CPX terminal 2) CPX terminal and electric supply plate (MPA) 3) 1) Two solenoid coils can be controlled per valve position. 2) A max. of 64 solenoid coils can be supplied. 3) A max. of 128 solenoid coils can be supplied. MPA1 4, 8, , 8, MPA2 2, 4, , 4, Tab.1/4: Number of valve positions of the CPX terminal with MPA pneumatics 1 Pneumatic interface for MPA pneumatics 2 Valve terminal pneumatics of type MPA 3 Right end plate 4 MPA1 pneumatic module Supply plate Fig.1/4: CPX terminal with MPA pneumatics 1 13

32 1. Overview of components Valve terminal pneumatics of type VTSA Valve terminal pneumatics of type VTSA are built up on a modular basis and can be equipped with combinations of valves in the following sizes: Size02 (to ISO ), 18mm Size01 (to ISO ), 26mm Size1 (to ISO5599 2), 42mm In this way adaptation to the requirements of the machine or system can also be made on the pneumatic side. The valve positions can be configured individually (sizes 18 and 26mm) or in steps of two (size 42mm) up to a maximum of 32 valve positions. Unused valve positions can be sealed with blanking plates. 1 Pneumatic interfaces for VTSA pneumatics Valve terminal pneumatics of type VTSA 3 3 Right end plate 4 Valves of size 18mm 5 Supply plate 6 Valves of size 26mm Fig.1/5: CPX terminal with VTSA pneumatics 1 14

33 1. Overview of components Valve terminal pneumatics of type Midi/Maxi Valve terminal pneumatics of type Midi/Maxi are also built up on a modular basis. These valve terminal pneumatics consist of MIDI and MAXI valves. Valves of both sizes can be oper ated together on a CPX terminal. In this way adaptation to the requirements of the machine or system can also be made on the pneumatic side. The valve positions can be configured in steps of two from 2 to 26 valve locations. Unused valve positions can be sealed with blanking plates. 1 Pneumatic interface for Midi/Maxi Valve terminal pneumatics of type Midi/Maxi 3 Right end plate 3 4 Maxi valves 5 Midi valves 5 4 Fig.1/6: CPX terminal with Midi/Maxi pneumatics 1 15

34 1. Overview of components Valve terminal pneumatics of type CPA Valve terminal pneumatics of type CPA are distinguished by compact exterior dimensions in proportion to the high flow rates. They have replaceable valve plates that are mounted on sub bases. The sub bases are connected mechanically by tie rods and have an end plate at the side. Valve plates are available in different sizes. The valve positions can be configured in single steps from 2 to 22valve positions. 1 Pneumatic interface for CPA (here CPA10) 2 Valve terminal pneumatics of type CPA 3 End plates 4 Valve plates (here CPA10) 1 2 ÌÌ ÌÌ ÌÌ ÌÌ ÌÌ ÌÌ Fig.1/7: CPX terminal with CPA pneumatics Further information on the pneumatics of your CPX valve ter minal can be found in the appropriate Pneumatics Manual. 1 16

35 1. Overview of components Structure of the electric CPX modules An electric CPX module always consists of: An interlinking block (see section1.1.3 for variants) An electronics module A connection block (selectable for I/O modules) Sub base (selectable housing upper part) 3 Interlinking block (selectable housing lower part) 2 Electronics module Fig.1/8: Structure of the CPX modules (example) Connection block The upper part of the housing selected for the CPX I/O mod ules is called the connection block. Connection blocks provide the necessary connections for sensors and actuators. In this way, the CPX terminal offers a high degree of flexibility with regard to adaptation to different applications and operating conditions. 1 17

36 1. Overview of components Electronic module The electronic module contains the electronic components. Itis connected to the interlinking block and to the connection block by means of electric plug connectors. Many electronics modules can be combined with various connection blocks. In the case of the CPX bus node, the connection technology is an integral part of the module; in other words, the connection block and the electronics module form a single unit. Interlinking block The lower part of the housing of the electric modules is called the interlinking block. Interlinking blocks serve for the electri cal and mechanical linking of the modules. They can provide aconnection for supplying the operating voltage and/or load voltage and transmit the operating and load voltages to the neighbouring modules (see section1.1.3). In the plastic ver sion of the interlinking blocks, the mechanical link between the electric modules is made via tie rods (see section2.2.1). Interlinking blocks in the metal version are bolted together individually (see section2.3). You can replace electronics modules with connection blocks during servicing without the need to dismantle the CPX ter minal or loosen individual connections. Instead the entire connection block is removed, the electronics module is re placed and the connection block is placed into position again (see manual for the CPX I/O modules", type P. BE CPX EA...). 1 18

37 1. Overview of components Note With a combination of connection blocks and interlinking blocks with metal on plastic or plastic on metal, always use the appropriate screws for the interlinking block (see With plastic interlinking block: thread cutting screws With metal interlinking blocks: screws with metric thread The power supply concept of the CPX terminal The operating and load voltages for the CPX terminal are sup plied via the interlinking blocks (see Tab.1/5 and Tab.1/6). These conduct the operating and load voltages to the neigh bouring modules. Interlinking blocks are available in various housing designs and with alternative connections: Type of plug con nector Number of pins Interlinking block in plastic version metal version M18 4 pin 7/8" 4 pin 5 pin Push pull 5 pin Available Not available Interlinking blocks with 5 pin plug connectors enable separ ate electrical circuits for the operating voltage for electronics/ sensors and the load voltage for outputs/valves. 1 19

38 1. Overview of components Interlinking blocks are available in plastic and metal designs and with various alternative connections: M18 plug, 4 pin 7/8" plug, 4 pin 7/8" plug, 5 pin Push pull plug, 5 pin The pin allocation for all alternative connections is described in Tab.3/4 and in the package insert for the interlinking blocks with supply. Section3.1.4 describes the criteria for selecting an appropri ate power supply unit, and calculation tables for designing the electrical circuits. 1 20

39 1. Overview of components Interlinking blocks M18 or 7/8" Description Types CPX (M )GE EV S... Interlinking blocks in plastic and metal version with system supply, of which precisely one of each must be available for each CPX terminal. Operating voltage for internal electronics and for the internal electronics of the CP modules connected to the CPX CP interface Sensor supply for internal input modules and for the CP input modules connected to the CPX CP interface Load voltage supply for internal output modules and valves Load voltage supply for the CP modules connected to the CPX CP inter face Types CPX (M )GE EV Z... 1) Interlinking blocks in plastic and metal version with additional power supply for electrical outputs Load voltage supply for the output module inserted and for the subsequent output modules inserted to the right. Type CPX GE EV V... 1) 2) Interlinking blocks with additional power supply for valves Load voltage supply for the pneumatic modules/valves inserted subsequently to the right. Load voltage supply for CP modules which are connected to the fitted CPX CP interface and to those CPX CP interfaces subsequently fitted to the right 1) Optional depends on the current consumption of the CPX modules and the connected compo nents. 2) Not available for all alternative connections. Tab.1/5: Interlinking blocks with supply (M18 or 7/8") 1 21

40 1. Overview of components Interlinking blocks Push pull Description Type CPX M GE EV S PP 5POL Interlinking blocks with push pull system supply, of which precisely one of each must be available for each CPX terminal. Operating voltage for internal electronics and for the internal electronics of the CP modules connected to the CPX CP interface Sensor supply for internal input modules and for the CP input modules connected to the CPX CP interface Load voltage supply for internal output modules and valves Load voltage supply for the CP modules connected to the CPX CP inter face Type CPX M GE EV S PP 5POL 1) Interlinking blocks with push pull forwarding function for supplying power to subsequent equipment Must be placed immediately to the right of the system power supply. Only one interlinking block with forwarding function may be used for each CPX terminal and The forwarding function must not be combined with additional power supplies. Interlinking blocks with a push pull forwarding function are identically constructed to those with with a push pull system power supply. It is therefore necessary to provide external protection in both cases (see section3.1.4) Type CPX M GE EV Z PP 5POL 1) Interlinking blocks in metal version with push pull additional power supply for electrical outputs Must be placed to the right of the system power supply. The additional power supply must not be combined with the forwarding function. Load voltage supply for the output module fitted and for the subsequent output modules fitted to the right. 1) Optional depends on the current consumption of the CPX modules and the connected compo nents. Tab.1/6: Interlinking blocks with supply (push pull) 1 22

41 1. Overview of components Interlinking blocks Description Types CPX (M )GE EV Interlinking blocks without supply Tab.1/7: Interlinking blocks without supply Intermediate supply for load voltage supply of valves in MPA When using MPA pneumatics, a max. of8 sub bases equipped with valves can be supplied electrically with load voltage by the CPX terminal. If the pneumatics side is expanded further (>8sub bases), an electric supply plate must be used for the power supply. For additional information about permissible power supplies, see the relevant manual for MPA... pneumatics", type P.BE MPA... in the section Replacing electronics modules". 1 23

42 1. Overview of components 1.2 Commissioning, diagnosis and operational functions The system reaction of the CPX terminal can be adapted to the relevant application. For this purpose, the CPX terminal provides extensive functions for commissioning, diagnosis and operation. Commissioning and operational functions The reaction of the CPX terminal can be adapted to individual requirements by parameterising. The following reactions of the CPX terminal can be influenced, for example, by accessing the internal parameters: The reaction of the outputs and valves to fieldbus com munication faults (fail safe settings) The reaction to fault elimination The debounce times for digital input signals The signal extension for digital input signals The force settings (force signal status) The operating method of the diagnostic memory The CPX terminal is supplied from the factory with preset parameters. Caution A different parametrisation will result in different characte ristics. Check especially when replacing CPX terminals to see which settings are necessary and make sure that these are restored (e.g. in the start up phase by the higher order PLC/IPC). 1 24

43 1. Overview of components Information about the module specific parameters supported by the module you use can be found in the manual for the relevant module. Basic information on the different para meters can be found in Appendix C in this manual. Diagnostic functions Extensive diagnostic information can be accessed depending on the fieldbus used. Status bits I/O diagnostic interface Diagnostic memory Common diagnostic messages (global error messages) are displayed by means of 8 internal inputs (8 status bits). With fieldbuses that do not possess extensive diagnostic functions, the diagnostic information of the CPX terminals is available via the I/O diagnostic interface. The I/O diagnostic interface enables bus independent access to diagnostic in formation, data and parameters via internal digital I/Os (16inputs and 16 outputs). Faults that occur during operation are entered in a diagnostic memory. The first or the last 40 entries are saved, as well as the relevant time measured from the moment the power sup ply was switched on. Fieldbus specific diagnos tic functions Special diagnostic functions or communication services are available, depending on the fieldbus used. For example communication services on: DPV1 (PROFIBUS) The PCP channel (Interbus) SDO access (CANopen) etc. 1 25

44 1. Overview of components 1 26

45 Assembly Chapter 2 2 1

46 2. Assembly Contents 2. Assembly General instructions on assembly and dismantling Assembling electric modules with plastic interlinking blocks Replacing a complete module or interlinking block with tie rod interlinking Increasing or reducing the number of electric modules Fitting the right hand end plates with Midi/Maxi valves Assembling electric modules with metal interlinking blocks Replacing a complete module or interlinking block Fitting the CPX terminal Fitting CPX terminals without pneumatics onto a H rail Fitting CPX terminals with pneumatics onto an H rail Fitting CPX terminals with Midi/Maxi pneumatics onto an H rail Wall mounting

47 2. Assembly 2.1 General instructions on assembly and dismantling Warning Uncontrolled movements of the connected actuators and uncontrolled movements of loose tubing can cause injury to human beings or damage to property. Before carrying out assembly and maintenance work, switch off the following: Compressed air supply The operating and load voltage supplies. Note Handle all modules and components of the CPX terminal with great care. Note especially the following: Screw connections must be fitted without distortion and mechanical tension. Screws must be fitted accurately (otherwise threads will be damaged). The specified torques must be observed. The modules must not be offset (IP 65). Contact surfaces must be clean (avoid leakage and con tact faults). The contacts of the midi/maxi valve solenoid coils must not be bent (not resistant to bending, i.e. they will break off if they are bent back). Electrostatically sensitive devices. Do not touch the contact surfaces of the plug connectors on the modules and components. 2 3

48 2. Assembly Rules for assembly Including the CPX bus node, a maximum of 10 electric modules plus a pneumatic interface are permitted on the electric side. For MPA pneumatics: The MPA pneumatic interface does not count as an elec tric module. Instead, the individual MPA pneumatic mod ules each represent an electric module with digital out puts for triggering the integrated valves. A maximum of 16MPA pneumatic modules are permissible. If there are more than 8modules, an additional load voltage power supply is needed for the valves. Except for the pneumatic interface, each electric module including the CPX bus node can be fitted in any position on the electrical side. The electric modules can be arranged in any sequence in the CPX terminal. Depending on the fieldbus protocol used, it may however be sensible to arrange modules of the same type one after the other. In these cases, the address assign ment and therefore communication between the fieldbus master and the individual CPX terminals can be optimised. The pneumatic interface must be placed on the right hand side as the last electric module. Interlinking blocks can be used universally for CPX bus nodes and I/O modules. If interlinking blocks with additional supply are not re quired, the interlinking block with the system supply can be fitted in any desired position. If interlinking blocks with additional supply are required, these must always be placed to the right of the system supply (see also section 1.1.3). Connection blocks can be used universally for different I/O modules. 2 4

49 2. Assembly The maximum number of pneumatic components sup ported is as follows: 128valve solenoid coils of type MPA (16MPA pneu matic modules with max.8valve solenoid coils each) 32valve solenoid coils of type VTSA/VTSA F 26valve solenoid coils of type Midi/Maxi 22valve solenoid coils of type CPA 2 5

50 2. Assembly 2.2 Assembling electric modules with plastic interlinking blocks Caution Inappropriate handling can result in damage to the mod ules. Observe the handling specifications for electrostatically sensitive devices. Discharge yourself before installing or removing sub assemblies to protect the sub assemblies from static discharges. You can adapt the CPX terminal to your requirements by ad ding or removing modules. The mechanical link between the electric modules is made via tie rods in the interlinking blocks. The length of the tie rod is determined by the possible number of interlinking blocks or electric modules. Dismantle the CPX terminal before you add or remove inter linking blocks. If you are using the additional fastenings of type CPX BG RW... for fastening onto a wall, it may be necessary to loosen existing fastenings (see also Tab.2/4). 2 6

51 2. Assembly Replacing a complete module or interlinking block with tie rod inter linking The interlinking blocks in the plastic version are connected to each other mechanically by means of two tie rods. The tie rods are situated in a groove in the housing open at the rear. 1 Tie rod groove 2 Tie rod 1 2 Fig.2/1: CPX terminal with tie rod interlinking (rear view) Dismantling Proceed as follows in order to remove a complete module or a interlinking block: 1. Dismantle the CPX terminal 2. Unscrew and remove completely the tie rod screws in the left hand end plate (see Fig.2/2). The interlinking blocks are now held together only by the electrical plug con nectors. 2 7

52 2. Assembly 1 Tie rod screw 2 Allen key size Fig.2/2: Dismantling electric I/O modules Caution Make sure that the electric plug connectors of the inter linking blocks are not bent. 3. Loosen the electrical plug connectors on the relevant interlinking block by taking the interlinking block apart carefully and without tilting it. 4. Now push the modules to the left of the module to be replaced approx. 3cm to the left. 5. Now push the module to be replaced approx. 1.5 cm to the left. 6. Make sure that the tie rod lies over the tie rod groove of the module to be replaced by shifting the module accord ingly (see arrow A in Fig.2/3). 2 8

53 2. Assembly 1 Tie rod 2 Loosened module 1 A 2 Fig.2/3: Dismantling a module or interlinking block 7. Carefully remove the loosened module by lifting it up wards. Assembly To insert a module or interlinking block, proceed as follows: 1. Insert the module in the desired position (see Fig.2/3). The tie rod must lie exactly over the tie rod groove. Caution When interlinking blocks are arranged in series: Make sure that the electric plug connectors of the inter linking blocks are not bent. 2. Align the CPX terminal on a flat surface so that the compo nents are not offset. Use the bearing surface for the H rail to align the component correctly. It is easier to align if you use an H rail. Alternatively, you can place the CPX ter minal without pneumatics or with the CPA pneumatics in such a way that the interlinking blocks electrical connec tions are facing upwards (see Fig.2/4). The tie rod is held in the tie rod groove by the force due to weight. 2 9

54 2. Assembly 1 Electrical connection faces upwards Tie rod 3 Tie rod groove Fig.2/4: CPX terminal with loosened tie rod interlinking (rear view) 3. Slide the interlinking blocks together carefully and with out tilting. 4. Place the end plate on the tie rod. 5. Make sure that the tie rods and plug connectors are correctly seated. Carefully screw the tie rod screws a few turns into the tie rods. 6. Then tighten the screws equally with a size3 internal hexagon socket with 2Nm ±0.3Nm. 7. Assemble the CPX terminal (see section2.4) Increasing or reducing the number of electric modules The length of the tie rod is determined by the possible number of interlinking blocks or electric modules. In order to add an electric module to the CPX terminal, you will require a tie rod extension (see Tab.2/1). 2 10

55 2. Assembly In order to increase or reduce the number of modules by more than one module, you must replace the tie rods by tie rods of the appropriate length. The following table contains alist of the tie rods which you will need in order to adapt the length of the tie rods to the desired number of modules. Type CPX ZA 1 CPX ZA 2... CPX ZA 9 CPX ZA 10 Number of modules Description Tie rod sets (each contains two tie rods of the appropriate length) CPX ZA 1 E +1 Tie rod extension for a further electric module (max. one tie rod extension per tie rod permitted) Tab.2/1: Tie rod sets and tie rod extension Fitting the tie rod extension Note Please observe the following instructions when fitting the tie rod extension in order to avoid damage to the CPX ter minal: Fit the tie rod extension so that it is flush with the tie rod (it need not be tightened). Only one tie rod extension is permitted for each tie rod. Maximum 10 electric modules including the CPX bus node plus a pneumatic interface are permitted for each CPX terminal. 2 11

56 2. Assembly Dismantling Remove the electric modules or interlinking blocks as follows (see also following Fig.2/5): 1. Unscrew and remove completely the tie rod screws in the left hand end plate (see Fig.2/2). The interlinking blocks are now held together only by the electrical plug con nectors. 2. Remove the left hand end plate from the tie rods. 3. To remove the interlinking blocks: Loosen the electrical plug connectors on the relevant in terlinking block by taking the interlinking block apart carefully and without tilting it. 4. Pull the loosened interlinking blocks away from the tie rod. 5. To remove a tie rod: With the aid of a suitable tool, e.g. a screwdriver, remove the appropriate fastening and locking plate in the pneu matic interface or in the right hand end plate (see Fig.2/5). 1 Screwdriver 2 Fastening plate and locking plate in the pneumatic interface or the right hand end plate 1 2 Fig.2/5: Fastening plate and locking plate in the pneumatic interface 2 12

57 2. Assembly Assembly Fit the tie rod and the electric modules or interlinking blocks as follows (see Fig.2/6): Note Place subsequently ordered modules where possible after the last module before the pneumatic interface or in front of the right hand end plate. Do not fit more than 10 electric modules and one pneu matic interface. Fit modules of the same type where possible in series (e.g. first all input modules then all output modules). This can be an advantage for the address assignment of the CPX terminal, depending on the fieldbus used. 1. Fasten the tie rod in the pneumatic interface or the right hand end plate, by placing the fastening plate over the locking plate and pushing these together into the groove intended for this purpose. The locking plate must lie on the side facing the pneumatics. The hooks on the locking plate must grip into the grooves in the fastening plate. 1 Locking plate 2 Fastening plate 3 Groove for tie rod fastening Fig.2/6: Fastening plate and locking plate in the pneumatic interface 2 13

58 2. Assembly 2. Push the interlinking blocks onto the tie rod carefully and without tilting. Caution When interlinking blocks are arranged in series: Make sure that the electric plug connectors of the inter linking blocks are not bent. 3. Align the CPX terminal on a flat surface so that the compo nents are not offset. Use the bearing surface for the H rail to align the component correctly. It is easier to align if you use an H rail. Alternatively, you can place the CPX ter minal without pneumatics or with the CPA pneumatics in such a way that the interlinking blocks electrical connec tions are facing upwards (see Fig.2/7). The tie rod is held in the tie rod groove by the force due to weight. 1 Electrical connection faces upwards Tie rod 3 Tie rod groove Fig.2/7: CPX terminal with loosened tie rod interlinking (rear view) 4. Slide the interlinking blocks together carefully and with out tilting. 5. Place the end plate on the tie rod. 2 14

59 2. Assembly 6. Make sure that the screw connectors are seated correctly and carefully screw the tie rod screws a few turns into the tie rods. 7. Then tighten the screws equally with a size3 internal hexagon socket with 2Nm ±0.3Nm Fitting the right hand end plates with Midi/Maxi valves Note With Midi/Maxi valves, the right hand end plate is earthed internally when the valve terminal is supplied from the factory. If you undertake extensions/conversions to the valve terminal, earth the right hand end plate of the valve terminal as described below. In this way, you will avoid interference from electromagne tic sources. Earth the end plates after extension/conversion as follows: 1. Right hand end plate (Midi/Maxi): In order to earth the right hand end plate, connect the cable fitted on the inside onto the appropriate contacts of the pneumatic module or the CPX bus node (see Fig.2/8). 2. Left hand end plate: The left hand end plate is connected conductively with the other components by means of rails in the interlinking block. Instructions on earthing the entire valve terminal can be found in section Fig.2/8 shows you how to fit the right hand end plates with Midi/Maxi valves. 2 15